Filling machine and method for filling a liquid product into bottles

Abstract

A filling machine (1) and a method for filling a liquid product into bottles (2) are described. The filling machine (1) comprises filling valves (4) rotating on a rotor, which can be opened by raising the bottles (2) into a vertical filling position (5) and closed again by lowering them, as well as rotating lifting units (6) with carriers (7) for the bottles (2) and pneumatically pre-tensioned lifting cylinders (8) for raising the carriers (7) and bottles (2). Furthermore, a mechanical cam control (9) is provided, which counteracts the lifting cylinders (8) to limit the upward stroke and to lower the carriers (7) and bottles (2).Because the filling machine (1) also includes rotating lowering units (13) that can be individually engaged with the lifting units (6) to counteract the lifting cylinders (8) and thereby lower the associated bottles (2) relative to the filling position (5), when the filling machine (1) is stopped, open filling valves (4) can be closed and / or vertical correction positions for fill level adjustment can be flexibly set. This prevents product loss and / or improves the filling quality.

Description

[0001] The invention relates to a filling machine and a method for filling a liquid product into bottles according to the preambles of claims 1 and 9.

[0002] Filling machines of this type are known, for example, from DE 9417044 U1 and DE 103308156 A1. In these filling machines, bottles are lifted from a support by means of pneumatic preload and pressed against rotating filling valves with the bottle mouth, sealing them. Cam controls counteract the pneumatic preload to limit the upward stroke and to lower the bottles from the filling valves.

[0003] EP 2 754 637 A1 also discloses the targeted lowering of previously filled bottles by means of lifting units into a position for fill level adjustment. EP 2 086 868 B1 further discloses a valve unit for filling bottles, in which the filling valve can be opened and closed independently of the positioning of the respective bottle, and in which a lifting cylinder can be activated to act downwards in such a way that the bottle to be filled can be kept at a distance from the dispensing opening and rinsed before the filling valve opens.

[0004] DE 37 32 882 C1 discloses a filling machine according to the preamble of claim 1.

[0005] Since the lifting units for raising the bottles during filling are permanently pre-tensioned from a common compressed air channel, and the bottles are lowered exclusively by cam control, open filling valves cannot be closed individually when the filling machine is at a standstill. If a defective bottle is then located at an open filling valve, the liquid product can continue to flow from the filling valve, which, in the worst case, could empty the filling machine's product chamber. This is particularly disadvantageous for relatively high-quality beverages, such as spirits.

[0006] In addition, it has proven disadvantageous that the final filling level correction of the bottles with regard to the vertical bottle position set and / or its timing cannot be optimized or can only be done with great equipment effort.

[0007] There is therefore a need for filling machines and methods for filling liquid products into bottles which can eliminate or at least mitigate at least one of the problems mentioned above.

[0008] The stated object is achieved with a filling machine according to claim 1. The filling machine is designed for filling bottles with a liquid product and for this purpose comprises: filling valves rotating on a rotor, which can be opened by the bottles being raised into a vertical filling position and closed again by lowering the bottles; lifting units rotating on the rotor, with supports for the bottles and pneumatically preloaded lifting cylinders for lifting the supports and bottles; and a mechanical cam control counteracting the lifting cylinders for limiting the upward stroke and for lowering the supports and bottles. According to the invention, the filling machine comprises rotating lowering units, which can be individually mechanically connected to the lifting units in order to counteract the lifting cylinders and thereby lower the associated bottles relative to the filling position.

[0009] The lowering units are individually actively driven to carry out downward strokes.

[0010] The filling position can be understood as a reference point for these downward strokes. The vertical filling position can be specified by the cam control and / or the filling valves and / or the non-connected lowering units. In particular, the vertical filling position is determined when the bottles are sealed against the filling valves.

[0011] The bottles can thus be lowered independently of each other by the filling valves, if necessary beyond a downward stroke specified by the mechanical cam control at the respective machine angle position. In contrast to the cam control, the lowering of the bottles by means of the lowering units is independent of the machine angle position of the individual bottles on the filling machine.

