Patent Description:
In the automated production of smoking articles, such as for example cigarettes, or suchlike, especially using machines with high productivity, it is known that one of the important aspects to be taken into consideration and one of the technical problems to overcome is the insertion of smoking material, for example incoherent material, such as tobacco, other smokable substances, or a combination thereof, inside a container, for example a casing, in a filling station, with which there can also be associated a station for feeding containers, disposed upstream, and, disposed downstream, a packaging station, a distribution station and possibly also a station for packing the finished smoking articles.

With regards to the insertion of the smoking material, it is known to prepare a strip of paper on which to deposit the incoherent material, usually consisting of tobacco. The paper strip is then wrapped in order to form a single tubular casing containing the incoherent material, which is then cut to size in order to obtain the individual smoking articles, according to the desired format.

It is also known to use apparatuses for inserting the incoherent material as above inside the containers, which use pneumatic movement systems to move the incoherent material from a containing hopper to the inside of each container, which for example consists of a casing for smoking articles. Such known apparatuses have the disadvantage of degrading the chemical-physical characteristics of the incoherent material that they treat.

Known apparatuses for filling containers with metered quantities of smokable material are also described in patent documents <CIT> and <CIT>. These solutions provide a system capable of preparing a predetermined quantity of such material, typically lower than the desired metered quantity, to which one or more residual quantities can be selectively added after the weight of the quantities involved has been checked.

However, the above known techniques do not allow to automatically fill containers in order to obtain finished products which also contain, for example, leaf material other than tobacco, which has various peculiarities linked, above all, but not only, to the chemical-physical characteristics of the material and which can contain, for example, resins and oils. In particular, these substances make moving the incoherent material very difficult, since the material tends to stick to the surfaces with which it comes into contact and make the apparatus inefficient, especially when a high hourly productivity, for example of the order of <NUM>,<NUM> finished products, is to be achieved.

Document <CIT> discloses a filling apparatus for filling containers with a desired metered quantity of an incoherent material of a fibrous type. The filling apparatus comprises a first filling station with a first filling assembly, having one or more delivery devices which are configured to deliver a first quantity of incoherent material into each of said containers. The filling apparatus also comprises pressing means disposed downstream of said first filling station. The pressing means are configured to be selectively inserted inside said containers after said first quantity of incoherent material has been delivered. Said document further discloses a corresponding filling method.

The technical problem that the present invention aims to resolve, in a new and original way, is that of providing an apparatus and perfecting a method for the automated filling of containers, and for this to also be done with incoherent materials comprising substances that make it difficult to feed them in very narrow spaces with very small sizes, such as for example a capsule or a casing for a smoking article, which is tubular and has a diameter of the order of a few millimeters, also taking into consideration that the metering has to be very precise, of the order of tenths of a gram, and that the aim is to achieve the high hourly productivity mentioned above, which implies that the average production time for each single finished product is of the order of approximately half a second.

At present, in fact, in the state of the art there are no filling apparatuses and methods which resolve the above technical problem, and which can achieve the above objectives.

Therefore, one purpose of the present invention is to provide a filling apparatus and to perfect a filling method for automatically filling containers, for example casings for smoking articles or capsules, which are simple and reliable and which at the same time allow to reach a high productivity, as indicated above, resolving the above technical problem.

Another purpose of the present invention is to provide a filling apparatus and to perfect a filling method for automatically filling containers which are capable of preventing the incoherent material from gluing or sticking to the surfaces of the feed elements, and can instead be easily conveyed to the inside of each container.

Another purpose of the present invention is to make available a filling apparatus and method for automatically filling containers which allow to obtain a very precise and reliable metering of the incoherent material inside each container and inside all the containers to be filled, so that all the containers contain exactly the same desired amount of incoherent material.

Another purpose of the present invention is to provide a filling apparatus and to perfect a filling method for automatically filling containers in which the filling of the containers can take place both serially and also in parallel, so that multiple containers can be filled simultaneously.

The dependent claims describe preferred embodiments of the present invention.

In accordance with the above purposes and in order to resolve the technical problem described above in a new and original way, achieving surprisingly positive results, the present invention provides a filling apparatus according to claim <NUM> for automatically filling containers with a desired metered quantity of incoherent material of the fibrous type.

The apparatus comprises a first filling station comprising a first filling assembly, having one or more delivery devices, which are configured to deliver a first quantity of incoherent material into each of the containers.

The apparatus also comprises at least a second filling station disposed downstream of the first filling station along a working line and comprising a second filling assembly having an additional one or more delivery devices, which are configured to deliver a second quantity of the incoherent material into each of the containers, into which the first quantity of incoherent material has already been delivered in the first filling station.

The apparatus also comprises pressing means disposed downstream of the first filling station and configured to be selectively inserted inside the containers after the first quantity of incoherent material has been delivered, in order to press the incoherent material before delivering the second quantity of incoherent material in the second filling station.

In accordance with one embodiment of the present invention, the apparatus also comprises a third filling station disposed along the working line downstream of the second filling station and comprising a third filling assembly having an additional one or more delivery devices, which are configured to deliver a quantity of incoherent material that is complementary with respect to the sum of the first and second quantities, so as to obtain the desired metered quantity of incoherent material.

In accordance with another embodiment of the present invention, the pressing means comprise first pressing members, disposed in a first pressing station which is located downstream of the first filling station and upstream of the second filling station, to press the first quantity of incoherent material before the second filling station delivers the second quantity of incoherent material.

In accordance with another embodiment of the present invention, the pressing means comprise second pressing members, disposed in a second pressing station which is located downstream of the second filling station and upstream of the third filling station, to press the second quantity of incoherent material before the third filling station delivers the complementary quantity of incoherent material, until the desired metered quantity of incoherent material is reached.

In accordance with one embodiment of the present invention, each of the delivery devices comprises weighing means to weigh the incoherent material, and the apparatus also comprises control means configured to command the delivery devices as a function of the weighing carried out by the weighing means in order to progressively deliver, as the containers advance along the working line, the desired metered quantity of incoherent material.

