Filling unit and method for filling a container

Abstract

Filling unit (1) for a packaging machine (100) for filling bulk material (50) into containers (60) and packaging machine with a filling unit (1) comprising a conveying device (2) by which bulk material (50) can be fed into containers (60) and a control device (3) adapted and designed for controlling a filling flow (4) into containers (60). A level sensor device (5) comprising a sensor device (6) is provided, which is adapted and designed to detect a first level (7) and a second level (8) of bulk material (50) in a container (60), wherein the first level (7) corresponds to a level which is lower than the second level (8). The control device (3) controls the filling flow (4) by means of the levels determined by the sensor device (6). The container is filled by the method according to the invention until the second level is detected. Subsequently, the filling flow is reduced until the first level is detected. The filling flow is then increased.

Description

[0001] This application is a divisional application of Chinese invention patent application 201980062698.0 entitled "Filling unit and method for filling container", filed on March 24, 2021. Technical Field

[0002] This invention relates to a filling unit of a packaging machine for filling bulk materials into containers, comprising at least one conveying device by means of which the bulk material can be conveyed into the container, and at least one control device adapted and configured to guide the filling flow into the container. The invention also includes a packaging machine comprising at least one of these filling units, and a method for filling containers with bulk material using this packaging machine. Background Technology

[0003] Existing technologies have disclosed various apparatuses and methods for filling bulk materials into open containers, such as open bags. Compaction of the bulk material after or during the filling process is also provided to reduce the number of containers and to allow for better and easier stacking of filled and sealed containers.

[0004] When bulk materials are filled into open containers or other types of containers, fluids such as air are added along with the bulk material to improve its flowability. In the case of very lightweight materials, a significant amount of air is likely to be present in the bulk material before filling begins.

[0005] To better compact bulk materials packed into containers, vibratory devices, such as bottom vibrators or external vibrators, arranged outside the container have been disclosed. Compaction can also be effectively achieved even inside the container using so-called negative pressure spray guns, which enter the open container from above during filling and draw in air by applying negative pressure to the outer surface of the spray gun, removing air from the inside. Insertion vibrators are also arranged inside the containers to be filled, thereby enabling effective compaction of bulk materials during, during, or after filling. Single or even combinations of all compaction types are conceivable.

[0006] However, a drawback of all these methods is that bulk materials can only be filled to a relatively large safety margin below the top edge of the open container to prevent spillage. Similarly, different bulk materials can exhibit drastically different properties. When a predetermined filling limit is reached at a sufficient distance from the container opening, compaction is first performed during a filling pause before filling continues. This prolongs the container's filling time.

[0007] Each product requires the determination of appropriate filling parameters based on experience, such as filling time, rotation speed, or conveyor capacity, while adhering to a relatively large safety margin to allow for future product changes. This also applies to filling pauses. Filling parameters can only be changed through manual operator intervention; otherwise, they are the same for every filling. Summary of the Invention

[0008] Therefore, the object of the present invention is to provide an apparatus and method by which bulk material can be reliably prevented from being filled beyond the permissible amount, thereby obtaining a self-optimizing filling process.

[0009] This objective is achieved by a filling unit having the features of claim 1, a packaging machine having the features of claim 11, and a method for filling containers having the features of claim 12.

[0010] Preferred embodiments of the present invention are the subject of the dependent claims. Other advantages and features of the invention can be seen from the embodiments.

[0011] A filling unit of a packaging machine according to the invention for filling bulk materials into containers includes at least one conveying device by means of which the bulk material can be conveyed or filled into the container, and at least one control device. The control device is adapted and configured to guide at least one filling flow into the container. According to the invention, at least one level sensor device including at least one sensor device is provided, adapted and configured to acquire at least one first level and at least one second level of bulk material in the container. The first level corresponds to a level lower than the second level. The control device controls the filling flow by the level determined by the level sensor device or the sensor device.

[0012] The filling unit for packaging machines according to the invention is particularly provided for filling bulk materials, preferably from above, into top-open containers, such as open bags. Particular or powdery bulk materials can be filled into top-open containers.