[0012] The rotating lowering units can be activated both during filling operation with rotating filling valves and when the filling machine is at a standstill, for example, during production breaks and / or in the event of a malfunction. Furthermore, the activation of the lowering units can be flexibly adapted to the respective production conditions, the product being filled, or similar requirements by programming the filling machine. In contrast to exclusive control via mechanical lifting cams and control rollers, the filling process, especially the final fill level correction, can be optimized by variably activating the lowering units, even without any installation work.

[0013] When not activated, the lowering units can act as a mechanical stop for the lifting units. This allows the upper stroke of the lifting cylinder to be limited in addition to or as an alternative to the filling valve and the cam control.

[0014] Preferably, the lowering units are designed to push a movable part of the respective associated lifting cylinder downward by means of a downward stroke. Within the meaning of the invention, the lifting cylinder is to be understood as a cylinder-piston unit that comprises either a stationary cylinder with a piston movable therein or a stationary piston with a cylinder movable therein.

[0015] With the piston stationary, the working chamber of the lifting cylinder, which is enclosed together with the cylinder, can be pressurized via the associated piston rod. The bottle holder can then be conveniently attached to the outside of the axially movable cylinder. This enables a compact lifting unit and a precisely guided stroke.

[0016] Instead, the lowering units could push the lifting units down on the brackets or on cross members connecting the brackets to the lifting cylinders.

[0017] Preferably, the lowering units are pneumatically driven. A pneumatic drive can be activated relatively easily by controlling the associated overpressure supply via a valve. Furthermore, the same medium, particularly compressed air, can be used to preload the lifting cylinders and drive the lowering units.

[0018] The lowering units preferably comprise pistons, particularly annular pistons, arranged coaxially above the lifting cylinders and extendable downwards. This enables a particularly compact arrangement of the lifting cylinders and lowering units with exclusively axially acting forces for lowering the lifting cylinders and / or supports. This also simplifies precise axial guidance of the lifting units.

[0019] Preferably, a pressure supply is provided for the lowering units to generate a higher drive pressure than in the preloaded lifting cylinders. Depending on the pressure difference, the lifting cylinders can be pushed downwards and positioned in a targeted manner by the lowering units.

[0020] Additionally or alternatively, the lowering units can have a larger effective piston area than the lifting cylinders to push them downwards. The lifting cylinders and the lowering units could then, in principle, be supplied with the same drive pressure. Due to their larger effective piston area, the activated lowering units would still push the lifting cylinders downwards. Effective piston areas include, for example, the end faces of the working chambers of the lowering units and lifting cylinders around a common fixed piston rod.

[0021] Preferably, the lowering units cover an uppermost portion of the total stroke of the supports specified by the lifting units and / or the cam control. The total stroke extends at least to the filling position. The portion covered by the lowering units comprises a downward stroke of 5 to 50 mm in length. When the lowering unit is not activated, the vertical filling position can be reached to open the associated filling valve. When the lowering unit is activated, a vertical closing position can be reached to close the filling valve and / or a vertical correction position can be reached to correct the fill level at the end of the respective filling process.

[0022] According to the invention, the lowering units are designed to lower the carriers to such an extent that the associated bottles are arranged in a vertical closed position, in which the filling valves are closed. By activating the lowering units, all filling valves can be closed independently of the upward stroke of the bottles permitted by the mechanical cam control and the resulting opening of the filling valves.

[0023] Preferably, the filling machine further comprises a programmable controller for automatically switching on the lowering units when the filling machine is stopped and / or at a standstill such that the carriers are lowered under open filling valves beyond a downward stroke predetermined by the cam control and the filling valves are thereby closed.

[0024] In principle, when the filling machine stops and / or is at a standstill, all lowering units can be switched on, whereby at least those lowering units that are located in a machine angle range with open filling valves have a position-changing effect on the lifting units.

[0025] In principle, the lowering units can also be designed as an upward-acting stop for the lifting units, such that the vertical filling position is determined by the lowering units, in particular by lowering units that are fully retracted upwards, i.e., not connected.

[0026] According to the invention, the lowering units are alternatively or additionally designed to lower the carriers to such an extent that the associated bottles are arranged in a vertical correction position for filling level correction.

