Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
EXTENDABLE CHAMBER BULK BAG AND PALLET BOX FILLER
[0001] TECHNICAL FIELD
[0002] The present invention generally relates to a bulk bag or pallet box
filler. More
particularly the invention relates to a device for filling large bulk bags or
large pallet boxes with
produce (such as but not limited to, potatoes, onions, carrots or round fruit)
in a continuous flow
all the way from an elevated in-feed conveyor down into the large bulk bag or
pallet box in a
gentle manner with minimal bruising or mechanical damage.
[0003] BACKGROUND
[0004] Large bulk bags are generally used to transport produce from the
grower or
packer to a processing facility where the produce may be re-bagged into
smaller packages or
the produce might further processed (for example, used in soups or prepared
meals). These bulk
bags commonly hold 1,000 to 1,200 kilograms of produce. Bulk bags may be
interchangeably
referred to herein as "tote bags".
[0005] Large pallet boxes are containers with rigid sides and are used to
store produce
or transfer produce and may hold from 1,000 to 1,400 kilograms.
[0006] Known bulk bag or pallet box fillers at various points in the
filling process allow
the produce to impact a hard surface with excessive force or be dropped with
excessive force
onto other produce, sometimes repeatedly. Potatoes dropped from a height of
more than 20
centimeters onto a hard surface have the potential to bruise the potato or
cause mechanical
damage.
[0007] A machine commonly used to fill bulk bags uses a fall breaker system
where
produce entering the top of the chute falls down a series of slanted platforms
until they reach
the bottom of the chute.
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[0008] Other machines use conveyors to lower the produce into the bulk
bags or pallet
box but at the end drop the produce into the conveyor from a height or at a
speed which
potentially damages the produce.
[0009] It is desirable to have a bulk bag or pallet box filler that allows
produce to flow
from an elevated conveyor down into a bulk bag or pallet box with minimal
impacts on hard
surfaces and less likelihood of bruising or mechanical damage.
SUMMARY
[0009.01] The present disclosure provides a bulk bag or pallet box filler
comprising an
extending flexible chamber comprised of four overlapping belts forming a
square or rectangle
with overlapping corners; rings on the exterior of the chamber deployed in pre-
set intervals
maintain the shape of the chamber and keep the corners overlapped; said
chamber, being open
at the top and enclosed at the bottom by a gate which can be opened or closed;
and sensors for
measuring how far the chamber has extended downward, and to determine how
close the
chamber is to the bottom of the bulk bag or pallet box.
[0009.02] A process is described herein whereby a combination of sensors,
programming, a programmable computer and an extending chamber facilitate the
continuous
flow of produce from an elevated conveyor down into a bulk bag or pallet box
where the level
of produce at the top of the chamber is maintained in a full or nearly full
condition until the
point where the bulk bag or pallet box are full.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009.03] Embodiments of the present disclosure will now be described, by
way of
example only, with reference to the attached Figures.
[0009.04] Fig. 1 shows a front view of an embodiment of the bulk bag and
pallet box filler.
[0009.05] Fig. 2 shows a side view of an embodiment of the bulk bag and
pallet box filler.
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[0009.06] Fig. 3 shows a top view of a roller layout of the bulk bag and
pallet box filler of
Fig. 1.
[0009.07] Fig. 4 shows a top view of a roller and belt layout of the bulk
bag and pallet box
filler of Fig. 2.
[0009.08] Fig. 5A shows a front view of an embodiment of the bulk bag and
pallet box
filler in operation, wherein produce flows from an in-feed conveyor. The fully
retracted position
is shown.
[0009.09] Fig. 5B shows a front view of an embodiment of the bulk bag and
pallet box
filler in operation, wherein produce flows past the in-feed gate.
[0009.10] Fig. 5C shows a front view of an embodiment of the bulk bag and
pallet box
filler in operation, wherein produce fills the chamber.
[0009.11] Fig. 5D shows a front view of an embodiment of the bulk bag and
pallet box
filler in operation, wherein the container is full of produce and is in the
fully extended position.
[0009.12] Fig. 5E shows a front view of an embodiment of the bulk bag and
pallet box
filler in operation, wherein the bottom gate opens and upward movement allows
produce to
flow down.
