A vertical stacked integrated sauce filling and packaging all-in-one machine and method

Abstract

This invention provides a vertically stacked integrated sauce filling and packaging machine and method. The filling outlet and a volumetric metering cylinder are vertically stacked and integrated above the packaging machine table via a bracket. The filling outlet is vertically aligned with the filling station of the packaging conveying device. The total length of the material conveying path does not exceed 80 cm and has no horizontal pipe sections. The distribution valve selectively connects the feed side to the metering cylinder or the metering cylinder to the filling outlet side. This invention fundamentally eliminates three major problems caused by long pipelines in separate production lines: pressure fluctuations and inaccurate metering, particle settling in horizontal pipe sections, and difficulty in pipeline cleaning. It also integrates an auxiliary positioning and shock absorption device, a T-type negative pressure linkage anti-drip stop valve, a square-to-round quick-release connector with no dead angles, and a large-diameter swing-type non-shearing reversing valve. The filling accuracy can be stabilized within ±1%, the particle distribution is uniform and complete, the changeover and cleaning efficiency is significantly improved, and the overall machine structure is compact and occupies little space.

Description

Technical Field

[0001] This invention belongs to the field of food packaging machinery technology, specifically relating to an integrated filling and packaging equipment suitable for viscous or particulate sauces, and more particularly to an integrated machine and method that vertically stacks a pneumatic piston quantitative filling unit and a rotary packaging machine platform in three-dimensional space. Background Technology

[0002] In the food processing industry, the quantitative filling and packaging of viscous or particulate sauces (such as chili sauce, sesame paste, salad dressings with fruit pulp, peanut butter, etc.) is a key process in the production flow. Currently, a split production line layout is commonly used in this field: a separate volumetric filling machine supplies material to a separate rotary packaging machine through long material pipelines. The filling machine is responsible for the quantitative intake and delivery of the sauce, while the packaging machine is responsible for container conveying, filling, and sealing. The two are connected by flexible or rigid pipelines, which are typically several meters long.

[0003] This split layout has revealed three interrelated and prominent problems in production practice.

[0004] First, pressure fluctuations in long pipelines lead to inaccurate metering. During long-distance pipeline transport, viscous pastes experience significant pressure losses due to their high viscosity and flow resistance. When the filling process is periodically started and stopped, the pressure within the pipeline fluctuates noticeably. This fluctuation is transmitted to the suction inlet of the volumetric metering device, directly affecting the filling degree and density consistency of the paste within the chamber during suction. This results in deviations in the actual mass of each suction, manifested as significant variations in the weight per cup. For high-value-added products or those with strict regulations regarding net content, this deviation can lead to compliance risks.

[0005] Secondly, there is the issue of particle settling and solid-liquid separation within horizontal pipelines. The sauce containing particles is a solid-liquid two-phase mixture. In long, horizontally arranged pipelines, when the sauce is stationary or flowing at low speed, solid particles with a density greater than the liquid carrier gradually settle to the bottom of the pipe under gravity. At the start of the next filling cycle, the particles deposited at the bottom of the pipe may be preferentially flushed out, resulting in abnormally high solids content in the earlier filled containers; conversely, in the later stages of continuous filling, the solids content in the pipe sections where the bottom sediment has been carried away is lower. This unevenness in solids content between the various filling containers severely affects the consistency of product quality and the consumer's eating experience.

[0006] Third, the process of changing production involves lengthy cleaning times and the risk of residue and contamination in the pipeline. Long pipeline systems have a large internal surface area, resulting in significant contact between the sauce and the pipe walls. Therefore, cleaning requires a large amount of cleaning solution and water for prolonged circulation and rinsing. Bends, joints, and valves within the pipeline can easily become unsanitary areas where sauce residue can accumulate. This residue can deteriorate and breed microorganisms, potentially contaminating subsequent batches of product when changing sauce varieties. Thorough cleaning and sterilization of the entire long pipeline is time-consuming and labor-intensive, significantly reducing equipment utilization and production efficiency in multi-variety, small-batch production.

[0007] The common root cause of the above three problems lies in the spatial separation between the filling unit and the packaging unit, and the resulting long-distance material transport pipelines. However, in the technological inertia of this field, the filling function and the packaging function have long been regarded as two independent process links, and their separate layout is considered to have the advantages of modularity and flexible configuration. Therefore, existing improvements usually focus on local optimization—such as adding pipeline pressure compensation devices, adding stirring or homogenizing mechanisms in the pipeline, or adopting CIP in-situ cleaning systems—rather than fundamentally reconstructing the equipment architecture.

[0008] Therefore, there is an urgent need in this field for an integrated filling and packaging solution that can fundamentally shorten the material conveying path, eliminate horizontal pipe sections, and take into account both filling accuracy and easy cleaning, thereby solving the three major problems of metering accuracy, particle uniformity and cleaning efficiency at the equipment architecture level. Summary of the Invention

[0009] This invention provides a vertically stacked integrated sauce filling and packaging machine and method, which vertically stacks and integrates a pneumatic piston quantitative filling unit with a rotary packaging machine platform in three-dimensional space, eliminating the root cause of the long pipeline structure that causes the above three major problems from the architectural level. The specific technical solution is as follows.

