Abstract:
A device for producing containers for liquid includes a shaping unit for shaping plastic preforms into plastic containers and a filling unit for filling the plastic containers with a liquid medium. At least one transporting device, which is used as an interface, lies between a discharging region of the shaping unit and a feeding region of the filling unit, the transporting device transporting plastic containers at least along some sections and individually between the shaping unit and the filling unit. The transporting device is designed such that at least one further process unit can be inserted between the shaping unit and the filling unit.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to an apparatus for the production of containers for liquid. Apparatus of this type have long been known from the prior art. In this case it is known in particular for containers, such as for example plastics material containers, during a production procedure first to be produced in a shaping procedure and then to be filled with a beverage. Apart from these basic facts, however, production plants of this type for containers for beverages are extremely varied. In this way, different beverages, for example mineral waters or juices, require very different degrees of purity or levels of sterilization. In addition, the nature of the labelling of containers is very different and can be carried out for example by the application of self-adhesive labels or by the application of labels by means of gluing. Furthermore, the most widely varying methods are also known in order to sterilize the containers themselves. For this reason, apparatus of this type should always be regarded as special machines which thus require a very high production outlay. 
     The object of the present invention is therefore to provide an apparatus which can be adapted with a comparatively low outlay to widely differing situations, such as for example widely differing situations of space or even different conceptual designs. 
     A further object of the present invention is to provide a method by which it is possible to set up, on the basis of specific information, for example customer information, a suitable plant. 
     SUMMARY OF THE INVENTION 
     An apparatus according to the invention for the production of containers for liquid has a shaping unit, in order to shape plastics material pre-forms into plastics material containers. Furthermore, a filling unit for filling the plastics material containers with a liquid medium, and in particular with a beverage, is provided, the filling units being arranged downstream with respect to the shaping unit in a conveying direction of the plastics material containers and the shaping unit having a supply region for supplying the plastics material pre-forms as well as a discharge region in order to discharge the shaped plastics material containers out of the shaping unit. Furthermore, the filling unit has a supply region for supplying the plastics material containers to the filling unit as well as a discharge region for discharging the plastics material containers filled with a liquid out of the filling unit. 
     According to the invention at least one conveying device, which acts as an interface and which conveys the plastics material containers—preferably in a conveying flow—at least locally and in an individual manner between the shaping unit and the filling unit, is situated between the discharge region of the shaping unit and the supply region of the filling unit, the conveying device being designed in such a way that at least one further unit for handling the containers is capable of being inserted into the apparatus between the shaping unit and the filling unit, and this further unit being capable of being attached to the conveying device in such a way that the conveying flow between the shaping unit and the filling unit runs by way of the further unit, i.e. the containers are also gripped and conveyed at least for a time by gripping elements which are associated with this further unit. In this way, handling of the containers by the further unit is made possible. 
     A modular design of the apparatus according to the invention is thus proposed, in which a conveying device between the shaping unit and the filling unit acts at the same time as an interface for essentially any further appliances, such as for example sterilization units. This conveying device is thus preferably able not only to pass on the containers from the shaping unit to the filling unit, but also to effect a synchronization between the shaping unit and the filling unit. 
     It is advantageous for the apparatus to have a plurality of conveying devices of the type described above, in which case these conveying devices are designed in a substantially similar manner. In this way, a modular design of the entire plant with a plurality of parts is possible. In this case it is possible for the conveying devices to be designed in an identical manner, but it would also be possible for them to differ with respect to features, such as the pitch circle radius of a conveying path for the containers. 
     It is preferable for the apparatus to have a control device for controlling the shaping unit and the filling unit. In this case the aforesaid conveying device can also be integrated into a control by this control device. 
     In the case of a further advantageous embodiment the conveying device has a drive device as well as preferably also a control input which is capable of being connected to a control output of the aforesaid control device in order to integrate the conveying device into the apparatus as a whole. In this way, expressed more precisely, the conveying device or the drive thereof is capable of being integrated into the entire control. In principle it would also be possible for a so-called master shaft to be used as a common drive device, and for it in turn to operate the individual parts of the plant. It is preferable, however, for a control as described here to be provided. This separate drive device is in particular, but not exclusively, a servo motor. As a result of this arrangement the conveying device is capable of being decoupled from the other parts of the plant, and this in particular is also important in the event of failure or in the case of maintenance and servicing. 
