EA042088B1 - FILLING MODULE AND METHOD OF FILLING CONTAINERS - Google Patents

Description

The present invention is a filling module of a packaging machine for filling bulk materials into containers, comprising at least one conveyor device with which bulk materials can be transported into containers, and at least one control mechanism that is suitable and designed to control the flow. The present invention also includes a packaging machine with at least one such filling module and a method for filling containers with bulk materials using such a packaging machine.

Various arrangements and methods for filling bulk materials into open containers such as open-mouthed bags have become known in the art. Bulk materials are also compacted after or during filling to reduce the amount of packaging material needed and ensure better and easier stacking of filled and closed bags.

For filling bulk materials into open-mouth bags or other containers, depending on the bulk materials, a liquid such as air may also be added to increase the fluidity of the bulk materials. In the case of lighter materials, a significant portion of the air is often already present in the bulk material prior to filling.

For better compaction of filled bulk material, vibratory devices such as soil compactor vibrators or surface vibrators located outside the container have become known. It is also possible to achieve sealing inside the container with the help of so-called vacuum lances, which are immersed in the open bag from above during filling and suck air through the outer surface of the lance and remove air from the inside.

Internal vibrators are also located inside the container being filled and can effectively compact the bulk material during filling, during filling breaks or after filling. Combinations of individual or even all seal types are also possible.

However, the disadvantage of all methods is that bulk material can only be loaded at a relatively large safety distance to the top end of the open bag to prevent it from overflowing. At the same time, different bulk materials can behave differently. If the predetermined filling limit is reached at a sufficient distance from the opening of the bag, it is first compressed during a filling break and then refilled. This increases the filling time of the container.

For each product, the relevant filling parameters, such as filling time and conveyor speed or power, must be determined empirically, with relatively high safety factors to account for future product changes. The same goes for filling breaks. The filling parameters can only be changed manually, otherwise they are identical for each filling.

Therefore, the aim of the present invention is to provide a device and a method by which overfilling with bulk material can be reliably avoided and thus self-optimizing filling can be achieved.

This goal is achieved using a filling module with the features of claim 1 of the claims, a packaging machine with the features of claim 11 of the claims and using a container filling method with the features of claim 12 of the claims. Preferred developments of the invention are the subject of additional claims. Other advantages and features of the present invention are set forth in an embodiment of the invention.

According to the present invention, the filling module of a packaging machine for filling bulk materials into containers comprises at least one conveyor device, with which bulk materials can be transported or loaded into a container, and at least one control mechanism. The control mechanism is designed to control at least one container filling flow. In accordance with the invention, at least one level sensor sensor device is provided, having at least one sensor designed to detect the first level and the second filling level of the bulk material in the container. The first level corresponds to a lower filling level than the second level. The control mechanism regulates the filling flow based on the filling levels determined by the filling level sensor or sensor device.

In the case of the filling module of the packaging machine according to the invention, in particular, bulk material is loaded from above into preferably open containers, such as open bags. In particular, granular or powdery bulk material can be loaded into open containers.

According to the invention, the conveyor device is provided with at least one active conveyor element, in particular in the case of so-called gross systems. In the case of so-called net systems, the conveyor device can also be provided with a dosing device. The dosing device can deliver bulk material pre-dosed into containers, either by means of an active conveyor element or by gravity.

Alternatively, however, it is also possible according to the invention to fill liquids or fluids, and in particular foaming liquids, into open containers such as canisters using a filling device.

According to the invention, a filling level sensor device or at least

- 1 042088 one sensor of the filling level sensor device can detect at least two different filling levels in the container, while the filling flow is regulated by the control mechanism to these levels. According to the invention, this means in particular the start and/or release of the flow of the filling module. It is particularly preferred that the flow of the filling module is directed into the container until a second, higher level of filling is detected. As soon as the second filling level is detected, the flow of the filling module is interrupted and/or reduced so that the bulk material introduced into the container can settle, with the bulk material in the container further agitated or compacted depending on the configuration.

