Cap application monitoring method and cap holder

Abstract

A method (600) for monitoring cap application in a filling machine (300) is presented. The filling machine (300) includes a peripheral element (102) surrounding a cap (106), a gripping element (104) connected to the peripheral element (102) and arranged to inhibit movement of the cap (106) relative to the peripheral element (102) during rotation about a central axis (A) of the peripheral element (102), a sensor arrangement portion (110) attached to the peripheral element (102), and a communication module (312) linked to the peripheral element (102) and communicatively connected to the sensor arrangement portion (110) and arranged to transmit sensor data to a data processing device (312). and a control system (324) configured to receive (602) sensor data (314) captured by the sensor placement unit (110), compare (604) the sensor data (314) with sensor reference data (320) held in a reference database (318) communicatively connected to the data processing unit (312), and send (608) a check notification (322) from the data processing unit (312) to a control system (324) if there is a discrepancy (606) between the sensor data (314) and the sensor reference data (320).

Description

[Technical field]

[0001] The present invention relates to the field of packaging, and more particularly to an apparatus and method for applying caps. [Background technology]

[0002] Currently, packages with screw caps are becoming more and more popular in the food packaging industry. One reason for their popularity is that this type of opening device has the positive effect of being reclosable and allowing the package to be stored horizontally after opening. Another reason for their popularity is that screw caps are easy to use for many consumers. Although some screw caps are difficult to use for people with weak strength, in general, screw caps are easier to use for most people compared to tear-off openings, etc.

[0003] There are various ways in which screw caps are applied during the manufacturing process. One common technique is to use a so-called cap applicator to screw the cap onto the threaded neck of the package. The general principle of such a device is to grip the cap, place it over the neck and rotate the cap while holding the package stationary so that the internal threads of the cap cooperate with the external threads of the neck. To ensure that the cap or neck are not damaged during the cap application process, the cap applicator is usually fine-tuned so that sufficient application is achieved without damaging the cap or neck. It is known to use camera-based systems to monitor the capping process.

[0004] While currently used cap applicators have generally performed well, increasing levels of customization have proven to be a challenge for some packaging lines. Different colored caps, for example, often have different material properties. For example, the material properties of the white and red plastic materials used in the two caps are different, so fitting a white cap onto the neck may require a different cap applicator setting than fitting a red cap.

[0005] In the field of cap applicators, there is an increasing desire to reduce the amount of plastic material used in caps and necks, both from a cost and environmental standpoint. When reducing the amount of plastic material used, tighter tolerances must be held when applying the caps. The upside of the material reduction is a more reliable cap application.

[0006] Based on the above examples, there is a need for an improved cap application process so that more reliable package manufacturing can be achieved, but there is also a need to provide packages that use less plastic material. Summary of the Invention [Problem to be solved by the invention]

[0007] It is an object of the present invention to at least partially overcome one or more of the limitations identified in the prior art above. In particular, it is an object to provide a method that allows for a more reliable and flexible cap application control. It is also an object to provide a method for monitoring cap application in a filling machine, such that data is generated for realizing a more reliable and flexible cap application control.

[0008] According to a first aspect, there is provided a method for monitoring cap application in a filling machine using a data processing device, the filling machine comprising a cap holder, the cap holder comprising: a peripheral element surrounding the cap; - a gripping element connected to the peripheral element and arranged to prevent movement of the cap relative to the peripheral element during rotation of the peripheral element about the central axis A; a sensor arrangement attached to the peripheral element; - a communication module associated with the peripheral element, communicatively connected to the sensor arrangement and arranged to transmit the sensor data to a data processing device; Equipped with The method comprises: receiving sensor data captured by the sensor arrangement; comparing the sensor data with sensor reference data held in a reference database communicatively connected to the data processing device; sending a check notification from the data processing device to the control system if there is a discrepancy between the sensor data and the sensor reference data; Equipped with.

[0009] The advantage of this method is that the cap application can be efficiently monitored. By mounting sensors on peripheral elements of the cap holder, also called the chuck, it is advantageous to detect deviations in the cap holder's movement and act accordingly. By providing an early and reliable indication that the cap application needs to be adjusted or is otherwise not working satisfactorily, the cap application can be checked and adjusted if necessary to avoid filling machine stoppages and quality issues. Furthermore, improved monitoring of the cap application process potentially allows for tighter tolerance levels, which can result in less plastic material being used in the packaging.

[0010] The sensor data includes angle data measured between a cap application start position and a cap application end position of rotation about a central axis.

