WO2020156231A1 - 一种灌装机实时监控方法 - Google Patents

一种灌装机实时监控方法 Download PDF

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Publication number
WO2020156231A1
WO2020156231A1 PCT/CN2020/072684 CN2020072684W WO2020156231A1 WO 2020156231 A1 WO2020156231 A1 WO 2020156231A1 CN 2020072684 W CN2020072684 W CN 2020072684W WO 2020156231 A1 WO2020156231 A1 WO 2020156231A1
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Prior art keywords
bottle
state
filling
bottles
stopper
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PCT/CN2020/072684
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English (en)
French (fr)
Inventor
李�杰
何远荣
黄少友
彭韬
钱瞻
袁臻敏
Original Assignee
楚天科技股份有限公司
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Publication of WO2020156231A1 publication Critical patent/WO2020156231A1/zh

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B57/00—Automatic control, checking, warning, or safety devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B67—OPENING, CLOSING OR CLEANING BOTTLES, JARS OR SIMILAR CONTAINERS; LIQUID HANDLING
    • B67B—APPLYING CLOSURE MEMBERS TO BOTTLES JARS, OR SIMILAR CONTAINERS; OPENING CLOSED CONTAINERS
    • B67B1/00—Closing bottles, jars or similar containers by applying stoppers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B67—OPENING, CLOSING OR CLEANING BOTTLES, JARS OR SIMILAR CONTAINERS; LIQUID HANDLING
    • B67C—CLEANING, FILLING WITH LIQUIDS OR SEMILIQUIDS, OR EMPTYING, OF BOTTLES, JARS, CANS, CASKS, BARRELS, OR SIMILAR CONTAINERS, NOT OTHERWISE PROVIDED FOR; FUNNELS
    • B67C3/00—Bottling liquids or semiliquids; Filling jars or cans with liquids or semiliquids using bottling or like apparatus; Filling casks or barrels with liquids or semiliquids
    • B67C3/02—Bottling liquids or semiliquids; Filling jars or cans with liquids or semiliquids using bottling or like apparatus
    • B67C3/22—Details
    • B67C3/24—Devices for supporting or handling bottles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B67—OPENING, CLOSING OR CLEANING BOTTLES, JARS OR SIMILAR CONTAINERS; LIQUID HANDLING
    • B67C—CLEANING, FILLING WITH LIQUIDS OR SEMILIQUIDS, OR EMPTYING, OF BOTTLES, JARS, CANS, CASKS, BARRELS, OR SIMILAR CONTAINERS, NOT OTHERWISE PROVIDED FOR; FUNNELS
    • B67C3/00—Bottling liquids or semiliquids; Filling jars or cans with liquids or semiliquids using bottling or like apparatus; Filling casks or barrels with liquids or semiliquids
    • B67C3/02—Bottling liquids or semiliquids; Filling jars or cans with liquids or semiliquids using bottling or like apparatus
    • B67C3/22—Details
    • B67C3/26—Filling-heads; Means for engaging filling-heads with bottle necks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B67—OPENING, CLOSING OR CLEANING BOTTLES, JARS OR SIMILAR CONTAINERS; LIQUID HANDLING
    • B67C—CLEANING, FILLING WITH LIQUIDS OR SEMILIQUIDS, OR EMPTYING, OF BOTTLES, JARS, CANS, CASKS, BARRELS, OR SIMILAR CONTAINERS, NOT OTHERWISE PROVIDED FOR; FUNNELS
    • B67C7/00—Concurrent cleaning, filling, and closing of bottles; Processes or devices for at least two of these operations

Definitions

  • the invention relates to the technical field of filling, in particular to a real-time monitoring method of a filling machine.
  • CN201610650512.1 discloses a device and method for rejecting defective vials of vials
  • CN201710126812.4 discloses a remote data collection and real-time analysis system of a filling production line.
  • the main purpose of the present invention is to provide a real-time monitoring method for a filling machine. During filling, each step of the filling can be monitored in real time, and the unqualified steps during filling can be found in time, and the cause of waste bottles can be found. , High efficiency and high accuracy.
  • the present invention discloses a real-time monitoring method for a filling machine.