     In the case of a further advantageous embodiment the conveying device has a plurality of gripping elements arranged on a carrier rotatable about a pre-set axis of rotation in order to grip the containers, these gripping elements being capable of being controlled at least in part. In this case these gripping elements preferably grip the containers in a neck region or below a carrier ring provided for this. At least some of these gripping elements, but preferably all the gripping elements, are made active or controllable. It is also possible, however, for these gripping elements to be capable of being changed over from an active control to a passive control, i.e. for the individual gripping elements to be able to act in both an active and a passive manner. As a result of this procedure, the conveying device is capable of being applied to different types of plant and it can be used in accordance with requirements. 
     In the case of a further advantageous embodiment the gripping elements are capable of being controlled in a manner dependent upon a rotational setting of the carrier with respect to the axis of rotation, in which case pre-set control positions are capable of being freely selected with respect to the rotational setting of the carrier. Expressed more precisely, with this embodiment it is possible to ascertain the angular settings in which for example a corresponding gripping element should open and those in which it should close. As a result of this ability of the angular positions to be freely selected, the possibilities of use for the corresponding gripping elements are likewise increased. In this way, for example, an opening and closing of the respective gripping element at any desired angle is possible. It is preferable for the opening and closing of the gripping element to be carried out by an electrical drive. 
     It is preferable for the drive device to be variable in its division, i.e. it can also be used under widely varying geometrical conditions. 
     It is thus preferred for the containers to be advanced by the gripping elements on a pre-set circular path, in which case the conveying device also allows a radius of curvature of this circular path to be set. This can be carried out for example in that a pivoting setting of the gripping elements is variable with respect to the carrier or even in that the individual gripping elements are able to be extended or retracted in a radial direction. 
     In the case of a further advantageous embodiment a conveying device is arranged in each case at the supply region and the discharge region of the shaping unit as well as at the supply region and the discharge region of the filling unit, these conveying devices being designed in a similar manner in each case. A similar design in this case is understood on the one hand as being that they are designed in a completely identical manner, while on the other hand conveying devices in which conveyor tracks with different radii are capable of being produced in each case are also understood as being “similar”. 
     In the case of a further advantageous embodiment at least one sterilization unit for sterilizing the containers by means of at least two similar conveying devices is integrated between the shaping unit and the filling unit. This sterilization unit can preferably be a sterilization unit which sterilizes the containers by means of an electron beam (e-beam). In this way, the sterilization unit does not directly adjoin the shaping unit or the filling unit, but one conveying device is present between these units in each case. 
     In the case of a further advantageous embodiment the conveying device has a separate conveying path for conveying the containers. This means that the conveying path on which the containers are conveyed by the conveying device is not integrated into other conveying paths. In this way for example no continuous conveying chain which connects the shaping unit to the filling unit is provided in this case, but the conveying path is interrupted by a separate conveying path of the conveying device. It is preferable for the other apparatus too, such as for example the filling unit and the shaping unit to have separate conveying paths in each case. As a result of this procedure the apparatus can be adapted to widely differing situations. It is preferable for the conveying device, as mentioned above, to be a conveying star wheel. 
     In the case of a further advantageous embodiment the apparatus is capable of being assembled with any desired handling units for handling containers whilst using substantially similar conveying devices of the type described above. In this way it is possible for a conveying flow of the containers to be interrupted at substantially any desired locations in order for example to introduce further units or to remove units from the apparatus in accordance with requirements. In this way it is preferable for each handling unit of the apparatus to have a separate conveying path for the containers. 
     In the case of a further advantageous embodiment a labelling device for labelling plastics material containers is capable of being integrated into the apparatus. 
     In addition, however, other plants, such as further sterilization units, washing units for the containers and the like, can also be integrated. 
     In the case of a further advantageous embodiment a conveying device for conveying the containers is arranged in at least one supply region or at least one discharge region. This further conveying device can be for example a conveyor belt or the like. 
     The present invention further relates to a conveying device, in particular for an apparatus of the type described above, which has a plurality of gripping elements arranged on a carrier rotatable about a pre-set axis of rotation in order to grip the containers, these gripping elements being capable of being controlled at least in part. Furthermore, a drive device for rotating the carrier is provided and preferably also a control device for controlling the aforesaid drive device. 