[0009.13] Fig. 5F shows a front view of an embodiment of the bulk bag and
pallet box
filler in operation, wherein the in-feed conveyor stops when the bulk bag or
pallet box is full.
[0009.14] Fig. 6A shows representative drawings of the front view of an
embodiment of
the bulk bag and pallet box filler.
[0009.15] Fig. 6B shows representative drawings of the side view of an
embodiment of the
bulk bag and pallet box filler.
DETAILED DESCRIPTION
[0010.01] The present disclosure provides a bulk bag or pallet box filler
comprising an
extending flexible chamber comprised of four overlapping belts forming a
square or rectangle
with overlapping corners; rings on the exterior of the chamber deployed in pre-
set intervals
maintain the shape of the chamber and keep the corners overlapped; said
chamber, being open
at the top and enclosed at the bottom by a gate which can be opened or closed;
and sensors for
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measuring how far the chamber has extended downward, and to determine how
close the
chamber is to the bottom of the bulk bag or pallet box. The filler may be
referred to herein,
interchangeably, as "the apparatus". The belts are of adequate width to herein
be referred to
interchangeably as "wide belts". Optionally, the bulk bag or pallet box filler
can include a
weigh scale to determine when the filler has filled the bulk bag or pallet box
to a
predetermined weight.
[0010.02] A
process is described which may employ the apparatus described herein. The
process employs a combination of sensors, programming, a programmable computer
and an
extending chamber to facilitate the continuous flow of produce from an
elevated conveyor down
into a bulk bag or pallet box. The level of produce at the top of the chamber
is maintained in a
full, or nearly full, condition until the point where the bulk bag or pallet
box is full of produce.
[0010.03] The bulk
bag or pallet box filler may be configured such that each of the four
belts comprising the four sides of the chamber are individually secured at the
upper end and
wrapped around a retaining roller which can be turned in one direction to
shorten the chamber
(lift it up) or turned in the other direction to lengthen the chamber (to make
it descend).
[0010.04] The
retaining rollers may comprise four rollers connected to each other at three
of the corners with 1:1 ratio gears, thereby causing the retaining rollers to
rotate at exactly the
same speed. Thus, when one roller is turned by a motor, all four shafts of the
retaining rollers
will rotate at the same rate. The motor may be electrically, pneumatically or
hydraulically
powered.
[0010.05] Each of
the four belts can be configured to pass over a guide roller, prior to the
location at which they form the chamber. For example, two sets of two opposing
guide rollers,
where one set of opposing guide rollers is at the same elevation as the
retaining rollers, and
where the pair of opposing belts form the two outside panels of the chamber
with the other set
of opposing guide rollers being elevated above the first set of opposing guide
rollers and these
belts forming the inside panels of the chamber.
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[0010.06] After passing over the guide rollers, each of the four corners of
the chamber
passes over a corner guide, which causes the belts at the corners of the
chamber to overlap.
[0010.07] As the four belts extend downward, forming a chamber with
overlapping
corners, retaining rings are deployed at set intervals encompassing the
circumference of the
chamber, thereby keeping the corners overlapped and the chamber from expanding
horizontally
as it fills with produce. When in the full upright position, the retaining
rings are held in place
by a mechanism designed to release the rings at intervals along the chamber as
it extends
downward. The interval between rings is determined by straps fastened to the
rings.
[0010.08] According to an embodiment of the bulk bag or pallet box filler
described herein,
each bottom end of the four sides is attached to one side each of a square
frame supporting the
bottom gate at the bottom of the chamber. When in the closed position, the
bottom gate keeps
produce from flowing out of the chamber. The bottom gate may be moved between
the open
position and the closed position in a controlled manner by an actuator; the
actuator optionally
being pneumatic or electric.
[0010.09] A proximity sensor may be positioned above the chamber, which may
be
connected to a programmable logic computer (PLC). The proximity sensor may be
used to
determine when produce entering the top of chamber has reached a predetermined
height,
causing the retaining rollers to spool or unspool the wide belts by a
predetermined amount,
thereby lowering or raising a chute.