As soon as the bulk material has settled due to the interruption of the filling flow and the filling level has fallen below the second level or to the first low filling level, the flow of the filling module can be activated again or increased to further fill the container.

The second filling level preferably corresponds to the maximum filling level of the container, which is not reached or is directly reached when the container is filled with a predetermined bulk material weight. This serves, inter alia, to ensure that the area of the closure, which, depending on the type of container, is the area of a subsequent seal or adhesive seam or other closure of the container, does not come into contact with the product. Then you can guarantee a secure closure of the container.

In order for at least one sensor to be able to detect two different filling levels, it is advisable to use different sensor configuration options. For example, in transparent containers, a camera and/or a laser device can be used to detect the first and second filling levels.

However, with other types of sensors, such as a capacitive sensor, it is also possible to define two different filling levels. In the case of a capacitive sensor, for example, the percentage value of the still dominant electric field can be used to determine different filling levels. For example, over the entire height of the sensor surface in contact with the opposite pole, a larger electric field is formed between the sensor and the opposite pole, and the electric field decreases as more is covered by the sensor surface or more bulk material accumulates between the sensor and the opposite pole.

The filling module according to the invention has many advantages. A significant advantage is that the flow of the filling module can be controlled or adjusted automatically in order to achieve optimal container filling in the shortest possible time.

To do this, a filling stream is fed into the container until a predetermined maximum filling level is reached. We then wait until the bulk material settles in the container or begins to actively contract until the fill level drops to the first fill level, which results in a resumption or increase in the filling flow.

In this way, a particularly efficient filling of the container can be achieved without fear of overfilling of the bulk material due to too fast or too long filling of the container or a change in the bulk density of the bulk material, for example by reducing the level of sealing.

Thus, according to the invention, productivity can be increased compared to known systems, since the system automatically adapts to changing product properties. When pre-setting, depending on the type, always consider the safety time or safety volume. In addition, the commissioning time of such systems is reduced, since type-specific parameters no longer need to be defined and preconfigured.

The sensor is preferably suitable and designed to monitor at least the headspace above the container. By free space is meant in particular the upper region of the container. The sensor is designed to detect the first and second filling levels in the top 30% of the container, preferably in the top 20% and in particular in the top 10% of the container. In general, in order to achieve optimal filling of the container, it is preferable that the maximum filling level is determined by the second filling level. However, it is also expedient that the first filling level, ie the lower filling level of both filling levels, be within the upper 30%, 20% and 10% respectively. The container can be filled at high speed with the so-called coarse flow and then switched to fine or controlled flow.

It is particularly advantageous to install at least two sensor devices, the first sensor detecting the first filling level and the second detecting the second filling level. If the two filling levels are recognized by different sensor devices, a particularly reliable detection of the filling flow is achieved. In addition, different sensors may be used depending on the design. In particular, in the case of capacitive sensors, the use of at least two sensor devices is advantageous in order to regulate a particularly precise and sensitive control of the filling flow by recognizing the filling level.

In expedient embodiments, the sensor devices are arranged at an angle to each other. In particular, it is preferable to arrange the sensor according to the shape or contour of the container to be

- 2 042088 filling. For example, the first sensor device, which detects the first filling level, can be oriented predominantly horizontally, the second sensor device, which detects the second filling level, is preferably inclined, for example, between 10 and 45°, which corresponds to the shape of the bag. In particular, it is preferred that each of the sensor devices be positioned as close as possible to the container.

Preferably, at least one sensor device contains at least one capacitive sensor. If several sensor devices are provided, in particular at least two or all of the sensor devices are designed as capacitive sensors or comprise a capacitive sensor. The use of capacitive sensors is preferred, especially when the walls of the container are opaque and therefore optical sensors are used. Thus, with the help of capacitive sensors, it is possible to ensure reliable detection of filling levels practically independently of the material and nature of the vessel wall, in particular as long as the electric field is not shielded by the vessel wall.

