In-line laser measurement system and method for monitoring pouch openings in automated filling machines

Abstract

The current invention relates to an in-line measurement system for monitoring pouch openings in an automated packaging machine, wherein the in-line measurement system comprises one or more sensors configured to measure a top opening of a pouch, and a processing unit configured to determine from the measurements of the one or more sensors whether the pouch is sufficiently open for filling and to control the filling process based on the measurements. The invention also relates to a method for monitoring pouch openings in an automated packaging machine, wherein the method comprises the steps of measuring a top opening of a pouch in real-time, determining whether the pouch is sufficiently open for filling, and controlling the filling process based on the measurements.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to European Patent App. No. 25157240.0 filed February 11, 2025, the disclosure of which is hereby incorporated by reference.FIELD OF THE INVENTION

[0002] The present invention relates to automated pouch filling machines, specifically to an in-line measurement system and method for monitoring the opening of pouches.BACKGROUND

[0003] In the field of automated packaging machines, ensuring that pouches, more specifically so called doypacks or stand-up pouches, are properly opened before filling, is a critical step. These machines handle both pre-made and roll stock pouches, requiring that the top and preferably also the bottom openings of the pouch are fully opened. Failure to achieve proper pouch opening can lead to several issues, including miss filling or underfilling, overfilling which can contaminate the seal area or machine parts, and the pouch being pushed out of its grippers due to the improper positioning. Additionally, seal contamination can result in defective sealing and machine downtime. Current methods often fail to detect these issues in real-time, as they either provide only partial measurements or require an additional station, leading to increased waste, machine stoppages, and reduced productivity. There is a significant need for a system that can monitor pouch openings in real-time and ensure that only properly opened pouches are filled at the filling stage, thereby preventing these common problems.SUMMARY OF THE INVENTION

[0004] To this end, the present invention relates to an in-line measurement system for monitoring pouch openings in an automated packaging machine.

[0005] The system comprises one or more sensors, preferably laser sensors, but also optionally white light or photogrammetry sensors, configured to measure the top opening of a pouch in real-time. A processing unit determines whether the pouch is sufficiently open for filling and controls the filling process based on these measurements. The system preferably integrates machine position feedback to enhance alignment precision. Optionally, optical elements are used to modify the light path of the sensors, allowing the system to fit within existing machine structures. If consecutive insufficient pouch openings are detected, the system preferably alarms the operator of such an event or stops the machine to prevent defective pouches from being filled and to prevent machine contamination. This invention offers several advantages, including ensuring optimal operation of machine components, easy retrofitting into existing machines, real-time detection of pouch opening issues and suggested corrective actions based on measurement data, minimizing rework costs and waste, and improving overall process efficiency and filling accuracy.

[0006] Preferred embodiments of the device are shown herein.

[0007] In a second aspect, the present invention relates to a method.

[0008] The method involves measuring the top opening and determining whether the pouch is sufficiently open for filling. Only when the top opening is sufficiently open, the pouch will be filled and sealed. The method is advantageous to avoid waste and seal contamination, resulting in an improved filling process and filling accuracy. The method is particularly advantageous because it can be applied to existing machines with minimal adjustments.

[0009] Preferred embodiments of the method are shown herein.DESCRIPTION OF FIGURES

[0010] FIG. 1 shows a schematic representation of an automated packaging machine.

[0011] FIG. 2A shows a schematic representation of the measurement of a top opening of a pouch using a laser line scanner.

[0012] FIG. 2B shows a schematic representation of the measurement of a bottom opening of a pouch using a laser line scanner.

[0013] FIG. 3A shows a schematic representation of the measurement of a top opening of a pouch using two laser pointers.

[0014] FIG. 3B shows a schematic representation of the measurement of a bottom opening of a pouch using two laser pointers.

[0015] FIGS. 4A-E show different cases wherein a pouch opening is tested against predefined tolerances.

[0016] FIGS. 5A-B show the determination of a detailed profile of a pouch opening.DETAILED DESCRIPTION OF THE INVENTIONDefinitions

[0017] Unless otherwise defined, all terms used in disclosing the invention, including technical and scientific terms, have the meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. By means of further guidance, term definitions are included to better appreciate the teaching of the present invention.

[0018] As used herein, the following terms have the following meanings:

[0019] “A”, “an”, and “the” as used herein refers to both singular and plural referents unless the context clearly dictates otherwise. By way of example, “a compartment” refers to one or more than one compartment.

[0020] “Comprise”, “comprising”, and “comprises” and “comprised of” as used herein are synonymous with “include”, “including”, “includes” or “contain”, “containing”, “contains” and are inclusive or open-ended terms that specifies the presence of what follows e.g. component and do not exclude or preclude the presence of additional, non-recited components, features, element, members, steps, known in the art or disclosed therein.

[0021] Furthermore, the terms first, second, third and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequential or chronological order, unless specified. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the invention described herein are capable of operation in other sequences than described or illustrated herein.

[0022] The recitation of numerical ranges by endpoints includes all numbers and fractions subsumed within that range, as well as the recited endpoints.

[0023] Whereas the terms “one or more” or “at least one”, such as one or more or at least one member(s) of a group of members, is clear per se, by means of further exemplification, the term encompasses inter alia a reference to any one of said members, or to any two or more of said members, such as, e.g., any ≥3, ≥4, ≥5, ≥6 or ≥7 etc. of said members, and up to all said members.

[0024] The term "in-line measurement system" refers in the present invention to a system integrated within the production line of an automated packaging machine, designed to measure the openings of pouches as they move through the machine, without requiring a separate measurement station. In a preferred embodiment, the measurement system is directly embedded within the machine structure, operating as part of its existing components rather than as a standalone unit within the production line.

[0025] By the term "pouch openings" is meant in the present invention an open space between a front film and a back film of the pouch. The top opening is where the filling nozzle is inserted and is closed after the filling. The bottom opening ensures the pouch is fully expanded for filling and is already sealed with a gusset before filling. Pouches with such top and bottom openings are commonly known as doypacks or stand-up pouches.

[0026] By the term "laser sensors" is meant in the present invention sensors that use laser technology to project a beam, line or point onto the pouch material and measure the reflection to determine the distance and dimensions of the pouch openings.

[0027] The term "real-time" refers to the capability of the system to process measurements and provide feedback instantaneously or with minimal delay as the pouch moves through the machine, ensuring immediate or in a timely manner detection and correction of any issues with pouch openings.

[0028] By the term "processing unit" is meant in the present invention a computing device or controller that receives measurement data from the sensors, processes this data to determine the status of the pouch openings, and controls the filling process based on this determination.

[0029] The term “electronic CAM” refers to the electronic equivalent of a mechanical cam, which is a rotating or sliding piece in a mechanical linkage and is used to control timing. The term “electronic CAM values” refers to numerical parameters or settings used to control and optimize manufacturing processes. In the context of this invention, electronic CAM values are specifically related to pouch delivery, pouch opening, pouch filling, and pouch sealing. These values play a critical role in the automated control of the packaging machine and the filling station, ensuring precise operation and maintaining process efficiency.

[0030] The term "machine position feedback" refers to data provided by the packaging machine that indicates the precise position and timing of the pouch within the machine, often using electronic CAM values or other positional indicators.

[0031] By the term "adaptive feedback system" is meant in the present invention a system that dynamically adjusts any of the components of the packaging machine, such as grippers or nozzles, based on the real-time measurements of the pouch openings to ensure optimal filling conditions.

[0032] The term "optical elements" refers to components used to alter the path of a light beam from or towards the one or more sensors, allowing the system to fit into compact spaces within existing machine structures without compromising measurement accuracy.

[0033] By the term "stopping the packaging machine" is meant in the present invention the action of halting the entire process, including the pouch filling and pouch transport, if the system detects consecutive insufficient pouch openings, thereby preventing defective pouches from being filled and reducing waste and the machine from being polluted with spilled goods.

[0034] By the term "stopping the filling process" is meant in the present invention the action of halting a filling action. This is done when the system detects a sporadic defect. Only the filling is stopped to reduce waste, stop the machine from being polluted with spilled goods and avoid unnecessary stopping the packaging machine.

[0035] The term "existing packaging machine structures" refers to the configurations and designs of automated packaging machines that are already in use, into which the in-line measurement system can be integrated or retrofitted.

[0036] By the term "multiple measurement points" is meant in the present invention the use of several distinct locations on the pouch where measurements are taken to create a comprehensive and detailed profile of the pouch opening, ensuring accurate assessment and control.