[0013] According to the invention, a conveying device is particularly provided in a so-called totalizing system by means of at least one active conveying member. In a so-called network system, the conveying device can be provided by a dispensing device. The dispensing device can guide previously dispensed bulk material into a container by means of an active conveying member or by gravity.

[0014] Alternatively, it is conceivable to fill fluids or liquids, especially foamy fluids, into open containers such as tanks using the filling unit according to the invention.

[0015] According to the invention, a level sensor device, or at least one sensor device of the level sensor device, can detect at least two different levels in the container, wherein the control device controls the filling flow by means of the levels. According to the invention, this is particularly understood to indicate that the filling flow is enabled and / or disabled.

[0016] Therefore, it is particularly preferable to guide the filling flow into the container until a higher second material level is detected. Once the second material level is detected, the filling flow is interrupted and / or reduced or lowered, so that the bulk material guided into the container can settle, wherein, depending on the configuration, the bulk material in the container is further vibrated or compacted.

[0017] Once the bulk material settles due to the interruption of the filling flow and the material level has dropped below the second material level or the lower first material level, the filling flow can be reactivated or increased to continue filling the container.

[0018] The second material level preferably corresponds to the container's maximum material level, which is either not reached or only just reached when the container is filled with a preset weight of bulk material. Depending on the container type, this level ensures that the enclosed area constituting a joint to be welded or glued, or another type of area to be sealed, remains product-free. This ensures a reliable container seal.

[0019] To enable at least one sensor device to detect two different material levels, sensor devices with different configurations can be advantageously employed. For example, in the case of a transparent container, a camera and / or laser device can be used to detect the first and second material levels.

[0020] However, other sensor types, such as capacitive sensors, also allow for the determination of two different material levels. In the case of capacitive sensors, for example, the percentage value of the electric field that still exists allows for conclusions about different material levels. For instance, a large electric field can be formed over the entire height of the sensor surface in contact with the counter electrode between the sensor and the counter electrode, and the electric field decreases inversely proportional to the area covered by the sensor surface or to the amount of bulk material accumulating between the sensor and the counter electrode.

[0021] The filling unit of the present invention has many advantages. One significant advantage is that the filling flow into the container can be automatically guided or controlled to achieve optimized filling of the container in the shortest feasible time.

[0022] This guides the filling flow into the container until the preset maximum material level is reached. Then, one waits for the bulk material in the container to settle or be actively compacted until the material level drops to the first level, which triggers the filling flow to restart or increase.

[0023] This allows for particularly efficient container filling without concerns about overflow due to excessively fast or long filling cycles or changes in the bulk density of the material, such as as the hopper level drops.

[0024] According to the present invention, production output can be increased compared to known systems because the system automatically adapts to changing supply material properties. When pre-setting based on product type, safety cycles or safety volumes must always be taken into account. Furthermore, because determining and pre-setting parameters by product type is eliminated, the startup time of these systems is reduced.

[0025] Preferably, the sensor device is adapted and configured to monitor at least the top space of the container. The top space is particularly understood to refer to the top region of the container. The sensor device is particularly adapted and configured to detect the first and second material levels within the top 30%, preferably within the top 20%, and especially within the top 10% of the container. Generally, it is preferable to obtain the optimal filling volume of the container, wherein the second material level, in particular, defines the maximum material level. It is also convenient that the first material level (i.e., the lower of the two material levels) is located within the top 30%, 20%, or 10%. Thus, the container can initially be filled at a high speed with a so-called high-speed flow, and then the operation can be switched to a low-speed flow or controlled flow.

[0026] Particularly preferred is the provision of at least two sensor devices, with a first sensor device detecting a first material level and a second sensor device detecting a second material level. Detecting two material levels using different sensor devices enables particularly reliable detection of the filling flow. Furthermore, different sensors can have different configurations. Especially in the case of capacitive sensors, using at least two sensor devices facilitates particularly precise and sensitive control of the filling flow by detecting material levels.

[0027] In conventional configurations, the sensor devices are arranged at an angle to each other. Particularly preferred is that the sensor devices are arranged according to the shape or contour of the container to be filled. For example, a first sensor device for detecting a first material level may be arranged substantially horizontally, while a second sensor device for detecting a second material level is preferably arranged at an angle, for example, between 10° and 45°, according to the shape of the container. Particularly preferred is that the sensor devices are arranged as close to the container as possible.

