Abstract:
A rotary filling machine includes a magnetic funnel attachment that can be easily installed, removed, and reinstalled into the machine for cleaning, changing the size of the funnel, inspecting, or replacing a damaged funnel. The magnetic funnel attachment includes a fill plate segment for receiving one or more funnels, and a funnel for attachment to the fill plate. The fill plate and funnel have mating alignment mechanisms to assist in the correct positioning of the funnel on the fill plate segment, and magnets to assist in the coupling of the funnel to the fill plate segment. This is especially helpful in creating a quick and easy method for funnel installation and removal.

Description:
CROSS-REFERENCE TO A RELATED APPLICATION 
     This application claims priority under 35 U.S.C. §119 based on U.S. Provisional Patent Application No. 61/718,785, which was filed on Oct. 26, 2012, the subject matter of each of which is incorporated by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention generally relates to the field of rotary filling machines for dispensing dry products and, more particularly, to a rotary filling machine fitted with magnetic funnel attachments for easy funnel removal and attachment. 
     2. Discussion of the Related Art 
     Rotary filling machines, sometimes referred to as rotary fillers, are routinely used for dispensing dry products into receiving containers. They can be used to fill both free-flowing and non-free-flowing products into rigid containers at rates of 100 to 400 containers per minute. Exemplary products commonly dispensed by rotary filling machines include infant formula, non-dairy creamer, spices, baking soda, drink mixes, and other products with similar characteristics. A rotary filling machine can have multiple funnels that attach to a main turret that is rotated to move the funnels around a path over the receiving container, which can be a ridged container or a pouch. A product is dispensed into the funnels and is allowed to flow into the receiving container. 
     Typical attachments for mounting the funnels to the turret include fasteners that bolt the funnel directly to a fill plate on the turret, spring loaded plungers that hold the funnel to the fill plate, and/or toggle clamps that hold the funnel to the fill plate. In these instances, all of these attachments have also been used in combination with tongue and groove receivers on one or more edges of the funnel. 
     The current attachment methods, however, suffer from drawbacks. For example, the requirements for complex mechanical fasteners render the funnels difficult to install and to remove. There are many instances in which funnels need to be removed or reinstalled in the process of using a rotary filling machine. For example, a funnel may need to be removed for cleaning, changing the size of the funnel, inspecting, or replacing a damaged funnel. However, the current methods make removing and reinstalling a funnel time-consuming and burdensome. The present invention provides an improvement over current rotary funnel attachments. 
     SUMMARY OF THE INVENTION 
     By way of summary, the present invention relates to a magnetic funnel attachment for a rotary filling machine. A primary aspect of the invention is to provide an improvement in the way funnels are attached to the turret. The present invention utilizes a magnetic system which allows the funnel to be installed and removed faster and more easily for the purposes of cleaning, changing over in sizes, inspection, or replacement. 
     In accordance with a first aspect of the invention, a magnetic funnel attachment is provided that includes a funnel and a fill plate. Installation of the funnel onto the fill plate may involve a two-step process. First, an interaction of alignment pins and receptacles or other alignment mechanisms on the funnel and fill plate allows for correct positioning of the funnel with respect to the fill plate. Second, magnetic forces secure the funnel to the fill plate. 
     In one example, two alignment pins guide the funnel into place as the magnets engage. The two alignment pins are provided on the front and hack of the fill plate to allow the funnel to be situated in the correct position during installation. The back pin aligns with a back slot of the funnel, and the front pin aligns with a front hole of the funnel so that, during installation, the back pin starts the alignment process and the front pin provides exact axial location. Other mechanical alignment locating mechanisms or features can be used instead of or in addition to the alignment pins and the corresponding hole and notch. 
     The magnets are mounted to the funnel and the fill plate with the poles oriented in opposite directions to allow for a pulling action by the magnets when they are in close proximity. The magnets of the funnel and fill plate may be located in pockets created in the funnel and fill plate, respectively. The pockets for the magnets can be made in several different ways. However, it is preferred that the pockets are made blind, i.e., they do not extend all the way through the funnel or fill plate, allowing for an easily cleanable surface above the magnet that is typically near the product contact zone. Alternately, a magnet may align with a ferrous material blind or surface mounted in the pockets. 