[0027] Preferably, the filling machine comprises a programmable control for automatically switching on the lowering units during filling operation such that the carriers are lowered under the previously closed filling valves beyond a downward stroke predetermined by the cam control for filling level correction.

[0028] The vertical correction position can be flexibly specified using electronic programming. The timing for approaching and maintaining the correction position can also be flexibly programmed. This allows for comparatively simple and flexible optimization of the filling process, especially during the final fill level correction.

[0029] The stated object is also achieved by a method according to claim 9. Accordingly, this method serves for filling a liquid product into bottles. For this purpose, filling valves supplied with the product rotate on a rotor during filling operation and are opened by raising the bottles into a vertical filling position and closed again by lowering them. Furthermore, the bottles are individually raised to the filling valves by means of pneumatic preload and lowered by means of a mechanical cam control that counteracts the preload. According to the invention, in order to close the filling valves when the filling machine is stopped and / or to correct the fill level during filling operation, the bottles are lowered relative to the filling position by mechanically connecting individually driven lowering units that counteract the preload.

[0030] This makes it possible to achieve the advantages described in claim 1 both for avoiding product loss when the filling machine is stopped and for a precise and flexibly adjustable filling level correction.

[0031] According to the invention, the lowering units automatically close at least filling valves that are open when the filling machine is stopped and / or at a standstill by lowering the bottles into a vertical closed position. When the filling machine is stopped and / or at a standstill, all lowering units can be activated. On filling valves that are already closed by means of a mechanical cam control, the lowering units may be ineffective depending on the downward stroke they perform. Nevertheless, uncontrolled product flow from filling valves with defective containers can be reliably prevented.

[0032] In addition or alternatively, the lowering units temporarily lower the circulating bottles with respect to the filling position into a vertical correction position for filling level correction, whereby the bottles are further lowered after the filling level correction by means of the mechanical cam control.

[0033] The lowering units therefore enable a fill level correction that can be flexibly optimized using electronic programming, for which only a comparatively small vertical adjustment range is required, while the mechanical cam control covers the larger part of the total stroke with comparatively simple technical means.

[0034] Preferably, the vertical correction position and / or a time window and / or a machine angle range for approaching and / or maintaining the vertical correction position are set by electronic programming, in particular product-specific and / or format-specific. Thus, the fill level correction can be flexibly and quickly adapted to changing production conditions through electronic programming without any installation effort.

[0035] During filling operation, permanently preloaded lifting cylinders are preferably supplied with working pressure from a common compressed air supply. This enables comparatively simple control of the lifting units, essentially by mechanical cam control against the preload.

[0036] In addition, the lowering units enable additional functions for closing the filling valves and for variably adjusting the filling level correction independent of the respective machine angle position over a comparatively small adjustment range and thus with comparatively compact dimensions.

[0037] A preferred embodiment of the invention is shown in the drawing. The only Figure 1 shows a partial view of the filling machine with a lifting unit in longitudinal section.

[0038] As the Figure 1 As can be seen, the filling machine 1 for filling a liquid product, such as a beverage, into bottles 2 comprises, in a known manner, continuously rotating filling valves 4 on a rotor 3, only one of which is indicated schematically.

[0039] The filling valves 4 are opened by the bottles 2 by lifting them into a vertical filling position 5, in which the respective mouth area 2a of the bottles 2 presses against a lower sealing surface 4a of the valves 4, thereby lifting a valve cone (not shown) present in the filling valve 4 from its valve seat. For the sake of simplicity, the filling valve 4 is shown in the filling position 5. The filling valve 4 can be closed again in a known manner by lowering the associated bottle 2.

[0040] The filling machine 1 further comprises, together with the filling valves 4, lifting units 6 rotating on the rotor 3 with (schematically indicated) supports 7 for the bottles 2 and lifting cylinders 8, which are preferably permanently pneumatically pretensioned by overpressure during filling operation in order to lift the supports 7, which are fastened for example to cross beams 7a, with the bottles 2 to open the filling valves 4.