In accordance with another embodiment of the present invention, the filling apparatus also comprises shaping means disposed upstream of the first filling station and configured to be selectively inserted into the empty containers in order to eliminate any wrinkles, or folds, present therein.

In accordance with another embodiment of the present invention, each delivery device comprises a first rotating member and a second rotating member which define means for metering the incoherent material, and which cooperate with each other to deliver a determinate metered quantity of incoherent material into each of the containers, which is equal to a fraction of the desired metered quantity.

In accordance with another embodiment of the present invention, the first rotating member and the second rotating member are configured to rotate at respective angular velocities, different from each other, and in opposite directions of rotation, so that together they convey the incoherent material toward the containers.

In accordance with another embodiment of the present invention, each of the one or more delivery devices comprises a conveying member having the shape of a funnel, with a wider part at the top, disposed below the first and second rotating members, and a narrower part at the bottom, configured and sized to be selectively inserted into one of the containers.

In accordance with another embodiment of the present invention, the conveying member is of the vibrating type, configured to be made to vibrate during the delivery of the incoherent material, so as to prevent the incoherent material that has been delivered by the first and second rotating members from accidentally remaining inside the conveying member.

In accordance with another embodiment of the present invention, the conveying member is connected to a respective actuator capable of moving the conveying member so as to make it vibrate.

In accordance with another embodiment of the present invention, the conveying member, in correspondence with the narrowest part at the bottom, occupies a surface measured on a horizontal section smaller than <NUM><NUM>.

In accordance with another embodiment of the present invention, the first rotating member is provided on its cylindrical surface with a plurality of sharp elements distributed angularly at regular intervals and aligned on a plurality of parallel rows; moreover, the second rotating member has a diameter smaller than the diameter of the first rotating member and it is provided on its cylindrical surface with a plurality of teeth distributed angularly at regular intervals, aligned on a plurality of parallel rows and axially offset with respect to the sharp elements.

The present invention also provides a filling method according to claim <NUM> for automatically filling containers with a desired metered quantity of an incoherent material of the fibrous type, comprises a delivery step in which one or more delivery devices deliver into each of the containers a determinate quantity of the incoherent material which is a fraction of the desired metered quantity.

The delivery step comprises a first sub-step of filling the containers with a first quantity of incoherent material, carried out in a first filling station comprising a first filling assembly which comprises at least one of the delivery devices. The method also comprises at least a second sub-step of filling the containers with a second quantity of incoherent material, carried out in a second filling station disposed downstream of the first filling station along a working line, and comprising a second filling assembly having an additional one or more delivery devices, which are configured to deliver a second quantity of incoherent material into each of the containers into which the first quantity of incoherent material has already been delivered in the first filling sub-step.

The method also comprises at least one pressing step, following the first filling sub-step, carried out by means of pressing means disposed downstream of the first filling station, in which the pressing means are selectively inserted inside the containers, already at least partly filled with the incoherent material, in order to press the latter.

In accordance with another embodiment of the present invention, the delivery step also comprises a third filling sub-step, carried out in a third filling station which is disposed along the working line downstream of the second filling station and comprising a third filling assembly having an additional one or more delivery devices, which are configured to deliver a quantity of incoherent material which is complementary with respect to the sum of the first and second quantities, so as to obtain the desired metered quantity of incoherent material.

In accordance with another embodiment of the present invention, in the first filling sub-step it is provided to deliver a first quantity comprised between <NUM>% and <NUM>% of the desired metered quantity of incoherent material, in the second filling sub-step it is provided to deliver a second quantity comprised between <NUM>% and <NUM>% of the desired metered quantity of incoherent material, and in the third filling sub-step it is provided to deliver a complementary quantity comprised between <NUM>% and <NUM>% of the desired metered quantity of incoherent material.

In accordance with another embodiment of the present invention, according to a preferred embodiment of the method, in the first filling sub-step it is provided to deliver approximately <NUM>% of the desired metered quantity of incoherent material, in the second filling sub-step it is provided to deliver approximately <NUM>% of the desired metered quantity of incoherent material, and in the third filling sub-step it is provided to deliver approximately <NUM>% of the desired metered quantity of incoherent material.

In any case, in the last filling step provided, which in the embodiments described here is the third filling sub-step, it is provided to deliver a quantity of incoherent material which is complementary with respect to the one already previously delivered inside the containers, with reference to the desired metered quantity with which the latter have to be filled.

This distribution of the quantities delivered in the different filling stations advantageously allows to dispose weighing members that have great sensitivity, reliability and speed of execution of the measurements, only in the last filling station, that is, in the third filling station. This allows to dispose less performing, and therefore less expensive, weighing members in the previous filling stations, that is, in the first and second filling stations.

In accordance with another embodiment of the present invention, the method also comprises a first pressing step carried out by first pressing members in a first pressing station disposed downstream of the first filling station and upstream of the second filling station, to press the first quantity of incoherent material, and a second pressing step carried out by second pressing members in a second pressing station disposed downstream of the second filling station and upstream of the third filling station to press the second quantity of incoherent material.

In accordance with another embodiment of the present invention, the filling method also comprises a shaping step, before the delivery step, carried out by means of shaping means disposed upstream of the first filling station, so as to selectively insert the shaping means into the empty containers in order to eliminate any wrinkles, or folds, present in the containers.

In accordance with another embodiment of the present invention, the method provides to deliver the quantities of incoherent material by making a first rotating member and a second rotating member rotate, which are comprised in each of the delivery devices and reciprocally cooperate to deliver the quantities of incoherent material.

In accordance with another embodiment of the present invention, the method also comprises making a conveying member rotate, which is comprised in each of the delivery devices and substantially has the shape of a funnel with a wider part at the top, disposed below the first and second rotating members, and a narrower part at the bottom, configured and sized to be selectively inserted into one of the containers.