[0011] By knowing the angle data, i.e. the angle between the start and end positions, a reliable monitoring of the cap application can be achieved. If the angle data deviates significantly, this indicates that the cap application process is not functioning properly.

[0012] The sensor data may include torque data measured during rotation of the cap about a central axis from a cap application start position to a cap application end position.

[0013] In addition to or as an alternative to the angle data, the torque data provides relevant information regarding the cap application: if the torque used in applying the cap deviates from the historical and / or set torque data, it indicates that the cap application needs to be readjusted.

[0014] The sensor data may include vertical angle data measured between a cap application start position and a cap application end position of rotation about a vertical axis, the vertical axis being perpendicular to the central axis.

[0015] If the cap holder rotates about a vertical axis, it is an indication that the cap application is not occurring as planned and the operator should investigate why the cap applicator is not working as expected.

[0016] The method further comprises: harvesting energy using an energy harvesting arrangement; The present invention may also include the following.

[0017] Having an energy harvesting arrangement has the advantage of extending the time between battery replacements. In some applications, where a power backup is deemed unnecessary, having an energy harvesting arrangement allows the battery to be omitted. By disposing the energy harvesting arrangement on the peripheral element, motion is generated upon application of the cap, providing energy that the energy harvesting arrangement captures.

[0018] The sensor data may further include data selected from the group consisting of translational motion data measured along the central axis, vibration data measured during rotation from the cap application start position to the cap application end position, accelerometer data measured during rotation from the cap application start position to the cap application end position, gyro data measured during rotation from the cap application start position to the cap application end position, and / or temperature data.

[0019] The cap holder further includes a memory for holding type data of the cap holder, and the method further includes: receiving the cap holder type data from the memory via the communication module; comparing the cap holder type data with cap holder type reference data obtained from the control system of the filling machine; If the cap holder type data and the cap holder type reference data are inconsistent, sending a cap holder type error notification to the control system; Be prepared to do so.

[0020] Since different cap holders may be used for different caps, there is a risk that the wrong cap holder will be used. This risk is increased when several different caps are used and these caps have similar properties, since the different cap holders have the effect of being similar. In such a situation, it may not be immediately obvious that the wrong cap holder has been used, and packages may be produced that appear fine at first glance, but have quality issues on closer inspection. By equipping the cap holder with a memory that holds the cap holder type data, this risk can be reduced or completely eliminated.

[0021] The filling machine may be equipped with two parallel cap holders, and sensor data from the two parallel cap holders may be received in parallel, and by comparing the sensor data from the two parallel cap holders, cap holder specific inconsistencies can be identified.

[0022] Using two cap holders in parallel allows for a relative comparison between the two, adding another possibility to identify when cap application is not working as planned.

[0023] The memory may comprise identification data.

[0024] Having identification data provided in the cap holder's memory, i.e. having a code for each cap holder, allows the cap holder to be identified, and the advantage is that by aggregating and tracking data from many cap holders over time, reliable models can be achieved to improve the understanding of the cap application process, for example by using AI, which allows improving the sensor reference data.

[0025] According to a second aspect there is provided a cap holder arranged to hold a cap upon rotational application to a package, the cap holder comprising: a peripheral element for surrounding the cap; a gripping element connected to the peripheral element and arranged to prevent movement of the cap relative to the peripheral element during rotation of the peripheral element about the central axis; a sensor arrangement attached to the peripheral element and arranged to generate sensor data; a communication module linked to the peripheral element, communicatively coupled to the sensor arrangement and arranged to transmit the sensor data; Equipped with.

[0026] Similar advantages and features presented with respect to the first embodiment are also valid for this second embodiment.

[0027] The sensor arrangement and the communications module may share the same circuit board.

[0028] The sensor arrangement and communication module, possibly energy harvesting arrangement and / or memory may be provided on the same circuit board, i.e. on the same unit, so that they can be easily attached to the cap holder. The advantage of this is that existing filling machines can be easily upgraded.

[0029] The cap holder may comprise an energy harvesting arrangement attached to the peripheral element for powering the sensor placement portion and / or the communication module.

[0030] The energy harvesting configuration may be selected from the group including: a moving coil configuration, a moving magnet configuration, a free impact mass configuration, a levitation configuration, a dual spring mass configuration.

[0031] According to a third aspect, there is provided a filling machine comprising a cap applicator comprising a cap holder according to the second aspect.

[0032] According to a fourth aspect there is provided a computer program product comprising instructions which, when executed by a data processing apparatus, cause the data processing apparatus to carry out a method according to the first aspect.