[0041] Counteracting the lifting cylinders 8, there is a mechanical cam control 9 which limits an upward stroke 10 of the lifting units 6 in the sense of a stop and / or forces a first downward stroke 11 on the lifting units 6 against their pneumatic preload.

[0042] In order to carry out a second downward stroke 12 which can be activated separately for each filling valve 4, the filling machine 1 further comprises, together with the lifting units 6 on the rotor 3, lowering units 13 which rotate. The lowering units 13 are preferably pneumatically driven by applying a first drive pressure 14 which is preferably higher than a second drive pressure 15 applied to the lifting cylinders 8. The drive pressures 14, 15 are each suitable overpressures.

[0043] The lowering units 13 are extendable and supplied with the first drive pressure 14 in such a way that, in the activated state, they push the lifting units 6 downwards in a targeted manner depending on the pressure difference between the drive pressures 14, 15. In the deactivated state, the lowering units 13 can be used as a stop to limit the upward stroke 10.

[0044] The lifting cylinders 8 preferably comprise vertically stationary piston rods 16 and vertically movable hollow cylinders 17, which are sealed in a manner known per se with respect to the piston rods 16 and, together with the piston rods, each enclose a working chamber 18 of the lifting cylinders 8. The working chamber 18 is preferably permanently pressurized with the second drive pressure 15. For this purpose, a common overpressure supply, for example with technical compressed air, is preferably provided for all lifting cylinders 8 of the filling machine 1.

[0045] The lowering units 13 are preferably arranged coaxially above the associated lifting cylinders 8. The lowering units 13 then preferably share the vertically fixed piston rod 16 with the respective associated lifting cylinders 8.

[0046] The lowering units 13 preferably comprise vertically stationary hollow cylinders 19 and annular pistons 20 which are vertically movable between the hollow cylinders 19 and piston rods 16. This encloses, with the hollow cylinders 19 and piston rods 16, a working chamber 21 of the lowering units 13 which is temporarily pressurized with the first drive pressure 14 in order to extend the respective annular piston 20 downwards out of its hollow cylinder 19.

[0047] In the Figure 1 For example, a lower end position 22 of the annular piston 20 and thus the lower end of the downward stroke 12 is shown schematically as a dashed line.

[0048] By applying the first drive pressure 14, the second downward stroke 12 can be carried out in a targeted manner in order to push the lifting units 6 downwards and thus, for example, starting from the vertical filling position 5, to move to a closing position 23 in which the filling valve 4 is closed as a result of the lowering of the bottle 2.

[0049] Alternatively or additionally, by applying or changing the first drive pressure 14, a vertical correction position 24 can be approached, in which the bottle 2 is arranged at a suitable distance from the filling valve 4 for fill level correction. The vertical correction position 24 can be approached with the second downward stroke 12 starting from the filling position 5, i.e., beyond the vertical closing position 23.

[0050] The vertical filling position 5 is determined by a stop limiting the upward stroke 10. This stop can be achieved, for example, by the mouth 2a of the bottle 2 striking the sealing surface 4a of the filling valve 4 and / or by an upper end face 8a of the lifting cylinder 8 striking a lower end face 13a of the associated lowering unit 13 and / or by the mechanical cam control 9.

[0051] The mechanical cam control 9 comprises in a known manner at least one stationary lifting cam segment 25 and control rollers 26 running along it and rotatably mounted on the lifting units 6. This is shown in the Figure 1 merely indicated as an example.

[0052] Since the lowering units 13 can be activated independently of their respective machine angular position on the filling machine 1, the second downward stroke 12 can be triggered automatically by an electronic control 27 (only schematically indicated) when the rotor 3 is at rest in order to close filling valves 4 opened by the lifting units 6 and the cam control 9, depending on their machine angular position, by lowering the associated bottles 2 into the closed position 23. This prevents uncontrolled flow of the liquid product through open filling valves 4, in particular if a tight closure of the affected product path cannot be achieved with at least one associated bottle 2, for example due to a broken bottle.

[0053] Furthermore, both the vertical correction position 24 for the fill level correction and the timing of such a fill level correction can be flexibly adapted and optimized by programmed control of the second downward stroke 12.