In accordance with another embodiment of the present invention, the method comprises both a weighing step, in which it is provided to weigh the incoherent material by means of weighing means comprised in each of the delivery devices, and also a step of controlling the delivery step by means of control means which are configured to command the delivery devices as a function of the weighing carried out by the weighing means, in order to progressively deliver, as the containers advance along the working line, the desired metered quantity of incoherent material.

In accordance with another embodiment of the present invention, the weighing and control steps preferably take place continuously, or at programmed time intervals, during the delivery step.

In accordance with another embodiment of the present invention, the method also comprises a step of transporting the containers by means of a transport apparatus which comprises a transport member configured to slide on a fixed guide, wherein the transport step provides to transport the containers along the working line parallel to a direction of working, sequentially passing at least in the first filling station and in the second filling station and stopping in each of them for a period of time equal to the cycle time, so as to allow the partial and progressive filling of the containers.

In accordance with another embodiment of the present invention, the method provides to carry out, in sequence, the shaping step, the first filling sub-step in which a first quantity of incoherent material is delivered, the first step of pressing the first quantity by means of a first pressing station disposed downstream of the first filling station and upstream of the second filling station, the second filling sub-step in which a second quantity of incoherent material is delivered, a second step of pressing the second quantity in a second pressing station disposed downstream of the second filling station and upstream of the third filling station, and finally the third filling sub-step.

These characteristics and advantages of the present invention will become apparent from the following description of some of its embodiments, given as a non-restrictive example with reference to the attached drawings wherein:.

With reference to <FIG>, a filling apparatus <NUM>, according to the present invention, for automatically filling containers <NUM> (<FIG>), for example casings for smoking articles or capsules, is configured to be associated with, or to be part of, a machine <NUM> (<FIG>) for the preparation of smoking articles, such as for example cigarettes, capsules, or suchlike.

The apparatus <NUM> is configured to fill the containers <NUM> with a fibrous material, for example incoherent material M, of an oily and/or resinous nature such as leaf material, chopped or shredded, derived from tobacco or other plants, or other substances, for example of the smokable type, or a combination thereof.

The machine <NUM> is schematized in the block diagram of <FIG> and, for example, comprises, in sequence, a feed station <NUM> configured to feed containers <NUM>, followed by the apparatus <NUM>, which constitutes the filling station, by a packaging station <NUM> configured to package the already filled containers <NUM>, for example to adequately close them, producing finished products such as smoking articles or capsules, and by a distribution station <NUM>, for example to forward the finished products toward a packing station <NUM>, possibly outside the machine <NUM>; however, the machine <NUM> is not limited to this. The machine <NUM> can also comprise a suitable transport apparatus <NUM> having the function of transporting the containers <NUM> along the entire working line from the feed station <NUM> (on the left in <FIG>) to the packing station <NUM> (on the right in fig. <FIG>), for example along a direction of working X, preferably rectilinear and horizontal; however, the machine <NUM> is not limited to this.

The feed station <NUM>, the packaging station <NUM>, the distribution station <NUM>, the packing station <NUM> and the transport apparatus <NUM> can be of any known type whatsoever, or one that will be developed in the future. Alternatively, the transport apparatus <NUM> can be, for example, of the type described in a correlated patent application for industrial invention filed by the same Applicant as the present patent application.

For example, the transport apparatus <NUM> comprises a transport member <NUM>, having the shape and function of a shuttle, which is configured to slide on a fixed guide <NUM> in the direction of working X. In the example provided here, the transport member <NUM> comprises four seatings <NUM>, hollow and made through, each of which has, for example, a truncated cone shape with sizes mating with those of a container <NUM>, or at least a lower part thereof. In the example provided here, the sizes of each seating <NUM> are such that each container <NUM>, when it is inserted in the seating <NUM>, protrudes not only from the upper surface of the transport member <NUM>, but also from the base of the latter, by a few millimeters (<FIG>, <FIG>, <FIG>, <FIG>, <FIG>, <FIG>).

It is clear that the number of seatings <NUM> can also be different from four, it being understood that their number influences the hourly productivity of the machine <NUM>. In fact, if a determinate cycle time TC expressed in seconds is required in order to perform a work cycle in each of the different stations <NUM>, <NUM>, <NUM> and <NUM> and in the apparatus <NUM>, or in a slower one, the hourly productivity of the machine <NUM> will be equal to <NUM>,<NUM> divided by the cycle time TC, multiplied by the number of seatings <NUM> of each transport member <NUM>. In fact, in the four seatings <NUM> the work occurs in parallel.

Each seating <NUM> is symmetrical with respect to a substantially vertical axis Y and is configured to house a container <NUM> inserted vertically from the top downward (<FIG>, <FIG>, <FIG>, <FIG>).

The distance D between two adjacent seatings <NUM> is defined in the design phase of the apparatus <NUM> and/or of the machine <NUM>, and it is suitable to manage the plurality of containers <NUM>, as will be described in detail below.

By way of a non-limiting indication, the machine <NUM> is able to prepare each product, such as a smoking article or a capsule, in a very short time, that is, with a cycle time TC of approximately two seconds, therefore it can have an hourly productivity of about <NUM>,<NUM> smoking articles, precisely because in each of the stations <NUM>, <NUM>, <NUM> and <NUM> and in the apparatus <NUM>, four containers <NUM> are worked simultaneously and therefore in parallel in order to shape, for example, filled smoking articles or capsules.

Before describing the apparatus <NUM> and its operation in detail, we will now describe an example of a container <NUM> (<FIG>). In particular, in the following description, the container <NUM> is conformed as a casing for producing smoking articles; however, it could also be a capsule or any other type of container suitable to contain the incoherent material M.

Each container <NUM> is made of sheet material, for example very thin paper, or other material suitable to make a cigarette, or other smokable product, and it is normally provided with a filter <NUM> of a known type.

The containers <NUM> have a length L which can vary according to the smoking article to be obtained and it is comprised, for example, between about <NUM> and about <NUM>.

