Note: Descriptions are shown in the official language in which they were submitted.
CA 02228112 1998-02-27
FIELD OF THE INVENTION
This invention consists of a new, highly accurate process, run
by an expert system, for filling containers of various kinds
with products of different consistencies and densities; products
can range from liquid to paste, with or without chunks.
BACKGROUND OF THE INVENTION
Filling machine is the generic name for a device that puts
products into containers. These machines are commonly used
in various sectors of industry and business.
There are many types of products to be packaged: dry ones,
ranging from powders to large pieces of different sizes and
shapes, pre-packaged or not; and liquids of various
consistencies.
Volumetric measuring systems are used in most filling
systems. For example, one type of system works by measuring
the product right in the container using a level sensor.
Another kind measures the product by the amount of time it
takes to flow into the container. Valve systems are included in
this category. These two systems may be gravity-fed or
pressure-fed. Pressure can be generated by pumps with
diaphragms, gears, pistons, etc. The level sensor or counter
sends a signal to shut off the product flow, regardless of the
consequences of product accumulating in the flow pipe.
Volumetric measuring systems may also use a cylindrical
chamber with a piston, whose position determines the volume
of product to be transferred into the container. The piston
draws the product by suction from the tank into a cylindrical
z,
CA 02228112 1998-02-27
chamber. A valve is activated to c;hannel the product to the
container, and the piston forces it in.
Weight-based systems use a stationary scale. The product is
transferred to the scale using gravity or an auger, the scale
sends a signal to the cutoff, and the product accumulates
either in a tank, for liquids, or right in the flow pipe, for
compressible substances.
To the applicant's knowledge, there is no process for weighing
and filling containers that is as ffE~xible as the one presented
here.
The system is a complex integration of several components,
using advanced mechanical, electrical and computer
technologies. The goal is to control weight and fill rate at all
times in spite of considerable variations in pressure, flow rate,
consistency, density, and viscosity, while processing in a closed
vessel.
CA 02228112 1998-02-27
SU14IMARY OF THE INVENTION
The main purpose of the invention is to achieve a universal
filling process capable of filling medium- to large-sized
containers at high speeds, with high accuracy and
repeatability.
The containers are of different sizes and shapes, and the
products have different flow rates, densities, and consistencies:
They can be liquid, low to high viscosity, or paste, and they
may have chunks of various sizes and shapes.
The invention is an integration of volumetric and weight-based
measuring principles with an expert system that can integrate
variables of the new process and product variables in order to
attain target flow rates and weights.
This invention uses pressure and compression chambers to
allow product to accumulate as the flow rate through the
control valve is adjusted during the last part of the X11 cycle,
until the weighing system signals that the target weight has
been attained.
In order to make a filling process work for products ranging
from liquid to paste, many variables must be dealt with that
influence filling accuracy. The products used vary in pressure,
density, viscosity, texture, flow rate, etc. due to prior
processing, and the weighing system can be influenced by the
speed at which substances flow into the container or their
impact on the bottom of the container.
CA 02228112 1998-02-27
Besides reducing deposit weights, the system takes
measurements that are reliable a:nd repeatable regardless of
the variables, thanks to an expert; system that integrates all
variables and can react to and act. on the various constituent
parts of the automatic filling system, as detailed in the
technical description in this document.
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CA 02228112 1998-02-27
DESCRIPTION OF THE PREFERRED EMBODIMENTS)
The filling machine integrates two main systems (see attached
drawing), unit A and unit B. Unit A, the subject of this patent
application, can be used in several other kinds of systems. It
raises the container to the dispensing nozzle, weighs it and
rotates it all at the same time. The function of unit B is to
feed the product into the monitored pressure and compression
chamber and into the container during rapid first-stage filling.
The cylinder in the pressure and compression chamber is
activated at a level that is pre-set. using statistical curves of
product weight, in order to control the product's discharge
force, the speed at which it comes out, and when the feed valve
should be closed.
The dispensing and filling unit (B) is made up of
1) the feed valve,
2) a pressure gauge,
3) a pressure and weight control chamber,
4) the cylinder that fills and empties the control chamber, and
5) a control valve for the first stage of filling, which cuts off
product intake when the cylinder completes the fill cycle.
All components of unit B and all of unit A are monitored by a
computer. The expert system's algorithms analyze and react
in real time based on the weight readings.