     A handle may be formed into or attached to the funnel to facilitate in installation and removal of the funnel from the full plate. 
     These and other features and aspects of the present invention will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following description, while indicating preferred embodiments of the present invention, is given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof, and the invention includes all such modifications. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A preferred exemplary embodiment of the invention is illustrated in the accompanying drawings in which like reference numerals represent like parts throughout, and in which: 
         FIGS. 1A-1B  are a side elevation and top plan view, respectively, showing a rotary filling machine with which a magnetic funnel attachment constructed in accordance with the invention is usable; 
         FIG. 2  is a perspective view of a magnetic funnel attachment assembly usable with the rotary filling machine of  FIGS. 1A and 1B  and constructed according to an embodiment of the present invention; 
         FIG. 3  is a top plan view of a fill plate segment of the magnetic funnel attachment assembly of  FIG. 2 ; 
         FIG. 4  is a side elevation view of the fill plate segment of  FIG. 2 ; 
         FIG. 5  is a bottom plan view of the fill plate segment of  FIGS. 2 and 3 ; 
         FIG. 6  is a top elevation view of one embodiment of a funnel of the funnel attachment assembly of  FIG. 2 ; 
         FIG. 7  is a side elevation view of the funnel of  FIG. 6 ; 
         FIG. 8  is a bottom plan view of the funnel of  FIGS. 6 and 7 ; 
         FIG. 9  is a front elevation view of the funnel of  FIGS. 6-8 ; 
         FIG. 10  is a fragmentary perspective view of the fill plate segment of  FIGS. 4-6   
         FIG. 11  is a fragmentary perspective view showing an intermediate position of the mounting of a funnel of  FIGS. 6-9  on a corresponding fill plate segment of  FIGS. 4-6 ; 
         FIG. 12  is a fragmentary perspective view of a funnel of  FIGS. 6-9 , showing the funnel fully mounted to a corresponding fill plate segment of  FIGS. 4-6 ; 
         FIG. 13  is a perspective view of a portion of the rotary filling machine of  FIGS. 1 and 2  with all of the funnels installed thereon using the funnel attachment assemblies of  FIGS. 2-12 ; 
         FIG. 14  is a perspective view of an alternative magnetic funnel assembly; and 
         FIG. 15  is a top elevation view of the magnet funnel assembly of  FIG. 14 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The present invention and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments described in detail in the following description. 
     Referring first to  FIGS. 1A ,  1 B, and  13 , a rotary filling machine  20  for dispensing flowable or non flowable dry products is illustrated and may include magnetic funnel attachments  22  ( FIGS. 2-13 ) constructed in accordance with the present invention. The rotary filling machine has multiple funnels  26  that are attached to a main turret  100 . The main turret  100  is rotated to move the funnels  26  around a path under a dispensing funnel  102  or other dispensing mechanism and over a receiving container  104  ( FIG. 13 ), which can be a ridged container or a pouch. Each funnel  26  dispenses a controlled amount of materials into the associated receiving container  104 . The receiving containers  104  feed into a series of rotating star wheels  106  and/or timing screws and then into the main turret  100 . 
     In operation, the containers  104  are timed via an initial star that syncs and transfers the containers to the main turret  100 , which transports the containers  104  and corresponding funnels  26 . The containers  104  and their associated funnels  26  are then transported beneath the dispensing funnel  102 , where a controlled amount of dry product is dispensed into the funnels  26 . Products can be dispensed to the dispensing funnel  102  using, for example an auger filler, a volumetric cup filler, a combination or linear scale, or any other filling mechanism that can continuously feed dry product or time the drop of the product into a funnel. The product then flows through the funnel  26  and into the container  104  being transported around the main turret  100 , thus allowing the product to settle into the container  104  as the main turret  100  continues to rotate. At the discharge of the main turret  100 , containers  104  are received by another timing star wheel  108  ( FIG. 13 ) to transfer the containers  104  from the main turret  100  to the discharge conveyor  110 . 