[0037] Reference throughout this specification to "one embodiment" or "an embodiment" means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to a person skilled in the art from this disclosure, in one or more embodiments. Furthermore, while some embodiments described herein include some, but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form different embodiments, as would be understood by those in the art. For example, in the following claims, any of the claimed embodiments can be used in any combination.Device

[0038] In a first aspect, the invention provides an in-line measurement system for monitoring pouch openings in an automated packaging machine.

[0039] In a preferred embodiment the in-line measurement system comprises one or more sensors and a processing unit.

[0040] The one or more sensors are configured to measure a top opening of a pouch. The one or more sensors form a first group of sensors. Non-limiting examples of suitable sensors are a laser line scanner, a laser pointer, a video camera, a photo camera, a 3D-camera, a white light scanner, … The one or more sensors of the first group are preferably configured to measure a top opening of a pouch at a distance from the top that is at most 25% of a total distance from top to bottom of the pouch, more preferably at most 20%, even more preferably at most 15% and most preferably at most 10%. The total distance from top to bottom is measured as a shortest distance from a top edge to a bottom edge of the front or back film of the pouch.

[0041] The processing unit is configured to determine from the measurements of the one or more sensors of the first group whether the pouch is sufficiently open for filling and to control the filling process based on the measurements. Preferably the processing unit determines at least an area of the top opening based on the measurements. The bounds of the area are represented by the measurements. The area is bounded by a front film and a back film of the pouch. The area is preferably substantially perpendicular to the front and back film. This is advantageous for determining if a top opening is sufficient for entering a filling nozzle in the pouch. Preferably the processing unit controls at least if filling the pouch is allowed based on the measurements. If the top opening is outside predefined tolerances, the system signals the machine to halt the filling process, thereby preventing defective pouches from being filled. Preferably the filling nozzle is not entered in the pouch. Preferably the pouch is ejected from the automated packaging machine.

[0042] In a preferred embodiment the in-line measurement system comprises one or more sensors configured to measure a bottom opening of a pouch.

[0043] The one or more sensors are configured to measure a bottom opening of a pouch. The one or more sensors form a second group of sensors. Non-limiting examples of suitable sensors are as for the first group of sensors. The one or more sensors of the second group are preferably configured to measure a bottom opening of a pouch at a distance from the bottom that is at most 25% of a total distance from top to bottom of the pouch, more preferably at most 20%, even more preferably at most 15% and most preferably at most 10%. The total distance from top to bottom is measured as defined before.

[0044] This embodiment is advantageous to determine if the pouch is also at the bottom opening fully expanded for filling. Automated packaging machines fill the pouches with a predetermined amount of goods. If the bottom opening is not fully expanded, the pouch will be overfilled. The pouch is already sealed with a bottom film before filling.

[0045] Preferably the in-line measurement system comprises both a first group and a second group of sensors.

[0046] In a preferred embodiment the one or more sensors are configured to measure a relative position of a front film and a back film of the pouch. This means that a relative position between the front film and the rear film is determined by using the one or more sensors. This is advantageous to determine if the top opening and preferably also the bottom opening are sufficient for entering a filling nozzle in the pouch and filling the pouch correctly. If the relative position between the front film and the rear film is too close then the pouch did not open sufficiently and filling the pouch will most likely result in one or more of the following problems: underfilled or empty pouches, overfilled pouches, seal contamination, improper seals, and contamination of the automated packaging machine, thus creating waste.

[0047] It is clear that the preferred embodiments for measuring the relative position of the front and back film of the pouch can be applied to the sensors of the first group, the second group, or both first and second groups.

[0048] In a preferred embodiment the one or more sensors are laser sensors.

[0049] Laser sensors are beneficial to measure the pouch openings. The laser sensors are preferably high-precision devices that enable accurate detection of the positions of the pouch films. This precise measurement ensures that any defects in the pouch openings are identified in real-time, thereby reducing the likelihood of filling errors. The laser sensors may preferably be positioned at strategic locations around the pouch to capture both the top and bottom openings. More preferably, these sensors are configured to provide continuous data as the pouch moves through the automated packaging machine. This is advantageous because it allows to determine a detailed profile of the top and / or bottom opening with a limited number of sensors, as described in a later embodiment. It is additionally beneficial because it allows for dynamic adjustments, if necessary, as described in a later embodiment. This setup ensures that the pouch is properly aligned and fully opened before the filling process begins.

[0050] It is clear that the embodiment with one or more laser sensors can be applied to the sensors of the first group or the sensors of the second group or the sensors of the first and second group.

[0051] In a further embodiment the laser sensors are laser line scanners.

[0052] Preferably the in-line measurement system comprises at least one laser line scanner for projecting a laser beam onto a top portion of the pouch's front and back films, capturing intersections at a top edge of the pouch opening. This allows for accurate detection of whether the pouch is fully open and whether the filling nozzle can be inserted without contact. A laser line sensor is additionally beneficial because only a single laser is needed for measuring at the top opening the relative position between the front film and the back film.

[0053] Preferably the in-line measurement system comprises at least one laser line scanner for projecting a laser beam onto a bottom portion of the pouch's front and back films, capturing intersections at a bottom edge of the pouch opening.

[0054] This embodiment is advantageous to ensure that the pouch expands fully before reaching the filling station of the automated packaging machine, preventing issues such as overfilling. A laser line sensor is additionally beneficial because only a single laser is needed for measuring at the bottom opening the relative position between the front film and the back film.

[0055] In an alternative embodiment the laser sensors are laser pointers.

[0056] The in-line measurement system comprises at least one first laser pointer for projecting a laser beam on the front film and at least one second laser pointer for projecting a laser beam on the back film. The at least one first laser and the at least one second laser have both a known position and orientation. The known position and orientation is preferably a fixed position and a fixed orientation. The laser pointers are suited for measuring a distance between the fixed position of the laser pointers and the front film or back film. Because the position of the laser pointers, the path of the laser beam and the distance to the front film and the back film are known, a relative position between the front film and the back film can be calculated from the measurements. At least one first laser pointer and at least one second laser pointer are required for measuring the top opening. When also the bottom opening is measured, at least one additional first laser pointer and at least one additional second laser pointer are required for measuring the bottom opening.

[0057] This alternative embodiment has as drawback that at least double the sensors are required compared to laser line scanners. However, this alternative embodiment is advantageous that when a pouch is present, only a single reflection is obtained per laser sensor. This allows the relative position between the front film and the back film to be determined more reliable.

[0058] In an embodiment the one or more sensors are video cameras or photo cameras for making images of the top or bottom opening.

[0059] The processing unit is configured to determine a detailed profile of the top opening based on the images. Preferably the processing unit is configured to determine a detailed profile of the top and bottom opening. The processing unit uses for instance image processing to detect the top edge or the bottom edge of the front film and the back film in the images.

[0060] In an embodiment the one or more sensors are 3D-cameras for making images of the front film and the back film.

[0061] The in-line measurement system comprises at least one first 3D-camera for making images of the front film and at least one second 3D-camera for making images of the back film. The at least one first 3D-camera and the at least one second 3D-camera have both a known position. The known position is preferably a fixed position. The 3D-cameras are suited for measuring a distance between the fixed position of the 3D-cameras and the front film or back film. Because the position of the 3D-cameras, the path of the light beams and the distance to the front film and the back film are known, a relative position between the front film and the back film can be calculated from the measurements.

[0062] This embodiment is advantageous compared to laser pointers because a single first 3D-camera and a single second 3D-camera can be used to measure both the top opening and the bottom opening, provided the pouch is visible from top to bottom to the 3D-camera. This embodiment is additionally advantageous because a detailed profile of the top and / or bottom opening can be determined based on a single image of the first 3D-camera and the second 3D-camera, provided that the pouch is visible to the 3D-camera over its entire width.

[0063] In a further embodiment the in-line measurement system comprises a single first 3D-camera for making images of the top of the pouch for making images of both the front and back film. The one first 3D-camera has a known position. The known position is preferably a fixed position. The 3D-camera is suited for measuring a distance between the fixed position of the 3D-cameras and the front film or back film. Because the position of the 3D-camera, the path of the light beams and the distance to the front film and the back film are known, a relative position between the front film and the back film can be calculated from the measurements. The consequence of working with a single 3D camera that either only the top or bottom opening are seen when we assume that the camera covers the full width of the pouch.