[0010.10] Produce flowing into the chamber of the filler may first
encounter a downward
sloping entry chute, wherein the downward slope of the entry chute deflects
the produce thereby
minimizing the impact force as the produce proceeds into the chamber. The
entry chute may
be referred to herein interchangeably as an "in-feed chute".
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[0010.11] The flow of produce first entering the entry chute may be
interrupted by a closed,
padded in-feed gate. The purpose of the in-feed gate is to minimize the
initial fall height of
produce entering the filler, by confining the initial inflow to the in-feed
chute until the overhead
sensor detects the produce in the entry chute has reached a predetermined
height at which point
the in-feed gate is raised in a controlled manner, thereby allowing the
produce to continue on
into the chamber. The "overhead sensor" may be referred to interchangeably
herein as an
"upper sensor".
[0010.12] The lengthening (downward movement) of the chamber can be
determined by
the amount of produce in the chamber, as monitored via the proximity sensor
positioned above
the entry chute and chamber. When the level of the produce has reached a
predetermined
height, the PLC can cause the belts to unspool a limited and predetermined
length and thus
lengthens (lowers) the chamber, creating space for more produce to enter the
top of the chamber.
As more produce enters the top of the chamber and the produce again reaches a
predetermined
level, the PLC once more causes the chamber to lower a predetermined amount
again creating
more room for produce to enter the top of the chamber. This cycle may continue
until the
chamber has descended to within a predetermined length from the bottom of the
bulk bag or
pallet box. The rate of descent of the chamber can be determined by how
quickly produce
enters the top of the chamber and how full the top of the chamber is.
[0010.13] Once the chamber has descended to within a predetermined length
from the
bottom of the bulk bag or pallet box, the PLC can activate a switch opening a
valve on an air
cylinder attached to the bottom gate, causing the bottom gate to open in a
controlled fashion.
This allows produce to flow down through the chamber and into the bulk bag or
pallet box
situated there. The outward flow can stop when the level of produce in the
bulk bag or pallet
box stabilizes and arrests the downward flow. The outflow of produce creates
more space at
the top of the chamber, leaving room for more produce to enter.
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[0010.14] The predetermined length from the bottom of the bulk bag or
pallet box can be
determined by either counting revolutions of the retaining rollers starting
from the full up
position, or by a proximity sensor mounted on the side of the gate.
[0010.15] When the chamber reaches the predetermined level from the bottom
of the bulk
bag or pallet box and the bottom gate is opened, once the level of produce at
the top of the
chamber again reaches a predetermined level the PLC can cause the retaining
rollers to rotate
in a reverse direction causing the belts to wrap around the retaining rollers
thereby shortening
the chamber (raising it) by a predetermined length. The upward movement of the
chamber
allows a limited amount of produce to flow down the chamber into the bulk bag
or pallet box,
thereby creating more room at the top of the chamber. As more produce flows
into the chamber
and it again reaches a predetermined height, the chamber is again raised by a
predetermined
length. This cycle can continue until the chamber has reached a predetermined
height or until
an input from a weigh scale indicates that the produce in the bulk bag (or
pallet box) has reached
a predetermined weight. The rate of ascent (retraction) of the chamber can be,
at all times,
determined by the rate of flow of produce into the top of the chamber, and/or
by the height of
the produce in the chamber.
[0010.16] Once the level of produce inside the bulk bag (or pallet box) has
reached a
predetermined height or predetermined target weight, the PLC can cause five
actions to occur.
First, the in-feed conveyor may be stopped for a short predetermined length of
time; second,
the in-feed gate can be lowered; third, as the in-feed gate is being lowered
the belts forming the
walls of the chamber may be quickly retracted and the chamber raised to its
full up position;
fourth, the bottom gate can be closed; and fifth (lastly) when all these
actions have occurred the
in-feed conveyor may be restarted, at which point the bulk bag filler is ready
to repeat the entire
cycle for filling a new (empty) bulk bag or pallet box.