[0033] Further objects, features, aspects and advantages of the present invention will become apparent from the following detailed description and drawings. [Means for solving the problem]

[0034] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: FIG. [Brief description of the drawings]

[0035] [Figure 1] FIG. 13 is a diagram showing an example of a cap holder. [Diagram 2] FIG. 1 shows an example of a cap applicator having two cap holders. [Diagram 3] FIG. 2 is a schematic diagram of a filling machine and a data processing device. [Figure 4] FIG. 2 is a diagram illustrating an example of a circuit board. [Diagram 5] 1A-1D illustrate various principles of energy harvesting configurations. [Figure 6] 1 is a flow chart illustrating a method for monitoring cap application. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0036] 1, a cap holder 100, sometimes referred to as a chuck, is shown. As shown, the cap holder 100 may be ring-shaped so that it can be placed over the cap 106. When placed over the cap 106, the peripheral element 102 of the cap holder 100 may surround the cap 100. In this position, a gripping element 104 housed within the peripheral element 102 can be used to grip the cap 106. After the gripping element 104 grips the cap 106, the peripheral element 102 can rotate about a central axis A so that the cap 106 is screwed onto the neck of the package.

[0037] A circuit board 108 comprising a sensor arrangement 110, a communication module 112, optionally an energy harvesting arrangement 114 and a memory 116 may be attached to the peripheral element 102. The circuit board 108 may be encapsulated or otherwise shielded from the environment within the filling machine so that it can withstand moisture, liquids and the like. The term "circuit board" in this context should be interpreted broadly and is understood to encompass any device such that different arrangements can be grouped together and handled as a unit by an operator.

[0038] An advantage of mounting the circuit board 108 to the peripheral element 102 is that the circuit board 108 can be mounted to an existing cap holder 100. In other words, since the sensor arrangement 110, the communication module 112, the optional energy harvesting arrangement 114 and the optional memory 116 are configured as one unit that can be easily mounted to the peripheral element 102, an advantage is that an existing base of cap applicators can be easily upgraded, so that the sensor data is easily available to food producers.

[0039] 2 exemplarily illustrates a portion of a cap applicator 200 that includes two cap holders 100 that are configured to operate in parallel. One reason for including parallel cap holders in the cap applicator 200 is to increase capacity.

[0040] In the example shown in Fig. 2, a translational movement element 202 is provided. By using this translational movement element, the two cap holders 100 can be translationally adjusted to achieve a proper fit with the package. A rotational movement element 204 can be used to rotate the cap holders 100. In the example shown, the rotational movement element 204 comprises a belt connected to the cap holders 100, via which the cap holders 100 can rotate about the central axis A. Other options are possible, such as directly connecting the cap holders 100 to a servo motor without using a belt.

[0041] The cap may be applied after the package has been filled with the food product. This is the case for PET bottles. Alternatively, the cap may be applied before the product is filled. This option may be used when the package is made from a carton-based material. In such cases, a web of packaging material may be fed to a filling machine, cut into pieces, folded into a sleeve, sealed longitudinally, provided with a plastic top, i.e. shoulder and neck, at a forming station, the cap applied, the food filled and the bottom sealed so that the package is closed. The advantage of applying the cap before filling is that the package can be freely reoriented when the cap is applied.

[0042] To provide that the cap application is being performed properly, e.g., that there is no misalignment, the sensor arrangement 110 may be arranged to measure vertical angle data about a vertical axis B that is perpendicular to the central axis A. If rotation occurs about the vertical axis B during cap application, i.e., between the cap application start position and the cap application end position, this may indicate that the adjustment of the cap applicator 200 needs to be reviewed.

[0043] 3 shows a schematic representation of an example filling machine 300. As mentioned above, different types of packaging are produced in different ways. The filling machine 300 shown here is a filling machine for producing carton packaging, e.g. Tetra Top®, but the principles can also be applied to other types of packaging with screw caps.

[0044] As shown, the filling machine 300 may include a sleeve former 302 arranged to receive a web of packaging material and form it into a sleeve of packaging material. As mentioned above, this may include cutting the web into segments and longitudinally sealing the segments into a sleeve. Additionally, there is the option of feeding the filling machine a blank that has been assembled by the sleeve former 302, i.e. a pre-made sleeve that has been folded flat.

[0045] After the sleeve is formed, a top is applied to the sleeve by a top molding machine 304. As described above, the top may be injection molded onto the sleeve so that the top of the sleeve is closed, although other methods are contemplated. For example, although not commonly used, it is possible to provide a pre-formed top that is sealed onto the top of the sleeve.