[0064] In an embodiment the one or more sensors are white light scanners. The white light scanners or structured light scanners comprise a white light projector for projecting a series of light patterns, usually stripes, onto the front film and the back film. The white light scanners comprise a camera positioned at known angles relative to the white light projector for capturing images of the deformed light patterns from different viewpoints. The displacement and deformation of the projected patterns give clues about the front film and back film geometry. Because the relative positions of the camera and the white light projector are known, the deformation of the patterns can be used for calculating depth or distance information and consequently a detailed profile of the top or bottom opening, similar to the use of 3D-cameras. The features and advantages as previously described for the 3D-cameras are mutatis mutandis also valid for the white light scanners.

[0065] In an embodiment the one or more sensors are line scan camera. Line scan cameras comprise a high-speed sensor that captures images one line at a time as a series of light patterns, usually stripes, are projected onto the front and back film. Line scan cameras are positioned at the same side of the light source, typically above or beside the moving pouch, to capture the reflected light as it interacts with the front or back film. One camera can measure the complete position of the front film, while another camera can measure the complete position of the back film, ensuring precise alignment and accurate measurement as the films pass through the scanning area. The high dynamic range of cameras provide sensitivity to detect materials with a lower sense detection and low contrast differences. The features and advantages as previously described for the 3D-cameras are mutatis mutandis also valid for the line scan cameras.

[0066] In a preferred embodiment the in-line measurement system comprises optical elements configured to modify the light path of the one or more sensors. The light path is for instance the path followed by a laser beam or a light beam captured by a camera. The optical elements are, for instance, but not limited to, mirrors, lenses or prisms. The optical elements create a light path from the pouch to the one or more sensors, even when there is no direct line of sight between the one or more sensors and the pouch. The optical elements allow for a more compact design that fits within tight spaces in existing machines. This compact design does not compromise measurement accuracy and allows for easy retrofitting into both new and existing automated packaging machines, without requiring significant modifications to the existing equipment. The optical elements are additionally beneficial to maintain and calibrate the in-line measurement system. For instance, the mirrors can be adjusted to fine-tune the light paths, ensuring consistent measurement accuracy over time.

[0067] It is clear that this embodiment can be applied to the sensors of the first group or the sensors of the second group or the sensors of the first and second group.

[0068] It is clear that several different types of sensors, as in previously described embodiments, can be advantageously combined.

[0069] In a preferred embodiment the processing unit is configured to generate a stop signal, to stop the automated packaging machine if a pre-determined number of consecutive insufficient pouch openings are detected. In a further embodiment the processing unit is configured to generate an alarm signal for the automated packing machine if a pre-determined number of consecutive pouch openings are detected. In an even further embodiment, the processing unit is configured to generate either a stop signal or an alarm signal for the automated packaging machine if a pre-determined number of consecutive insufficient pouch openings are detected. Pouch opening can mean the top opening, bottom opening or top and bottom opening. If the pouches are not opened sufficiently in succession, this could indicate a problem with the automatic packaging machine or its settings, a quality problem with the pouches, or a combination of several causes. These embodiments are beneficial for preventing large-scale defects in the filling process. This feature helps reduce waste and prevents downstream contamination of the automated packaging machine and subsequent pouches.

[0070] The system utilizes predefined tolerances to assess whether the pouch opening meets the required specifications or falls outside acceptable limits. In a preferred embodiment, these required specifications include, but are not limited to, film alignment, pouch opening dimensions, positional accuracy, and material deviations. In a further embodiment, the required specifications may be entered through various methods, including but not limited to: an AI-trained model, manual input via a user interface, statistical processing using historical data, sensor calibration, or auto-tuning. For the top opening, the tolerance is based on ensuring that the filling nozzle can fit within the pouch without touching the sides. For the bottom opening, the tolerance ensures that the pouch expands to its full volume to avoid overfilling.

[0071] In a preferred embodiment the processing unit is configured to process the measurements of the one or more sensors in real-time. This is beneficial to give the automated packaging machine a defect prevention capability, which minimizes rework costs by detecting and correcting defective pouches before the filling process. This proactive approach ensures that each pouch is filled correctly on the first attempt, reducing waste and improving the overall efficiency of the production line.

[0072] It is clear that this embodiment can be applied to the sensors of the first group or the sensors of the second group or the sensors of the first and second group.

[0073] In a preferred embodiment the processing unit comprises an interface for receiving machine position feedback from the automated packaging machine. The machine position feedback are for instance electronic CAM values. It is clear that the machine position feedback can be achieved in alternative ways. This interface allows the system to synchronize the top and / or bottom opening measurements with the machine's operational cycle.

[0074] Processing both the sensor data and the machine position feedback in the processing unit is beneficial to generate a detailed profile of the top and / or bottom opening. This is especially beneficial when the sensors are laser pointers. Laser pointers are measuring only at a single point of the front or back film. By taking measurements of the top and / or bottom opening at different times and combining this with the machine position feedback, an accurate profile of the top and / or bottom opening can be determined.

[0075] In an embodiment the in-line measurement system comprises an adaptive feedback mechanism configured to adjust components of the automated packaging machine based on the measurements of the one or more sensors. The adaptive feedback mechanism allows the machine to adjust its operations based on the measurements of the top and / or bottom opening. This feedback mechanism preferably provides real-time data to a control system of the automated packaging machine, enabling it to make precise adjustments to for instance grippers or filling nozzles to ensure proper pouch opening and filling on a first attempt.

[0076] In a further embodiment, the adaptive feedback system may provide diagnostic capabilities. These diagnostics may include alerts for sensor malfunctions, deviations in pouch opening dimensions, or issues with machine components. The diagnostic information can preferably be displayed on a user interface, allowing operators to quickly identify and address any problems. This feature enhances the overall reliability and maintainability of the packaging machine, ensuring consistent performance and reducing downtime.

[0077] In an embodiment the processing unit is configured to analyze the measurements of the top opening or bottom opening and compare it against predefined tolerances. Preferably the processing unit is configured to analyze the measurements of both the top and bottom opening. If the measurements fall outside the acceptable range, the system preferably sends an immediate signal to stop the filling process, thereby preventing the filling of defective pouches and reducing waste on the production line. The tolerance levels for the pouch openings are predefined based on the specific requirements of the filling process. For example, the top opening tolerance is preferably set to ensure that the filling nozzle can fit inside the pouch without touching its sides, while the bottom opening tolerance ensures that the pouch is fully expanded to its maximum volume capacity. These tolerances are adjustable within a range, allowing for customization based on different pouch sizes and filling materials.

[0078] In an embodiment the in-line measurement system is integrated in an automated packaging machine. Preferably the automated packaging machine comprises a pouch opening station with grippers for gripping and opening pouches. The grippers are for instance mechanical fingers, suction cups or another suitable means. The automated packaging machine comprises of one or more filling stations with one or more filling nozzles for filling the pouches. The automated packaging machine preferably comprises a sealing station with sealing means, for instance sealing bars, to close and seal the pouches after filling. Preferably the automated packaging machine comprises a supply station for delivering subsequent empty pouches to be opened and filled. Preferably the automated packaging machine comprises a discharge station for removing filled and sealed pouches.

[0079] In an embodiment, the in-line measurement system includes a user interface that displays real-time data regarding the pouch opening and preferably the machine position. This interface allows operators to monitor the filling process and make manual adjustments if necessary. The user interface may also provide alerts or notifications if the in-line measurement system detects persistent misalignments or other issues, enabling operators to take corrective action promptly.Method

[0080] In a second aspect, the invention relates to a method for monitoring pouch openings in an automated packaging machine.

[0081] In a preferred embodiment the method comprises the steps of measuring a top opening of a pouch in real-time, determining whether the pouch is sufficiently open for filling, and controlling the filling process based on the measurements.

[0082] The top opening of the pouch is measured using one or more sensors. Non-limiting examples of suitable sensors are a laser line scanner, a laser pointer, a video camera, a photo camera, a 3D-camera, a white light scanner, … The top opening is measured at a distance from the top that is at most 25% of a total distance from top to bottom of the pouch, more preferably at most 20%, even more preferably at most 15% and most preferably at most 10%. The total distance from top to bottom is measured as a shortest distance from a top edge to a bottom edge of the front or back film of the pouch. The top opening is preferably measured in real-time when the pouch transitions from a pouch opening station to a filling station of the automated packaging machine.

[0083] The measurements of the one or more sensors are used to determine whether the top of the pouch is sufficiently open for entering a filling nozzle. Preferably at least an area of the top opening is determined based on the measurements. The area is bounded by a front film and a back film of the pouch. The bounds of the area are represented by the measurements. The area is preferably substantially perpendicular to the front and back film. If the top opening is outside predefined tolerances, the filling process is stopped, thereby preventing defective pouches from being filled. Preferably the filling nozzle is not entered in the pouch. Preferably the pouch is ejected from the automated packaging machine. This method significantly reduces the risk of miss filling, overfilling, and seal contamination, which are common issues in automated pouch filling operations.