[0010] In a first aspect, the present invention provides a vertically stacked integrated sauce filling and packaging machine, comprising a frame, a packaging conveying device mounted on the frame, a distribution valve, a volumetric metering cylinder, and a filling outlet. The filling outlet and the volumetric metering cylinder are stacked and integrated on the platform of the frame via a bracket, with the filling outlet vertically facing the filling station on the packaging conveying device. The distribution valve, the cavity of the volumetric metering cylinder, and the outlet of the filling outlet are connected by pipelines to form a material conveying path. The total length of the material conveying path does not exceed 80 cm, and there are no horizontal pipe sections along the entire material conveying path. The distribution valve has a suction position and a filling position. In the suction position, the distribution valve connects the inlet side to the cavity of the volumetric metering cylinder; in the filling position, the distribution valve connects the cavity of the volumetric metering cylinder to the filling outlet side. The above architecture vertically stacks the filling functional module above the packaging functional module, allowing the sauce to flow from top to bottom throughout the conveying path, utilizing gravity-assisted conveying, while compressing the material path to an extremely short length. The short path reduces the internal volume of the pipeline, thereby significantly reducing the impact of pressure fluctuations on metering and suction conditions; the absence of horizontal pipe sections eliminates the conditions for particle settling and separation in the horizontal direction, and, combined with gravity flow, allows particles to move synchronously with the liquid carrier; the short path and dead-angle-free design significantly reduce the pipeline area required for rinsing and the amount of cleaning fluid used. These three technical issues are simultaneously resolved through the same architectural approach.

[0011] Furthermore, the packaging conveying device is a rotary indexing turntable, and the filling station is set on the rotary indexing turntable. The rotary indexing turntable is a preferred conveying implementation of the present invention, and its intermittent indexing motion is well coordinated with the timing of the filling action, and it is convenient to set up an auxiliary positioning device at the filling station.

[0012] Furthermore, an auxiliary positioning and vibration damping device is provided at the aforementioned filling station. This device includes an upper positioning component, fixed to the platform directly below the filling outlet, which has a downwardly protruding conical surface; and a lower receiving component, fixed to the bottom of the mold on the rotating indexing turntable, with a V-shaped notch on its upper surface. When the mold rotates to the filling station, the V-shaped notch engages with the conical surface of the upper positioning component, forming a mechanical interlock. After filling, the rotating indexing turntable rotates to disengage the V-shaped notch from the conical surface. This auxiliary positioning and vibration damping device utilizes the turntable's own rotational indexing motion to achieve passive mechanical locking with self-locking upon arrival and self-unlocking upon departure, eliminating the need for additional clamping power and independent timing control. The engagement between the conical surface and the V-shaped notch also has a circumferential self-guiding function, compensating for minor angular deviations in the turntable's indexing positioning.

[0013] Furthermore, the upper positioning component is a truncated cone, smaller at the top and larger at the bottom, with the cone surface being the lower outer cone surface of the truncated cone. The truncated cone is a body of revolution, and it has an inwardly converging guide surface throughout its circumference, providing guiding compensation in any direction of rotation.

[0014] Furthermore, it also includes a hopper with a rectangular outlet, through which material is supplied from the feed side. A quick-release connector with a square-to-round transition is provided between the hopper's outlet and the feed side. This connector is a one-piece hollow structure, including an upper rectangular flange that connects to the hopper's rectangular outlet; a middle square-to-round transition section where the inner cavity smoothly transitions from a rectangular cross-section to a circular cross-section, and the inner wall of this transition section is a seamless, integrally formed surface; and a lower circular quick-release interface that connects to the feed side. Food-grade clamps are used to achieve detachable connections between the upper rectangular flange and the hopper's outlet, and between the lower circular quick-release interface and the feed side. This square-to-round quick-release connector integrates three functions: anti-bridging, no dead angle, and quick release.

[0015] Furthermore, the filling outlet is a filling nozzle, and an anti-drip shut-off valve is provided at the internal outlet of the filling nozzle. This shut-off valve includes a valve seat, horizontally fixed to the inner wall of the filling nozzle outlet section, and the valve seat has a central circular hole; the valve core is a T-shaped component, including a vertical rod, a horizontal rod located at the top of the vertical rod, and an inverted conical plug fixed to the lower end of the vertical rod, with the vertical rod passing through the central circular hole of the valve seat. The inner wall of the filling nozzle outlet has an inner conical surface, and the outer conical surface of the inverted conical plug mates with this inner conical surface. During filling, the paste, under the pushing pressure of the metering cylinder, acts on the upper surface of the crossbar, overcoming the weight of the valve core and pushing it downwards, causing the inverted conical plug to disengage from the filling nozzle outlet. The upper surface of the crossbar of the T-shaped valve core is configured to withstand the pushing pressure of the paste during filling to push the valve core downwards, and to withstand the back suction force generated by the negative pressure at the end of filling. At the end of filling, the piston of the metering cylinder retracts slightly, creating negative pressure. This negative pressure, together with the weight of the valve core, pulls the valve core upwards, causing the inverted conical plug to reseal the filling nozzle outlet. This anti-drip shut-off valve uses the slight retraction of the volumetric metering cylinder simultaneously for two purposes: preparing for the next suction cycle and using the negative pressure generated by the retraction to transiently drive the valve core to close, eliminating the need for a separate valve-closing drive and its control timing.

[0016] Furthermore, the distribution valve is specifically a large-diameter swing-type directional valve, including a valve body with a cylindrical inner cavity. The valve body has a first interface, a second interface, and a third interface. The first interface connects to the feed side, the second interface connects to the cavity of the volumetric metering cylinder, and the third interface connects to the filling outlet side. The swing valve core, which is a fan-shaped block or an arc-shaped valve disc, is oscillatingly mounted in the cylindrical inner cavity of the valve body via a rotating shaft. One end of the rotating shaft extends out of the valve body and is driven by a swing cylinder. The swing valve core has a large-diameter arc-shaped channel inside. The outer surface of the swing valve core and the inner wall of the large-diameter arc-shaped channel smoothly transition through rounded corners, allowing particles in the sauce to pass through without damage. This large-diameter arc-shaped channel has no narrow gaps or shearing edges, ensuring that particles in the sauce pass through without damage. This large-diameter swing-type directional valve is specially designed for the specific needs of sauces containing particles. The entire channel has a large-diameter arc-shaped cross-section, preventing solid particles in the sauce from being sheared, squeezed, or ground when passing through the valve.