Particularly preferred is the presence of at least one vibratory device suitable for compacting the bulk material in the container. Compaction can be carried out with a vibrating device during the transport of the bulk material and/or during filling pauses. In particular, a deep vibrator, a surface vibrator and/or a soil compaction vibrator can be used as the vibrating device.

In addition, a vacuum lance can be provided which is located inside the container to be filled and at least temporarily sucks in air to compress the bulk material. Such a vacuum lance can advantageously be made in combination with another vibrating device, and in particular with a vibrator.

In additional embodiments, the vibrating device and/or the vacuum lance form at least one opposite pole of at least one capacitive sensor. The vibrating device is preferably located at least in sections of the container being filled during the filling process. In such an arrangement, in which the vibrating device is located at least in the sections of the container during filling, the use of a vibrator is particularly preferred. If a vibrator is not provided in the container, for example if a surface vibrator and/or a vibratory soil compactor is used, then a paddle or other type of opposite pole positioned behind the container may be inserted into the container as an alternative. Depending on the design, an opposite pole can be installed in the container, since a small distance between the capacitive sensor and the opposite pole can be achieved in this way. Alternatively, however, it is also possible that the vibrating device is provided, for example, in the form of a plate surface vibrator and that even in such a construction the vibrating device functions as the opposite pole of a capacitive sensor which is then mounted outside the container.

It is desirable to provide at least one adjustment device for adjusting the sensitivity of the sensor. In particular, it is preferable that the sensor does not recognize the bulk material being loaded into the bag or the filling flow, not as a filling level, but only as an actual filling level. For example, in order to prevent the capacitive sensor from recognizing the inflow, the interruption of the inflow of bulk material as a filling level, the sensitivity of the sensor devices can be adjusted, for example, using a potentiometer.

Preferably, at least one weighing device is provided. With the help of a weighing device, it allows you to additionally control and possibly manage the filling of containers, especially in the case of gross systems. For example, until a predetermined weight is reached or until a predetermined filling level is recognized, filling can be performed, for example, at a higher filling speed. In addition, it is also possible to determine the final tare weight so that the filling process is properly completed. Even with net systems, a weighing device can be used to control the filling of containers with bulk material by weight.

The packaging machine according to the present invention comprises at least one filling module according to one of the preceding claims.

The packaging machine also offers the advantages already described above for the filling module according to the invention.

The method for filling a container with bulk material according to the invention by means of a packaging machine having at least one filling module as described above is characterized by the following steps in the respective sequence. Bulk material is loaded into the container until a second filling level, i.e. a higher filling level, is recognized. The filling flow is then reduced until the first filling level is reached and recognized. The reduction, in particular, also means stopping the filling flow or reducing the filling flow quantitatively. After the first filling level is determined, the filling flow is increased again until the second filling level or, alternatively, the predetermined final tare weight is recognized again. Reducing steps if necessary

- 3 042088 and filling level increases are repeated until the predetermined tare filling weight is reached.

The method for filling containers according to the invention offers the already described advantages of the packaging machine and the filling module.

Preferably, the bulk material in the container is compacted by means of a vibrating device, at least when the filling flow is reduced. In this way, in the event of an interruption in the filling flow of the bulk material, effective settling or compaction in the container can be achieved. Depending on the design, compaction can also be carried out continuously or cyclically while the bulk material is loaded into the container.

The filling flow is preferably stopped during filling or to reduce the filling flow. In the event of an interruption in the filling flow, a particularly rapid reduction in the filling level from the second filling level to the first filling level can be achieved. Thus, in particular, a synchronized filling of the container is achieved.

The filling level of the bulk material in the container is especially equalized between the first and second filling levels by adjusting the filling flow with the control device. In this way, continuous filling of the container can be ensured without the filling level in the container having to rise above the second higher filling level.