[0084] In a preferred embodiment the method comprises the additional step of measuring a bottom opening of a pouch in real-time.

[0085] The bottom opening is measured with one or more sensors. Non-limiting examples of suitable sensors are as for measuring the top opening. The bottom opening is preferably measured at a distance from the bottom that is at most 25% of a total distance from top to bottom of the pouch, more preferably at most 20%, even more preferably at most 15% and most preferably at most 10%. The total distance from top to bottom is measured as defined before.

[0086] Measuring the bottom opening is advantageous to determine if the pouch is also at the bottom opening fully expanded for filling. Automated packaging machines fill the pouches with a predetermined amount of goods. If the bottom opening is not fully expanded, the pouch will be overfilled. The pouch is already sealed with a bottom film during filling.

[0087] In a preferred embodiment the measurements are combined with machine position feedback from the automated packaging machine. The machine position feedback are for instance electronic CAM values. It is clear that the machine position feedback can be achieved in alternative ways. Combining the measurements with the machine position feedback allows to synchronize the top and / or bottom opening measurements with the machine's operational cycle. This is beneficial to generate a detailed profile of the top and / or bottom opening. By taking measurements of the top and / or bottom opening at different times and combining this with the machine position feedback, a detailed profile of the top and / or bottom opening can be determined.

[0088] In a preferred embodiment the measurements are taken using one or more laser sensors. The use of laser sensors is highly advantageous due to their ability to provide accurate and consistent measurements, which are crucial for ensuring the proper functioning of the automated filling process. The laser sensors may be positioned at various strategic points around the pouch to measure the top and / or bottom openings. Preferably, the sensors are placed in such a manner that they can detect the exact position and alignment of the pouch films as they move through the machine. This precise detection is in particular beneficial for reconstructing the opening profile of the pouch in real-time. Overall, the use of laser sensors provides a highly precise and reliable method for measuring pouch openings, significantly enhancing the efficiency and accuracy of the automated filling process.

[0089] In a preferred embodiment the method comprises the additional step of stopping the machine if a pre-determined number of consecutive insufficient pouch openings are detected. Pouch opening can mean the top opening, bottom opening or top and bottom opening. Consecutive insufficient pouch openings indicates a problem with the automatic packaging machine or its settings, a quality problem with the pouches, or a combination of several causes. This embodiment is beneficial to reduce waste, preventing multiple defective pouches from being filled.

[0090] In a preferred embodiment the pouch opening is measured at multiple points, wherein the multiple measurement points are used to reconstruct a detailed profile of the pouch opening. Pouch opening can mean the top opening, bottom opening or top and bottom opening. The measurements are used to determine a relative position of the front film and back film of the pouch at the multiple points. The front film and back film bound an area. This area is used to determine if the top opening is sufficiently for entering a filling nozzle in the pouch or if the pouch is sufficiently expanded at the bottom opening.

[0091] In a preferred embodiment a relative position of a front film and a back film of the pouch are measured during measuring the opening of the pouch. This can be at the top, bottom or both. A relative position between the front film and the rear film is determined using the one or more sensors. This is advantageous to determine if the top opening and preferably also the bottom opening are sufficiently for entering a filling nozzle in the pouch and filling the pouch correctly. If the relative position between the front film and the rear film is too close, the pouch did not open completely and filling the pouch will most likely result in one of the following problems: creating waste, seal contamination, underfilled or empty pouches, improper seals, overfilling, and contamination of the automated packaging machine.

[0092] In an embodiment, the system generates adaptive feedback signals based on current measurements of the top and / or bottom opening to adjust components of the automated packaging machine. This adaptive feedback mechanism is designed to enhance the overall efficiency of the pouch filling process by minimizing the need for rework. Optionally, if the pouch opening measurements fall outside the acceptable range, feedback signals are generated to adjust for instance the grippers or filling nozzles of the automated packaging machine. This adjustment is preferably carried out in real-time, allowing the automated packaging machine to correct the pouch opening before the filling process begins. More preferably, the feedback signals are transmitted to control unit of the automated packaging machine, which then executes the necessary adjustments to the machine components. This approach ensures that each pouch is properly opened and aligned before filling, thereby reducing the likelihood of defects.

[0093] In a further embodiment, an adaptive feedback loop is used for generating the adaptive feedback signals, that continuously refines the machine's performance based on historical data and real-time measurements. This adaptive loop is preferably designed to learn from previous operations and make incremental adjustments to improve the accuracy and efficiency of the pouch filling process. For example, if a recurring issue with pouch openings is detected, the gripper tension or filling nozzle position may be automatically adjusted to address the problem.

[0094] In an embodiment the method comprises the additional step of calculating an area of the pouch opening. Pouch opening can mean the top opening, bottom opening or top and bottom opening. The area is the plain bounded by the front and back film at the pouch opening. When the area is smaller than a predefined threshold, the pouch opening is determined as insufficient. Subsequent steps can be as described in other embodiments of the method. This embodiment is especially beneficial for the bottom opening.

[0095] In an embodiment the method comprises the additional step of comparing a position of the front film and the back film of the pouch with a position of a filling nozzle. In this step it is verified that the filling nozzle is completely positioned inside the area bounded by the front and back film at the pouch opening. Preferably this step is executed before the filling nozzle is lowered in the pouch. It is clear that this step can be executed after the pouch is opened and even before the pouch is positioned under the filling nozzle. The relative position between the front film and the back film does normally not change while displacing the pouch to for instance a filling station of an automated packaging machine. Preferably the positions are compared at the filling station. Preferably a tolerance is used around the filling nozzle. The tolerance is a minimum distance between the filling nozzle and the front and back film. The tolerance is a minimum of 0 mm, preferably 1 mm, more preferably 2 mm and even more preferably 3 mm. This embodiment is especially beneficial for the top opening.

[0096] A person skilled in the art will appreciate that a method according to the second aspect is preferably performed with an in-line measurement system according to the first aspect and that in-line measurement system according to the first aspect is preferably configured to perform a method according to the second aspect. Each feature described in this document, both above and below, may therefore relate to any of the two aspects of the present invention.

[0097] The invention is further described by the following non-limiting figures which further illustrate the invention, and are not intended to, nor should they be interpreted to, limit the scope of the invention.DESCRIPTION OF FIGURES

[0098] FIG. 1 shows a schematic representation of an automated packaging machine.

[0099] The automated packaging machine (1) comprises a supply station (2) for delivering empty pouches (3). The pouches (3) follow a circular path through the automated packaging machine (1). The automated packaging machine (1) comprises grippers (4) for opening the pouches (3). The grippers (4) are in this embodiment suction cups. After opening, the pouch (3) continues its path towards a filling station (5). An in-line measurement system according to an embodiment of the current invention is installed at the grippers (4) at the earliest and at the filling station (5) at the latest. After filling, the pouch (3) is sealed at a sealing station (6). The sealing station (6) comprises a sealing bar (7) for sealing the pouch (3). The filled and sealed pouch (3) is removed from the automated packaging machine (1) at the discharge station (8).

[0100] It is clear to the skilled person that several different embodiments of the automated packaging machine (1) can be envisaged.

[0101] FIG. 2A shows a schematic representation of the measurement of a top opening of a pouch using a laser line scanner.

[0102] The pouch (3) is gripped by two grippers (4), one at each side of the pouch (3). The two grippers (4) are in this embodiment mechanical fingers. The pouch (3) is opened by bringing the grippers (4) closer to each other. The in-line measurement system comprises a laser line scanner (9) to measure a top opening (10) of the pouch (3). The top opening (10) is open to allow a filling nozzle to enter the pouch (3). The laser line scanner (9) projects a laser beam (11) onto a top portion of the pouch (3). This results in lines (12) on the front (14) and back film (15) of the pouch (3). The in-line measurement systems determines intersections (13) of the laser beam (11) with the top edge of the pouch (3). The laser beam (11) is projected on the pouch (3) while the pouch (3) follows it path through an automated packaging machine (1). The solid line (12) is at the current position of the laser beam (11), while the dashed lines (12) are at previous and future positions of the laser beam (11). A detailed profile of the top opening (10) can be determined by combining the intersections (13) with machine position feedback of the automated packaging machine (1). The top opening (10) is in this embodiment measured at the top of the pouch (3).

[0103] FIG. 2B shows a schematic representation of the measurement of a bottom opening of a pouch using a laser line scanner.