     According to the invention the gripping elements are capable of being controlled in a manner dependent upon a rotational setting of the carrier with respect to an axis of rotation, in which case pre-set control positions are capable of being freely selected with respect to the rotational setting of the carrier. As mentioned above, it is also possible in this case to select the angular positions in which a specified gripping element should be closed or opened and those by way of which a gripping element should be kept closed or opened. The control device preferably has a control input, with the aid of which it can be integrated into an overriding machine control. 
     The present invention additionally relates to a method of assembling an apparatus of the type described above. In this case a specific product requirement is submitted in a first method step, and, after that, the necessary components are determined for these specific product requirements and information which is characteristic of the necessary components is issued to a user, this information being ascertained on the basis of the product requirement. The specific product requirement can be for example the category of a beverage to be poured in or a specific degree of sterilization. 
     The aforesaid product requirement thus preferably contains at least one parameter which is characteristic of a degree of purity in the interior of the containers to be produced. In this way, information as to which units must necessarily be used, which units are optional and which alternative units are likewise capable of being used can be issued for example to the user. Furthermore, it is possible to indicate which conveying devices and optionally how many conveying devices of the type mentioned above have been used. The aforesaid product requirements can, as mentioned above, be the category of a beverage to be poured in or even, for example, the nature of an outer wall of the containers, for example the thickness thereof or even further properties. Furthermore, the product requirements can also be spatial circumstances for a corresponding apparatus. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Further embodiments and advantages are evident from the accompanying drawings. In the drawings 
         FIG. 1  shows an apparatus according to the invention in a first embodiment; 
         FIG. 2  is diagrammatic illustration of an apparatus according to the invention in order to illustrate possible parts of the plant; 
         FIG. 3  shows a first embodiment of a conveying device according to the invention, and 
         FIG. 4  shows a further embodiment of a conveying device according to the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  shows an apparatus according to the invention in a first embodiment. This apparatus  1  has a shaping unit  2  which shapes the pre-forms  10  into containers  20 . It is preferably a stretch blow moulding machine which shapes the pre-forms into containers by acting upon them with compressed air. A heating unit for the pre-forms, such as for example a furnace  8 , is situated in front of this shaping unit, i.e. in this case upstream in the conveying direction R. This shaping unit  2  is adjoined by a sterilization unit  6 , with the aid of which the now shaped containers  20  are sterilized. In particular, an internal sterilization of the containers  20  is carried out in this case. For this purpose, the sterilization unit  6  can have for example beam fingers or the like, which dip into the containers  20  and sterilize the inner wall thereof in this way. This sterilization unit  6  is adjoined by a filling unit  4  in which the now sterilized containers are filled with a liquid, such as for example a beverage. 
     In this case the shaping unit  2  has both a supply region  22  for the pre-forms and a discharge region  24  for the containers. In these supply regions and discharge regions conveying elements  46  can be provided which supply the respective containers to a central carrier wheel  25 . In a corresponding manner, the filling unit also has a supply region  42  and a discharge region  44  for the supply and discharge respectively of the now filled containers. 
     Conveying elements  46  and a carrier wheel  45  can in turn also be provided in these regions. In this case it should be noted that both the shaping unit  2  and the filling unit  4  have in each case a plurality of gripping elements for the containers, in which case for example these gripping elements are arranged on the carrier wheel  25  and thus move on a continuous circular path (along the arrow P 1 ). The gripping elements of the filling unit  4  are also arranged on a carrier wheel  45  in a corresponding manner and thus likewise move on a continuous circular path (arrow P 2 ). 
     A significant aspect of the present invention is this separation of the individual gripping elements of the different parts of the plant. In this way, a continuous conveying chain which moves the containers from one unit to the next is not used, as is customary in the prior art but each unit has its own separate gripping elements for the containers. In this way, each gripping element remains in the region of that part of the plant with which it is associated. Both the mechanical and the control connections between the conveying devices  30  and the other parts of the plant, such as the filling unit and the shaping unit, are capable of being separated with comparatively little outlay. 
     Conveying devices  30  according to the invention are arranged in each case between the shaping unit  2 , the sterilization unit  6  and the filling unit  4 . The containers are conveyed from one unit to the next unit in each case by means of these conveying units  30  which likewise have a self-contained system of gripping clamps in each case. In this case these conveying units  30  are interchangeable, so that the most widely differing modules can be combined with one another by way of the respective conveying units  30 . The individual conveying units  30  have in each case drive elements  32  in the form of servo motors. 