[0028] Preferably, at least one sensor device includes at least one capacitive sensor. If multiple sensor devices are provided, in particular at least two or all of them are configured as or include capacitive sensors. Using capacitive sensors is advantageous, especially in cases where the container wall is opaque and optical sensors cannot be used. Thus, capacitive sensors allow for reliable level detection almost independent of the material and properties of the container wall, especially as long as the container wall does not shield the electric field.

[0029] Particularly preferred is the provision of at least one vibrating device suitable for and designed for compacting bulk materials within the container. Compaction can be performed using the vibrating device during the feeding of bulk materials and / or during filling pauses. The vibrating device used may be, in particular, an immersion vibrator, an external vibrator, and / or a bottom vibrator.

[0030] In an advantageous embodiment, a negative pressure spray gun may be provided, which is arranged inside the container to be filled, to at least intermittently extract air to compact the bulk material. This negative pressure spray gun may preferably also be used in conjunction with another vibrating device or configured to be combined with another vibrating device, and especially with an immersion vibrator.

[0031] In a convenient particular embodiment, the vibrating device and / or negative pressure spray gun form at least one counter pole with respect to at least one capacitive sensor. The vibrating device is preferably at least partially arranged within the container to be filled during the filling process. Given this configuration, where the vibrating device is at least partially arranged within the container during filling, the use of an insert vibrator is particularly advantageous. If an insert vibrator is not provided within the container, for example, if an external vibrator and / or a bottom vibrator are used, a blade or other type of counter pole may be alternatively introduced into the container and / or positioned at the rear of the container. Providing the counter pole within the container, depending on the configuration, is advantageous because it allows for a narrow distance between the capacitive sensor and the counter pole. Alternatively, the vibrating device may also be provided, for example, as a plate-shaped external vibrator, in which the vibrating device also operates as a counter pole with respect to the capacitive sensor, which is then arranged outside the container.

[0032] Preferably, at least one adjustment device is provided to adjust the sensitivity of the sensor device. Particularly preferred is the ability to configure the sensor device to detect only the actual material level, rather than bulk material or filling flow falling into the container. For example, a potentiometer can set the sensitivity of the sensor device such that, for example, a capacitive sensor will not detect the falling or flowing of bulk material as material level.

[0033] Preferably, at least one weighing device is provided. The weighing device can be used, particularly in a bulk system, to monitor and potentially control the filling of containers. For example, a higher filling speed can be used until a preset weight is reached, or until a preset material level is detected. Additionally, the final weight of the container can be detected, causing the filling process to stop accordingly. In a network system, a weighing system can also be used to monitor the filling of bulk material in the container by weight.

[0034] The packaging machine according to the invention includes at least one filling unit according to any one of the preceding claims.

[0035] The packaging machine according to the invention also has the advantages described above regarding the filling unit according to the invention.

[0036] The method of the present invention for filling containers with bulk material using a packaging machine comprising at least one filling unit as described above is characterized by the following steps in a suitable sequence: The bulk material is poured into the container until a second material level, i.e., a higher material level, is detected. The filling flow is then reduced until a first material level is reached and detected. Reduction specifically refers to interrupting the filling flow or a quantitative reduction in the filling flow. Once the first material level is detected, the filling flow is increased again until a second material level or a preset final weight of the container is detected. The steps of reducing and increasing the material level are repeated until the preset filling weight of the container is reached.

[0037] The method for filling containers according to the present invention provides the advantages described above regarding the packaging machine and filling unit.

[0038] Preferably, at least while reducing the filling flow, the bulk material inside the container is compacted by means of a vibrating device. This effectively achieves settling or compaction of the bulk material inside the container, especially during interruptions in the filling flow. Depending on the configuration, the bulk material inside the container can also be continuously or periodically compacted during the feeding process.

[0039] Preferably, the filling flow is interrupted during or in order to reduce the filling flow. Interrupting the filling flow allows the material level to settle down, particularly rapidly, from the second level to the first level. This particularly enables the indexing filling of the container.