[0104] Measuring a bottom opening (16) of the pouch (3) is very similar to measuring the top opening (10) of the pouch, as described in FIG. 2A. FIG. 2A and 2B are comparable and the description of FIG. 2A applies mutatis mutandis to FIG. 2B. A first difference is that the bottom opening (16) is already sealed with a bottom film (17) during filling. A second difference is that the laser line scanner (9) is now positioned at the bottom of the pouch (3). It is clear that when the in-line measurement system measures both the top opening (10) and the bottom opening (16), the in-line system comprises a laser line scanner (9) at the top and a laser line scanner (9) at the bottom of the pouch (3). The laser line scanner (9) projects in this case a laser beam (11) onto a bottom portion of the pouch (3). This results again in lines (12) on the front (14) and back film (15) of the pouch (3). The lines on the back film (15) are represented as thinner dashed and solid lines (12). The solid lines (12) are again at the current position. As described for FIG. 2A, the intersections (13) are determined and combined with machine position feedback to obtain a detailed profile of the bottom opening (16). The bottom opening (16) is in this embodiment measured at the bottom of the pouch (3).

[0105] FIG. 3A shows a schematic representation of the measurement of a top opening of a pouch using a laser pointer.

[0106] FIG. 3A shows an alternative way of measuring the top opening (10), using two laser pointers (18), instead of a laser line scanner (9) as in FIG. 2A. A first laser pointer (18) projects a laser beam (11) on the front film (14). A second laser pointer (18) projects a laser beam (11) on the back film (15). The first and second laser pointer (18) have both a known position. The first laser pointer (18) measures a distance between the front film (14) and its known position. The second laser pointer (18) measures a distance between the back film (15) and its known position. A relative position between the front film (14) and the back film (15) can be determined from these distances and known positions. The laser beam (11) is projected on the pouch (3) while the pouch (3) follows it path through an automated packaging machine (1). Multiple measurement points are obtained along a path (19) on the front film (14) and the back film (15). The path (19) on the back film (15) is represented with a thinner dashed line than the path (19) on the front film (14). A detailed profile of the top opening (10) can be determined by combining the multiple measurements with machine position feedback of the automated packaging machine (1). The top opening (10) is measured in this embodiment at a distance from the top of the pouch (3) that is about 10% of a total distance from top to bottom of the pouch (3).

[0107] FIG. 3B shows a schematic representation of the measurement of a bottom opening of a pouch using a laser pointer.

[0108] FIG. 3B shows how in a similar way as described for FIG. 3A the bottom opening (16) of the pouch (3) can be measured with two laser pointers (19). The description of FIG. 3A applies mutatis mutandis to FIG. 3B. It is clear that when the in-line measurement system measures both the top opening (10) and the bottom opening (16), the in-line system comprises a first and a second laser line pointer (18) at the top and a first and a second laser line pointer (18) at the bottom of the pouch (3). The bottom opening (16) is measured in this embodiment at a distance from the bottom of the pouch (3) that is about 10% of a total distance from top to bottom of the pouch (3).

[0109] FIGS. 4A-E show different cases wherein a pouch opening is tested against predefined tolerances.

[0110] In these examples two different tolerances are illustrated, being a tolerance (21) around a filling nozzle (20), represented by a dashed line, and a calculated area (22) of a pouch opening (10, 16), represented by diagonal hatching. When the tolerance (21) around the filling nozzle (20) is completely positioned inside the area bounded by the front (14) and back film (15) at the pouch opening (10, 16), the pouch opening (10, 16) is considered sufficient. When the calculated area (22) is lower than a predefined threshold, the pouch opening (10, 16) is considered insufficient. The first predefined tolerance is especially beneficial for the top opening (10) and the second predefined tolerance for the bottom opening (16). Nevertheless, it is clear that both predefined tolerances are suited for the top opening (10) and the bottom opening (16). It is also clear that both predefined tolerances can be used simultaneously for a single pouch opening (10, 16). In that case, preferably both predefined tolerances must be met before the pouch opening (10, 16) is considered sufficient.

[0111] FIG. 4A shows an example wherein the calculated area (22) is above the predefined threshold and wherein the tolerance (21) around the nozzle (20) is completely positioned inside the area bounded by the front (14) and back film (15) at the pouch opening (10, 16). The pouch opening (10, 16) is considered sufficient.

[0112] In FIG. 4B the calculated area (22) is still above the predefined threshold, but the tolerance (21) around the nozzle (20) is not completely positioned inside the area bounded by the front (14) and back film (15) at the pouch opening (10, 16). When using the latter, the pouch opening (10, 16) would be insufficient.

[0113] FIG. 4C shows an example wherein the calculated area (22) is, despite its odd shape, still above the predefined threshold, but the tolerance (21) around the nozzle (20) is again not completely positioned inside the area bounded by the front (14) and back film (15) at the pouch opening (10, 16). When using the latter, the pouch opening (10, 16) would be insufficient.

[0114] FIG. 4D shows an example wherein the calculated area (22) is below the predefined threshold, and the tolerance (21) around the nozzle (20) is also not completely positioned inside the area bounded by the front (14) and back film (15) at the pouch opening (10, 16). No matter which predefined tolerance is used, the pouch opening (10, 16) would be insufficient.

[0115] FIG. 4E shows an example wherein the tolerance (21) around the nozzle (20) is completely positioned inside the area bounded by the front (14) and back film (15) at the pouch opening (10, 16), but in this case the calculated area (22) is below the predefined threshold. When using the calculated area (22) as the predefined tolerance, the pouch opening (10, 16) would be insufficient.

[0116] FIGS. 5A-B show the determination of a detailed profile of a pouch opening.

[0117] The detailed profile of the pouch opening (10, 16) is in this embodiment based on measurements obtained with laser pointers (18) as previously described. Multiple measurements of the distance (24) from a first laser pointer (18) to the front film (14) and of the distance (25) from a second laser pointer (18) to the back film (15) are made while a pouch (3) follows its path through an automated packaging machine (1). The distances (24, 25) are combined with machine position feedback (23). The machine position feedback (23) allows to calculate a distance the pouch (3) has moved between two measurements. The measured distances (24, 25) and the machine position feedback (23) are represented in FIG. 5A. Because the relative positions of the laser pointers (18) are known, a relative position of the front film (14) and the back film (15) can be calculated. This is represented on FIG. 5B. Graphically this corresponds to shifting the curves (24, 25) until the front film (14) and the back film (15) touch each other at edges of the pouch (3). It is now also possible to calculate the area (22) and to verify if the tolerance (21) around the filling nozzle (20) is completely positioned inside the area bounded by the front (14) and back film (15) at the pouch opening (10, 16).

[0118] The numbers in the figures refer to:

[0119] 1. Automated packaging machine

[0120] 2. Supply station

[0121] 3. Pouch

[0122] 4. Gripper

[0123] 5. Filling station

[0124] 6. Sealing station

[0125] 7. Sealing bar

[0126] 8. Discharge station

[0127] 9. Laser line scanner

[0128] 10. Top opening

[0129] 11. Laser beam

[0130] 12. Lines

[0131] 13. Intersection

[0132] 14. Front film

[0133] 15. Back film

[0134] 16. Bottom opening

[0135] 17. Bottom film

[0136] 18. Laser pointer

[0137] 19. Path of multiple measurement points

[0138] 20. Filling nozzle

[0139] 21. Tolerance around filling nozzle

[0140] 22. Area of pouch opening

[0141] 23. Machine position feedback

[0142] 24. Distance to front film

[0143] 25. Distance to back film

Examples

Embodiment Construction

Definitions

[0017]Unless otherwise defined, all terms used in disclosing the invention, including technical and scientific terms, have the meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. By means of further guidance, term definitions are included to better appreciate the teaching of the present invention.

[0018]As used herein, the following terms have the following meanings:

[0019]“A”, “an”, and “the” as used herein refers to both singular and plural referents unless the context clearly dictates otherwise. By way of example, “a compartment” refers to one or more than one compartment.

[0020]“Comprise”, “comprising”, and “comprises” and “comprised of” as used herein are synonymous with “include”, “including”, “includes” or “contain”, “containing”, “contains” and are inclusive or open-ended terms that specifies the presence of what follows e.g. component and do not exclude or preclude the presence of additional, non-recited components, fe...