[0017] Furthermore, limiting components are provided in the cylindrical inner cavity of the valve body at the corresponding suction and filling positions to limit the repeatability of the working position of the oscillating valve core at the suction and filling positions. The limiting components ensure that the valve core reaches the exact same working position after each oscillation, and the effective cross-section of the channel is consistent, thereby ensuring a high degree of repeatability of the flow conditions for suction and filling, and further guaranteeing metering accuracy.

[0018] Furthermore, it also includes a control system, which is electrically connected to the drive components of the packaging conveying device, the reversing drive components of the distribution valve, and the forward and backward drive components of the volumetric metering cylinder to coordinate the timing of the filling action.

[0019] Furthermore, the platform of the frame is inclined towards the drain outlet and is equipped with a liquid collection tank. The inclined platform guides the cleaning fluid to the drain outlet, and the liquid collection tank collects the liquid, preventing the cleaning fluid from accumulating on the platform.

[0020] Secondly, the present invention provides an integrated method for filling and packaging sauces, using the vertically stacked integrated sauce filling and packaging machine described in any of the above claims, comprising the following steps: S1: The packaging conveying device conveys the mold to the filling station; S2: The distribution valve switches to the suction position, and the volumetric metering cylinder retracts to suction material; S3: The distribution valve switches to the filling position, and the volumetric metering cylinder advances to push material, injecting the sauce into the container in the mold through the filling outlet; S4: After filling is completed, the piston of the volumetric metering cylinder retracts slightly, establishing negative pressure in the filling outlet, driving the anti-drip shut-off valve in the filling outlet to close, and confirming closure after a preset delay; S5: After confirming the closure of the anti-drip shut-off valve, the packaging conveying device conveys the next mold to the filling station; S6: Repeat steps S1 to S5. There is a timing interlock relationship between steps S4 and S5 of this method: before the valve closure confirmation is completed in step S4, the mold conveying action in step S5 is not executed, thereby ensuring that the valve closure action precedes the mold movement.

[0021] Furthermore, in step S4, the piston of the volumetric metering cylinder retracts slightly by a distance of 2mm to 5mm, and the delay time for confirming the closure of the anti-drip shut-off valve in step S4 is 50ms to 200ms.

[0022] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. Significantly Improved Filling Accuracy. By shortening the material conveying path to within 80 cm and eliminating horizontal pipe sections, the internal volume of the pipeline is greatly reduced, and pressure loss and fluctuation along the pipeline are simultaneously decreased. The suction conditions of the volumetric metering cylinder are highly stable, and the consistency of the suction volume per cup is greatly improved. Simultaneously, the auxiliary positioning and vibration damping devices at the filling station eliminate the impact of residual rotational vibration on instantaneous filling accuracy. The synergistic effect of these two accuracy improvements allows the filling accuracy to be consistently maintained within ±1%. This effect of improving filling accuracy through both path shortening and vibration elimination is not taught in existing technologies—existing technologies typically rely on the accuracy of the metering device itself, neglecting the systemic impact of pipeline system and equipment vibration on accuracy.

[0023] 2. Significantly improved particle distribution uniformity and preserved particle morphology. The vertical or steeply inclined descent path throughout the entire process fundamentally eliminates the conditions for particle settling and separation in horizontal pipe sections. The sauce is transported by gravity from the hopper to the filling nozzle, with particles and liquid carrier moving synchronously, resulting in a uniform solids content in each cup. The large-diameter swing-type reversing valve's arc-shaped channel, free of narrow gaps and shearing edges, avoids shearing and breakage of particles in the sauce, preserving the original shape, size, and taste quality of the particles. The uniformity of particle distribution and the integrity of particle morphology are achieved through the combined synergistic effect of a large-diameter, shear-free channel without horizontal pipe sections; neither of these measures alone could achieve both effects simultaneously.

[0024] 3. Eliminate dripping and contamination during filling. The T-shaped self-weight negative pressure interlocking shut-off valve built into the filling nozzle utilizes the slight retraction of the metering cylinder after filling to establish negative pressure within the nozzle. This negative pressure, combined with the valve core's own weight, drives the valve core to close the nozzle, resulting in a rapid valve closure response. Simultaneously, the negative pressure draws back residual paste from the nozzle, strictly interlocking with the rotary table's indexing sequence to effectively prevent residual material from dripping and contaminating the cup rim and sealing area, thus improving the sealing pass rate. This design, which parasitizes the valve closure action with the cylinder's retraction, relies on the unique short-pipeline, small-volume conditions of this solution and cannot be implemented in long-pipeline, split-type production lines. Those skilled in the art, without understanding the short-path architecture of this solution, could not have foreseen this interlocking design of using cylinder retraction to achieve negative pressure valve closure at the filling nozzle.

[0025] 4. Extremely high changeover cleaning efficiency. Hoppers, square-to-round quick-release joints, distribution valves, filling nozzles, and other material contact pipelines can all be quickly disassembled without tools using clamps. The material path is short, with fewer bends, and the joints are smooth with no dead angles, significantly reducing the amount of cleaning fluid and rinsing time required. Compared to the long pipeline systems of split production lines, cleaning fluid consumption is expected to be reduced by more than 50%, and changeover cleaning time can be shortened to a few minutes, significantly improving the utilization rate and flexibility of multi-variety, small-batch production equipment.

[0026] 5. The machine has a compact structure and a small footprint. The filling unit is vertically stacked and integrated above the packaging machine turntable, eliminating the space required for a separate filling machine and the material conveying line between the two machines. This significantly reduces the projected area of ​​the equipment and greatly improves the utilization rate of workshop space. Attached Figure Description

[0027] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0028] Figure 1 This is a front view of an embodiment of the present invention: a vertically stacked integrated sauce filling and packaging machine.

[0029] Figure 2 This is a side view of a vertically stacked integrated sauce filling and packaging machine according to an embodiment of the present invention.

[0030] Figure 3 This is a top view of an embodiment of the present invention: a vertically stacked integrated sauce filling and packaging machine.