[0040] Particularly preferred is the use of a control device to control the filling flow, thereby stabilizing the material level in the bag between a first and a second level. This allows for continuous filling of the container, where the material level does not rise above the higher second level.

[0041] In a useful configuration, settings regarding the filling flow are received for subsequent containers and modified as needed. Thus, for example, during product changeover, optimal control of the filling flow can be determined when filling the first container, which is then applied to subsequent containers, where the sensor device effectively prevents underfilling and, in particular, overfilling of containers. Attached Figure Description

[0042] Other advantages and features of the invention can be seen from the embodiments, which will be discussed below with reference to the accompanying drawings.

[0043] The diagram shows:

[0044] Figure 1 A schematic top view of an embodiment of the packaging machine according to the present invention;

[0045] Figure 2 A schematic perspective view of an embodiment of the filling unit according to the present invention;

[0046] Figure 3 Figure 2Enlarged view of the area shown within the dashed line;

[0047] Figure 4 according to Figure 2 A schematic side view of the filling unit;

[0048] Figure 5 Figure 4 Enlarged view of the area shown within the dashed line;

[0049] Figure 6 The filling process includes the container according to Figure 4 The illustration.

[0050] List of reference numerals

[0051] 1. Filling unit; 2. Conveying device; 3. Control device; 4. Filling flow; 5. Material level sensor device; 6. Sensor device; 7. First material level; 8. Second material level; 9. Sensor device; 10. Angle; 11. Capacitive sensor; 12. Vibration device; 13. Pole; 14. Adjustment device; 15. Weighing device; 16. Top space; 17. Filling nozzle; 18. Insertion vibrator; 50. Bulk material; 60. Container; 61. Open bag; 100. Packaging machine; 101. Position; 102. Position; 103. Conveying component; 104. Delivery device; 105. Container feeder; 106. Unloading device. Detailed Implementation

[0052] Figure 1 A packaging machine 100 according to the invention is schematically shown, currently shown as a rotary packaging machine 100, comprising a plurality of filling units 1 according to the invention distributed circumferentially.

[0053] At position 101, container supplier 105 supplies a single empty container 60 to a filling unit 1 via transfer device 104. In the illustrated embodiment, the empty container 60 is transferred at position 102 to conveyor member 103 via unloading device 106, and is typically filled during the rotation of packaging machine 100.

[0054] Figure 2 A perspective view of the filling unit 1 according to the invention, used in a packaging machine according to the invention, is shown schematically from a frontal view.

[0055] In the illustrated embodiment, container 60 (in this example, open bag 61) is supplied to filling unit 1 or functionally connected to filling nozzle 17. Container 60 is not shown in detail in the figure. Bulk material 50 is fed into open bag 61 from above.

[0056] Bulk material 50 is supplied by means of conveying device 2, wherein control device 3 controls filling flow 4.

[0057] To ensure effective filling of container 60, a level sensor device 5 is provided according to the present invention, which includes two sensor devices 6 and 9 in the illustrated embodiment. In the illustrated embodiment, these two sensor devices 6 and 9 allow for the determination or detection of a first level 7 and a second level 8.

[0058] The configurations of sensor devices 6 and 9 can differ. For example, at least one sensor device 6 or 9 may be configured as or include a camera and / or a laser. This is particularly advantageous if the walls of container 60 are transparent, allowing the material level to be determined by means of optical sensors.

[0059] In the illustrated embodiment, sensor devices 6 and 9 each include a capacitive sensor 11, which detects the electromagnetic field between the counter electrode 13 and the capacitive sensor 11.

[0060] Furthermore, the filling unit 1 according to the invention includes a weighing device 15 in the illustrated embodiment, which allows determination of the total weight of the container 60 to be filled. Thus, a preset filling amount in the container 60 can be detected, causing the filling process to stop when the container contains the predetermined filling amount.

[0061] Alternatively, the filling volume can be weighed first, and only this amount is supplied to the container. Then, management is done solely by volume until the entire, pre-set filling volume is present in the container.

[0062] in addition, Figure 2 The diagram schematically illustrates the provision of an adjustment device 14 for setting and adjusting the sensitivity of sensor devices 6, 9. This sensitivity can thus be specifically matched to the bulk material 50 to be filled.