  • the filling and stoppering of the bottle by the filling machine includes the following steps:
  • Bottle feeding the bottles to be filled and stoppered at each station are transferred to the filling machine through the bottle feeding conveyor in turn, and the bottle feeding status is detected when the bottle is fed;
  • step S2 Filling, the filling machine fills the bottle in step S1, and detects the filling state of the bottle during filling;
  • step S3 Weigh, weigh the bottle filled in step S2, and then check the weighing status of the bottle;
  • step S4 Stopper, stopper the bottle weighed in step S3, and then check the stopper state and stopper state of the bottle in turn;
  • steps S1 to S4 and S6 when each state is normal, the information of each state is stored as normal; when each state is abnormal, the information of each state is stored as abnormal.
  • the bottle feeding transmission device includes a bottle unscrambler tray and a bottle feed track, the bottle feed track and the bottle unscramble tray are docked, the bottle feed rail is docked with the bottle feeding wheel of the filling machine, and the bottle feeder One side of the track is also provided with a bottle feed auger, and a bottle feed detection device is provided at the bottle feed wheel;
  • the bottle feeding state is abnormal.
  • the filling machine further includes a horizontal conveyor belt, and a filling pump is provided on the horizontal conveyor belt;
  • a weighing sensor is provided downstream of the filling pump
  • the bottle is weighed by a load cell, and the net weight is obtained by subtracting the bottle weight from the weighing value;
  • the weighing state is normal when the deviation between the net weight and the set value does not exceed the set limit
  • the weighing state is abnormal.
  • a stopper device is provided downstream of the load cell, and the bottle is stoppered by the stopper device;
  • the stoppering device is provided with a stoppering detection device, and the first stoppering device detects whether the bottle is stoppered;
  • the stopper detection device detects that the bottle has been stoppered, the stopper state is normal
  • the stopper detection device detects that the bottle is not stoppered, the stopper state is abnormal.
  • the stoppering device is also provided with a cork detection device, and the corked bottle is tested by the cork detection device whether the cork is normal;
  • the state of the stopper is abnormal.
  • the bottle discharge track and the reject track are arranged downstream of the stoppering device, and the bottle discharge track is provided with a bottle detection device;
  • the bottle-out detection device When the bottle-out detection device does not detect the passage of the bottle, the re-inspection state is abnormal.
  • the filling machine when the bottle feeding state, filling state, weighing state, stopper state, and stopper state of the bottle are all normal and the recheck state is abnormal, the filling machine sends an alarm signal.
  • the bottle inlet detection device and the bottle outlet detection device are mirror reflection sensors
  • the stopper detection device is a diffuse reflection sensor
  • the bottle stopper detection device is a groove sensor
  • the present invention detects each state of bottle filling at the same time, and performs "logical AND" operation on the bottle's filling state, canning state, weighing state, stoppering state, and stopper state. If the status is all qualified, it is a qualified bottle, and if one or more unqualified, it is a waste bottle. The qualified bottle is sent out through the bottle outlet track, and the waste bottle is sent out through the reject track. Check whether the reject is normal. Whether the bottles are normally conveyed from the bottle outlet track and whether the waste bottles are normally conveyed from the reject track. This re-inspection state and the above five states are stored for real-time monitoring.
  • the present invention has the following advantages:
  • Each filling step has real-time status monitoring, which can effectively prevent human intervention in data and ensure the accuracy of data for the entire drug packaging.
  • Figure 1 is a schematic diagram of the structure of the present invention.
  • Figure 2 is a schematic diagram of the monitoring of the present invention.
  • Bottle discharge track 24. Waste rejection track; 25. Bottle discharge detection device; 33. Bottle unscramble tray; 34. Bottle feed track; 35. Bottle feed wheel; 36. Bottle feed auger 37. Bottle feeding detection device; 43. Horizontal conveyor belt; 44. Filling pump; 53, Weighing sensor; 63. Stoppering device; 64. Stoppering detection device; 65. Bottle stopper detection device.
  • the terms “connected”, “fixed”, etc. should be interpreted broadly.
  • “fixed” can be a fixed connection, a detachable connection, or a whole; It can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, and it can be the internal communication between two components or the interaction relationship between two components, unless specifically defined otherwise.
  • “fixed” can be a fixed connection, a detachable connection, or a whole; It can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, and it can be the internal communication between two components or the interaction relationship between two components, unless specifically defined otherwise.
  • the specific meanings of the above terms in the present invention can be understood according to specific circumstances.