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to European Patent App. No. 25157240.0 filed February 11, 2025, the disclosure of which is hereby incorporated by reference.FIELD OF THE INVENTION

[0002] The present invention relates to automated pouch filling machines, specifically to an in-line measurement system and method for monitoring the opening of pouches.BACKGROUND

[0003] In the field of automated packaging machines, ensuring that pouches, more specifically so called doypacks or stand-up pouches, are properly opened before filling, is a critical step. These machines handle both pre-made and roll stock pouches, requiring that the top and preferably also the bottom openings of the pouch are fully opened. Failure to achieve proper pouch opening can lead to several issues, including miss filling or underfilling, overfilling which can contaminate the seal area or machine parts, and the pouch being pushed out of its grippers due to the improper positioning. Additionally, seal contamination can result in defective sealing and machine downtime. Current methods often fail to detect these issues in real-time, as they either provide only partial measurements or require an additional station, leading to increased waste, machine stoppages, and reduced productivity. There is a significant need for a system that can monitor pouch openings in real-time and ensure that only properly opened pouches are filled at the filling stage, thereby preventing these common problems.SUMMARY OF THE INVENTION

[0004] To this end, the present invention relates to an in-line measurement system for monitoring pouch openings in an automated packaging machine.

[0005] The system comprises one or more sensors, preferably laser sensors, but also optionally white light or photogrammetry sensors, configured to measure the top opening of a pouch in real-time. A processing unit determines whether the pouch is sufficiently open for filling and controls the filling process based on these measurements. The system preferably integrates machine position feedback to enhance alignment precision. Optionally, optical elements are used to modify the light path of the sensors, allowing the system to fit within existing machine structures. If consecutive insufficient pouch openings are detected, the system preferably alarms the operator of such an event or stops the machine to prevent defective pouches from being filled and to prevent machine contamination. This invention offers several advantages, including ensuring optimal operation of machine components, easy retrofitting into existing machines, real-time detection of pouch opening issues and suggested corrective actions based on measurement data, minimizing rework costs and waste, and improving overall process efficiency and filling accuracy.

[0006] Preferred embodiments of the device are shown herein.

[0007] In a second aspect, the present invention relates to a method.

[0008] The method involves measuring the top opening and determining whether the pouch is sufficiently open for filling. Only when the top opening is sufficiently open, the pouch will be filled and sealed. The method is advantageous to avoid waste and seal contamination, resulting in an improved filling process and filling accuracy. The method is particularly advantageous because it can be applied to existing machines with minimal adjustments.

[0009] Preferred embodiments of the method are shown herein.DESCRIPTION OF FIGURES

[0010] FIG. 1 shows a schematic representation of an automated packaging machine.

[0011] FIG. 2A shows a schematic representation of the measurement of a top opening of a pouch using a laser line scanner.

[0012] FIG. 2B shows a schematic representation of the measurement of a bottom opening of a pouch using a laser line scanner.

[0013] FIG. 3A shows a schematic representation of the measurement of a top opening of a pouch using two laser pointers.

[0014] FIG. 3B shows a schematic representation of the measurement of a bottom opening of a pouch using two laser pointers.

[0015] FIGS. 4A-E show different cases wherein a pouch opening is tested against predefined tolerances.

[0016] FIGS. 5A-B show the determination of a detailed profile of a pouch opening.DETAILED DESCRIPTION OF THE INVENTIONDefinitions

[0017] Unless otherwise defined, all terms used in disclosing the invention, including technical and scientific terms, have the meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. By means of further guidance, term definitions are included to better appreciate the teaching of the present invention.

[0018] As used herein, the following terms have the following meanings:

[0019] “A”, “an”, and “the” as used herein refers to both singular and plural referents unless the context clearly dictates otherwise. By way of example, “a compartment” refers to one or more than one compartment.

[0020] “Comprise”, “comprising”, and “comprises” and “comprised of” as used herein are synonymous with “include”, “including”, “includes” or “contain”, “containing”, “contains” and are inclusive or open-ended terms that specifies the presence of what follows e.g. component and do not exclude or preclude the presence of additional, non-recited components, features, element, members, steps, known in the art or disclosed therein.

[0021] Furthermore, the terms first, second, third and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequential or chronological order, unless specified. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the invention described herein are capable of operation in other sequences than described or illustrated herein.

[0022] The recitation of numerical ranges by endpoints includes all numbers and fractions subsumed within that range, as well as the recited endpoints.

[0023] Whereas the terms “one or more” or “at least one”, such as one or more or at least one member(s) of a group of members, is clear per se, by means of further exemplification, the term encompasses inter alia a reference to any one of said members, or to any two or more of said members, such as, e.g., any ≥3, ≥4, ≥5, ≥6 or ≥7 etc. of said members, and up to all said members.

[0024] The term "in-line measurement system" refers in the present invention to a system integrated within the production line of an automated packaging machine, designed to measure the openings of pouches as they move through the machine, without requiring a separate measurement station. In a preferred embodiment, the measurement system is directly embedded within the machine structure, operating as part of its existing components rather than as a standalone unit within the production line.

[0025] By the term "pouch openings" is meant in the present invention an open space between a front film and a back film of the pouch. The top opening is where the filling nozzle is inserted and is closed after the filling. The bottom opening ensures the pouch is fully expanded for filling and is already sealed with a gusset before filling. Pouches with such top and bottom openings are commonly known as doypacks or stand-up pouches.

[0026] By the term "laser sensors" is meant in the present invention sensors that use laser technology to project a beam, line or point onto the pouch material and measure the reflection to determine the distance and dimensions of the pouch openings.

[0027] The term "real-time" refers to the capability of the system to process measurements and provide feedback instantaneously or with minimal delay as the pouch moves through the machine, ensuring immediate or in a timely manner detection and correction of any issues with pouch openings.

[0028] By the term "processing unit" is meant in the present invention a computing device or controller that receives measurement data from the sensors, processes this data to determine the status of the pouch openings, and controls the filling process based on this determination.

[0029] The term “electronic CAM” refers to the electronic equivalent of a mechanical cam, which is a rotating or sliding piece in a mechanical linkage and is used to control timing. The term “electronic CAM values” refers to numerical parameters or settings used to control and optimize manufacturing processes. In the context of this invention, electronic CAM values are specifically related to pouch delivery, pouch opening, pouch filling, and pouch sealing. These values play a critical role in the automated control of the packaging machine and the filling station, ensuring precise operation and maintaining process efficiency.

[0030] The term "machine position feedback" refers to data provided by the packaging machine that indicates the precise position and timing of the pouch within the machine, often using electronic CAM values or other positional indicators.

[0031] By the term "adaptive feedback system" is meant in the present invention a system that dynamically adjusts any of the components of the packaging machine, such as grippers or nozzles, based on the real-time measurements of the pouch openings to ensure optimal filling conditions.

[0032] The term "optical elements" refers to components used to alter the path of a light beam from or towards the one or more sensors, allowing the system to fit into compact spaces within existing machine structures without compromising measurement accuracy.

[0033] By the term "stopping the packaging machine" is meant in the present invention the action of halting the entire process, including the pouch filling and pouch transport, if the system detects consecutive insufficient pouch openings, thereby preventing defective pouches from being filled and reducing waste and the machine from being polluted with spilled goods.

[0034] By the term "stopping the filling process" is meant in the present invention the action of halting a filling action. This is done when the system detects a sporadic defect. Only the filling is stopped to reduce waste, stop the machine from being polluted with spilled goods and avoid unnecessary stopping the packaging machine.

[0035] The term "existing packaging machine structures" refers to the configurations and designs of automated packaging machines that are already in use, into which the in-line measurement system can be integrated or retrofitted.

[0036] By the term "multiple measurement points" is meant in the present invention the use of several distinct locations on the pouch where measurements are taken to create a comprehensive and detailed profile of the pouch opening, ensuring accurate assessment and control.

[0037] Reference throughout this specification to "one embodiment" or "an embodiment" means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to a person skilled in the art from this disclosure, in one or more embodiments. Furthermore, while some embodiments described herein include some, but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form different embodiments, as would be understood by those in the art. For example, in the following claims, any of the claimed embodiments can be used in any combination.Device

[0038] In a first aspect, the invention provides an in-line measurement system for monitoring pouch openings in an automated packaging machine.

[0039] In a preferred embodiment the in-line measurement system comprises one or more sensors and a processing unit.

[0040] The one or more sensors are configured to measure a top opening of a pouch. The one or more sensors form a first group of sensors. Non-limiting examples of suitable sensors are a laser line scanner, a laser pointer, a video camera, a photo camera, a 3D-camera, a white light scanner, … The one or more sensors of the first group are preferably configured to measure a top opening of a pouch at a distance from the top that is at most 25% of a total distance from top to bottom of the pouch, more preferably at most 20%, even more preferably at most 15% and most preferably at most 10%. The total distance from top to bottom is measured as a shortest distance from a top edge to a bottom edge of the front or back film of the pouch.