[0031] Figure 4 This is a cross-sectional schematic diagram of an auxiliary positioning and shock absorption device for a filling station according to an embodiment of the present invention.

[0032] The correspondence between the numbers and component names in the diagram is as follows: 1. Frame, 101. Tabletop, 2. Packaging conveyor, 201. Filling station, 203. Mold, 3. Hopper, 4. Distributor valve, 402. Valve body, 403. Swing valve core, 5. Volumetric metering cylinder, 6. Filling outlet, 601. Valve seat, 602. Valve core, 9. Bracket, 10. Upper positioning component, 11. Lower receiving component, 12. Square to round quick-release connector. Detailed Implementation

[0033] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be described in detail below with reference to embodiments. The following embodiments are only used to more clearly illustrate the technical solutions of this invention and should not be used to limit the scope of protection of this invention.

[0034] This embodiment provides a vertically stacked integrated sauce filling and packaging machine suitable for filling chili sauce containing granules.

[0035] This embodiment of the vertical stacking integrated sauce filling and packaging machine includes a frame 1, a rotary indexing turntable mounted on the frame 1, a hopper 3, a distribution valve 4, a volumetric metering cylinder 5, a filling nozzle, and a control system. The rotary indexing turntable is a specific implementation of the packaging conveying device 2 in this embodiment. The rotary indexing turntable is driven by an indexing drive component and rotates intermittently at a fixed indexing angle, conveying the mold 203 sequentially to the filling station 201, the sealing station, and the discharge station. As an alternative implementation of the packaging conveying device, the packaging conveying device can also be a linear stepping conveyor belt, which pushes the mold sequentially to the filling station at a fixed step distance using a linear stepping motor or pneumatic lever. In this alternative implementation, the filling outlet is also vertically aligned with the top of the filling station. As another alternative implementation of the packaging conveying device, the packaging conveying device can also be a stepping chain circulating conveyor. This device includes two parallel circulating chains with multiple carrier seats fixed at intervals on the chains, and the mold is fixed on the carrier seats. The chain is driven by a stepper motor through a sprocket, making intermittent cyclic movements, each step covering one station interval. The filling station is located at a fixed position above the chain, with the filling outlet vertically facing the mold that stops at the filling station.

[0036] The filling nozzle is the specific implementation of the filling outlet 6 in this embodiment. The filling nozzle and the volumetric metering cylinder 5 are stacked and integrated on the table 101 of the frame 1 via a bracket 9. The bracket 9 is a rigid support frame made of steel or aluminum profiles, its bottom is fixed to the table 101 by bolts, and its upper part supports the volumetric metering cylinder 5 and the filling nozzle. The filling nozzle is vertically aligned with the filling station 201 on the rotating indexing turntable. Figure 4This is a schematic cross-sectional view of a portion of the filling station structure of the present invention. To clearly demonstrate the cooperation principle of the core components and simplify the drawing, conventional auxiliary structures such as supports, pipelines, and housings are omitted. As an alternative implementation of the filling outlet, the filling outlet can also be an open filling port without a built-in shut-off valve. In this case, the material is injected directly into the container from the distribution valve through a short vertical pipe. As another alternative implementation of the filling outlet, the filling outlet does not need to have a separate filling nozzle. Instead, the discharge port of the distribution valve housing is directly machined into a downward-opening filling port. In this case, the anti-drip shut-off valve can be directly integrated into the discharge port of the distribution valve housing, with the valve seat fixed to the inner wall of the discharge port and the valve core accommodated in the discharge cavity.

[0037] Hopper 3 is located at the top of the equipment and is used to store and supply the sauce to be filled. The bottom of hopper 3 has a rectangular outlet. Distributor valve 4 is installed below hopper 3. A quick-release connector 12 with no dead angle is connected between the rectangular outlet of hopper 3 and the inlet of distributor valve 4. Distributor valve 4 is connected to the cavity of volumetric metering cylinder 5 and the filling nozzle through pipelines. The specific material conveying path is as follows: the outlet of hopper 3 passes through quick-release connector 12 with no dead angle, the first interface of distributor valve 4, the inside of distributor valve 4, the second interface of distributor valve 4 to the cavity of volumetric metering cylinder 5 to form a suction path; the cavity of volumetric metering cylinder 5 passes through the second interface of distributor valve 4, the inside of distributor valve 4, the third interface of distributor valve 4 to the outlet of filling nozzle to form a filling path. Measured along the center line of the above flow channel, the total length of the material conveying path in this embodiment is about 55 cm, which does not exceed 80 cm, and the angle between the axis of each pipeline in the path and the horizontal plane is greater than 45°, with no pipeline sections where the axis is horizontal throughout the entire path. As an alternative implementation of the path length, in designs with more compact equipment size, the total length of the material conveying path can be further shortened to within 50 cm or 40 cm; in larger equipment models, the path length can also be 60 cm to 80 cm. In the preferred series of this embodiment, the total length of the material conveying path is preferably no more than 60 cm, more preferably no more than 50 cm, and even more preferably no more than 40 cm. In this embodiment, "no horizontal pipe section" is specifically defined as all pipes in the material conveying path having an angle greater than 15° with the horizontal plane, more preferably greater than 30°, even more preferably greater than 45°, and most preferably vertically oriented.