  • a real-time monitoring method for a filling machine includes the following steps:
  • Bottle feeding the bottles to be filled and stoppered at each station are transferred to the filling machine through the bottle feeding conveyor in turn, and the bottle feeding status is detected when the bottle is fed;
  • step S2 Filling, the filling machine fills the bottle in step S1, and detects the filling state of the bottle during filling;
  • step S3 Weigh, weigh the bottle filled in step S2, and then check the weighing status of the bottle;
  • step S4 Stopper, stopper the bottle weighed in step S3, and then check the stopper state and stopper state of the bottle in turn;
  • the information of each state in steps S1 to S4 and S6 is stored.
  • the information of each state is stored and displayed through audio and video equipment, such as an LED display screen or a PC monitor.
  • steps S1 to S4, S6 when each state is normal, the information of each state is stored as normal; when each state is abnormal, the information of each state is stored as abnormal.
  • the bottle feeding conveying device includes a bottle unscramble tray 33 and a bottle feed track 34, the bottle feed track 34 and the bottle unscramble tray 33 are docked, the bottle feed track 34 is docked with the bottle feed wheel 35 of the filling machine, and one side of the bottle feed track 34 is also There is a bottle feed screw 36 and a bottle feed detection device 37 at the bottle feed wheel 35;
  • the filling machine also includes a horizontal conveyor belt 43 on which a filling pump 44 is arranged;
  • the filling pump 44 When the bottle passes through the filling pump 44, if the filling pump 44 is activated, the filling state is normal;
  • the filling pump 44 When the bottle passes through the filling pump 44, if the filling pump 44 is not activated, the filling state is abnormal.
  • a load cell 53 is provided downstream of the filling pump 44;
  • the bottle is weighed by the load cell 53, and the net weight is obtained by subtracting the bottle weight from the weighing value;
  • the weighing status is normal when the deviation between the net weight and the set value does not exceed the set limit
  • the weighing status is abnormal when the deviation between the net weight and the set value exceeds the set limit.
  • a stopper device 63 is provided downstream of the load cell 53, and the bottle is stoppered by the stopper device 63;
  • the stopper device 63 is provided with a stopper detection device 64, and the first stopper device 63 detects whether the bottle is stoppered;
  • the stopper detection device 64 detects that the bottle has been stoppered, the stopper state is normal
  • the stopper detection device 64 detects that the bottle is not stoppered, the stopper state is abnormal.
  • the stoppering device 63 is also provided with a stopper detection device 65, and the bottle after the stopper passes the stopper detection device 65 to detect whether the stopper is normal;
  • the stopper state is abnormal.
  • the bottle outlet track 23 and the reject track 24 are arranged downstream of the stoppering device 63, and the bottle outlet track 23 is provided with a bottle detecting device 25;
  • the bottle-out detecting device 25 When the bottle-out detecting device 25 does not detect the passage of the bottle, the re-inspection state is abnormal.
  • the filling machine When the bottle's feeding status, filling status, weighing status, stoppering status, and stopper status are all normal and the recheck status is abnormal, the filling machine will send an alarm signal.
  • the bottle-in detection device 37 and the bottle-out detection device 25 are mirror reflection sensors, the stopper detection device 64 is a diffuse reflection sensor, and the bottle plug detection device 65 is a trough sensor.
  • the judging method of qualified bottles and waste bottles is specifically as follows:
  • Qualified bottle bottle-in state && filling state && weighing state && stoppering state && cork state;
  • Unfilled bad bottle bottle-in state &&NOT filling state
  • Uncorked bad bottle bottle feeding state && filling state && weighing state &&NOT plugging state;
  • unfilled bad bottles, abnormally bad bottles, unplugged bad bottles, and abnormally badly plugged bottles are all waste bottles.
  • No. 14 station has a bottle, which has been filled, weighed, and stoppered, but the stopper is in an abnormal state, so the product at this station is an abnormally stoppered bottle;
  • this embodiment adopts a real-time monitoring system to count qualified bottles and waste bottles more accurately.
  • No. 16 station is a qualified bottle, and the re-inspection status is 1, so it meets the "accumulative conditions for qualified products".
  • No. 15 station is a qualified bottle, but the re-inspection status is 0, which means that the product has not entered the bottle outlet track 23 correctly due to the abnormal rejection function.
  • the filling machine will alarm and stop, prompting the operator of the abnormal rejection function.