In the respective versions, the filling flow setting is applied to subsequent containers and adjusted if necessary. For example, in the case of a product change during the filling of the first containers, an optimal filling flow control can be determined, which is then applied to subsequent containers. The sensor devices effectively prevent incorrect filling and, in particular, overfilling of the container.

Other advantages and features of the present invention result from the embodiments, which are explained below with reference to the accompanying drawings.

The following is shown:

fig. 1 is a purely schematic plan view of an embodiment of a packaging machine according to the invention;

fig. 2 is a purely schematic perspective view of an embodiment of a filling module according to the invention;

fig. 3 is an extension of the dotted area in FIG. 2;

fig. 4 is a purely schematic side view of the filling module as shown in FIG. 2;

fig. 5 is an extension of the dotted area in FIG. 4 FIG. 6 is a view during filling according to FIG. 4 with container.

The packaging machine 100 according to the present invention is shown purely schematically in FIG. 1, which is represented here as a rotary packaging machine 100, which has several filling modules 1 according to the present invention around its perimeter.

The empty container 60 from the input device 105 is fed to the filling module 1 at position 101 by means of a transport carriage 104. The empty container 60, which is usually filled during the rotation of the packaging machine 100, moves from the receiving device 106 to the conveyor element 103 at position 102, as shown in the embodiment.

In FIG. 2 the filling module 1 of the packaging machine according to the invention is shown at an angle from the front in a purely schematic perspective.

In the depicted embodiment, the container 60, which is represented here as an open-mouth bag 61, is fed to the filling module 1 or connected to the inlet 17. The container 60 is not shown in the figure. Bulk material 50 is fed into the open bag 61 from above.

Bulk material 50 is loaded using a conveyor device 2, while the filling flow 4 is controlled using a control device 3.

In order to ensure efficient filling of the container 60, according to the invention, a filling level sensor device 5 is provided, which in the exemplary embodiment shown here has two sensor devices 6, 9. With these two sensor devices 6, 9, the first filling level 7 and the second filling level 8 may be determined or recognized in the embodiment shown.

The sensor devices 6, 9 may be of various designs. For example, at least one sensor 6, 9 may be in the form of a camera and/or a laser, or may comprise a camera and/or a reader. This is particularly advantageous when the wall of the container 60 is transparent so that the filling level can be determined using an optical sensor.

However, in the embodiment shown, each of the sensor devices 6, 9 includes a capacitive sensor 11 which detects an electromagnetic field between the opposite pole 13 and the capacitive sensor 11.

In addition, in the embodiment shown here, the filling module 1 according to the invention comprises a weighing device 15, with which it is possible to determine the total container 60 to be filled. filling ended on a certain filled container.

Alternatively, the fill material can be weighed in advance and only that amount will be loaded into the container. It is regulated purely by volume until the entire specified volume of the substance is in the container.

In addition, in FIG. 2 shows purely schematically that an adjusting device 14 is provided for adjusting the sensitivity of the sensor devices 6, 9. In this way, the sensitivity can be adapted in particular to the filling material 50.

The opposite pole 13 for sensor 6, 9 or for capacitive sensors 11 can be located outside or inside the container 60. In the embodiment shown, a vibrating device 12 is provided, which here is made in the form of a vibrator 18. This internal vibrator 18 is inserted into the container 60 during filling process and, when activated, leads to compaction of bulk material 50 in container 60.

In the embodiment shown, the opposite pole 13 is provided with a vibrator 18 or vibrating device 12. Thus, in the embodiment shown here, the opposite pole 13 is located inside the container 60 or bag 61 with an open mouth.

The installation of the opposite pole 13 in the container 60 provides advantages depending on the configuration. For example, it is preferable that the opposite pole 13 can be brought relatively close to the capacitive sensors 11. Alternatively, however, a vibrating device 12 can also be provided located outside the container 60. In the case of a surface vibrator, for example, this can be made in in the form of a lamellar vibrator on the outer side of the container 60 and serve as the opposite pole 13 for at least one capacitive sensor 11.