[0038] An auxiliary positioning and shock absorption device is provided at the filling station 201. This device consists of upper and lower parts. The upper positioning component 10 is fixedly installed on the platform 101 directly below the filling nozzle. In this embodiment, the upper positioning component 10 is a truncated cone, smaller at the top and larger at the bottom, with a downwardly protruding conical surface at its lower part. The upper end face of the truncated cone has a threaded hole and is fixed to the platform 101 by bolts. As an alternative lower implementation, the upper positioning component 10 can also be a trapezoidal block with conical guide surfaces on both sides. Another alternative implementation of the upper positioning component is a ball-head pin. The top of the ball-head pin is a spherical surface, which forms a downwardly protruding conical surface and a guide surface. The V-shaped notch contacts the spherical surface during engagement, and the automatic centering effect of the spherical surface guides the mold to the correct position. The lower receiving component 11 is a rectangular block, fixedly installed at the bottom of the mold 203 on the rotating indexing turntable, with one corresponding to each filling station 201. The upper surface of the lower receiving part 11 has a V-shaped notch. The opening angle of the V-shaped notch matches the cone angle of the cone surface of the upper positioning part 10. The table 101 of the frame 1 is inclined towards the drain outlet, with an inclination angle of 1° to 5°, and is equipped with a liquid collection tank. To maintain the vertical accuracy of the upper positioning part 10, a partial horizontal mounting surface is provided on the table 101 at the corresponding position of the filling station 201, and the upper positioning part 10 is mounted on this partial horizontal surface. Alternatively, a wedge-shaped pad can be added between the bottom of the upper positioning part 10 and the inclined table. As another alternative to achieve compatibility between the table inclination and the vertical accuracy of the positioning part, the bottom of the upper positioning part is provided with a mounting base, which has three or four height adjustment bolts. By adjusting the screw depth of each bolt, the axis of the upper positioning part can be precisely adjusted to a vertical state. When the rotary indexing turntable rotates and brings a mold 203 to the filling station 201, the lower receiving part 11, fixed at its bottom, moves with the mold 203 to directly below the upper positioning part 10, and the V-shaped notch precisely engages with the outer conical surface of the cone. The inward guiding effect of the cone ensures that the V-shaped notch is smoothly guided to the engagement position where it is in complete contact with the cone. After engagement, the mold 203 is mechanically locked to the table 101 in both the radial and circumferential directions, remaining stable and stationary during filling. After filling is completed, the rotary indexing turntable begins its next indexing rotation, and the lower receiving part 11 disengages from the conical surface of the upper positioning part 10 as the turntable rotates. The mold 203 unlocks and moves out of the filling station 201 with the turntable. As an alternative to the auxiliary positioning and shock absorption device, the auxiliary positioning of the filling station can also adopt an active pin hole positioning device. In this alternative, the positioning pin fixed to the table is driven by a small positioning cylinder and can extend and retract in the vertical direction; a positioning hole is provided at the corresponding position on the bottom of the turntable mold. When the mold reaches the filling station, the control system controls the positioning cylinder to extend and insert the positioning pin into the positioning hole at the bottom of the mold to achieve active mechanical locking; after filling is completed, the positioning cylinder retracts, the positioning pin exits the positioning hole, and the mold is unlocked.

[0039] The outlet of hopper 3 is rectangular, and the inlet of distribution valve 4 is circular. A quick-release connector 12 with no dead angle is located between the two. The quick-release connector 12 is a hollow, integrally formed structure made of food-grade 304 or 316L stainless steel, with a polished inner wall and a surface roughness of no more than 0.8μm. This connector includes three functional sections: an upper rectangular flange, the rectangular cross-section of which matches the rectangular outlet of hopper 3; a middle square-to-circular transition section, the inner cavity of which smoothly transitions from a rectangular cross-section to a circular cross-section along the flow direction, the length of the transition section matching the cross-sectional change ratio, and the transition angle no more than 30°; and a lower circular quick-connect interface, the circular cross-section of which is consistent with the cross-section of the inlet of distribution valve 4. Food-grade clamps are used to achieve detachable connections between the upper rectangular flange and the outlet of hopper 3, and between the lower circular quick-connect interface and the inlet of distribution valve 4. The clamp consists of two semi-circular clamps and a locking handle, allowing for tightening and loosening by hand without the need for any tools. After removing the two clamps, the quick-release connector 12 (square to round without dead angles) can be removed separately for soaking and cleaning or replacement.

[0040] A drip-proof shut-off valve is provided at the internal outlet of the filling nozzle. The filling nozzle is a vertically arranged tubular body, and its lower outlet inner wall is machined with an inner conical surface. The valve seat 601 is a circular thin plate with a central hole, made of stainless steel, and is horizontally fixed to the inner wall of the filling nozzle outlet section. In this embodiment, the inner wall of the filling nozzle is machined with an annular stepped surface, and the outer edge of the valve seat 601 abuts against the stepped surface, and is axially limited above by an elastic retaining spring. As an alternative fixing method, the valve seat 601 can also be directly pressed into the corresponding position of the inner wall of the filling nozzle using an interference fit. As another alternative implementation of the valve seat fixing method, the valve seat can be pressed and fixed to the inner wall of the filling nozzle outlet section by a threaded pressure ring. The valve core 602 is a T-shaped component, comprising: a vertical rod, a slender cylindrical rod that passes downward through the central circular hole of the valve seat 601, with a rod diameter slightly smaller than the diameter of the circular hole; a horizontal rod, located at the top of the vertical rod, which is a horizontal pin or flat rod with a length greater than the diameter of the central circular hole of the valve seat 601; and an inverted conical plug, fixed to the lower end of the vertical rod, whose outer conical surface mates with the inner conical surface of the filling nozzle outlet. The working process of the valve core 602 is as follows: During filling, the piston of the volumetric metering cylinder 5 advances, pushing the paste forward, and the paste flows downward under pressure. The pressure of the paste acts on the upper surface of the horizontal rod, generating a downward thrust, which overcomes the self-weight of the valve core 602 and pushes the entire valve core 602 downward. The inverted conical plug then moves downward, disengaging from the inner conical surface of the filling nozzle outlet, opening the nozzle, and the paste flows out through the annular gap between the vertical rod and the central circular hole of the valve seat 601, and the gap between the inverted conical plug and the inner wall of the nozzle. At the end of filling, the piston of the metering cylinder reaches the end of its pushing stroke. The control system controls the piston to retract slightly, by a distance of 2mm to 5mm. This retraction creates a transient negative pressure in the internal pipeline of the filling nozzle. Due to the extremely short material transport path and small pipeline volume, the slight retraction of the piston is sufficient to create an effective transient negative pressure within the filling nozzle. This negative pressure generates an upward suction force, acting on the lower surface of the crossbar of valve core 602 and the upper surface of the inverted conical plug. Together with the weight of valve core 602, this pulls valve core 602 upward. The inverted conical plug then re-fits onto the inner conical surface of the filling nozzle outlet, forming a seal and closing the nozzle. Simultaneously, the negative pressure also draws back a small amount of residual paste from the nozzle into the pipeline. In this embodiment, the closing force of valve core 602 is provided by both the negative pressure suction force and its own weight, providing double protection. Alternatively, an auxiliary return spring can be fitted onto the vertical rod, with the spring force and its own weight serving as a backup closing force in case of negative pressure failure. As an alternative to assisting the valve core's closing force, a permanent magnet ring can be fixed to the upper surface of the inverted conical plug or at an appropriate position on the vertical rod, while another permanent magnet ring is fixed to a corresponding position on the inner wall of the filling nozzle outlet section. The two permanent magnet rings are configured to attract each other, with the magnetic attraction and their own weight serving as the closing force. As an alternative to the anti-drip shut-off valve, the anti-drip shut-off valve inside the filling outlet can also be electromagnetically driven. In this alternative, an electromagnetic coil is wound around the filling nozzle outlet section, and an armature is fixed to the vertical rod or plug of the valve core.During filling, the solenoid coil is de-energized, and the valve core is pushed open under the pressure of the filling body; when filling is finished, the control system energizes the solenoid coil, generating a magnetic force that attracts the valve core upward, causing the plug to seal the filling outlet.