  • No. 8 station has been bottled, not filled, or weighed unqualified, and will be rejected as unfilled bad bottles in the future;
  • the No. 12 station has been bottled, filled, weighed qualified, stoppered, and the stopper is in normal state, and no follow-up process has been carried out;
  • the bottle at No. 16 station has been bottled, filled, weighed, stoppered, bottle stopper is normal, and the recheck status is normal, indicating that the bottle at this station has entered the bottle outlet track 23 normally;
  • No. 14 station has been bottled, filled, weighed, stoppered, bottle stopper in abnormal state, no re-inspection state, it means that the bottle in this station has entered the reject track 24 and was normally rejected;
  • No. 15 station has been bottled, filled, weighed, stoppered, and the stopper is normal, but there is no re-inspection state, which means that the bottle at this station was originally a qualified bottle, but was mistakenly rejected, and it is filled at this time Opportunity to alarm and shut down.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Filling Of Jars Or Cans And Processes For Cleaning And Sealing Jars (AREA)
  • Basic Packing Technique (AREA)

Abstract

一种灌装机实时监控方法，包括以下步骤： S1：进瓶，瓶子依次通过进瓶传输装置传送至灌装机，进瓶时检测瓶子的进瓶状态； S2：灌装，灌装机对瓶子灌装，灌装时检测瓶子的灌装状态； S3：称重，将灌装后的瓶子称重，然后检测瓶子的称重状态； S4：加塞，将称重后的瓶子加塞，然后依次检测瓶子的加塞状态、瓶塞状态； S5：进行"逻辑与"运算，所有状态均为合格的瓶子为合格瓶，其余为废瓶； S6：剔废复检，将合格瓶通过出瓶轨道（23）传送出去，废瓶通过剔废轨道（24）传送出去，同时将瓶子复检状态的信号反馈出去；将步骤S1至S4、S6中各状态的信息存储起来。该监控方法可以应用于灌装技术领域的实时监控。

Description

一种灌装机实时监控方法 技术领域
本发明涉及灌装技术领域，具体涉及一种灌装机实时监控方法。
 背景技术
传统灌装加塞机对产品是否合格的检验和产品数量的统计几乎都是过终端传感器检测来判断的。单一的传感器检测，无法判断分装异常的确切原因，同时无法防止人为对整个药品分装产品计数的干预。
（1）传统对工艺流程的检验主要通过如下方法：
在靠近出瓶位置安装检塞传感器，如果传感器检测到有塞子，则认为是合格品，当未检测到塞子时则认为是不良品；合格品和不良品通过对阀的控制进行分拣，分别进入不同的通道。
（2）传统对合格品和不良品的计数方法如下：
在合格品通道和不良品通道分别安装传感器，当有瓶子通过时累计数量加1。