[0041] The processing unit is configured to determine from the measurements of the one or more sensors of the first group whether the pouch is sufficiently open for filling and to control the filling process based on the measurements. Preferably the processing unit determines at least an area of the top opening based on the measurements. The bounds of the area are represented by the measurements. The area is bounded by a front film and a back film of the pouch. The area is preferably substantially perpendicular to the front and back film. This is advantageous for determining if a top opening is sufficient for entering a filling nozzle in the pouch. Preferably the processing unit controls at least if filling the pouch is allowed based on the measurements. If the top opening is outside predefined tolerances, the system signals the machine to halt the filling process, thereby preventing defective pouches from being filled. Preferably the filling nozzle is not entered in the pouch. Preferably the pouch is ejected from the automated packaging machine.

[0042] In a preferred embodiment the in-line measurement system comprises one or more sensors configured to measure a bottom opening of a pouch.

[0043] The one or more sensors are configured to measure a bottom opening of a pouch. The one or more sensors form a second group of sensors. Non-limiting examples of suitable sensors are as for the first group of sensors. The one or more sensors of the second group are preferably configured to measure a bottom opening of a pouch at a distance from the bottom that is at most 25% of a total distance from top to bottom of the pouch, more preferably at most 20%, even more preferably at most 15% and most preferably at most 10%. The total distance from top to bottom is measured as defined before.

[0044] This embodiment is advantageous to determine if the pouch is also at the bottom opening fully expanded for filling. Automated packaging machines fill the pouches with a predetermined amount of goods. If the bottom opening is not fully expanded, the pouch will be overfilled. The pouch is already sealed with a bottom film before filling.

[0045] Preferably the in-line measurement system comprises both a first group and a second group of sensors.

[0046] In a preferred embodiment the one or more sensors are configured to measure a relative position of a front film and a back film of the pouch. This means that a relative position between the front film and the rear film is determined by using the one or more sensors. This is advantageous to determine if the top opening and preferably also the bottom opening are sufficient for entering a filling nozzle in the pouch and filling the pouch correctly. If the relative position between the front film and the rear film is too close then the pouch did not open sufficiently and filling the pouch will most likely result in one or more of the following problems: underfilled or empty pouches, overfilled pouches, seal contamination, improper seals, and contamination of the automated packaging machine, thus creating waste.

[0047] It is clear that the preferred embodiments for measuring the relative position of the front and back film of the pouch can be applied to the sensors of the first group, the second group, or both first and second groups.

[0048] In a preferred embodiment the one or more sensors are laser sensors.

[0049] Laser sensors are beneficial to measure the pouch openings. The laser sensors are preferably high-precision devices that enable accurate detection of the positions of the pouch films. This precise measurement ensures that any defects in the pouch openings are identified in real-time, thereby reducing the likelihood of filling errors. The laser sensors may preferably be positioned at strategic locations around the pouch to capture both the top and bottom openings. More preferably, these sensors are configured to provide continuous data as the pouch moves through the automated packaging machine. This is advantageous because it allows to determine a detailed profile of the top and / or bottom opening with a limited number of sensors, as described in a later embodiment. It is additionally beneficial because it allows for dynamic adjustments, if necessary, as described in a later embodiment. This setup ensures that the pouch is properly aligned and fully opened before the filling process begins.

[0050] It is clear that the embodiment with one or more laser sensors can be applied to the sensors of the first group or the sensors of the second group or the sensors of the first and second group.

[0051] In a further embodiment the laser sensors are laser line scanners.

[0052] Preferably the in-line measurement system comprises at least one laser line scanner for projecting a laser beam onto a top portion of the pouch's front and back films, capturing intersections at a top edge of the pouch opening. This allows for accurate detection of whether the pouch is fully open and whether the filling nozzle can be inserted without contact. A laser line sensor is additionally beneficial because only a single laser is needed for measuring at the top opening the relative position between the front film and the back film.

[0053] Preferably the in-line measurement system comprises at least one laser line scanner for projecting a laser beam onto a bottom portion of the pouch's front and back films, capturing intersections at a bottom edge of the pouch opening.

[0054] This embodiment is advantageous to ensure that the pouch expands fully before reaching the filling station of the automated packaging machine, preventing issues such as overfilling. A laser line sensor is additionally beneficial because only a single laser is needed for measuring at the bottom opening the relative position between the front film and the back film.

[0055] In an alternative embodiment the laser sensors are laser pointers.

[0056] The in-line measurement system comprises at least one first laser pointer for projecting a laser beam on the front film and at least one second laser pointer for projecting a laser beam on the back film. The at least one first laser and the at least one second laser have both a known position and orientation. The known position and orientation is preferably a fixed position and a fixed orientation. The laser pointers are suited for measuring a distance between the fixed position of the laser pointers and the front film or back film. Because the position of the laser pointers, the path of the laser beam and the distance to the front film and the back film are known, a relative position between the front film and the back film can be calculated from the measurements. At least one first laser pointer and at least one second laser pointer are required for measuring the top opening. When also the bottom opening is measured, at least one additional first laser pointer and at least one additional second laser pointer are required for measuring the bottom opening.

[0057] This alternative embodiment has as drawback that at least double the sensors are required compared to laser line scanners. However, this alternative embodiment is advantageous that when a pouch is present, only a single reflection is obtained per laser sensor. This allows the relative position between the front film and the back film to be determined more reliable.

[0058] In an embodiment the one or more sensors are video cameras or photo cameras for making images of the top or bottom opening.

[0059] The processing unit is configured to determine a detailed profile of the top opening based on the images. Preferably the processing unit is configured to determine a detailed profile of the top and bottom opening. The processing unit uses for instance image processing to detect the top edge or the bottom edge of the front film and the back film in the images.

[0060] In an embodiment the one or more sensors are 3D-cameras for making images of the front film and the back film.

[0061] The in-line measurement system comprises at least one first 3D-camera for making images of the front film and at least one second 3D-camera for making images of the back film. The at least one first 3D-camera and the at least one second 3D-camera have both a known position. The known position is preferably a fixed position. The 3D-cameras are suited for measuring a distance between the fixed position of the 3D-cameras and the front film or back film. Because the position of the 3D-cameras, the path of the light beams and the distance to the front film and the back film are known, a relative position between the front film and the back film can be calculated from the measurements.

[0062] This embodiment is advantageous compared to laser pointers because a single first 3D-camera and a single second 3D-camera can be used to measure both the top opening and the bottom opening, provided the pouch is visible from top to bottom to the 3D-camera. This embodiment is additionally advantageous because a detailed profile of the top and / or bottom opening can be determined based on a single image of the first 3D-camera and the second 3D-camera, provided that the pouch is visible to the 3D-camera over its entire width.

[0063] In a further embodiment the in-line measurement system comprises a single first 3D-camera for making images of the top of the pouch for making images of both the front and back film. The one first 3D-camera has a known position. The known position is preferably a fixed position. The 3D-camera is suited for measuring a distance between the fixed position of the 3D-cameras and the front film or back film. Because the position of the 3D-camera, the path of the light beams and the distance to the front film and the back film are known, a relative position between the front film and the back film can be calculated from the measurements. The consequence of working with a single 3D camera that either only the top or bottom opening are seen when we assume that the camera covers the full width of the pouch.

[0064] In an embodiment the one or more sensors are white light scanners. The white light scanners or structured light scanners comprise a white light projector for projecting a series of light patterns, usually stripes, onto the front film and the back film. The white light scanners comprise a camera positioned at known angles relative to the white light projector for capturing images of the deformed light patterns from different viewpoints. The displacement and deformation of the projected patterns give clues about the front film and back film geometry. Because the relative positions of the camera and the white light projector are known, the deformation of the patterns can be used for calculating depth or distance information and consequently a detailed profile of the top or bottom opening, similar to the use of 3D-cameras. The features and advantages as previously described for the 3D-cameras are mutatis mutandis also valid for the white light scanners.

[0065] In an embodiment the one or more sensors are line scan camera. Line scan cameras comprise a high-speed sensor that captures images one line at a time as a series of light patterns, usually stripes, are projected onto the front and back film. Line scan cameras are positioned at the same side of the light source, typically above or beside the moving pouch, to capture the reflected light as it interacts with the front or back film. One camera can measure the complete position of the front film, while another camera can measure the complete position of the back film, ensuring precise alignment and accurate measurement as the films pass through the scanning area. The high dynamic range of cameras provide sensitivity to detect materials with a lower sense detection and low contrast differences. The features and advantages as previously described for the 3D-cameras are mutatis mutandis also valid for the line scan cameras.