[0063] The counter electrode 13 of the sensor devices 6, 9 or the capacitive sensor 11 may be arranged outside or inside the container 60. In the illustrated embodiment, a vibration device 12 is provided, which is currently configured as an insert vibrator 18. This insert vibrator 18 is positioned inside the container 60 during filling and causes compaction of the bulk material 50 inside the container 60 upon activation.

[0064] In the illustrated embodiment, the counter electrode 13 is provided by an insert vibrator 18 or a vibration device 12. Thus, in the illustrated embodiment, the counter electrode 13 is arranged inside the container 60 or the open bag 61.

[0065] Inserting the counter electrode 13 into the container 60 offers advantages in terms of configuration. One advantage is, for example, that the counter electrode 13 can be relatively close to the capacitive sensor 11. Alternatively, a vibration device 12 can be provided disposed outside the container 60. In the case of an external vibrator, it can be provided, for example, as a plate located on the outside of the container 60 and can be used as the counter electrode 13 with respect to at least one capacitive sensor 11.

[0066] As already described, the illustrated embodiment provides the counter electrode 13 via an insert vibrator 18. In this configuration, the bulk material 60 passes between the capacitive sensor 11 and the counter electrode 13 during filling, or the bulk material falls into the open bag 61, passing through the area between the capacitive sensor 11 and the counter electrode 13.

[0067] This is why an adjustment device 14 is provided in the illustrated embodiment, by which the sensitivity of the capacitive sensor 11 can be set and adjusted. This setting specifically enables the capacitive sensor to detect the actual material levels 7 and 8, rather than the loose material falling into them.

[0068] Other types of sensors and other configurations of the counter electrode 13 also facilitate the use of the adjustment device 14 to change the sensitivity of the sensor device.

[0069] Figure 3 Schematic illustration in Figure 2 Enlarged view of the details shown within the dashed lines. Again, the level sensor device 5, provided by the capacitive sensor 11, is recognized in the illustrated embodiment comprising two sensor devices 6, 9.

[0070] The same embodiment in Figure 4 and Figure 5 It is illustrated in the side view. Figure 5 It shows in Figure 4 The area within the dashed line is shown in an enlarged view.

[0071] The level sensor device 5, provided by two capacitive sensors 11, is again recognized in these illustrations. A vibration device 12, currently an insert vibrator 18, is provided for the opposite pole 13 of the capacitive sensors 11, which is arranged inside the container 60 while the bulk material 50 is being filled into the container 60.

[0072] exist Figure 5 In the illustrated embodiment, the two sensor devices 6 and 9 are arranged at an angle 10 relative to each other. This particular configuration at an angle 10 in the illustrated embodiment originates from the contours of the container 60 used. The sensor devices 6 and 9 are preferably arranged as close as possible to the wall of the container 60.

[0073] Figure 6 exist Figure 5 The modified diagram schematically illustrates the operating principle of the filling unit 1 or the level sensor device 5. The sensor devices 6 and 9 are arranged to monitor the top space 16, i.e., the top area of ​​the container 60.

[0074] The container 60 (in the illustrated embodiment, an open bag 61 made of flexible material) is suspended to the filling nozzle 17 or arranged below the filling nozzle.

[0075] The vibrating device 12 or the insert vibrator 18 is arranged inside the suspended open bag 61. The insert vibrator 18 represents the opposite pole 13 of the capacitive sensor 11.

[0076] Bulk material 50 is filled from above into open bag 61 by means of conveying device 2 and under the control of conveying device 2. As a result, the material level inside container 60 changes.

[0077] The sensitivity of sensor devices 6, 9 or capacitive sensor 11 is set and adjusted by means of adjustment device 14 so that sensor devices 6, 9 do not detect changes in material level when bulk material 50 falls between capacitive sensor 11 and counter electrode 13.

[0078] As the material level rises, there is loose material 50 between the counter electrode 13 and the lower sensor 6, and the dominant electromagnetic field between the lower sensor 6 and the counter electrode 13 decreases to a level that allows the sensor device 6 to determine the first material level 7.