[0010.17] Having completed these five actions, the produce can continue to
flow into the
apparatus until the chamber has descended by a predetermined length, at which
point (or before
which point) the operator may confirm to the PLC by activating a switch or
control button that
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a new bag or box has been put in position. In this embodiment, if the operator
does not confirm
a new bulk bag or pallet box has been put in place, the in-feed conveyor will
be stopped and
the chamber will stop its downward motion. Thus, in this embodiment the
filling operation
would not continue until the operator confirms to the PLC the new bulk bag or
pallet box has
been put in place.
[0010.18] The bulk bag or pallet box filler may additionally comprising a
built-in buffering
hopper. When the filler has completed filling a bulk bag or pallet box and has
cycled back to
the start position, the filler can continue to accept new produce even before
the new bulk bag
or pallet box has been placed beneath the chamber. Thus, the chamber may
continue to fill and
descend up to a predetermined length which may be calculated to be just above
the height of an
empty bulk bag (or pallet box), at which point the operator can push a button
or remote control
connected to the PLC confirming an empty bulk bag or pallet box has been
placed underneath
the chamber to keep the filler operating. A person operating the apparatus may
push a button
or remote control connected to the PLC, confirming an empty bulk bag or pallet
box has been
placed underneath the chamber to keep the filler operating. However, if it is
not confirmed that
an empty container has been placed under the chamber, then the PLC may cause
the in-feed
conveyor to stop, and thus the chamber can stop its downward motion.
[0011] THE APPARATUS: The filler includes a padded in-feed chute (1), a
padded in-
feed gate (2) and an extendable chamber with flexible sides formed of wide
belts (7) which also
has a padded bottom gate (10) at the bottom. The sides of the chamber are
formed by wide belts
(7) connected to an arrangement of retaining rollers (4), lower guide rollers
(5), upper guide
rollers (6), and a corner guide (23) at the top of the chamber. An upper
sensor (3) disposed
above the in-feed chute (1) monitors the height of the produce in the in-feed
chute and the
chamber. The in-feed gate (2) has been constructed such that is does not
interfere with the
upper sensor (3). A lower sensor (11) mounted at near the bottom of the
chamber at the side of
the bottom gate (10) detects how close the extending chamber comes to the
bottom of the bulk
bag or pallet box. The chamber is extended downward as it fills with produce
and then slowly
retracted back up again as the produce is transferred to into the bulk bag or
pallet box, as
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depicted in Fig. 5A to Fig. 5F. Optionally, the lower sensor (11) may be
attached to a square
frame (9) located below the retaining rings, which support the bottom gate of
the chamber.
[0011.1] Retaining rings (8) spaced at intervals along the chamber keep its
shape as it
extends. The downward extension and upward retraction of the chamber is
determined by how
fast produce enters the chamber and by the level of produce in the chamber.
How far the
chamber travels downward is determined by either counting revolutions of the
retaining rollers
(4) or by the proximity to the lower sensor (11) mounted near the bottom gate
(10). A pallet
box, or a large tote bag or bulk bag (16) is positioned below the filler.
Hanging bars (12) are
included on which to suspend the bulk bag (16). A magazine (18) is provided to
store up to 24
empty bulk bags for east access to replace full bulk bags which have been
removed.
[0011.2] A PLC (programmable logic computer) monitors and controls the
operation of
the filler. There are controls which the operator uses to initiate filling a
new bag or pallet box,
for stopping the filler, for setting target weights or heights, for causing
the filler to pause its
operation and for resetting the filler. Load cells (15), shown in Fig. 1 and
Fig. 2, are positioned
under the filler to measure the combined weight of the filler, pallet (13),
bulk bag (16) or pallet
box and any produce in the chamber. The load cells (15) provide input to the
PLC which
determines when the produce in the bulk bag or pallet box has reached a preset
target weight.
A plate (14), as shown in Fig. 1 and Fig. 2, supports the pallet (13) for the
bulk bag (16) or
pallet box. A support frame (17) supports the chamber and in-feed chute (1)
above the bulk bag
or pallet box.
[0012] Advantageously, the use of the apparatus allows the produce to flow
from an
elevated position down into a large container with minimal or no impact with
hard surfaces, for
the entire filling process, thereby limiting opportunities for mechanical
damage or bruising of
the produce.