[0054] The execution of the second downward stroke 12 for filling level correction can be carried out instead of the first downward stroke 11 as a result of the cam control 9 or also as a supplement to the first downward stroke 11.

[0055] While the first downward stroke 11 of the cam control 9 is fixed by the shape of the stroke curve segment 25 for certain machine angle positions of the filling valves 4, the vertical position of the bottles 2 can be adjusted with the second downward stroke 12 independently of the respective machine angle position of the filling valve 4.

[0056] Using the control 27, the second downward stroke 12 can be adjusted, and each lowering unit 13 can be individually activated to move to the vertical correction position 24. Likewise, both the time or the machine angle position for moving to the vertical correction position 24 and the time period or the machine angle range for maintaining the vertical correction position 24 can be adjusted in this way.

[0057] Thus, the fill level correction on the filling machine 1 can be flexibly adapted for different liquid products, such as beverage types, different bottle formats, or the like, and optimized if necessary during ongoing filling operations. Accordingly, type-specific and / or format-specific filling programs for controlling the lowering units 13 can be stored and retrieved from the control system.

[0058] In addition, product losses can be reliably avoided when the filling machine 1 is at a standstill. For this purpose, either only those lowering units 13 located within a machine angle range with open filling valves 4 can be activated, or all lowering units 13 can be activated. In the latter case, only those lowering units 13 are effective for closing the filling valves 4 whose second downward stroke 12 exceeds the first downward stroke 11 specified by the mechanical cam control 9 depending on the respective machine angle position.

[0059] A pneumatic drive of the lowering units 13 is advantageous due to the media supply with air pressure or similar compressed gases generally present on filling machines and with regard to the control elements of conventional design available for this purpose.

[0060] In principle, however, other individually controllable drives for the lowering units 13 are also conceivable, such as electromagnetic drives and / or hydraulic drives. These can also be selectively activated and controlled to move to the vertical closing positions 23 and / or vertical correction positions 24.

[0061] The filling machine 1 can be operated, for example, as follows: The bottles 2 to be filled are transferred in a conventional manner by an inlet star wheel (not shown) or the like to the holders 7. These can also be of conventional design and are therefore Figure 1 merely indicated schematically. Additional guides or the like for the bottles 2 may be present in the area of the lifting units 6.

[0062] The bottles 2 are transferred to the lifting units 6 in a lower vertical transfer position (not shown) and lifted by means of the pneumatic preload in the lifting units 6, i.e., by applying the second drive pressure 15 to the lifting cylinders 8. The lifting of the bottles 2 can be controlled by gradual stroke limitation using the mechanical cam control 9.

[0063] In this way, the bottles 2 are lifted to the filling valves 4 until the mouths 2a of the bottles 2 seal the product path into the bottles 2 with the sealing surfaces 4a of the filling valves 4 and the vertical filling position 5 is reached and the filling valve 4 is thus opened.

[0064] In the vertical filling position 5, the lowering units 13 preferably rest against the lifting cylinders 8, for example in that their corresponding end faces 8a, 13a touch each other.

[0065] Towards the end of each filling process, the associated lowering unit 13 is automatically activated and extended by means of the electronically programmed controller 27 in order to lower the bottle 2 into a programmed vertical correction position 24 for fill level correction. The time for moving to the vertical correction position 24 or the machine angle position provided for this purpose is preferably also predetermined by electronic programming and could be called up on a product-specific and / or format-specific basis, for example on a control unit (not shown) of the controller 27. Likewise, the period of time during which the vertical correction position 24 remains in place or the associated machine angle range can be suitably specified or adjusted by means of electronic programming.

[0066] After the fill level has been corrected, the container 2 is lowered by the mechanical cam control 9 through the downward stroke 11 into a lower vertical transfer position for transfer to a discharge star (not shown) or the like. It goes without saying that this process is carried out identically for all filling valves 4 present on the filling machine 1 or on the rotor 3 during normal filling operation.

[0067] If the rotor 3 comes to a standstill, for example, due to a production interruption, a malfunction, or the like, at least some of the lowering units 13 are activated to move to the vertical closing position 23. For the sake of simplicity, all lowering units 13 can be activated or only those associated with an open filling valve 4. This reliably prevents product loss at open filling valves 4 despite potentially defective bottles 2.