[0041] In this embodiment, the distribution valve 4 is specifically a large-diameter swing-type directional valve. The valve body 402 is made of stainless steel and has a cylindrical inner cavity machined inside. The valve body 402 has three interfaces: a first interface, which connects to the feed side via a quick-release connector 12 (square to round without dead angles) and the hopper 3; a second interface, which connects to the cavity of the volumetric metering cylinder 5 via a pipeline; and a third interface, which connects to the filling nozzle side via a pipeline. In this embodiment, the first interface is located on the upper left side of the valve body 402, the second interface is located on the lower left side of the valve body 402, and the third interface is located on the right side of the valve body 402. The swing valve core 403 is a sector-shaped block that can be swing-mounted in the cylindrical inner cavity of the valve body 402 via a rotating shaft. As an alternative implementation, the swing valve core 403 can also be an arc-shaped valve disc. As an alternative implementation of the oscillating valve core, the oscillating valve core can be an eccentric arc-shaped channel plug valve core. This valve core is a cylindrical plug body with an eccentric arc-shaped channel machined inside. The channel cross-section is a circle with no reduction in diameter. The cylindrical plug body can be rotatably fitted into the cylindrical inner cavity of the valve body. The upper end of the rotating shaft extends out of the valve body 402 and is coaxially connected to the output shaft of an oscillating cylinder via a coupling. As an alternative drive method, a fork linkage mechanism can also be used to convert the linear motion of the oscillating cylinder into the rotational motion of the rotating shaft. As an alternative implementation of the connection between the oscillating cylinder and the rotating shaft, the oscillating cylinder can be a linear reciprocating cylinder. A rack is fixedly connected to the end of its piston rod, and a gear is coaxially fixed on the rotating shaft. The rack meshes with the gear, and the linear motion drives the gear to rotate through the rack. A rotary seal is provided at the penetration point between the rotating shaft and the valve body 402 to prevent leakage of the valve body along the rotating shaft. The oscillating valve core 403 has a large-diameter arc-shaped channel inside. The cross-section of the arc-shaped channel is circular or elliptical, and its equivalent diameter is not less than the nominal diameter of the connecting pipeline. The entire inner wall of the arc-shaped channel is smoothly transitioned, without narrow gaps or shear edges. The swing valve core 403 has two working positions. In the suction position, the swing cylinder drives the rotating shaft to swing the swing valve core 403 to the left, and the large-diameter arc-shaped channel connects the first interface and the second interface. The paste in the hopper 3 can enter the cavity of the volumetric metering cylinder 5 through the first interface, the large-diameter arc-shaped channel, and the second interface. In the filling position, the swing cylinder drives the rotating shaft to swing the swing valve core 403 to the right, and the large-diameter arc-shaped channel connects the second interface and the third interface. The paste in the cavity of the volumetric metering cylinder 5 can enter the filling nozzle through the second interface, the large-diameter arc-shaped channel, and the third interface. In the cylindrical inner cavity of the valve body 402, corresponding to the suction position and the filling position, two adjustable limit screws are provided as limit elements. The limiting screw is screwed into the outer wall of the valve body 402, and its inner end face forms a mechanical stop surface for the swing valve core 403 to swing into position. By adjusting the screwing depth of the limiting screw, the stopping angle of the swing valve core 403 in the suction position and the filling position can be precisely calibrated. As an alternative to the distribution valve, the distribution valve in this embodiment can also be an axial reciprocating directional valve.This axial reciprocating directional valve includes a valve body with a cylindrical inner cavity and a cylindrical spool valve core, which can slide axially within the valve body. The valve body also has a feed inlet, a cylinder inlet, and a filling inlet; the spool valve core has two annular grooves and an axial through hole. By switching the spool valve core between two axial working positions, the feed inlet and cylinder inlet can be connected to form a suction position, or the cylinder inlet and filling inlet can be connected to form a filling position.