Furthermore, each container <NUM> can have a truncated cone shape and comprise a first end <NUM> in correspondence with the filter <NUM> and a second open end <NUM> with a diameter larger than the first end, and configured for the insertion of the incoherent material M inside the container <NUM>. On average, the diameter of each container <NUM> is of the order of a few millimeters, for example from <NUM> to <NUM>, like that of a traditional cigarette.

If the container <NUM> were a capsule, it would for example have a truncated cone or hemispherical shape and it would also comprise a first end, closed, and a second end, opposite the first end, open and configured for the insertion of the incoherent material M.

The apparatus <NUM> (<FIG>) comprises a series of work units mounted on a fixed structure <NUM>, each disposed in a respective work station. The work units and stations are disposed sequentially and contiguous to each other along a working line parallel to the direction of working X; the disposition with which the work units and stations are disposed on the working line is such that there is a progressive order of intervention from left to right, looking at <FIG>, as will be clear from the description of the operation of the apparatus disclosed below.

In accordance with one embodiment of the present invention, the work units comprise at least a first filling assembly <NUM> configured to fill the containers <NUM> with the incoherent material M (<FIG>) and which will be described in detail below.

In accordance with another embodiment of the present invention, upstream of the first filling assembly <NUM> there is a shaping assembly <NUM> (<FIG>).

In accordance with other embodiments of the present invention, the work units also comprise a second filling assembly <NUM> and possibly also a third filling assembly <NUM>, which are the same as the first filling assembly <NUM>.

In accordance with other embodiments of the present invention, the work units also comprise first pressing means, or a first pressing assembly <NUM>, disposed downstream of the first filling assembly <NUM>, and possibly also second pressing means, or a second pressing assembly <NUM>, disposed downstream of the second filling assembly <NUM>.

The first filling assembly <NUM> (<FIG>) comprises a mobile structure <NUM> sliding vertically on a vertical guide <NUM> of the fixed structure <NUM>.

On the upper part of the mobile structure <NUM> there is mounted a hopper <NUM> suitable to contain the incoherent material M to be used to fill the containers <NUM>, and below which there are disposed four delivery devices <NUM> (<FIG> and <FIG>), each configured to fill a container <NUM> disposed on a seating <NUM> of the transport member <NUM>.

The first filling assembly <NUM> also comprises weighing means, configured for example as a weighing unit <NUM> (<FIG>, <FIG>, <FIG>) disposed below the four delivery devices <NUM> and suitable to weigh each container <NUM> during a first filling sub-step provided in a step of delivery of the incoherent material M into the containers <NUM>, as will be described in detail below.

The hopper <NUM> comprises at least a front wall <NUM>, a rear wall <NUM>, both vertical, and a base <NUM> inclined downward by an angle α (<FIG>), for example comprised between about <NUM>° and about <NUM>°.

Inside the hopper <NUM> there are disposed four feed members <NUM>, each disposed along a corresponding feed axis S parallel to the base <NUM>. Please note that the hopper <NUM> and the four feed members <NUM> define means for feeding the incoherent material M.

On the lower part of the front wall <NUM> of the hopper <NUM> there are four through holes <NUM> (<FIG>), substantially centered with respect to the feed axes S and configured to allow the outflow of the incoherent material M moved by the feed members <NUM> toward the corresponding delivery devices <NUM>.

Each feed member <NUM> comprises a movement element <NUM> (<FIG> and <FIG>), for example with a helical shape, attached on the rotating shaft of a first actuator <NUM> (<FIG>) mounted on the rear wall <NUM> of the hopper <NUM> and configured to make the movement element <NUM> rotate, causing a motion of advance of the incoherent material M toward the corresponding hole <NUM>, substantially without exerting any compression on the material itself.

According to one variant, not shown in the drawings, a single first actuator <NUM> could make the four movement elements <NUM> rotate simultaneously.

On the internal surface of the base <NUM>, that is, inside the hopper <NUM>, and below each movement element <NUM> (<FIG> and <FIG>) a groove is created, configured to promote the outflow of the incoherent material M toward the corresponding hole <NUM>.

In one embodiment of the present invention, the four delivery devices <NUM> are made using a same plate <NUM>, substantially vertical, attached on the mobile structure <NUM> (<FIG>) and shaped so as to have four substantially vertical conveying cavities <NUM> (<FIG> and <FIG>), one for each delivery device <NUM>, in the upper part of which the four holes <NUM> open. Each conveying cavity <NUM> is configured to vertically guide the incoherent material M coming from the hopper <NUM> and is shaped so as not to hinder its downward fall.

The four conveying cavities <NUM> are closed at the front by a closing plate <NUM> (<FIG>), which can be made of transparent material, for example plastic or glass, in order to allow the flow of incoherent material M inside them to be viewed.

Each conveying cavity <NUM> is shaped in such a way as to have, in its lower part, an exit aperture <NUM> (<FIG> and <FIG>) aligned along a vertical axis V and in proximity of which two seatings <NUM> and <NUM> are made, first and second seating respectively, which are disposed on opposite sides with respect to the vertical axis V. In particular, the two seatings <NUM> and <NUM> are defined by partly cylindrical surfaces and have a common zone. Two metering rollers <NUM> and <NUM> are mounted rotatable in the two seatings <NUM> and <NUM>, rotating in reciprocally opposite directions about two respective substantially horizontal axes of rotation T and U, which are also disposed on opposite sides with respect to the vertical axis V. Each axis of rotation T is substantially vertically aligned with the corresponding hole <NUM>. In the example provided here, each first metering roller <NUM> is configured to rotate in a clockwise direction in order to convey the incoherent material M coming from the hopper <NUM> toward the corresponding exit aperture <NUM>.

The four vertical axes V are distanced from each other by the same distance D by which the seatings <NUM> of a same transport member <NUM> are distanced.

In the embodiment described here, the axes of rotation T and U of each delivery device <NUM> lie on a same horizontal plane P1 or P2. Furthermore, in order to optimize the overall sizes and to respect the distance D between the vertical axes V, the horizontal planes P1 and P2 of each delivery device <NUM> are offset vertically with respect to each other. For example, with reference to <FIG>, the horizontal plane P1 associated with the first and with the third delivery device <NUM>, starting from the left, is lower than the horizontal plane P2 associated with the second and with the fourth delivery device <NUM>.