However, as already described, the opposite pole 13 is provided by the internal vibrator 18 in the illustrated embodiment. In this configuration, the bulk material 60 is passed between the capacitive sensor 11 and the opposite pole 13 during filling, or the bulk material is loaded into the bag 61 with an open mouth and passes through the area between the capacitive sensors 11 and the opposite pole 13.

Therefore, in the embodiment shown here, a control device 14 is provided, with which the sensitivity of the capacitive sensors 11 can be adjusted. In particular, it has been found that the capacitive sensors actually detect a certain filling level 7, 8, and not the incoming bulk material.

With other types of sensors, as well as with a different arrangement of the opposite pole 13, it is possible to use the adjusting device 14 mainly for adapting the sensitivity of the sensor devices.

In FIG. 3, the dotted portion of FIG. 2 is shown purely schematically in an enlarged view. Here you can also see the filling level sensor 5, which in the embodiment shown has two sensor devices 6, 9, which here are equipped with capacitive sensors 11.

The same embodiment is shown purely schematically in lateral view in FIG. 4 and 5. In FIG. 5, the area marked with dotted lines in FIG. 4 is shown enlarged.

The filling level sensor device 5 with two capacitive sensors 11 can be seen again in these drawings. The opposite pole 13 to the capacitive sensors 11 is made with a vibration device 12, in this case a deep vibrator 18, which is placed inside the container 60 when filled with bulk material 50.

In particular, in FIG. 5 it can be seen that in the embodiment shown, the two sensor devices 6 and 9 are located at an angle of 10 to each other. In the embodiment shown, this particular 10 angle arrangement is due to the contour of the container 60 used. Here it is preferred that the sensor devices 6, 9 are positioned as close as possible to the wall of the container 60.

In FIG. 6 when modified from FIG. 5 shows in a purely schematic way the principle of operation of a filling module 1 or a filling level sensor device 5. The sensor devices 6, 9 are arranged in such a way as to monitor the empty space in the upper part 16, i.e. the top of the container 60.

The container 60 in the embodiment shown here, an open-mouth bag 61, is attached to or below the inlet 17.

Vibrating device 12 or vibrator 18 is placed inside the attached bag 61 with an open mouth. Deep vibrator 18 is the opposite pole 13 of the capacitive sensors 11.

From above, by means of a conveyor device 2 and controlled by a control device 2, bulk material 50 is loaded into an open bag 61. This changes the filling level inside the container 60.

The sensitivity of the sensor devices 6, 9 or capacitive sensors 11 is set using the adjusting device 14 in such a way that the sensor devices 6, 9 do not recognize loose material 50 passing between the capacitive sensors 11 and the opposite, pole 13 as a change in the filling level.

If the filling level rises so that the bulk material 50 is between the opposite pole 13 and the lower sensor 6, the electromagnetic field prevailing between the lower sensor device 6 and the opposite pole 13 is reduced so that the sensor 6 recognizes the first filling level 7.

In FIG. 6 shows that the filling level has not yet risen and that the bulk material 50 is between the second sensor 9 and the opposite pole 13. Thus, the second filling level 8 has not yet been detected by the sensor 9 and filling continues. If the filling level continues to rise until the second filling level 8 is detected, the filling flow 4 is reduced or interrupted by the control device 3.

Thus, the container 60 cannot be overfilled. Depending on the design, the level is now maintained by the vibrating device 12 until the bulk material 50 settles or compacts. If the filling level then drops from the detected second filling level 8 to the first filling level 7, the filling flow 4 is increased or activated so that the bulk material 50 is loaded into the container 60 again. to bulk material compaction 15 in container 60.

If the filling level continues to rise and the second filling level 8 is recognized again, the material flow 4 is interrupted or reduced again. These steps are repeated several times until, for example, a predetermined weight of the material in the tare is recognized, or until the pre-weighed material is completely loaded into the tare 60.

