WO1995022042A1

WO1995022042A1 - Method and apparatus for the provision of pre-packaged components

Info

Publication number: WO1995022042A1
Application number: PCT/AU1994/000067
Authority: WO
Inventors: Frank Dungan
Original assignee: Precision Preweighs Pty. Ltd
Priority date: 1994-02-15
Filing date: 1994-02-15
Publication date: 1995-08-17

Abstract

A method and apparatus are described for accurately weighing, in package form for subsequent use, mixtures or combinations of a number of separate components. The apparatus consists of a plurality of containers (1) for storage of the individual, separate components prior to weighing and packaging, and means (5) for transporting suitable packaging (2, 3) in sequence past and under said storage means (1) so as to allow the required content to be delivered from each separate storage means (1) as to make up the required mixture or combination.

Description

METHOD AND APPARATUS FOR THE PROVISION OF PRE-PACKAGED COMPONENTS

The present invention relates, in general terms, to a method and apparatus for the provision of pre-packaged components, such as for example chemicals and the like, for use in a variety of different contexts. More particularly, but not exclusively, the invention relates to a method and apparatus for the provision of accurately weighed and pre-packaged combinations of chemicals, compounds, components, etc., the method and apparatus in accordance with the invention being capable of delivering such pre-packaged combinations in a continuous and yet cost-effective manner.

Throughout the ensuing description reference will be made to an especially preferred embodiment of or use for the method and apparatus in accordance with the present invention, namely for the pre-packaging of additives or the like for use in a chemical process.

It should be realised, however, that the invention is not to be considered limited to such a use. Indeed, the method and apparatus in accordance with the present invention could equally well be employed for the "creation" of a basic mixture of any number of components, chemicals, etc. for any purpose whatsoever, but especially for use in any given manufacturing process. In that regard it should be understood that the method and apparatus of the present invention is equally suited for use with solid-meaning particulate or powdered or liquid materials. Nowadays in many manufacturing contexts, such as for example in the manufacture of rubber, plastics material and many other types of finished - and/or unfinished - products, there can be expected to be involved at least one, and more often than not more than one, additive or the like which is to be included in the overall mixture at some stage during the relevant manufacturing process. Such additive(s) may be in the form of anti-oxidant(s), accelerator(s), emulsifier(s), stabilisers), etc. and will more often than not make up less than 5% (by volume and/or weight) of the finished - or unfinished - product. In the past problems have been encountered in the actual procedure of addition of such additive(s) to the overall manufacturing process. More particularly, such problems were associated with the capability of delivering such additive(s) on demand and in the prescribed amount (by weight and/or volume). In accordance with long-known and in use techniques, such additives and the like materials were first weighed, using manual means, for subsequent inclusion in an overall manufacturing process. In more recent times, however, with the advent and development of computer technology and electronic weighing devices or means, so- called computer batching has become an alternative to manual weighing. In that regard computer batching machines as currently in use are best described as being of two distinct types, namely either dedicated or remote machines. Machines referred to as "dedicated" are designed and intended to be attached, affixed or in some way connected to or with the manufacturers' overall processing equipment whereby to deliver the prescribed additive or additives, in the desired amount, directly into such equipment. In other words so-called dedicated machines incorporate apparatus intended to itself extract, from a master source or sources of supply, the prescribed amount or amounts of the or each relevant additive for subsequent delivery to the processing method or equipment. In contrast thereto so-called "remote" machines are intended to create or generate pre¬ packaged amounts of the or each additive for subsequent adding into the overall mixture as already within the processing equipment. In accordance with known techniques the additive or additives, in the prescribed amounts and mix, are deposited into appropriate receptacles, preferably in the form of plastics material bags or the like. The total packaged units of weighed additives are hereinafter referred to as "pre- weighs".

The present invention concerns itself particularly with so- called remote batching machines, being machines wherein any and all additives required for a subsequent manufacturing process are first weighed into plastics material bags or other receptacles (hence becoming pre-weighs) at a location remote from the actual scene of manufacture of the relevant products, for consequent delivery to the manufacturing site for inclusion as desired in an overall mix.

In accordance with an especially preferred arrangement a remote batching machine in accordance with the present invention allows for the sequential addition, to a plastics material bag or other container for subsequent transfer to a plastics material bag, of a predetermined and prescribed amount of any number of different additives for any given manufacturing process.

In accordance with a first aspect of the present invention, therefore, there is provided an apparatus for the provision of accurately pre-weighed and packaged combinations or mixtures of chemicals, compounds, components or the like, said apparatus including: a plurality of storage means for receiving and retaining for dispensing a supply of each of the individual chemicals, compounds, components or the like; means for transporting receptacles for said combinations or mixtures of chemicals, compounds, components or the like in sequence past and below said storage means; and means associated with each said storage means for extracting a metered amount (quantity) of content therefrom for deposition into a receptacle disposed therebelow.