[0013] When the filler begins operation, produce flowing in from an in-feed
conveyor
enters the in-feed chute (1), as depicted in Fig. 5A. The in-feed chute is
angled downward so
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that produce comes in at an acute angle to minimize the impact force. Optional
padding on the
bottom of the in-feed chute can further dampen the forces exerted on the
produce entering the
filler.
[0013.1] Near the bottom of the in-feed chute, the initial flow of produce
is arrested by a
padded in-feed gate (2) as shown in Fig. 5A, which has rotated downward to
block entry to the
chamber. The short travel distance experienced by the initial produce entering
the in-feed chute
(1) prevents the produce from reaching a velocity where bruising can occur if
an incoming item
of produce strikes another surface or another item of produce.
[0013.2] A proximity sensor, depicted in Fig. 5A as upper sensor (3), is
positioned above
the chamber to measure the height of the produce in the in-feed chute and the
chamber. When
the produce has reached a pre-determined height the PLC activates an actuator
(the actuator can
be either pneumatic or electric) which causes the in-feed gate to rise and the
flow of produce
continues down the in-feed chute and into the flexible extendable chamber
which has a closed
bottom gate at the bottom of the chamber. For the initial inflow of produce,
the chamber will
be in its fully retracted position as illustrated in Fig. 5A.
[0014] The flexible extendable chamber is comprised of four wide belts (7)
on rollers
arranged so that as they unspool they form a generally rectangular or square
chamber with
overlapping corners, as shown in Fig. 4. At the upper terminal end, each belt
(7) is attached to
a retaining roller (4), which when rotated one way winds up the belt (7) and
thereby shortens
(raises) the chamber and which rotated the other way allows the belt to
unspool, thereby
extending (lowering) the chamber. The retaining rollers (4) of the four belts
(7) comprising the
chamber are arranged in opposing pairs as depicted in Fig. 3 and Fig. 4, and
are connected via
gears (21) having a 1:1 ratio, located at three of the corners (as shown in
Fig. 3). Thus, when
one of the shafts is turned all of the shafts turn at the same rate, thereby
lowering or raising each
of the four sides (the belts) of the chamber synchronously. The retaining
rollers (4) are also
supported by a bearing (22) at the fourth corner, as depicted in Fig. 3. A
motor (20), attached
to any one of the gears (21) at the three corners, rotates the shafts.
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[0015] As can be seen in Fig. 1, from the lower retaining rollers (4) the
belts (7) that
form the flexible sides of the chamber pass over lower guide rollers (5) and
upper guide rollers
(6) and then extend downward. Two opposing lower guide rollers (5) are
arranged parallel to
each other at approximately the same level as the retaining rollers (4). The
two opposing upper
guide rollers (6) are elevated above the first pair of retaining rollers (4).
The belts (7) which
pass over the lower guide rollers (5) will overlap on the outside of the
corners of the chamber
while the belts (7) which pass over the upper guide rollers will overlap the
corners on the inside
of the chamber. As shown in Fig. 3, the lower and upper guide rollers (5, 6)
are arranged in a
square or rectangle configuration.
[0016] As seen in Fig. 3 and Fig. 4, as the four belts (7) extend downward
they pass
through a corner guide (23) which causes the belts to overlap at the corners
and so form the
shape of the chamber.
[0017] The chamber retains its shape and integrity via retaining rings (8)
encircling the
outside of the chamber deployed at intervals along the chamber, as seen in
Fig. 1 and Fig. 2, as
the flexible sides formed of the belts (7) extend downwardly. When the chamber
is fully
retracted in its start position the retaining rings (8) are gathered at the
top and may be held in
place by a mechanism which causes the rings to deploy in a specific order. The
spacing of the
rings is determined by straps (24) on each side of the chamber. The retaining
rings (8) are
fastened to the belts (7) at consistent and fixed intervals.
[0018] The bottom of the chamber is enclosed by .a padded bottom gate (10)
at the
bottom of the chamber, retaining produce in the chamber while it the bottom
gate (10) is in the
up position or while the chamber is extending downward.