     A plurality of magnetic funnel attachments  22  may be attached to the turret  100  of the rotary filling machine  20  to provide for the mounting of funnels  26  in an annular pattern circumferentially around the main turret  100  of machine  20 , as seen from above in FIGS.  2  and  10 - 13 . 
     Referring now to  FIGS. 2-5 , each magnetic funnel attachment  22  includes 1) a segment  24  of a fill plate and 2) one or more funnels  26  attached to a bottom surface of each fill plate segment  24 . The circumferentially arranged fill plate segments  24  may be formed on a unitary or segmented ring attached to and moving with the main turret  100 . In the illustrated embodiment, each fill plate segment  24  receives three funnels  26  at three evenly spaced mounting locations as best seen in  FIGS. 2 ,  3 , and  5 . Each counting location has a central opening that opens into a respective funnel  26 . Each fill plate segment  24  may be formed from a rigid, durable material such as aluminum or steel. 
     Each mounting location of each fill plate segment  24  has a front aligning pin  28  and a back aligning pin  30  that each penetrate the fill plate  24  and protrude outwardly from the top and bottom surfaces of the fill plate  24 , as seen from the side view in  FIG. 4 . The front aligning pin  28  and rear aligning pin  30  assist to couple the fill plate  24  to the rotary filling machine  20  and to properly align the funnel  26  with an associated fill opening  48  in the fill plate segment  24  through which product flows during a filling operation. Moreover, a back notch  46  may be formed in the fill plate segment  24  to help locate the fill plate segment  24  at the appropriate location on rotary filling machine  20  by, for instance, mating with a pin or similar protuberances (not shown) on the main turret  100 . 
     Referring briefly to  FIGS. 10-12 , each fill plate segment  24  is coupled to the rotary filling machine  20  via the upwardly extending front aligning pin  28  and back aligning pin  30 . Specifically, these pins  28  and  30  extend upwardly through apertures in an annual shoulder on the main turret  100  and receive fasteners such as nuts. 
     At least one magnet is provided on at least one of the fill plate segment  24  and the base plate  36  for securing the base plate  36  to the corresponding mounting location on the fill plate segment  24 . If one or both of the fill plate segment  24  and the base plate  36  are formed from stainless steel or another magnetizable material, a magnet conceivably could be provided in only one of the fill plate segment  24  and the base plate  36 . It is presently preferred, however, that magnets be provided in both the fill plate segment  24  and the base plate. Hence, referring to  FIGS. 2 ,  3 , and  5  each fill plate segment  24  has a plurality of fill plate pockets  32  on the front end and the back end thereof. The fill plate pockets  32  carry a plurality of first magnets  34 . The fill plate pockets  32  preferably are made “blind” so that the pockets  32  do not go all the way through the fill plate segment  24  so that, while the face of the magnets  34  may be exposed from the bottom of the plate, as seen in  FIG. 5 , they are not exposed from the top of the fill plate segment  24 , as seen in  FIG. 3 . This provides for a smooth surface on the top of the fill plate segment  24 , which contacts the rotary filling machine  20 . Each magnet  34  may be mounted in the corresponding pocket  32  by, for example, one or more of a press fit, a chemical bond with an adhesive, and a mechanical bond with a fastener. 
     Referring now to  FIGS. 6-9 , each funnel  26  has a horizontal base plate  36  and a hollow generally frusto-conical funnel body  37  extending downwardly from the bottom surface of the base pate  36 . Suitable materials for each funnel  26  include, but are not limited to, stainless steel, mild steel, aluminium other metals, plastic, fiberglass, urethane and other synthetic materials that can be molded. The funnel  26  may also be created on a 3D printer. A central aperture  39  is formed through the base plate  36 . Aperture  39  is surrounded by the funnel body  37  and has a size and shape that at least generally correspond to those of the corresponding opening  48  in the fill plate segment  24 . 