[0046] Once the top is formed, the cap 106 is applied to the top in a cap applicator 200. The cap applicator 200 may be embodied in a variety of ways, the example shown in Figure 2 being one of several possible options.

[0047] The food product is then filled into the package through the open bottom of the package once the cap 106 is attached. After filling, the bottom is sealed and possibly folded over the bottom of the package. This is done in a bottom former, which may be divided into several sub-units, such as a bottom sealer and a final former.

[0048] To ensure proper cap application, sensor data 314 may be provided from the cap applicator 200, and more particularly the cap holder 100, to a data processing device 312. As shown, the data processing device 312 may be a server, or a server farm, or a computer located locally to the filling machine 300.

[0049] The sensor data 314 may be continuously provided from the cap applicator 200 to the data processing device 312, but may also be provided on demand. In the latter case, a request 316 may be sent from the data processing device 312 to the cap applicator 200. The request 316 may be sent at regular intervals, but may also be triggered by other events indicating that the application of the cap needs to be checked. For example, such a trigger may be generated by a vision-based quality system.

[0050] To evaluate the sensor data 314, the sensor reference data 320 may be retrieved from a database 318. This database 318 may be specific to the filling machine, but may be shared among multiple filling machines. The advantage of sharing among multiple filling machines is that a more reliable model, either a statistical model or an AI model, can be established. This is especially true when a wide variety of parameters are considered, such as translational motion data, accelerometer data, gyro data, temperature data, torque data, plastic material type data (providing information on the material used for the cap and / or neck), etc. Furthermore, by measuring over time, the model can be further improved, and as a result, the sensor reference data 320 generated by the model can be further improved. The advantage of measuring over time is that the past data can be used as a basis for making predictions, such as predictive maintenance. In other words, if the comparison of the sensor data 314 and the sensor reference data 320 is not consistent, i.e. the sensor data 314 indicates that something in the cap application is not working as planned, it may suggest that the cap application is currently working but is at risk of not working within a certain period of time in the future.

[0051] If there is a discrepancy between the sensor data 314 and the sensor reference data 320, i.e. between the current and expected values, a check notification 322 may be issued and sent to a control system 324 of the filling machine 300, which may result in a notification message being sent to an operator or a service event being scheduled. Although the control system 324 is illustrated as part of the filling machine 300, the control system may be stand-alone or may form part of other equipment.

[0052] 4 shows the circuit board 108 as an example. In this particular example, a battery is provided at the left end of the board 108 to ensure power supply even when the energy harvesting arrangement 114 does not generate electrical energy. A microphone is provided at the right end. With the microphone, the sensor data 314 may further include audio data.

[0053] To further facilitate attachment of the circuit board 108 to the peripheral element 102, communication between the circuit board 108 and the data processing device 312 may be at least partially wireless, so as to avoid wires that may interfere with rotation of the cap holder 100.

[0054] Having the energy harvesting arrangement 114 reduces the need for battery replacement and, therefore, the need for frequent service intervals for the circuit board 108. As shown in FIG. 4, to ensure reliable operation, the circuit board 108 may include a battery as a complement to the energy harvesting arrangement 114.

[0055] Since the peripheral element 102 of the cap holder 100 moves during operation of the filling machine 300, it is beneficial to use the energy harvesting arrangement 114 in this context. In other words, a positive effect of placing the circuit board 108 with the energy harvesting arrangement 114 on the peripheral element 102 is that the movement of the energy harvesting arrangement 114 is provided to generate electricity for the circuit board. In addition to generating electricity, the energy harvesting arrangement 114 may function as a wake-up arrangement and a close-down arrangement, i.e., input from the energy harvesting arrangement 114 may be used to set the circuit board in an idle mode or a low power mode.

[0056] As shown in FIG. 5, the energy harvesting configuration 114 may use different principles for energy harvesting, such as a moving coil configuration (A), a moving magnet configuration (B), a free impact mass configuration (C), a levitation configuration (D), and a dual spring mass configuration (E).

[0057] 6 is a flow chart illustrating a method 600 for monitoring cap application in a filling machine 300. In a first step 602, sensor data 314 is received. In a second step 604, the sensor data 314 is compared with sensor reference data 320. If there is a discrepancy 606 between the two, in a third step 608, a check notification 322 is sent.

[0058] Optionally, in a fourth step 610, energy is harvested using an energy harvesting arrangement 114 to reduce service needs and improve energy efficiency.