In accordance with a further aspect of the invention there is provided a method for the provision of an accurately pre-weighed and packaged combination or mixture of chemicals, compounds, components or the like wherein a receptacle is sequentially moved past an array of sources of supply of the or each individual chemical, compound, component or the like, said receptacle being disposed beneath each source of supply for a sufficient period of time to allow for a predetermined amount of the contents thereof to be extracted therefrom and deposited in the receptacle.

In order that the invention may be more clearly understood and put into practical effect there shall now be described in detail preferred embodiments of a remote batching apparatus, and method for the operation thereof, in accordance with the invention. The ensuing description is given by way of non-limitative example only and is with reference to the accompanying drawings, wherein:

FIG. 1 is a side elevational view of a remote batching apparatus in accordance with the invention, being an apparatus specifically designed for the addition of prescribed amounts of five different additives to a plastics material bag or the like container; FIG. 2 is a view taken along the line 2-2 of FIG. 1, showing a feed station in its inoperative condition; FIG. 3 is an exploded view of a feed station of the hopper of FIG. 2, in its operative condition whereby to allow for passage of material from the hopper itself; FIGS. 4 to 6 are exploded views of a bag-carrier of the overall apparatus in accordance with the invention, illustrating therein the various stages of operation of a means or device employed to isolate the bag-carrier and associated bag from the conveyor means for purposes of filling of the bag;

FIG. 7 is a view taken along the line for 7-7 of FIG. 1; FIG. 8 is a view taken along the line 8-8 of FIG. 1. FIG. 9 is a plan view of a hopper suspension system in accordance with an alternate embodiment of an apparatus in accordance with the present invention, which allows for the hopper itself to be relocatable in a manner to be described; FIG. 10 is a view taken along the line 10-10 in FIG. 9; and FIG. 11 is a plan view of a suspension storage rack for hoppers which are not in use.

Referring firstly to FIG. 1, there is shown therein a preferred embodiment of an apparatus in accordance with the present invention consisting of an array of feed stations for different components of a final mix, whether such components be in the form of additives for an overall process or alternatively of an actual mixture for subsequent treatment. In the preferred embodiment illustrated means are available for the creation of a mixture of five different substances. It should be realised, however, that any number of different substances, in any given amounts, can equally well be utilised.

Again with reference to FIG. 1, there is illustrated therein a plurality (in this case five) of feed hoppers 1 of any given type. In a practical sense the nature of the or each hopper 1 is not of the essence of the invention. Again in a practical sense the hoppers 1 employed may allow for continuous loading, or sporadic loading, or sporadic reloading as the amount of substance stored therewithin reaches a predetermined minimum. The array of hoppers 1 is disposed so as to allow for location therebelow, in a sequential manner, of a series of bag carriers 2 and associated bags 3, with the bags 3 when filled making up the aforementioned pre- weighs. In the preferred embodiment illustrated each bag-carrier 2 and associated bag 3 is adapted to be appropriately disposed, either by manual means or automatically, as illustrated on a structure which is in itself adapted to be movable from one hopper 1 to the next in sequence and to be located below a feed outiet 4 of each hopper 1 for a sufficient period of time to allow for deposition into the bag 3 of the prescribed amount of substance from the or each hopper 1. In that regard, in an especially preferred embodiment an electric or electronic weighing means of any known type may be associated with the or each hopper 1, thereby allowing for removal from the hopper 1, for deposition into the bag 3, of a predetermined amount of content. Once the predetermined amount or quantity is deposited within the bag 3, such bag 3 is then moved along to the next feed station and associated hopper 1 whereby to allow for receipt therefrom of the prescribed amount of the contents thereof. In such a way in a sequential series of steps the prescribed combination of elements, components, chemicals or the like will be deposited within a bag 2.

A suitable conveyor means 5, preferably in the form of a chain-or belt-conveyor, may be employed for purposes of moving the bags 3 and bag-carriers 2 in sequence past (under) the array of hoppers 1. Once the bag-carrier 2 and associated bag 3 exits from the final hopper, then the resulting so-called pre-weigh can be removed, sealed and stored for subsequent transfer to a manufacturing site. A fresh bag 3 can then be suitably disposed on the then empty bag-carrier 2, which is then returned via the conveyor means 5 to the first hopper 1 for further movement through the various feed stations as desired.