[0042] The control system includes a PLC programmable logic controller and a touch screen human-machine interface. The control system is electrically connected to the indexing drive, the swing cylinder, and the forward and backward drive of the volumetric metering cylinder 5. The human-machine interface allows setting process parameters such as filling volume, packaging speed, and sealing temperature. The control program contains timing interlock logic between each action, ensuring that the next rotary table indexing action is only allowed after the valve closure confirmation is completed at the end of filling. The bottom of the frame 1 is equipped with casters and adjustable feet for easy movement and leveling and locking after positioning. A filter and pressure regulating valve is installed at the air source inlet to filter and regulate the pressure of the air entering all pneumatic components of the equipment.

[0043] The following describes the working process of the vertically stacked integrated sauce filling and packaging machine of this embodiment using a complete work cycle as an example. In the initial state, the previous filling of the rotating indexing turntable has been completed, and the next mold 203 to be filled has been positioned at the filling station 201 as the turntable rotates. At this time, the V-shaped notch of the lower receiving part 11 has been engaged in the conical surface of the upper positioning part 10, and the mold 203 is mechanically locked. The swing valve core 403 of the distribution valve 4 is in the suction position. Step S1: The control system issues a command, the distribution valve 4 maintains the suction position, and the piston of the volumetric metering cylinder 5 retracts under the drive of compressed air, generating negative pressure in the cylinder cavity. The sauce is sucked into the cavity of the metering cylinder from the hopper 3 through the square-to-round quick-release connector 12 and the large-diameter arc-shaped channel of the distribution valve 4. The piston stops after retracting to the preset stroke end point, completing the quantitative suction. Step S2: The control system controls the swing cylinder to swing from the suction position to the filling position. The connection relationship of the large-diameter arc-shaped channel is switched to the second interface connecting to the third interface. Step S3: The control system controls the piston of the volumetric metering cylinder 5 to advance and push the paste. The paste enters the filling nozzle under pressure, acting on the upper surface of the crossbar of the T-shaped valve core 602, overcoming the self-weight of the valve core 602 and pushing it downward, causing the inverted conical plug to disengage from the filling nozzle outlet. The paste is injected into the container in the mold 203 located at the filling station 201 through the filling nozzle. Step S4: The piston of the metering cylinder reaches the end of the pushing stroke, and the filling ends. The control system immediately controls the piston of the metering cylinder to retract slightly, with a retraction distance of 2mm to 5mm, establishing a transient negative pressure in the material conveying pipeline. The negative pressure is transmitted to the filling nozzle, acting on the valve core 602, and together with its own weight, pulls the valve core 602 upward, causing the inverted conical plug to reseal the filling nozzle outlet. The control system delays for 50ms to 200ms to confirm valve closure. Step S5: After the valve closure confirmation is completed, the control system issues a command to rotate the indexing turntable for one indexing rotation. The lower receiving part 11 disengages from the conical surface of the upper positioning part 10 as the turntable rotates, and the filled mold 203 moves out of the filling station 201. The next mold to be filled 203 enters the filling station and is positioned, with the V-shaped notch of its lower receiving part 11 engaging with the conical surface of the upper positioning part 10, forming a new mechanical interlock. Step S6: The control system controls the distribution valve 4 to switch back to the material suction position, entering the next work cycle. There is a timing interlock between steps S4 and S5, that is, if the valve closure confirmation is not completed in step S4, the unlocking and indexing actions in step S5 will not be executed.

[0044] During the changeover cleaning process, operators loosen the clamps at both ends of the quick-release connector 12 (square to round, no dead angle) and remove the connector for cleaning; loosen the connecting clamps of the filling nozzle and remove the valve seat 601 and valve core 602 for cleaning; loosen the connecting clamps of the distribution valve 4 and remove the swing valve core 403 for cleaning. All material contact parts can be quickly disassembled without tools, soaked in cleaning solution, rinsed, sterilized, and then reassembled. The changeover preparation can be completed within minutes.

[0045] To clarify the difference between the present invention's completely horizontal pipe section-free system and the existing partially inclined pipe system, the following supplementary explanation is provided. In a sauce filling system, if the filling unit and packaging unit are still separately arranged, but the pipe connecting them is set at an angle of 15° or 20° to the horizontal plane, while this inclined pipe can alleviate particle deposition at the bottom of the pipe to some extent, the pipe length is still on the order of several meters, and the pressure fluctuation problem within the pipe remains unresolved. Furthermore, the lower end of the inclined pipe still has a lowest point; when the equipment is stopped, particles in the sauce will accumulate and deposit at this lowest point, resulting in a deviation in the solids content of the first batch of filled products upon restarting. The present invention, through its stacked integrated architecture, achieves a completely horizontal pipe section-free system. Its essential difference lies not in the specific numerical value of the pipe's inclination angle, but in the extremely short material path and consistent gravity direction determined by the stacked architecture. The pipe has no lowest accumulation point, and particles have no space or time to settle.

Claims

1. A vertically stacked integrated sauce filling and packaging machine, comprising a frame (1), a packaging conveying device (2) mounted on the frame (1), a distribution valve (4), a volumetric metering cylinder (5), and a filling outlet (6), characterized in that, The filling outlet (6) and the volumetric metering cylinder (5) are stacked and integrated on the table (101) of the frame (1) via a bracket (9), and the filling outlet (6) is vertically facing the filling station (201) on the packaging conveying device (2). The distribution valve (4), the cavity of the volumetric metering cylinder (5) and the outlet of the filling outlet (6) are connected by pipelines to form a material conveying path. The total length of the material conveying path does not exceed 80 cm, and there are no horizontal pipe sections along the entire material conveying path. The distribution valve (4) has a suction position and a filling position. In the suction position, the distribution valve (4) connects the feed side to the cavity of the volumetric metering cylinder (5). In the filling position, the distribution valve (4) connects the cavity of the volumetric metering cylinder (5) to the filling outlet (6).

2. The vertically stacked integrated sauce filling and packaging machine according to claim 1, characterized in that, The packaging conveying device (2) is a rotary indexing turntable, and the filling station (201) is located on the rotary indexing turntable.