[0059] Optionally, to prevent the wrong type of cap holder, also known as a chuck, from being used, in a fifth step 612, cap holder type data is received from memory 116. In a sixth step 614, the cap holder type data is compared to cap holder type reference data. If there is a mismatch 616, in a seventh step 618, a cap holder type error notification is sent.

[0060] From the foregoing description, while various embodiments of the present invention have been described and illustrated, the invention is not limited thereto and may be embodied in other ways within the scope of the subject matter defined in the following claims.

Claims

1. A method (600) for monitoring cap application in a filling machine (300) using a data processing device (312), the filling machine (300) comprising a cap holder (100), the cap holder comprising: a peripheral element (102) surrounding the cap (106); a gripping element (104) connected to the peripheral element (102) and arranged to prevent movement of the cap (106) relative to the peripheral element (102) during rotation about a central axis (A) of the peripheral element (102); a sensor arrangement (110) attached to the peripheral element (102); a communication module (112) linked to the peripheral element (102), communicatively connected to the sensor arrangement (110), and arranged to transmit sensor data to a data processing device (312); Equipped with The method comprises: receiving (602) the sensor data (314) captured by the sensor arrangement (110); comparing (604) the sensor data (314) with sensor reference data (320) maintained in a reference database (318) communicatively connected to the data processing device (312); sending (608) a check notification (322) from the data processing device (312) to the control system (324) if there is a discrepancy (606) between the sensor data (314) and the sensor reference data (320); Method (600).

2. the sensor data (314) includes angle data measured between a cap application start position and a cap application end position of rotation around the central axis (A); The method of claim 1.

3. the sensor data (314) includes torque data measured during rotation of the cap about a central axis (A) from a cap application start position to a cap application end position; The method of claim 1.

4. the sensor data (314) comprises vertical angle data measured between a cap application start position and a cap application end position of rotation about a vertical axis (B), the vertical axis (B) being perpendicular to the central axis (A); The method of claim 1.

5. harvesting (610) energy using an energy harvesting arrangement (114); The method of claim 1.

6. the sensor data (314) further comprises data selected from the group consisting of translational data measured along the central axis (A), vibration data measured during rotation from the cap application start position to the cap application end position, accelerometer data measured during rotation from the cap application start position to the cap application end position, gyro data and / or temperature data measured during rotation from the cap application start position to the cap application end position, The method of claim 1.

7. The cap holder further includes a memory (116) for holding cap holder type data, and the method further comprises: receiving (612) cap holder type data from said memory (116) via a communication module (112); comparing (614) said cap-holder type data with cap-holder type reference data obtained from the control system (324) of the filling machine (300); If there is a mismatch between the cap-holder type data and the cap-holder type reference data (616), sending a cap-holder type error notification to a control system (324) (618); Prepare for this. The method of claim 1.

8. The filling machine comprises two parallel cap holders (100), receiving sensor data (314) from the two parallel cap holders (100) in parallel and comparing the sensor data (314) from the two parallel cap holders (100) to identify cap holder specific discrepancies; The method of claim 1.

9. the memory (116) comprises identification data; The method of claim 7.

10. A cap holder (100) arranged to hold a cap (106) during rotational application to a package, said cap holder comprising: a peripheral element (102) surrounding said cap (106); a gripping element (104) connected to the peripheral element (102) and arranged to prevent movement of the cap (106) relative to the peripheral element (102) during rotation of the peripheral element (102) about a central axis (A) of the peripheral element (102); a sensor arrangement (110) attached to the peripheral element (102) and arranged to generate the sensor data (314); a communication module (112) linked to the peripheral element (102), communicatively connected to the sensor arrangement (110), and arranged to transmit the sensor data (314); A cap holder (100) comprising:

11. The sensor arrangement portion (110) and the communication module (112) share the same circuit board. A cap holder (100) according to claim 10.

12. further comprising an energy harvesting arrangement (114) attached to the peripheral element (102) for powering the sensor placement portion (110) and / or the communication module (112); The cap holder (100) of claim 10.

13. the energy harvesting arrangement (114) is selected from the group comprising a moving coil arrangement, a moving magnet arrangement, a free impact mass arrangement, a levitation arrangement, and a dual spring mass arrangement; The cap holder (100) of claim 12.

14. A filling machine (300) comprising a cap applicator (306) comprising a cap holder (100) according to claim 10.

15. A computer program comprising instructions that, when executed by a data processing device (312), cause the data processing device (312) to perform the method of claim 1.

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