     The reference number  5  relates to a central control device for the plant as a whole. This control device is connected in each case in terms of communication  52 ,  54  and  56  to the shaping unit  2 , the sterilization unit  6  and the filling unit  4 . The aforesaid units or the drives thereof respectively are synchronized with one another by way of these communication connections. The central control device is also connected in terms of communication to the drive unit  32  of the conveying device  30  and (not shown) also to the drive units of the further conveying devices  30  by way of a further communication connection  58 . In this way, it is also possible to integrate a plurality of conveying devices  30  into the entire control means, in which case the position of these conveying devices depends upon the circumstances of the plant as a whole. The reference letter R designates the conveying direction of the containers. 
       FIG. 2  is an illustration to show possible combinations of the plants. In this case different parts of the plant are shown which can be used in machines of this type, the present invention allowing essentially any combination of these parts of the plant which is adapted to the purpose of application. 
     The reference number  71  relates to a production unit for producing pre-forms. In this case a plastics material supply unit  72  which supplies the plastics material to the production unit  71  is further provided. The plastics material pre-forms produced in this way can be supplied to a heating device  8 . Instead of or in addition to the heating device  8 , however, it is also possible for other heating devices to be used, such as for example a microwave oven  9 , it also being possible for sterilization units for sterilizing the pre-forms to be used in a microwave oven  9  of this type. These sterilization units can be for example electron beam modules, UV modules or even sterilization units which sterilize by means of hydrogen peroxide. A pre-form supply unit in the form of a roller unit  8   a  or even in the form of a disc feed  8   b  can be provided on the furnace  8 . 
     It is also possible for a further sterilization unit  11  of the type described above to adjoin the furnace  8 . In this case this sterilization unit  11  can be attached directly to the furnace, but it would also be possible for the attachment to be effected by way of a conveying device  30 . A robot unit  88  for an automatic mould change can be attached for example to the shaping unit  2  or the blow moulding module  2  respectively. In addition, a labelling unit  76  and/or a buffer unit  75  can also be attached to the shaping unit  2 , in which case the attachment can also be effected with the aid of a conveying device according to the invention. The reference number  80  likewise relates to a labelling unit and the reference number  85  to a buffer unit. This means that a labelling of the container is possible at different times during the production process. 
     A coating unit  81  as well as the sterilization units  6  and  7  already mentioned can be integrated into the process downstream of the shaping unit  2 . The reference number  83  relates to a metering unit to which valve nodes  87  can be attached. Valve nodes  87  of this type can also be attached to the filling unit  4 . The reference numbers  6  and  7  designate further sterilization units. 
     An injection unit  91  for nitrogen for example as well as a closure unit  93  for closing the filled containers with closures  93  can be provided downstream with respect to the filling unit  4 . This closure unit  93  can also have integrated sterilization units. The reference number  92  relates to a closure supply unit for container closures and the reference number  94  relates to a sterilization unit for the container closures. 
     It is thus evident that depending upon the technical requirements the most widely differing units can be combined with one another. On account of the conveying devices  30  provided between the units in each case it is possible for these units of the plant to be assembled as desired. In this case, as indicated in  FIG. 2 , the individual conveying devices  30  have pitch circle radii which are different in part or different tracks, along which the containers are conveyed. The conveying devices  30  are in this case capable of conveying both pre-forms and already shaped containers. 
       FIGS. 3 and 4  each show a conveying device  30  according to the invention in two different embodiments. In this case two conveying devices  30  have in each case a carrier or a carrier wheel  64  on which a plurality of gripping clamps  62  are arranged. It is possible in this case for the gripping clamps  62  to be pivotable about a pivot axis Y in the plane of this carrier wheel  64 , so that the transfer of containers can be facilitated in this way or the radius of a conveyor track for the containers  10  is also capable of being changed. 
     In addition, as mentioned in the introduction, it is possible for the gripping elements  62  to be displaced in their entirety in the radial direction with respect to the carrier wheel  64 . In this way, it is possible to change the radius of a conveyor track of the containers. The gripping clamps in this case are capable of being actuated electrically and preferably independently of one another. It is preferable for electrically actuated drive elements, such as in particular but not exclusively electric motors or electromagnets, to be provided in order to switch the gripping clamps between a closed state and an opened state. In this case, in contrast to the prior art it is preferable to provide not a cam in order to adjust the gripping elements, but individual drives for the individual gripping elements. It would also be possible, however, for an adjustable cam to be provided. 