3. The vertically stacked integrated sauce filling and packaging machine according to claim 2, characterized in that, It also includes an auxiliary positioning and vibration damping device installed at the filling station (201), the auxiliary positioning and vibration damping device comprising: The upper positioning component (10) is fixed on the platform (101) directly below the filling outlet (6), and the upper positioning component (10) has a downwardly protruding conical surface; The lower receiving part (11) is fixed to the bottom of the mold (203) of the rotating indexing turntable, and a V-shaped notch is provided on the upper surface of the lower receiving part (11); When the mold (203) rotates to the filling station (201), the V-shaped notch is engaged in the conical surface of the upper positioning part (10) to form a mechanical interlock. After filling is completed, the rotating indexing turntable rotates to make the V-shaped notch disengage from the conical surface.

4. The vertically stacked integrated sauce filling and packaging machine according to claim 3, characterized in that, The upper positioning component (10) is a truncated cone with a smaller upper part and a larger lower part, and the cone surface is the lower outer cone surface of the truncated cone.

5. The vertically stacked integrated sauce filling and packaging machine according to claim 1, characterized in that, It also includes a hopper (3), the outlet of which is a rectangular outlet, and the feed side is supplied with material through the hopper (3); A quick-release connector (12) with no dead angle is provided between the outlet of the hopper (3) and the feed side. The quick-release connector (12) with no dead angle is an integrally formed hollow structure, including: The upper rectangular flange is connected to the rectangular outlet of the hopper (3); The central square-to-round transition section has an inner cavity that smoothly transitions from a rectangular cross-section to a circular cross-section, and the inner wall of this transition section is a seamless, integrally formed surface. The lower circular quick-connect interface connects to the feed side. Food-grade clamps are used to achieve detachable connection between the upper rectangular flange and the outlet of the hopper (3), and between the lower circular quick-connect interface and the feed side.

6. The vertically stacked integrated sauce filling and packaging machine according to claim 1, characterized in that, The filling outlet (6) is a filling nozzle, and an anti-drip shut-off valve is provided at the internal outlet of the filling nozzle. The anti-drip shut-off valve includes: A valve seat (601) is horizontally fixed to the inner wall of the outlet section of the filling nozzle, and the valve seat (601) has a central circular hole; The valve core (602) is a T-shaped component, including a vertical rod, a horizontal rod located at the top of the vertical rod, and an inverted conical plug fixed to the lower end of the vertical rod. The vertical rod passes through the central circular hole of the valve seat (601). The inner wall of the filling nozzle outlet has an inner conical surface, and the outer conical surface of the inverted conical plug mates with the inner conical surface; During filling, the paste acts on the upper surface of the crossbar under the pushing pressure of the metering cylinder (5), overcoming the weight of the valve core (602) and pushing the valve core (602) downward, and the inverted conical plug disengages from the outlet of the filling nozzle; the upper surface of the crossbar of the T-shaped valve core (602) is configured to withstand the pushing pressure of the paste during filling to push the valve core downward, and to withstand the back suction force generated by the negative pressure at the end of filling; at the end of filling, the piston of the metering cylinder (5) generates a slight backward movement to form a negative pressure, which works together with the weight of the valve core (602) to pull the valve core (602) upward, so that the inverted conical plug re-seals the outlet of the filling nozzle.

7. The vertically stacked integrated sauce filling and packaging machine according to any one of claims 1 to 6, characterized in that, The distribution valve (4) is a large-diameter swing-type directional valve, including: The valve body (402) has a cylindrical inner cavity. The valve body (402) is provided with a first interface, a second interface and a third interface. The first interface is connected to the feed side, the second interface is connected to the cavity of the volumetric metering cylinder (5), and the third interface is connected to the filling outlet (6) side. The swing valve core (403) is a fan-shaped block or an arc-shaped valve disc, which is swingably installed in the cylindrical inner cavity of the valve body (402) via a rotating shaft. One end of the rotating shaft extends out of the valve body (402) and is driven by a swing cylinder. The swing valve core (403) has a large-diameter arc-shaped channel inside. The outer surface of the swing valve core (403) and the inner wall of the large-diameter arc-shaped channel are smoothly transitioned by rounded corners so that particles in the sauce can pass through without damage. The large-diameter arc-shaped channel has no narrow gaps or shearing edges so that particles in the sauce can pass through without damage.

8. The vertically stacked integrated sauce filling and packaging machine according to claim 7, characterized in that, The cylindrical inner cavity of the valve body (402) is provided with limiting members corresponding to the material suction position and the filling position, respectively, to limit the repeatability accuracy of the working position of the swing valve core (403) at the material suction position and the filling position.

9. The vertically stacked integrated sauce filling and packaging machine according to claim 1, characterized in that, It also includes a control system, which is electrically connected to the drive of the packaging conveying device (2), the reversing drive of the distribution valve (4), and the forward and backward drive of the volumetric metering cylinder (5) to coordinate the timing of the filling action.

10. A method for integrated sauce filling and packaging, using a vertically stacked integrated sauce filling and packaging machine as described in any one of claims 1 to 9, characterized in that, Includes the following steps: S1: The packaging conveying device (2) conveys the mold (203) to the filling station (201). S2: The distribution valve (4) switches to the suction position, and the volumetric metering cylinder (5) retracts to suction material; S3: The distribution valve (4) switches to the filling position, the volumetric metering cylinder (5) pushes the material forward, and the sauce is injected into the container in the mold (203) through the filling outlet (6); S4: After filling is completed, the piston of the volumetric metering cylinder (5) retracts slightly, creating a negative pressure in the filling outlet (6), driving the anti-drip shut-off valve in the filling outlet (6) to close, and confirming closure after a preset delay. S5: After confirming that the anti-drip shut-off valve is closed, the packaging conveyor (2) will transport the next mold to the filling station (201). S6: Repeat steps S1 to S5.

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