[0019] As produce flows into the chamber, an upper sensor (3) positioned
above the
chamber measures when the produce reaches a predetermined height (calculating
when the
chamber is full), at which point the PLC instructs the motor (20) attached to
the retaining rollers
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to unroll the belts in a synchronous fashion for a predetermined time interval
or a predetermined
number of revolutions, thereby lengthening the chamber and creating some space
at the top of
the chamber to accommodate more produce.
[0020] The predetermined time or number of revolutions are generally set
so that the
chamber moves up or down in increments of less than 10 centimeters so
additional produce
entering the top of the chamber from the in-feed chute doesn't fall more than
10 to 15 cm onto
the produce already in the chamber. Falls of more than 20 cm have the
potential to bruise the
produce.
[0021] Positioned below the chamber is an empty bulk bag suspended on bulk
bag
hangers (also referred to herein as "hanging bars"), or an empty pallet box.
Before the chamber
has extended by a predetermined distance above where the top of the hanging
bulk bag would
be, the filler operator can push a control button, or a remote control device
communicating with
the PLC, confirming that an empty bulk bag or empty pallet box is in place
below the chamber.
If the PLC does not receive this confirmation it can stop the in-feed conveyor
and thus stop the
chamber from descending further. If the button is pushed the filler will
continue operation.
[0022] When sensors indicate produce flowing into the top of the chamber
has filled the
chamber again, the chamber is then extended a predetermined distance again,
leaving more
room for produce to flow into the top via the in-feed chute. When it fills
again, the chamber
extends downward again for a predetermined distance and this cycle continues
(as illustrated in
Fig. 5A to Fig. 5C) for as long as produce continues to flow into the top of
chamber or until the
chamber extends to within a predetermined distance from the bottom of the bulk
bag or pallet
box. How quickly the chamber descends can be determined by how fast the
produce entering
the chamber keeps filling the top.
[0023] When the chamber has extended to the point that it reaches the
bottom of the
bulk bag or pallet box, the bottom gate at the bottom of the chamber is opened
in a controlled
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manner allowing some produce to flow down through the chute and out into the
container (Fig.
5D), this creates space at the top of the chamber for more produce.
[0024] Having reached the bottom of the bulk bag or pallet box and having
opened the
bottom gate and when the chamber has been filled again, the PCL reverses the
direction of the
chamber's movement and causes it to retract (raise) a predetermined distance.
[0025] The upward movement allows some amount of produce to flow down and
out
of the chamber creating space for more produce at the top (Fig. 5E). An
operator may control
approximately how much produce flows out of the chamber in the upward cycle at
each interval
by altering the predetermined height the chamber is raised at each interval.
Produce will flow
down and out of the chute until the flow backs up and stops the downward flow.
[0026] When sensors indicate the chamber is full again the it is retracted
a
predetermined distance again allowing more produce to flow down and out of the
chute,
creating more room at the top for more produce to enter the filler and this
cycle continues until
the bulk bag or pallet box are filled to a predetermined height or until the
bulk bag or pallet box
achieve a predetermined weight; at this point the PLC determines that the bulk
bag or pallet
box is full.
[0027] When the bulk bag or pallet box is full, a series of events occurs;
first the in-feed
conveyor is stopped and the in-feed gate (2) is closed (Fig. 5F). When the in-
feed gate closes,
the in-feed conveyor is restarted. While this is happening the chamber is
quickly retracted to
its start position and the bottom gate is closed (Fig. 5F).
[0028] If another container (bulk bag or pallet box) needs to be filled,
the in-feed chute
and extending chamber will act as a buffer hopper and will continue to fill
while the full bulk
bag or pallet box is taken away and an empty container is put in place.
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[0029] The
filler will operate until it reaches a point above where an empty bulk bag
would be hung, at which point the in-feed conveyor will be stopped and the
filler stops the
descent of the chamber unless an operator pushes the button to instruct the
PCL that a new
empty container has been put in place. If the button is pushed, the filler
will continue to fill the
container.
[0030] Fig. 6A and Fig 6B show representative drawings of the front view and
side view,
respectively, of an embodiment of the bulk bag and pallet box filler similar
to that depicted in
Fig. 1 and Fig. 2.
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