[0079] Figure 6 This indicates that the material level has not yet risen to that height, and the bulk material 50 is located between the second sensor device 9 and the counter electrode 13. Therefore, the sensor device 9 has not yet detected the second material level 8, and filling continues. When the material level continues to rise until the second material level 8 is detected, the control device 3 reduces or interrupts the filling flow 4.

[0080] This prevents container 60 from being overfilled. Now, depending on the configuration and supported by the vibration device 12, further settling or compaction of the bulk material 50 is awaited. Next, as the material level decreases from the detected second level 8 to the first level 7, the filling flow 4 is increased or restarted to continue filling the bulk material 50 into container 60. During filling pauses or continuous filling, the vibration device 12 can compact the bulk material 12 within container 60.

[0081] As the material level continues to rise, a second material level 8 is detected again, and the filling flow 4 is interrupted or reduced. These steps are then repeated until, for example, the preset filling weight of the container is detected, or all previously weighed products are inside container 60.

[0082] Depending on the configuration, the container 60 can be filled in a graduated manner. However, depending on the configuration, the material level can be stabilized between the first material level 7 and the second material level to achieve continuous filling of the container 60.

Claims

1. A filling unit (1) of a packaging machine (100) for filling bulk material (50) into a container (60), comprising at least one conveying device (2) by which the bulk material (50) can be fed into the container (60), and at least one control device (3) adapted and designed to control the filling flow (4) entering the container (60). Its features are, At least one level sensor device (5) is provided, comprising at least two sensor devices (6, 9), said level sensor device being adapted and designed to detect at least one first level (7) and at least one second level (8) of bulk material (50) in a container (60), said at least two sensor devices (6, 9) being arranged at an angle (10) to each other, the sensor devices (6, 9) being arranged according to the shape or profile of the container to be filled, wherein the first level (7) corresponds to a level lower than the second level (8), wherein the first sensor device (6) detects the first level (7). It is adapted and designed to at least monitor the top space (16) of the container (60), and the second sensor device (9) detects the second material level (8), and wherein the control device (3) controls the filling flow (4) based on the material level determined by the sensor device (6), wherein the control device is adapted and designed to stabilize the material level (50) of the bulk material (50) in the container (60) between the first material level (7) and the second material level (8) by adjusting the filling flow (4). During the filling process, at least one blade and / or at least one plate are arranged at least partially inside and / or behind the container (60) to be filled, the blade and / or plate forming at least one pair of poles (13) of the capacitive sensor (11).

2. The filling unit (1) according to claim 1, characterized in that, At least one vibrating device (12) is provided, which is adapted and designed to compact bulk material (50) in a container (60).

3. The filling unit (1) according to claim 1 or 2, characterized in that, in During the filling process, the vibration device (12) is at least partially arranged inside the container (60) to be filled, and the vibration device (12) forms at least one pair of poles (13) with respect to the capacitive sensor (11).

4. The filling unit (1) according to claim 1 or 2, characterized in that, At least one adjustment device (14) is provided for adjusting the sensitivity of the sensor device (6,9).

5. The filling unit (1) according to claim 1 or 2, characterized in that, At least one weighing device (15) is provided.

6. A packaging machine (100) comprising at least one filling unit (1) according to any one of the preceding claims.

7. A method for filling a container (60) with bulk material (50) using a packaging machine according to the preceding claim, characterized in that, By following these steps in the appropriate order: - Fill the bulk material (50) into the container (60) until the second material level (8) is detected. - Reduce the filling flow (4) until the first material level (7) is reached and detected. - Increase the filling flow (4) until the second material level (8) is detected. - It is preferable to repeat the last two steps until the preset filling weight of the container (60) is reached; Thus, by adjusting the filling flow (4) with the help of the control device (3), the level of the bulk material (50) in the container (60) tends to stabilize between the first level (7) and the second level (8).

8. The method according to the preceding claim, characterized in that, At least during the process of reducing the filling flow (4), the bulk material (50) in the container (60) is compacted by the vibrating device (12).

9. The method according to any one of the preceding two claims, characterized in that, During the process of reducing the filling flow (4), the filling flow (4) is interrupted.

10. The method according to the preceding claim, characterized in that, Receive and adjust the filling flow (4) for subsequent containers (60) as needed.

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