The first metering roller <NUM> of each delivery device <NUM> is provided with a plurality of sharp elements <NUM> on its cylindrical surface (<FIG>), which are angularly distributed at regular intervals, for example one approximately every <NUM>°, and are aligned on a plurality of rows parallel to the axis of rotation T. The external diameters of the sharp elements <NUM> are slightly smaller than the diameter of the corresponding first seating <NUM>.

The second metering roller <NUM> of each delivery device <NUM> has a diameter smaller than the diameter of the first metering roller <NUM>, and it is provided with a plurality of teeth <NUM> on its cylindrical surface which are angularly distributed at regular intervals, for example one approximately every <NUM>°, and are aligned on a plurality of rows parallel to the axis of rotation U and axially offset with respect to the sharp elements <NUM>. The external diameters of the teeth <NUM> are slightly smaller than the diameter of the corresponding second seating <NUM>.

Furthermore, in each delivery device <NUM> the center distance between the axes of rotation T and U, the diameters of the metering rollers <NUM> and <NUM>, and the external diameters of the sharp elements <NUM> and of the teeth <NUM> are chosen so that the latter intersect each other along the vertical axis V, without touching.

The first metering roller <NUM> is configured to rotate at a first relatively low angular velocity ω1, of the order of about <NUM> revolutions per minute, and has the function of conveying, with the sharp elements <NUM>, the incoherent material M coming from the hole <NUM> and directing it toward the second metering roller <NUM>, which is instead configured to rotate in the opposite direction, that is, counterclockwise, at a second relatively high angular velocity ω2, of the order of about <NUM> revolutions per minute.

Furthermore, in each conveying cavity <NUM>, a sector <NUM> of the first seating <NUM> adjacent to the second seating <NUM> defines a calibrated passage for the incoherent material M, so as to be able to easily control the quantity of the latter fed by the first metering roller <NUM> toward the second metering roller <NUM> and then carry out a precise metering of the incoherent material M, as a function of the amplitude of the rotation of the first metering roller <NUM>.

The second metering roller <NUM>, rotating at the second relatively high angular velocity ω2, has the function of completely removing the incoherent material M in contact with the first metering roller <NUM> and pushing it downward, substantially in the direction of the vertical axis V, into the exit aperture <NUM>.

The four first metering rollers <NUM> are made to selectively rotate by four corresponding second actuators <NUM> (<FIG>), connected to them by means of four corresponding shafts <NUM>. The four second metering rollers <NUM> are made to selectively rotate by four corresponding third actuators <NUM>, connected to them by means of four corresponding shafts <NUM>. For simplicity, <FIG> schematically shows only two second actuators <NUM> and two third actuators <NUM>.

Alternatively, a single actuator, or a different number of actuators, could command two or more metering rollers <NUM> and/or <NUM>.

Inside each of the four conveying cavities <NUM> there is an agitation member <NUM> (<FIG> and <FIG>), for example comprising or consisting of a vertical rod, possibly curvilinear, configured to promote the descent of the incoherent material M toward the corresponding first metering roller <NUM>.

The four agitation members <NUM> (<FIG>), for example, are mounted on a horizontal bar <NUM> disposed above the plate <NUM>. A fourth actuator <NUM> is connected to the horizontal bar <NUM> in order to move it so that the four agitation members <NUM> can vibrate and/or move inside the corresponding four conveying cavities <NUM>.

Each delivery device <NUM> also comprises a conveying member <NUM> (<FIG>, <FIG>, <FIG>), having substantially the shape of a funnel, disposed below the exit aperture <NUM> and close to the latter, coaxially to the corresponding vertical axis V.

Each conveying member <NUM> is configured to receive the incoherent material M coming from the exit aperture <NUM> and convey it inside a container <NUM>. In particular, each conveying member <NUM> has a lower part <NUM> with a cylindrical tubular shape, having an external diameter slightly smaller than the diameter of the second end <NUM> (<FIG> and <FIG>) of a container <NUM>. By way of a non-limiting example, the surface measured on a horizontal section in correspondence with the lower part <NUM> is comprised between about <NUM> and about <NUM><NUM>, and in any case is smaller than about <NUM><NUM>. The lower part <NUM> has a terminal end truncated diagonally in the opposite direction to the direction of working X, in order to generate a pointed end <NUM> (<FIG>). In fact, during the operation of the apparatus <NUM>, each lower part <NUM> is selectively partly introduced into the second end <NUM> of a container <NUM>, as will be described in detail below, and this conformation of the lower part <NUM> facilitates its introduction inside the container <NUM>.

The four conveying members <NUM> are connected to one or more fifth actuators <NUM> (<FIG>) capable of making them vibrate in order to facilitate the outflow of the incoherent material M downward, and therefore toward the corresponding containers <NUM>.

The selective vertical movement of the mobile structure <NUM> with respect to the vertical guide <NUM>, in order to displace the lower parts <NUM> of the four conveying members <NUM> between an idle position PR1 thereof (<FIG>), in which the same lower parts <NUM> are raised by a few millimeters with respect to the underlying containers <NUM>, and a lowered operating position PO1 (<FIG>), in which the lower parts <NUM> are inserted in the second ends <NUM> of the containers <NUM>, and vice versa, is commanded by a sixth actuator <NUM> (<FIG>), connected to a first slider <NUM>, sliding on the vertical guide <NUM>. The first slider <NUM> is therefore part of the mobile structure <NUM>. The extent of the travel C of the first slider <NUM>, which is equal to the distance between the two positions PR1 and PO1, depends on the length L of the container <NUM>.

The weighing unit <NUM> (<FIG>, <FIG>, <FIG>, <FIG>) is disposed below the transport member <NUM> and is partly housed in a lower cavity <NUM> of the fixed guide <NUM>.