Claims

1. Filling machine (1) for filling a liquid product into bottles (2), comprising: - circulating filling valves (4) which can be opened by the bottles (2) being raised into a vertical filling position (5) and closed again by their lowering; - circumferential lifting units (6) with carriers (7) for the bottles (7) and pneumatically preloaded lifting cylinders (8) for lifting the carriers (7) and bottles (2); and - a mechanical cam control (9) counteracting the lifting cylinders (8) for limiting upward movement and for lowering the carriers (7) and bottles (2), characterized by circulating lowering units (13) which are individually actively driven to perform downward strokes and which can be individually mechanically connected to the lifting units (6) in order to counteract the preloaded lifting cylinders (8) and thereby lower the associated bottles (2) relative to the filling position (5), wherein the lowering units (13) are designed to lower the carriers (7) to such an extent that the associated bottles (2) are arranged in a vertical closing position (23) in which the filling valves (4) are closed, and / or wherein the lowering units (13) are designed to lower the carriers (7) to such an extent that the associated bottles (2) are arranged in a vertical correction position (24) for filling level correction.

2. Filling machine according to claim 1, wherein the lowering units (13) are designed to press down a movable part of the respective associated lifting cylinder (8).

3. Filling machine according to claim 1 or 2, wherein the lowering units (13) are pneumatically driven.

4. Filling machine according to one of the preceding claims, wherein the lowering units (13) comprise pistons, in particular ring pistons (20), which are arranged coaxially above the lifting cylinders (8) and can be extended downward.

5. Filling machine according to one of the previous claims, wherein a pressure supply is provided for the lowering units (13) to generate a higher drive pressure (14) than that present in the preloaded lifting cylinders and / or the lowering units (13) have a larger effective piston area than the lifting cylinders (8).

6. Filling machine according to at least one of the previous claims, wherein the lowering units (13) cover an upper part of a total stroke of the carriers (7) specified by the lifting units (6) and / or the cam control (9), in particular a part with a stroke of 5-50 mm.

7. Filling machine according to at least one of the previous claims, further comprising a programmable control (27) for automatically switching on the lowering units (13) when the filling machine (1) stops and / or comes to a standstill in such a way that the carriers (7) are lowered beyond a downward stroke (11) specified by the cam control (9) with the filling valves (4) open, thereby closing the filling valves (4).

8. Filling machine according to at least one of the previous claims, further comprising a programmable control (27) for automatically switching on the lowering units (23) during filling operation in such a way that the carriers (7) are lowered below the previously closed filling valves (4) by a downward stroke (11) specified by the cam control (9) for filling level correction.

9. Method for filling a liquid product into bottles (2), wherein filling valves (4) supplied with the product rotate during filling operation and are opened by raising the bottles (2) into a filling position (5) and closed again by lowering them, and wherein the bottles (2) are raised individually to the filling valves (4) by means of pneumatic pre-tensioning and lowered by means of a mechanical cam control (9) counteracting the pre-tensioning, characterized in that that the bottles (2) are lowered relative to the filling position (5) by mechanically switching on individually driven lowering units (13) counteracting the preload in order to close the filling valves (4) when the filling machine (1) is stopped and / or to correct the filling level during filling operation, wherein the lowering units (13) automatically close filling valves (4) which are open when the filling machine (1) is stopped and / or at a standstill by lowering the bottles (2) into a vertical closing position (23), and / or wherein the lowering units (13) temporarily lower the immediately previously filled bottles (2) into a vertical correction position (24) for filling height correction and the bottles (2) are further lowered after the filling height correction by means of the mechanical cam control (9).

10. Method according to claim 9, wherein the vertical correction position (24) and / or a time window and / or machine angle range for starting and / or maintaining the vertical correction position (24) is set by electronic programming, in particular product-specific and / or format-specific.

11. Method according to at least one of claims 9 to 10, wherein the pneumatic preload is permanently maintained during filling operation, in particular by means of a common compressed air supply from the filling valves to associated lifting cylinders (8).

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