     First and second alignment mechanisms are provided on the base plate  36  and the fill plate segment  24  for assuring proper positioning of the funnel  26  on the machine. The base plate  36  of this embodiment carries one or more receptacles for mating with one or more alignment devices on the fill plate segment  24 . In the illustrated embodiment, the base plate  36  carries two pin receptacles for mating with the corresponding pins  28  and  30  in the fill plate segment  24 . The pin receptacles take the form of a front hole  38  and a back notch  40  located in front of and behind the funnel body  37 , respectively. The hole  38  and notch  40  mate with the front and rear pins  28  and  30  respectively, of the corresponding fill plate segment  24 . 
     It should be noted that the pins  28  and  30  on the base plate segment  24  and the hole  38  and notch  40  on the funnel base plate  36  could be replaced with other alignment mechanisms or features that assure the desired alignment of the funnel  26  with the corresponding receiving area of the base plate segment  24 . For example, upwardly facing pins or other protuberances could be provided on the funnel base plate  36  for mating with corresponding holes, notches, or other receptacles in the base plate segment  24 . 
     Referring to  FIGS. 6 and 8 , the base plate  36  has a plurality of pockets  42  in front of and behind the opening  39  that are alignable with the fill plate pockets  32  of the fill plate segment  24 . The base pockets  42  carry a plurality of second magnets  44  with opposite polarity as the first magnets  34 . In one embodiment as shown in  FIGS. 14-15 , the base pockets  42  will be “blind pockets” that stop short of the top surface of the base plate  36 . This allows the top surface of the base plate  36  to be free of uneven surfaces, which allows the base plate  36  to easily be cleaned after use. Each second magnet  44  may be mounted in the corresponding pocket  42  by, for example, one or more of a press fit, a chemical bond with an adhesive, and a mechanical bond with a fastener. In this embodiment, the second magnets  44  will be sufficiently strong to attract the first magnets  34  through the base plate  36 . A handle opening  50  may be formed in or through the front end of the base plate  36  to assist the user in attachment and removal of the funnel  26 . The handle opening  50  could be supplemented with or replaced by a knob, if desired. 
     Alternatively, the base pockets  42  may extend through the base plate  36  so that the faces of the second magnets  44  are exposed from the top and bottom of the base plate  36 , as seen in  FIGS. 6 and 8 . In another embodiment, the pockets  42  may be “blind pockets” that stop short of the bottom surface of the base plate  36 . In either case, each magnet  44  preferably is mounted in the corresponding pocket  42  so that its upper face is exposed and thus capable of direct contact with the mating magnet  34  in the fill plate segment  24 . Each magnet  44  may be mounted in the corresponding pocket  42  by, for example, one or more of a press fit, a chemical bond with an adhesive, and a mechanical bond with a fastener. A handle opening  50  may be formed in or through the front end of the base plate  36  to assist the user in attachment and removal of the funnel  26 . The handle opening  50  could be supplemented with or replaced by a knob, if desired. 
     Referring now to  FIGS. 10-12  and initially to  FIG. 10 , the funnel  26  is mounted on the fill plate segment  24  using only one hand by grasping the funnel  26  using the handle opening  50  and inserting the back aligning pin  30  of the fill plate  24  with the back notch  40  of the base plate  36 . Referring now to  FIG. 11 , the funnel  26  is then pivoted upwardly so that the front aligning pin  28  is inserted into the front hole  38  of the base  36 . As the second magnets  44  approach the first magnets  34 , the magnetic force attracts the funnel  26  to the fill plate segment  24  to create a strong attachment, as seen in  FIG. 12 . Alternately, the magnet may be attracted to a metal plate. 
     To remove a funnel  26 , all one needs to do is to grasp the handle opening  50  and pull the funnel  26  down against the resistance of the magnets  34 ,  44  to a position in which the hole  38  in the base plate  36  clears the bottom end of the front aligning pin  28  in the base plate segment  24 , whereupon the funnel  26  can then be pulled forwardly and downwardly with the notch  40  in the base plate  36  moving away from the rear aligning pin  30  in the base plate segment  24 . 
     Many changes and modifications could be made to the invention without departing from the spirit thereof. The scope of these changes and modifications will become apparent from the appended claims.