Depending on the design, synchronous filling of the container 60 can be ensured. However, it is also possible, depending on the design, that the filling level between the first filling level 7 and the second filling level is increased in order to ensure continuous filling of the container 60.

List of conventions.

capacitive sensor

Fill level sensor

Touch device

First filling level

Second filling level

Touch device

corner

filling module

Conveyor

control device

Filling current

Vibrating device 1

weighing device

100

102

103

104

105

Empty space at the top of the container

Loading pipe

Deep vibrator

bulk material

Tara

Open mouth bag

Packing machine

Position

Position

conveyor element

transport carriage

tare supply device

106 | receiving device

Claims (16)

CLAIM 1. The filling module (1) of the packaging machine (100) for packing bulk materials (50), containing at least one conveyor device (2), with which bulk materials (50) are moved into containers (60), and at least one control device (3) for controlling the flow of filling (4) of the container (60), characterized in that at least one filling level sensor device (5) is equipped with at least two sensors (6, 9), which are designed to to define at least one first filling level (7) and at least one - 6 042088 second filling level (8) of bulk material (50) in a container (60), the first filling level (7) corresponds to a lower filling level than the second filling level (8), and the first sensor (6) recognizes the first filling level (7) and the second sensor (9) recognizes the second filling level (8), while the control device (3) regulates the filling flow (4) based on the filling levels determined by the sensor (6). 2. Filling module (1) according to claim 1, characterized in that the sensor (6) is suitable and designed to monitor at least the empty space (16) in the upper part of the container (60). 3. Filling module (1) according to any one of claims 1 and 2, characterized in that the touch sensors (6, 9) are located at an angle (10) to each other. 4. Filling module (1) according to any one of claims 1 to 3, characterized in that at least one sensor (6, 9) contains at least one capacitive sensor (11). 5. Filling module (1) according to claim 1, characterized in that it has at least one vibration device (12), which is designed to compact bulk material (50) in a container (60). 6. Filling module (1) according to claims 4 and 5, characterized in that the vibrating device (12) is located in sections with containers (60) filled during filling, and that the vibrating device (12) has at least one opposite pole (13) of the capacitive sensor (11). 7. Filling module (1) according to any one of claims 1 and 6, characterized in that at least one blade and/or one plate is located in sections inside and/or behind the filled container (60) during filling and that the blade and /or the plate form at least one opposite pole (13) of the capacitive sensor (11). 8. Filling module (1) according to claim 1, characterized in that at least one adjustment device (14) is provided for adjusting the sensitivity of the sensor (6, 9). 9. Filling module (1) according to claim 1, characterized in that at least one weighing device (15) is provided. 10. A packaging machine (100) comprising at least one filling module (1) according to any one of the preceding claims. 11. The method of filling containers (60) with bulk material (50) using a packaging machine (100) according to claim 10, characterized in that it includes the following steps: loading bulk material (50) into the container (60) until the recognition of the second filling level (8); decreasing the filling flow (4) until the first filling level (7) is reached and recognized; increasing the filling flow (4) until the second filling level (8) is recognized. 12. The method of filling the container (60) according to claim 11, characterized in that the decrease and increase in the filling flow (4) is repeated until the specified weight of the substance in the container (60) is reached. 13. The method of filling the container (60) according to claim 11, characterized in that when the filling flow (4) decreases, the bulk material (50) in the container (60) is compacted by means of a vibration device (12). 14. Method for filling a container (60) according to any one of claims 11 to 13, characterized in that the filling flow (4) is interrupted when the filling flow (4) decreases. 15. The method of filling the container (60) according to any one of claims 11-14, characterized in that the filling level of bulk material (50) in the container (60) is leveled by adjusting the filling flow (4) using an adjusting device (3) between the first filling level (7) and a second filling level (8). 16. Method for filling containers (60) according to any one of claims 14 and 15, characterized in that the filling flow settings (4) are transferred to subsequent containers (60) and adjusted if necessary.