以上对工艺流程的监管存在很多缺陷：①合格品和不合格品的分拣不能仅仅依靠有无塞子去判断，还应该判断该工位是否有瓶子、是否灌装、装量是否合格、压塞高度是否合格等属性。②合格品与不合格品的计数仅依靠传感器检测存在误检的可能，并且无法避免人为干预，例如如果设备因为异常情况碎瓶了，操作人员手动补进去一个手动压好塞并未灌装的瓶子并通过合格品计数传感器，这样合格品数量就会加1，甚至直接通过手动干预合格品计数传感器就能使得合格品数量加1，因此无法限制人工干预产品数量统计。
CN201610650512.1公开了一种用于西林瓶加塞次品的剔除装置及方法；
CN201710126812.4公开了一种灌装生产线的远程数据采集与实时分析系统。
上述对比文件公开的技术方案中仅公开了灌装生产线数据采集、分析方法和剔除方法，对于上述技术问题没有任何技术启示。
 技术问题
本发明的主要目的是提供了一种灌装机实时监控方法，灌装时，能够实时对灌装的各步骤进行监控，能够及时发现灌装时不合格的步骤，找出产生废瓶的原因，效率高、准确率高。
 技术解决方案
为了实现上述目的，本发明公开了一种灌装机实时监控方法，灌装机对瓶子灌装加塞包括以下步骤：
S1：进瓶，各工位上的待灌装加塞的瓶子依次通过进瓶传输装置传送至灌装机，进瓶时检测瓶子的进瓶状态；
S2：灌装，灌装机对步骤S1中的瓶子灌装，罐装时检测瓶子的罐装状态；
S3：称重，将步骤S2中灌装后的瓶子称重，然后检测瓶子的称重状态；
S4：加塞，将步骤S3中称重后的瓶子加塞，然后依次检测瓶子的加塞状态、瓶塞状态；
S5：进行“逻辑与”运算，步骤S1至S4中工位上所有状态均为合格的瓶子为合格瓶，其余为废瓶；
S6：剔废复检，将步骤S1至S4中合格瓶通过出瓶轨道传送出去，废瓶通过剔废轨道传送出去，同时将瓶子复检状态的信号反馈出去；
将步骤S1至S4、S6中各状态的信息存储起来。
进一步改进的，步骤S1至S4、S6中，各状态正常时，各状态的信息存储为正常；各状态异常时，各状态的信息存储为异常。
进一步改进的，所述进瓶传输装置包括理瓶盘和进瓶轨道，所述进瓶轨道和理瓶盘对接，所述进瓶轨道和灌装机的进瓶拨轮对接，所述进瓶轨道的一侧还设有进瓶绞龙，所述进瓶拨轮处设有进瓶检测装置；
所述工位上的瓶子从进瓶拨轮经过时，进瓶状态为正常；
所述工位上的瓶子未从进瓶拨轮经过时，进瓶状态为异常。
进一步改进的，所述灌装机还包括水平传送带，所述水平传送带上设有灌装泵；
所述瓶子经过灌装泵时，若灌装泵启动，则灌装状态为正常；
所述瓶子经过灌装泵时，若灌装泵未启动，则灌装状态为异常。
进一步改进的，所述灌装泵的下游设有称重传感器；
所述瓶子通过称重传感器称重，称重值减去瓶重后得到净重；
所述净重与设定值的偏差未超过设定界限时称重状态为正常；
所述净重与设定值的偏差超过设定界限时称重状态为异常。
进一步改进的，所述称重传感器的下游设有加塞装置，所述瓶子通过加塞装置加塞；
所述加塞装置处设有加塞检测装置，通过第一加塞装置检测瓶子是否加塞；
所述加塞检测装置检测到瓶子已加塞时，则加塞状态为正常；
所述加塞检测装置检测到瓶子未加塞时，则加塞状态为异常。
进一步改进的，所述加塞装置处还设有瓶塞检测装置，加塞后的瓶子通过瓶塞检测装置检测瓶塞是否正常；
若瓶塞正常时，所述瓶塞状态为正常；
若瓶塞异常时，所述瓶塞状态为异常。
进一步改进的，所述出瓶轨道和剔废轨道设在加塞装置的下游，所述出瓶轨道上设有出瓶检测装置；
所述出瓶检测装置检测到瓶子经过时，所述复检状态为正常；
所述出瓶检测装置未检测到瓶子经过时，所述复检状态为异常。
进一步改进的，所述瓶子的进瓶状态、灌装状态、称重状态、加塞状态、瓶塞状态均为正常且复检状态为异常时，所述灌装机发出报警信号。
进一步改进的，所述进瓶检测装置、出瓶检测装置为镜反射传感器，所述加塞检测装置为漫反射传感器，所述瓶塞检测装置为槽型传感器。
 有益效果
与现有技术相比，本发明技术方案的有益效果：
本发明在瓶子灌装的过程中，同时检测瓶子灌装的各状态，对瓶子的进瓶状态、罐装状态、称重状态、加塞状态、瓶塞状态进行“逻辑与”运算，这五个状态均为合格时为合格瓶，有一个或多个不合格时为废瓶，将合格瓶通过出瓶轨道传送出去，将废瓶通过剔废轨道传送出去，并检测剔废是否正常，即合格瓶是否正常从出瓶轨道被传送出去，废瓶是否正常从剔废轨道被传送出去，把这种复检状态及上述五种状态均存储起来进行实时监控。本发明具有以下优势：