In an especially preferred embodiment the conveyor and filling line consists of a row, of any given number, of material storage hoppers 1 disposed adjacent to a row of weighing means, perhaps of a mechanical type but more preferably of an electric or electronic type. A separate weighing means may be provided for each hopper 1 intended to measure the amount of material being extracted from that hopper 1 for deposition into a bag 3 disposed therebelow. In an alternative embodiment, a so-called loss-of-weight- feeder can be fitted to each hopper 1. It must be realised, however, that the actual means for achieving weighing of the material being removed from the hopper 1 is not of the essence of the invention.

The weight of material in fact fed into each bag 3 is preferably controlled automatically. Preferably the feeding of material from a given hopper 1 into a bag 3 disposed therebelow will be achieved in a two stage process, involving a first stage wherein the bulk - in terms of quantity - of the prescribed amount of material is fed rapidly, and a second, slower stage wherein additional material is fed in more slowly to "top up" the bag 3 to the desired overall weight. In the case of solid materials, each hopper 1 will include two screw-type (See FIG. 2) feeders 10 and 11 at the outlet 4 thereof, a first of such feeders 10 being of substantially large diameter, of the order of from 30 to 100 millimetres, for purposes of rapid material feeding to what might be termed coarse tolerance, with the second of such feeders 11 being of smaller diameter, typically of the order of from 5 to 20 millimetres, for purposes of topping-up on fine tolerance. In an alternative arrangement, not shown, feeders of the vibratory type may be employed. In the situation wherein liquids are being dispensed from the or each hopper 1, or in fact one or more selected hoppers 1, then a variable speed pump may preferably be employed.

With reference now to Figs. 4 to 7 of the drawings in particular, there is illustrated therein a preferred means employed in accordance with the present invention for locating the or each bag- carrier 2 in position for loading of the bag 3 associated therewith. As shown in Fig. 4, when the conveyor means 5 is in operation a push- tab, pin or the like projecting member 20 thereof is in engagement with the base section of the bag-carrier 2. At or in the vicinity of each feed station there is provided a series of spaced-apart, substantially conical-shaped ramps 21 having a land 22 therebetween. The conveyor means 5 is electronically (or in fact in any known manner) controlled or regulated so as to be in operation until such time as the leading wheel or the like member 6 of the bag-carrier 2 is located at the top of the first ramp 21 (See Fig.4). The conveyor means 5 is then stopped. The bag-carrier 2 then, under the influence of gravity, runs down that ramp 21 to assume the position as shown, for example, in Fig. 5. When in such a position the bag-carrier 2 is momentarily, or for a finite time, actually isolated from the conveyor means 5, with the push-tab 20 not being in contact therewith (See

Fig. 5). It is when the bag-carrier 2, and associated bag 3, is in that isolated position or condition that feeding of material into the bag 3 is programmed to take place. Once the loading cycle is completed, then the conveyor means 5 is again actuated, with the push-tab or pin-member 20 again coming into contact with the bag-carrier 2, thereby forcing the wheels thereof up the other side or slope of the ramps 21. The bag-carrier 2 is then no longer isolated from the conveyor means 5 and in fact is now free to move to the next feed station as desired.

The weighing cycle will then be repeated for each hopper station. As the bag carrier 2 leaves the last hopper station, it can preferably be passed through a bag 3 sealing device and, in an especially preferred embodiment, each such sealed bag 3 (now a so- called pre-weigh) will be re-weighed whereby to ensure compliance with the given specification therefor.

Each feed hopper 1 preferably consists of a flexible sleeve 30 attached at the top thereof to a so-called hopper-cone 31. A pneumatic clamp 32 will be situated above the feeder 33 to drop materials into the feeder 33, thus overcoming the problem of

"bridging" of the material.

The bag carrier 2 employed in accordance with the invention serves to hold the bag or resulting pre-weigh 3 open at the top whereby to have such bag or pre-weigh 3 in a condition suitable to accept materials once weighed from the respective hoppers 1. Once the last material from the final hopper is weighed in and deposited in the bag 3, the movable supports for the bag 3 allow the bag 3 itself to be closed. In an especially preferred embodiment excess air can be removed from the bag 3 in any given manner and the bag 3 then sealed.

The aforegoing description refers to one embodiment of an apparatus in accordance with the present invention, wherein the hoppers 1 are, to all intents and purposes, substantially fixed relative to the conveyor means 5. In this regard reference will be made hereinafter to FIGS. 9 to 11, the hoppers 1 are so constructed and arranged as to be selectively and continuously movable into and out of position relative to the conveyor means 5. In other words the hoppers are selectively movable between two distinct positions, namely a first or storage position when not in use and a second or operating position when the contents are to be metered therefrom. Such an embodiment improves the operation of the method and apparatus in accordance with the invention, in terms of flexibility. With such an arrangement a given conveyor system for bag-carriers 2 and bags 3 can be used with any given number of separate hoppers 1, and more importantly can be readily adapted for a variety of different tasks. Hoppers containing substances not to be pre- weighed may simply be withdrawn from the operating cycle or system for storage at a remote site, or more correctly at a site removed from the conveyor means 5, until needed. Such an embodiment serves to optimise available floor space.