The weighing unit <NUM> comprises a support plate <NUM> attached to the fixed structure <NUM> and on which there are mounted four weighing members <NUM> coaxial to the four vertical axes V and each comprising, or consisting of, for example, a load cell of a type known per se.

Each weighing member <NUM> (<FIG>) comprises an inclined wall <NUM>, configured to accompany the second end <NUM> of the container <NUM> above it while the same container <NUM> is moved in the direction of working X by means of the transport member <NUM>. The container <NUM> stops in a substantially central position with respect to the weighing member <NUM> in order to be weighed both when it is empty and also when it is at least partly filled with the incoherent material M.

In accordance with another embodiment, not shown in the drawings, each weighing member <NUM> is configured to be axially displaced by a corresponding actuator between an idle position, in which it is slightly distant from the corresponding first end <NUM> of the container <NUM>, and a raised operating position, in which it is raised and in contact with the same end <NUM>, in order to weigh the same container <NUM> both when it is empty and also when it is at least partly filled with the incoherent material M.

The shaping assembly <NUM> (<FIG>, <FIG>) is disposed adjacent to the feed station <NUM> (<FIG>) and has the function of eliminating any wrinkles, or folds, present in the containers <NUM>, in particular in the case of casings for smoking articles such as that described with reference to <FIG>, before proceeding with their filling, as will be described in detail below.

The shaping assembly <NUM> (<FIG>) comprises a substantially horizontal support element <NUM>, mounted on a second slider <NUM>, sliding vertically on a vertical guide <NUM> of the fixed structure <NUM>. On the support element <NUM> there are attached for conical elements <NUM> that are the same as each other and each have shapes and sizes substantially mating with those of the internal part of a container <NUM>. The four conical elements <NUM> are disposed on corresponding vertical axes R which are distanced from each other by the same distance D by which the seatings <NUM> of a same transport member <NUM> are distanced.

A seventh actuator <NUM> (<FIG>), of a type known per se, is connected to the second slider <NUM> in order to command its selective lowering from an idle position PR2, in which the conical elements <NUM> are distant from the underlying containers <NUM>, to a lowered operating position PO2, in which the same conical elements <NUM> are inserted inside the containers <NUM>, for example up to the proximity of their filter <NUM>, and vice versa.

One or more control devices <NUM> can be associated upstream and/or downstream of the shaping assembly <NUM>, only one of which is schematically shown in <FIG>, which are suitable to check the shape of the containers <NUM>.

Each pressing assembly <NUM> and <NUM> (<FIG>, <FIG>) is substantially the same as the shaping assembly <NUM>, with the exception of the four conical elements <NUM> which are here replaced by four vertical bars <NUM>, for example cylindrical, having the function of selectively entering inside a container <NUM> containing the incoherent material M in order to lightly press it.

The four vertical bars <NUM> are each disposed along a corresponding vertical axis W. The four vertical axes W are distanced from each other by the same distance D by which the seatings <NUM> of a same transport member <NUM> are distanced.

Each pressing assembly <NUM> and <NUM> comprises a substantially horizontal support element <NUM>, mounted on a third slider <NUM> sliding vertically on a vertical guide <NUM> of the fixed structure <NUM> and commanded by an eighth actuator <NUM>.

The four vertical bars <NUM> are mounted on the support element <NUM> and are vertically mobile, in both directions, along the corresponding vertical axes W between a raised idle position PR3, in which they are distant from the underlying containers <NUM>, and a lowered operating position PO3, in which their ends are partly inserted inside the containers <NUM> and lightly press the incoherent material M, and vice versa.

It is clear that the travel of each of the four vertical bars <NUM> depends on the quantity of incoherent material M present inside the corresponding container <NUM>.

The apparatus <NUM> also comprises means for controlling its operation, for example configured as an electronic control unit <NUM> (<FIG>), in particular of the programmable type, which is configured to control one or more, even all, of the actuators <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> and <NUM>, and to receive signals from each control device <NUM> and/or from other sensors or control devices associated with the different assemblies of the apparatus <NUM> and not shown in the drawings. The electronic control unit <NUM>, or another control member connected to it, not shown in the drawings, for example another control unit of the machine <NUM>, can also command the transport apparatus <NUM>.

In general, any movement made by using any one of the actuators mentioned above can be obtained by means of an electric motor, or any other type of actuation, for example pneumatic or fluid dynamic.

Furthermore, every movement of the various components of the work units described above can be slave to one or more control devices of a known type and not shown in the drawings, which can send one or more feedback signals to the electronic control unit <NUM> so that the latter can control the different actuators in order to optimize the method for filling the different containers <NUM>.

The operation of the apparatus <NUM> described heretofore, which corresponds to the method according to the present invention, comprises the following steps.

Starting from an initial condition in which all the work units described above are in their idle positions, in order to automatically fill a plurality of containers <NUM> with the incoherent material M, the electronic control unit <NUM> (<FIG>) commands, directly or indirectly, the transport apparatus <NUM> so that a first transport member <NUM> with four containers <NUM> on board (<FIG>), which are positioned in the respective seatings <NUM>, moves into a first shaping station A1, exactly below the shaping assembly <NUM>, with the axes Y of the four seatings <NUM> aligned with the four vertical axes R of the conical elements <NUM>.

The control devices <NUM> (<FIG>) check the shape of each empty container <NUM> and signal to the electronic control unit <NUM> the presence of any defective containers <NUM>, so that the latter are not filled, thus preventing any waste of incoherent material M.

The electronic control unit <NUM> then commands the shaping assembly <NUM> (<FIG>, <FIG>) so that it carries out a shaping step, during which the seventh actuator <NUM> (<FIG>) lowers the second slider <NUM>, together with the four conical elements <NUM> mounted thereon, from the idle position PR2 to the operating position PO2. In this way, the first conical elements <NUM> go inside the containers <NUM> and thus eliminate any wrinkles or folds, after which they return to their idle position PR2.

The shaping step described above is carried out in the cycle time TC of approximately two seconds.