（1）能够方便操作人员对每个灌装步骤进行监控，对异常的灌装步骤可迅速做出反应。
（2）更合理的方法来判断产品是否合格，保证产品的质量。
（3）合格品计数与废瓶计数考虑的因素更全面，并具备稳定的复检功能。
（4）每道灌装步骤都有实时状态监控，有效防止人为干预数据，保证整个药品分装的数据准确性。
 附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图示出的结构获得其他的附图。
图1为本发明结构示意图。
图2为本发明监控示意图。
图中各标号表示：23、出瓶轨道；24、剔废轨道；25、出瓶检测装置；33、理瓶盘；34、进瓶轨道；35、进瓶拨轮；36、进瓶绞龙；37、进瓶检测装置；43、水平传送带；44、灌装泵；53、称重传感器；63、加塞装置；64、加塞检测装置；65、瓶塞检测装置。
 本发明的实施方式
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明的一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
需要说明，本发明实施例中所有方向性指示（诸如上、下、左、右、前、后……）仅用于解释在某一特定姿态（如附图所示）下各部件之间的相对位置关系、运动情况等，如果该特定姿态发生改变时，则该方向性指示也相应地随之改变。
另外，在本发明中如涉及“第一”、“第二”等的描述仅用于描述目的，而不能理解为指示或暗示其相对重要性或者隐含指明所指示的技术特征的数量。由此，限定有“第一”、“第二”的特征可以明示或者隐含地包括至少一个该特征。在本发明的描述中，“多个”的含义是至少两个以上，例如三个等，除非另有明确具体的限定。
在本发明中，除非另有明确的规定和限定，术语“连接”、“固定”等应做广义理解，例如，“固定”可以是固定连接，也可以是可拆卸连接，或成一体；可以是机械连接，也可以是电连接；可以是直接相连，也可以通过中间媒介间接相连，可以是两个元件内部的连通或两个元件的相互作用关系，除非另有明确的限定。对于本领域的普通技术人员而言，可以根据具体情况理解上述术语在本发明中的具体含义。
另外，本发明各个实施例之间的技术方案可以相互结合，但是必须是以本领域普通技术人员能够实现为基础，当技术方案的结合出现相互矛盾或无法实现时应当认为这种技术方案的结合不存在，也不在本发明要求的保护范围之内。
一种灌装机实时监控方法，灌装机对瓶子灌装加塞包括以下步骤：
S1：进瓶，各工位上的待灌装加塞的瓶子依次通过进瓶传输装置传送至灌装机，进瓶时检测瓶子的进瓶状态；
S2：灌装，灌装机对步骤S1中的瓶子灌装，罐装时检测瓶子的罐装状态；
S3：称重，将步骤S2中灌装后的瓶子称重，然后检测瓶子的称重状态；
S4：加塞，将步骤S3中称重后的瓶子加塞，然后依次检测瓶子的加塞状态、瓶塞状态；
S5：进行“逻辑与”运算，步骤S1至S4中工位上所有状态均为合格的瓶子为合格瓶，其余为废瓶；
S6：剔废复检，将步骤S1至S4中合格瓶通过出瓶轨道23传送出去，废瓶通过剔废轨道24传送出去，同时将瓶子复检状态的信号反馈出去；
将步骤S1至S4、S6中各状态的信息存储起来，优选的，各状态的信息存储后通过音视频设备显示出来，如LED显示屏或PC显示器等。
步骤S1至S4、S6中，各状态正常时，各状态的信息存储为正常；各状态异常时，各状态的信息存储为异常。
进瓶传输装置包括理瓶盘33和进瓶轨道34，进瓶轨道34和理瓶盘33对接，进瓶轨道34和灌装机的进瓶拨轮35对接，进瓶轨道34的一侧还设有进瓶绞龙36，进瓶拨轮35处设有进瓶检测装置37；
工位上的瓶子从进瓶拨轮35经过时，进瓶状态为正常；
工位上的瓶子未从进瓶拨轮35经过时，进瓶状态为异常。
灌装机还包括水平传送带43，水平传送带43上设有灌装泵44；
瓶子经过灌装泵44时，若灌装泵44启动，则灌装状态为正常；
瓶子经过灌装泵44时，若灌装泵44未启动，则灌装状态为异常。
灌装泵44的下游设有称重传感器53；
瓶子通过称重传感器53称重，称重值减去瓶重后得到净重；
净重与设定值的偏差未超过设定界限时称重状态为正常；
净重与设定值的偏差超过设定界限时称重状态为异常。
称重传感器53的下游设有加塞装置63，瓶子通过加塞装置63加塞；