With the embodiments of FIGS. 9 to 11, in order to carrv out a hopper change-over a front panel 34 of each hopper 1 hinges to one side, thereby giving access to a relocatable part of the associated feed station, in other words the sleeve 30 and feeder 33 which are preferably each suspended from overhead conveyor means 35, as for example tracks, via suspension rods 36. In operation, when a hopper 1 is disconnected from the hopper cone 31, then such hopper 1 can be conveyed to a hopper storage facility, as for example storage racks as shown in FIG. 11.

In an especially preferred embodiment the formation of each pre-weigh will be controlled electronically, as for example by a computer or the like means. The actual formulation required within each pre-weigh will be stored on files within the computer program and the filling cycle controlled at each stage by the computer itself. The weighing means will be interfaced to the computer to allow continuous monitoring of the fill cycle. The computer will access when to phase the so-called coarse fill cycle into the top-up cycle whereby to allow for precise weighing at the maximum possible cycle speed.

In closing it should be realised that the aforegoing description refers merely to preferred embodiments of the present invention and that variations and modifications will be possible thereto without departing from the spirit and scope of the invention, the ambit of which is to be determined from the following claims.

Claims

CLAIMS:

1. An apparatus for the provision of accurately pre-weighed and packaged combinations or mixtures of chemicals, compounds, components or the like, said apparatus including: a plurality of storage means for receiving and retaining for dispensing a supply of each of the individual chemicals, compounds, components or the like; means for transporting receptacles for said combinations or mixtures of chemicals, compounds, components or the like in sequence past and below said storage means; and means associated with each said storage means for extracting a metered amount

(quantity) of content therefrom for deposition into a receptacle disposed therebelow.

2. The apparatus as claimed in claim 1, including means associated with the or each said storage means for determining the quantity (by weight or volume) exiting therefrom for deposition into a receptacle disposed therebelow.

3. The apparatus as claimed in claim 2, wherein said quantity determining means includes electric or electronic weighing means associated with each said storage means, and wherein said storage means takes the form of a hopper or the like, said hopper including a flexible sleeve member attached at the top thereof to a substantially conically shaped member, and having means associated therewith for directing content to a feeder means, at the bottom of said hopper, for metered passage to a receptacle, and wherein each hopper includes a pneumatic or hydraulic clamp means associated with said flexible sleeve member to assist in passage of the content of said hopper from the top to the bottom thereof for metered feeding to said receptacle.

4. The apparatus as claimed in claim 3, wherein said receptacle is a plastics material bag or the like container adapted to be removably attached to or disposed on said transporting means and adapted, in use, to travel between said hoppers, and wherein said transporting means include a plurality of carriers adapted to be disposed on a conveyor means, said conveyor means preferably being in the form of a chain or belt conveyor.

5. The apparatus as claimed in claim 4, wherein said carriers are releasably attached to said conveyor means for movement, in a sequential and cyclic manner, past and under said plurality of storage means, wherein said storage means are adapted to be selectively movable between respective operative and storage positions, said operative position corresponding to a position allowing for dispensing of content as desired, and wherein each hopper or the like storage means includes means adapted to control the flow of contents therefrom.

6. The apparatus as claimed in claim 5, wherein said flow control means is in the form of one or more augers associated with each said hopper.

7. The apparatus as claimed in claim 6, including a vibration type feeder means for controlling or regulating the flow of content from the or each hopper.

8. The apparatus as claimed in claim 7, including means for locating a receptacle relative to the or each said hopper and for ensuring accurate dispensing from said hopper of the contents thereof, said locating means including, at or in the vicinity of each hopper, a series of spaced apart ramps or the like to be engaged by the or each said carrier, said ramps allowing for temporary isolation of said carrier from said conveyor means whereby to allow for receipt by the receptacle of content metered from the hopper disposed thereabove.

9. A method for the provision of an accurately pre-weighed and packaged combination or mixture of chemicals, compounds, components or the like wherein a receptacle is sequentially moved past an array of sources of supply of the or each individual chemical, compound, component or the like, said receptacle being disposed beneath each source of supply for a sufficient period of time to allow for a predetermined amount of the contents thereof to be extracted therefrom and deposited in the receptacle.

10. A pre-weighed and packaged combination or mixture of chemicals, compounds, components or the like, when produced by the apparatus as claimed in claim 1 and/or the method as claimed in claim 9.