Once the shaping step described above has been completed, the first transport member <NUM> (<FIG>) is displaced by one pitch PT toward the first filling assembly <NUM>, that is, toward the right in the direction of working X. In the example provided here, the pitch PT is equal to four times the distance D between two adjacent seatings <NUM> of the transport member <NUM>. In this way, the first transport member <NUM> reaches a first filling station A2, exactly below the four delivery devices <NUM> and above the weighing unit <NUM>. At the same time, a second transport member <NUM> is taken into the first shaping station A1, where the shaping assembly <NUM> will carry out a shaping step, like the one described above, in another four corresponding containers <NUM> which are located in the seatings <NUM> of the second transport member <NUM>.

In the first filling station A2 the four axes Y of the four seatings <NUM> of the first transport member <NUM> are coincident with the four vertical axes V (<FIG>).

In the displacement toward the first filling station A2, the containers <NUM> disposed inside the seatings <NUM> slide with their second end <NUM> on the inclined wall <NUM> (<FIG> and <FIG>) and they are raised until they rest at the upper part on the weighing members <NUM>, stopping in a substantially central position thereof.

The electronic control unit <NUM> then commands a first weighing step, in which the containers <NUM>, still empty, are weighed, detecting the weight, that is, the tare, of each one of them, and a substantially simultaneous first delivery step, while it is controlling the shaping step in the first shaping station A1.

In accordance with another embodiment, the electronic control unit <NUM> activates a corresponding actuator so that it raises the four weighing members <NUM> in order to take them against the corresponding first ends <NUM> of the containers <NUM>, and then adequately lifts the containers <NUM> in order to detect the weight of each one of them.

At the same time, the electronic control unit <NUM> commands the start of a delivery step, in particular of a first filling sub-step, in which first of all the sixth actuator <NUM> lowers the mobile structure <NUM> to thus take the lower parts <NUM> of the conveying members <NUM> inside the second ends <NUM> of the containers <NUM> (operating position PO1 in <FIG>). Advantageously, the electronic control unit <NUM> can command the sixth actuator <NUM> in order to lower the mobile structure <NUM> so that the pointed ends <NUM> (<FIG> and <FIG>) of the lower parts <NUM> enter first in the second ends <NUM> of the containers <NUM> starting substantially from the center of the latter, while the first transport member <NUM> is still moving toward the first filling station A2. In this way, the relative motion between the lowering of the pointed ends <NUM> and the advance of the containers <NUM> allows the possible remodeling of the second ends <NUM> of the containers <NUM> by means of the lower parts, and prevents the generation of wrinkles or folds in the containers.

We must clarify that the first filling sub-step is performed while the electronic control unit <NUM> continues to keep the weighing step active, so that the weight of each container <NUM> associated with a corresponding weighing unit <NUM> is continuously detected.

Immediately afterward, or simultaneously, the electronic control unit <NUM> commands the activation of the actuators <NUM>, <NUM>, <NUM>, <NUM> and <NUM> which drive, respectively, the movement elements <NUM> inside the hopper <NUM>, the agitation members <NUM> inside the conveying cavities <NUM>, the metering rollers <NUM> and <NUM> and the conveying members <NUM>, thus carrying out a first metered filling of a desired quantity of incoherent material M inside the containers <NUM>.

In some embodiments of the present invention, the electronic control unit <NUM> can selectively activate each of the first actuators <NUM> so that inside the corresponding conveying cavity <NUM> there is always a determinate quantity of incoherent material M on the corresponding first metering roller <NUM>.

Furthermore, in some embodiments of the present invention, the electronic control unit <NUM> can selectively activate the fourth actuator <NUM> in order to drive the agitation members <NUM> with a periodic timing, even with a period greater than the cycle time TC.

In the embodiment shown in <FIG>, the complete filling of the containers <NUM> is carried out using the three filling assemblies <NUM>, <NUM> and <NUM>, whereby, in this first filling sub-step, approximately one third of the total quantity of incoherent material M is inserted in each container <NUM>, that is, for example, approximately <NUM>-<NUM> grams.

In particular, in each delivery device <NUM>, the downward sliding of the incoherent material M into the conveying cavity <NUM> is optimized by the agitation member <NUM>. Each first metering roller <NUM>, by means of the sharp elements <NUM>, collects the incoherent material M present in the conveying cavity <NUM> and transports it toward the second metering roller <NUM>, which pushes it toward the exit aperture <NUM>. The vibration of the underlying conveying member <NUM> facilitates the sliding of all the incoherent material M toward the corresponding container <NUM>.

It should be noted that, regardless of the quantity of incoherent material M that is delivered in the unit of time by each feed member <NUM> toward the corresponding conveying cavity <NUM>, the actual quantity of incoherent material M delivered in each container <NUM> is directly proportional to the amplitude of the rotation of each first metering roller <NUM> and it is constantly measured by the corresponding weighing member <NUM>.

In fact, the electronic control unit <NUM>, during each filling sub-step, continues to carry out the weighing step and, when the desired weight of the container <NUM> has been reached, it stops the delivery of incoherent material M, deactivating the corresponding actuators <NUM>, <NUM>, <NUM>, <NUM> and <NUM>. Immediately thereafter, the electronic control unit <NUM> commands the sixth actuator <NUM> in order to return the mobile structure <NUM> upward into the idle position PR1 (<FIG>).

The end of each filling sub-step for each delivery device <NUM> is commanded by the electronic control unit <NUM>, both on the basis of the data supplied by the weighing members <NUM> during the weighing step, and also on the basis of statistical data which give a prediction on the quantity of incoherent material M that is actually conveyed inside the containers <NUM> after the stop command of the first and second metering rollers <NUM> and <NUM>, thus allowing to obtain a very precise metering of incoherent material M in each of the containers <NUM>. In fact, as a function of the vertical distance between the metering rollers <NUM> and <NUM>, which lie on different horizontal planes (P1 and P2), and the containers <NUM>, there could be a residual quantity of non-uniform incoherent material M which falls into the latter after the metering rollers <NUM> and <NUM> have been stopped.