加塞装置63处设有加塞检测装置64，通过第一加塞装置63检测瓶子是否加塞；
加塞检测装置64检测到瓶子已加塞时，则加塞状态为正常；
加塞检测装置64检测到瓶子未加塞时，则加塞状态为异常。
加塞装置63处还设有瓶塞检测装置65，加塞后的瓶子通过瓶塞检测装置65检测瓶塞是否正常；
若瓶塞正常时，瓶塞状态为正常；
若瓶塞异常时，瓶塞状态为异常。
出瓶轨道23和剔废轨道24设在加塞装置63的下游，出瓶轨道23上设有出瓶检测装置25；
出瓶检测装置25检测到瓶子经过时，复检状态为正常；
出瓶检测装置25未检测到瓶子经过时，复检状态为异常。
瓶子的进瓶状态、灌装状态、称重状态、加塞状态、瓶塞状态均为正常且复检状态为异常时，灌装机发出报警信号。
进瓶检测装置37、出瓶检测装置25为镜反射传感器，加塞检测装置64为漫反射传感器，瓶塞检测装置65为槽型传感器。
在本实施例中，各工位上瓶子经过灌装步骤后，各状态的信息正常时，在音视频设备上显示为1，各状态的信息异常时，在音视频设备上显示为0。
在本实施例中，合格瓶和废瓶的判断方法具体为：
1、合格瓶＝进瓶状态&&灌装状态&&称重状态&&加塞状态&&瓶塞状态；
2、未灌装不良瓶＝进瓶状态&&NOT灌装状态；
3、装量异常不良瓶＝进瓶状态&&灌装状态&&NOT称重状态；
4、未加塞不良瓶＝进瓶状态&&灌装状态&&称重状态&&NOT加塞状态；
5、加塞异常不良瓶＝进瓶状态&&灌装状态&&称重状态&&加塞状态&&NOT瓶塞状态；
其中，未灌装不良瓶、装量异常不良瓶、未加塞不良瓶、加塞异常不良瓶均为废瓶。
以图2为例：
（1）14号工位有瓶子，已灌装、称重合格、已加塞，但是瓶塞状态异常，因此该工位的产品属于加塞异常不良瓶；
（2）16号工位上所有的状态均正常，因此该工位上的产品为合格品。
相比传统的使用单一传感器信号计数的方法，本实施例采用实时监控系统统计合格瓶与废瓶更加精确。
（1）合格品累加条件＝合格瓶&&复检状态
（2）不合格品累加条件＝废瓶&&NOT复检状态
以图2为例：
（1）14号工位为加塞不良瓶状态，且复检状态为0，所以符合“不合格品累加条件”；
（2）16号工位为合格瓶，且复检状态为1，所以符合“合格品累加条件”。
本实施例中，通过实时监控系统，可以快速的复检出剔废功能是否正常。
（1）剔废正常＝（合格瓶&&复检状态）||（废瓶&&NOT复检状态）
（2）剔废异常＝（合格瓶&&NOT复检状态）||（废瓶&&复检状态）
以图2为例：
15号工位为合格瓶，但是复检状态为0，表示由于剔废功能异常导致该产品未正确进入出瓶轨道23，此时灌装机会报警停机，提示操作者剔废功能异常。
请参照图2，图2中各工位上瓶子的状态表示如下：
1、3、4、5号工位已进瓶，未进行后续工艺；
2号工位未进瓶；
6号工位已进瓶、已灌装，未进行后续工艺；
7号工位已进瓶、已灌装、且称重合格，未进行后续工艺；
8号工位已进瓶、未灌装、称重不合格，后续将按照未灌装不良瓶剔除；
9、10号工位已进瓶、已灌装、称重合格、已加塞，未进行后续工艺；
11、12号工位已进瓶、已灌装、称重合格、已加塞、瓶塞状态正常，未进行后续工艺；
13、16号工位已进瓶、已灌装、称重合格、已加塞、瓶塞状态正常、复检状态正常，表示该工位的瓶子已正常进入了出瓶轨道23；
14号工位已进瓶、已灌装、称重合格、已加塞、瓶塞状态不正常、无复检状态，表示该工位的瓶子已经进入剔废轨道24被正常剔除；
15号工位已进瓶、已灌装、称重合格、已加塞、瓶塞状态正常、但无复检状态，表示该工位的瓶子本来为合格瓶，但是被误剔，此时灌装机会报警停机。
以上所述仅为本发明的优选实施例，并非因此限制本发明的专利范围，凡是在本发明的发明构思下，利用本发明说明书及附图内容所作的等效结构变换，或直接/间接运用在其他相关的技术领域均包括在本发明的专利保护范围内。

Claims (10)

  1. 一种灌装机实时监控方法，其特征在于，灌装机对瓶子灌装加塞包括以下步骤：
    S1：进瓶，各工位上的待灌装加塞的瓶子依次通过进瓶传输装置传送至灌装机，进瓶时检测瓶子的进瓶状态；
    S2：灌装，灌装机对步骤S1中的瓶子灌装，罐装时检测瓶子的罐装状态；
    S3：称重，将步骤S2中灌装后的瓶子称重，然后检测瓶子的称重状态；
    S4：加塞，将步骤S3中称重后的瓶子加塞，然后依次检测瓶子的加塞状态、瓶塞状态；