     The reference number  74  relates to a fastening element for arranging the carrier wheel on a central drive  32 . It is also possible, by way of an adjustment mechanism  78  for the individual gripping clamps to be displaced in the radial direction. The reference number  68  relates to a housing in which the drive device or a drive shaft for the conveying device  30  is arranged. The conveying device  30  can be attached by way of a connection point  66  to further elements, such as for example the shaping unit  2  or the filling unit  4 . The reference number  82  designates in its entirety a stand which has an element  84  extensible in a telescopic manner as well as a base element or a base plate  86 . In this case this telescopic element  84  is capable of being vertically adjusted, so that as a whole the entire conveying device or the gripping clamps  30  are capable of being altered in height H. 
     In general, it is preferable for a height of the gripping clamps  62  of the conveying device  30  to be capable of being altered, so that in this way too it is easier for an adaptation to different circumstances of the plant to be effected. The conveying device  30  can be integrated into a plant in terms of the control by way of control inputs and outputs respectively (not shown). 
     In the case of a preferred embodiment the carrier  64  is capable of being removed from the housing  68  by the gripping clamps  62 . In this way, the same basic housing  68  can be used for all the conveying devices  30  and, depending upon requirements, different carriers (for example with different numbers of gripping elements or with different radii of the conveyor tracks) can be arranged on the housing  68 . In this way, the number of the similar parts for a corresponding plant can be increased. In this case for example the drive device  32  can be situated in the housing and a unitary attachment means to which different carriers  64  can be connected (for example with different numbers of gripping clamps) can be provided in the housing. 
     A further embodiment of a conveying device  30  according to the invention is shown in  FIG. 4 . It is evident in this case that, as compared with the embodiment shown in  FIG. 4   a , a plurality of gripping devices or gripping clamps  62  are provided and, in addition, the radius of the conveyor track of these gripping devices  62  is larger than in the case of the embodiment shown in  FIG. 4   a . In this case the individual gripping clamps  62  are in each case controlled elements, i.e. each individual gripping clamp  62  can be controlled with respect to its opening and closing setting. It is further possible to select in this case the angle positions in which a specific gripping element  62  adjoins in working operation and the angle positions in which it opens. 
     In this way, it can be established for example that the gripping devices  62  close at the position A in the peripheral direction in order to grip a container in this way and open at the position B in the peripheral direction in order to deliver this container again. In addition, the conveying device permits a variable conveying speed of the gripping devices and the carrier  64  respectively. In this case the respective opening and closing positions can be pre-set by the central control device. Other opening and closing positions as well as opening and closing portions can also be freely defined. 
     In this way, it is possible to select freely the locations at which a container is to be taken up by another unit in the course of a rotation and the locations at which it is to be delivered to a further unit. In this way, the conveying devices  30  are capable of being used in a variable manner for widely varying plants. A drive motor (not shown in detail) is provided for each individual conveying device  30 , in which case this drive motor and also a control means for the individual gripping clamps can be integrated into an overall control concept for the plant. 
     All the features disclosed in the application documents are claimed as being essential to the invention, insofar as they are novel either individually or in combination as compared with the prior art. 
     LIST OF REFERENCES 
     
         
           1  apparatus 
           2  shaping unit 
           4  filling unit 
           5  central control device 
           6  sterilization unit 
           8  furnace 
           9  microwave oven 
           10  pre-forms 
           11  further sterilization unit 
           20  containers 
           22  supply region 
           24  discharge region 
           25 ,  64  carrier wheel 
           30  conveying device 
           32  drive element 
           45  carrier wheel 
           46  conveying elements 
           42  supply region 
           44  discharge region 
           52 ,  54 ,  56 ,  58  communication connection 
           62  gripping clamp 
           64  carrier 
           66  connection point 
           68  housing 
           71  production unit 
           72  plastics material supply unit 
           74  fastening element 
           75 ,  85  buffer unit 
           76 ,  80  labelling unit 
           78  adjustment mechanism 
           81  coating unit 
           82  stand 
           83  metering unit 
           84  telescope-like element 
           86  base element 
           87  valve node 
           88  robot unit for mould change 
           91  injection unit 
           92  closure supply unit 
           93  closure unit 
           94  sterilization unit for container closures 
         R conveying direction 
         H height 
         A, B opening and closing positions for gripping clamps 
         R conveying direction of the container closures 
         Y pivot axis for gripping clamps  62