The first filling sub-step and the corresponding weighing step described above are also carried out overall in the cycle time TC of about two seconds.

Once these steps have been completed, the first transport member <NUM> (<FIG>) is further displaced by one pitch PT toward the first pressing assembly <NUM>, that is, toward the right in the direction of working X. In this way, the first transport member <NUM> reaches a first pressing station A3, exactly below the four vertical bars <NUM>. At the same time, a third transport member <NUM> is taken into the first shaping station A1, where the shaping assembly <NUM> will carry out a shaping step, like the one described above, in four other corresponding containers <NUM> which are located in the seatings <NUM> of the third transport member <NUM>, and the second transport member <NUM> is taken into the first filling station A2, where the first filling assembly <NUM> will carry out a first filling sub-step and a simultaneous weighing step, like the ones described above, in four other corresponding containers <NUM> which are located in the seatings <NUM> of the second transport member <NUM>.

In the first pressing station A3, the four axes Y of the four seatings <NUM> of the first transport member <NUM> are coincident with the four vertical axes W of the vertical bars <NUM> of the first pressing assembly <NUM>.

The electronic control unit <NUM>, while it commands the shaping and weighing steps, and the first delivery sub-step in the two stations A1 and A2, as described above, also commands a first pressing step in the first pressing station A3, by means of the first pressing assembly <NUM>. In particular, the electronic control unit <NUM> commands the eighth actuator <NUM> (<FIG> and <FIG>) in order to lower the four vertical bars <NUM> from the idle position PR3 to the operating position PO3, and to partly insert them inside the corresponding containers <NUM> in order to perform a light pressing of the incoherent material M contained therein, without flattening it excessively, but making it more uniform.

Subsequently, the electronic control unit <NUM> commands the eighth actuator <NUM> in order to return the four vertical bars <NUM> to the idle position PR3. This first pressing step is also carried out in the cycle time TC of approximately two seconds.

In accordance with one embodiment of the present invention, it is provided that after the first pressing step there follow a second filling sub-step with correlated weighing step, and possibly a third filling sub-step with corresponding weighing step.

In the example provided here, in the second filling sub-step the electronic control unit <NUM> commands the second filling assembly <NUM> in order to insert about half of the total quantity of incoherent material M in each container <NUM>, that is, for example, approximately <NUM> grams. In the third filling sub-step, the electronic control unit <NUM> commands the third filling assembly <NUM> in order to insert in each container <NUM> the complementary quantity of incoherent material with respect to the material already present inside it, in order to reach the total quantity of incoherent material M provided. In the example provided here, this complementary quantity can be equal to approximately <NUM> grams.

In an alternative embodiment, the apparatus <NUM> can comprise only the first and the second filling stations, in correspondence with which the corresponding filling sub-steps are carried out, since it does not have the third filling station and the corresponding third filling sub-step. In this case, it is evident that the second quantity of incoherent material delivered by the second filling station is complementary to the first quantity of incoherent material delivered by the first filling station with respect to the desired metered quantity.

Furthermore, if three filling sub-steps and as many weighing steps are provided, between the second and the third of these a second pressing step is carried out, by means of the second pressing assembly <NUM> (<FIG>).

In this case, one proceeds in the same way as described above, displacing all the support members <NUM> by one pitch PT at a time from left to right, until the first of them, and then all the others, is taken first into a second filling station A4, in correspondence with the second filling assembly <NUM>, where a second weighing step and a second filling sub-step, substantially the same as the first weighing step and the first filling sub-step described above, can possibly be carried out; then into a second pressing station A5, in correspondence with the second pressing assembly <NUM>, where a second pressing step, substantially the same as the first pressing step described above, can possibly be carried out; finally, into a third filling station A6, in correspondence with the third filling assembly <NUM>, where a third weighing step and a third filling sub-step, substantially the same as the first weighing step and the first filling sub-step described above, can possibly be carried out.

At the end of all the steps, the containers <NUM> will have been filled with the desired quantity of incoherent material M and the support members <NUM> can be transferred from the apparatus <NUM> to the adjacent packaging station <NUM> (<FIG>) of the machine <NUM>, for example, by means of the transport apparatus <NUM>.

The electronic control unit <NUM>, suitably programmed, is able to simultaneously manage all the different steps of shaping, folding, delivery, including the various sub-steps of progressive filling, and pressing described above, in coordination with the advance of the transport members <NUM> along the fixed guide <NUM>.

Therefore, all the purposes disclosed above are achieved by the filling apparatus <NUM> and by the filling method described above, including the precision of the filling of each container <NUM> with incoherent material M and the high hourly productivity of approximately <NUM>,<NUM> filled containers <NUM>, which corresponds to a similar quantity of finished products.

It is clear that modifications and/or additions of parts or steps may be made to the filling apparatus <NUM> and method for automatically filling containers as described heretofore, provided that they fall within the scope of the present invention as defined by the claims.

Claim 1:
Filling apparatus (<NUM>) for filling containers (<NUM>) with a desired metered quantity of an incoherent material (M) of a fibrous type, comprising a first filling station (A2) comprising a first filling assembly (<NUM>), having one or more delivery devices (<NUM>) which are configured to deliver a first quantity of incoherent material (M) into each of said containers (<NUM>), wherein said apparatus (<NUM>) comprises at least a second filling station (A4) disposed downstream of said first filling station (A2) along a working line and comprising a second filling assembly (<NUM>) having additional one or more delivery devices (<NUM>), which are configured to deliver a second quantity of said incoherent material (M) into each of said containers (<NUM>), into which said first quantity of incoherent material (M) has already been delivered in said first filling station (A1), wherein said apparatus (<NUM>) also comprises pressing means (<NUM>, <NUM>) disposed downstream of said first filling station (A2) and configured to be selectively inserted inside said containers (<NUM>) after said first quantity of incoherent material (M) has been delivered, in order to press it before delivering said second quantity of incoherent material (M) in said second filling station (A4).