    S5：进行“逻辑与”运算，步骤S1至S4中工位上所有状态均为合格的瓶子为合格瓶，其余为废瓶；
    S6：剔废复检，将步骤S1至S4中合格瓶通过出瓶轨道（23）传送出去，废瓶通过剔废轨道（24）传送出去，同时将瓶子复检状态的信号反馈出去；
    将步骤S1至S4、S6中各状态的信息存储起来。
  2. 根据权利要求1所述的灌装机实时监控方法，其特征在于，步骤S1至S4、S6中，各状态正常时，各状态的信息存储为正常；各状态异常时，各状态的信息存储为异常。
  3. 根据权利要求2所述的灌装机实时监控方法，其特征在于，所述进瓶传输装置包括理瓶盘（33）和进瓶轨道（34），所述进瓶轨道（34）和理瓶盘（33）对接，所述进瓶轨道（34）和灌装机的进瓶拨轮（35）对接，所述进瓶轨道（34）的一侧还设有进瓶绞龙（36），所述进瓶拨轮（35）处设有进瓶检测装置（37）；
    所述工位上的瓶子从进瓶拨轮（35）经过时，进瓶状态为正常；
    所述工位上的瓶子未从进瓶拨轮（35）经过时，进瓶状态为异常。
  4. 根据权利要求3所述的灌装机实时监控方法，其特征在于，所述灌装机还包括水平传送带（43），所述水平传送带（43）上设有灌装泵（44）；
    所述瓶子经过灌装泵（44）时，若灌装泵（44）启动，则灌装状态为正常；
    所述瓶子经过灌装泵（44）时，若灌装泵（44）未启动，则灌装状态为异常。
  5. 根据权利要求4所述的灌装机实时监控方法，其特征在于，所述灌装泵（44）的下游设有称重传感器（53）；
    所述瓶子通过称重传感器（53）称重，称重值减去瓶重后得到净重；
    所述净重与设定值的偏差未超过设定界限时称重状态为正常；
    所述净重与设定值的偏差超过设定界限时称重状态为异常。
  6. 根据权利要求5所述的灌装机实时监控方法，其特征在于，所述称重传感器（53）的下游设有加塞装置（63），所述瓶子通过加塞装置（63）加塞；
    所述加塞装置（63）处设有加塞检测装置（64），通过第一加塞装置（63）检测瓶子是否加塞；
    所述加塞检测装置（64）检测到瓶子已加塞时，则加塞状态为正常；
    所述加塞检测装置（64）检测到瓶子未加塞时，则加塞状态为异常。
  7. 根据权利要求6所述的灌装机实时监控方法，其特征在于，所述加塞装置（63）处还设有瓶塞检测装置（65），加塞后的瓶子通过瓶塞检测装置（65）检测瓶塞是否正常；
    若瓶塞正常时，所述瓶塞状态为正常；
    若瓶塞异常时，所述瓶塞状态为异常。
  8. 根据权利要求7所述的灌装机实时监控方法，其特征在于，所述出瓶轨道（23）和剔废轨道（24）设在加塞装置（63）的下游，所述出瓶轨道（23）上设有出瓶检测装置（25）；
    所述出瓶检测装置（25）检测到瓶子经过时，所述复检状态为正常；
    所述出瓶检测装置（25）未检测到瓶子经过时，所述复检状态为异常。
  9. 根据权利要求8所述的灌装机实时监控方法，其特征在于，所述瓶子的进瓶状态、灌装状态、称重状态、加塞状态、瓶塞状态均为正常且复检状态为异常时，所述灌装机发出报警信号。
  10. 根据权利要求8所述的灌装机实时监控方法，其特征在于，所述进瓶检测装置（37）、出瓶检测装置（25）为镜反射传感器，所述加塞检测装置（64）为漫反射传感器，所述瓶塞检测装置（65）为槽型传感器。
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CN202988690U (zh) * 2012-11-22 2013-06-12 天津中新药业集团股份有限公司第六中药厂 一种中药滴丸用瓷瓶灌装装置
CN203998913U (zh) * 2014-05-23 2014-12-10 上海华东制药机械有限公司 一种灌装加塞一体机
CN105004364A (zh) * 2015-06-05 2015-10-28 楚天科技股份有限公司 一种灌装加塞机的瓶塞检测系统
CN109625458A (zh) * 2019-01-31 2019-04-16 楚天科技股份有限公司 一种灌装机实时监控方法

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