[0066] In a preferred embodiment the in-line measurement system comprises optical elements configured to modify the light path of the one or more sensors. The light path is for instance the path followed by a laser beam or a light beam captured by a camera. The optical elements are, for instance, but not limited to, mirrors, lenses or prisms. The optical elements create a light path from the pouch to the one or more sensors, even when there is no direct line of sight between the one or more sensors and the pouch. The optical elements allow for a more compact design that fits within tight spaces in existing machines. This compact design does not compromise measurement accuracy and allows for easy retrofitting into both new and existing automated packaging machines, without requiring significant modifications to the existing equipment. The optical elements are additionally beneficial to maintain and calibrate the in-line measurement system. For instance, the mirrors can be adjusted to fine-tune the light paths, ensuring consistent measurement accuracy over time.

[0067] It is clear that this embodiment can be applied to the sensors of the first group or the sensors of the second group or the sensors of the first and second group.

[0068] It is clear that several different types of sensors, as in previously described embodiments, can be advantageously combined.

[0069] In a preferred embodiment the processing unit is configured to generate a stop signal, to stop the automated packaging machine if a pre-determined number of consecutive insufficient pouch openings are detected. In a further embodiment the processing unit is configured to generate an alarm signal for the automated packing machine if a pre-determined number of consecutive pouch openings are detected. In an even further embodiment, the processing unit is configured to generate either a stop signal or an alarm signal for the automated packaging machine if a pre-determined number of consecutive insufficient pouch openings are detected. Pouch opening can mean the top opening, bottom opening or top and bottom opening. If the pouches are not opened sufficiently in succession, this could indicate a problem with the automatic packaging machine or its settings, a quality problem with the pouches, or a combination of several causes. These embodiments are beneficial for preventing large-scale defects in the filling process. This feature helps reduce waste and prevents downstream contamination of the automated packaging machine and subsequent pouches.

[0070] The system utilizes predefined tolerances to assess whether the pouch opening meets the required specifications or falls outside acceptable limits. In a preferred embodiment, these required specifications include, but are not limited to, film alignment, pouch opening dimensions, positional accuracy, and material deviations. In a further embodiment, the required specifications may be entered through various methods, including but not limited to: an AI-trained model, manual input via a user interface, statistical processing using historical data, sensor calibration, or auto-tuning. For the top opening, the tolerance is based on ensuring that the filling nozzle can fit within the pouch without touching the sides. For the bottom opening, the tolerance ensures that the pouch expands to its full volume to avoid overfilling.

[0071] In a preferred embodiment the processing unit is configured to process the measurements of the one or more sensors in real-time. This is beneficial to give the automated packaging machine a defect prevention capability, which minimizes rework costs by detecting and correcting defective pouches before the filling process. This proactive approach ensures that each pouch is filled correctly on the first attempt, reducing waste and improving the overall efficiency of the production line.

[0072] It is clear that this embodiment can be applied to the sensors of the first group or the sensors of the second group or the sensors of the first and second group.

[0073] In a preferred embodiment the processing unit comprises an interface for receiving machine position feedback from the automated packaging machine. The machine position feedback are for instance electronic CAM values. It is clear that the machine position feedback can be achieved in alternative ways. This interface allows the system to synchronize the top and / or bottom opening measurements with the machine's operational cycle.

[0074] Processing both the sensor data and the machine position feedback in the processing unit is beneficial to generate a detailed profile of the top and / or bottom opening. This is especially beneficial when the sensors are laser pointers. Laser pointers are measuring only at a single point of the front or back film. By taking measurements of the top and / or bottom opening at different times and combining this with the machine position feedback, an accurate profile of the top and / or bottom opening can be determined.

[0075] In an embodiment the in-line measurement system comprises an adaptive feedback mechanism configured to adjust components of the automated packaging machine based on the measurements of the one or more sensors. The adaptive feedback mechanism allows the machine to adjust its operations based on the measurements of the top and / or bottom opening. This feedback mechanism preferably provides real-time data to a control system of the automated packaging machine, enabling it to make precise adjustments to for instance grippers or filling nozzles to ensure proper pouch opening and filling on a first attempt.

[0076] In a further embodiment, the adaptive feedback system may provide diagnostic capabilities. These diagnostics may include alerts for sensor malfunctions, deviations in pouch opening dimensions, or issues with machine components. The diagnostic information can preferably be displayed on a user interface, allowing operators to quickly identify and address any problems. This feature enhances the overall reliability and maintainability of the packaging machine, ensuring consistent performance and reducing downtime.

[0077] In an embodiment the processing unit is configured to analyze the measurements of the top opening or bottom opening and compare it against predefined tolerances. Preferably the processing unit is configured to analyze the measurements of both the top and bottom opening. If the measurements fall outside the acceptable range, the system preferably sends an immediate signal to stop the filling process, thereby preventing the filling of defective pouches and reducing waste on the production line. The tolerance levels for the pouch openings are predefined based on the specific requirements of the filling process. For example, the top opening tolerance is preferably set to ensure that the filling nozzle can fit inside the pouch without touching its sides, while the bottom opening tolerance ensures that the pouch is fully expanded to its maximum volume capacity. These tolerances are adjustable within a range, allowing for customization based on different pouch sizes and filling materials.

[0078] In an embodiment the in-line measurement system is integrated in an automated packaging machine. Preferably the automated packaging machine comprises a pouch opening station with grippers for gripping and opening pouches. The grippers are for instance mechanical fingers, suction cups or another suitable means. The automated packaging machine comprises of one or more filling stations with one or more filling nozzles for filling the pouches. The automated packaging machine preferably comprises a sealing station with sealing means, for instance sealing bars, to close and seal the pouches after filling. Preferably the automated packaging machine comprises a supply station for delivering subsequent empty pouches to be opened and filled. Preferably the automated packaging machine comprises a discharge station for removing filled and sealed pouches.

[0079] In an embodiment, the in-line measurement system includes a user interface that displays real-time data regarding the pouch opening and preferably the machine position. This interface allows operators to monitor the filling process and make manual adjustments if necessary. The user interface may also provide alerts or notifications if the in-line measurement system detects persistent misalignments or other issues, enabling operators to take corrective action promptly.Method

[0080] In a second aspect, the invention relates to a method for monitoring pouch openings in an automated packaging machine.

[0081] In a preferred embodiment the method comprises the steps of measuring a top opening of a pouch in real-time, determining whether the pouch is sufficiently open for filling, and controlling the filling process based on the measurements.

[0082] The top opening of the pouch is measured using one or more sensors. Non-limiting examples of suitable sensors are a laser line scanner, a laser pointer, a video camera, a photo camera, a 3D-camera, a white light scanner, … The top opening is measured at a distance from the top that is at most 25% of a total distance from top to bottom of the pouch, more preferably at most 20%, even more preferably at most 15% and most preferably at most 10%. The total distance from top to bottom is measured as a shortest distance from a top edge to a bottom edge of the front or back film of the pouch. The top opening is preferably measured in real-time when the pouch transitions from a pouch opening station to a filling station of the automated packaging machine.

[0083] The measurements of the one or more sensors are used to determine whether the top of the pouch is sufficiently open for entering a filling nozzle. Preferably at least an area of the top opening is determined based on the measurements. The area is bounded by a front film and a back film of the pouch. The bounds of the area are represented by the measurements. The area is preferably substantially perpendicular to the front and back film. If the top opening is outside predefined tolerances, the filling process is stopped, thereby preventing defective pouches from being filled. Preferably the filling nozzle is not entered in the pouch. Preferably the pouch is ejected from the automated packaging machine. This method significantly reduces the risk of miss filling, overfilling, and seal contamination, which are common issues in automated pouch filling operations.

[0084] In a preferred embodiment the method comprises the additional step of measuring a bottom opening of a pouch in real-time.

[0085] The bottom opening is measured with one or more sensors. Non-limiting examples of suitable sensors are as for measuring the top opening. The bottom opening is preferably measured at a distance from the bottom that is at most 25% of a total distance from top to bottom of the pouch, more preferably at most 20%, even more preferably at most 15% and most preferably at most 10%. The total distance from top to bottom is measured as defined before.

[0086] Measuring the bottom opening is advantageous to determine if the pouch is also at the bottom opening fully expanded for filling. Automated packaging machines fill the pouches with a predetermined amount of goods. If the bottom opening is not fully expanded, the pouch will be overfilled. The pouch is already sealed with a bottom film during filling.

[0087] In a preferred embodiment the measurements are combined with machine position feedback from the automated packaging machine. The machine position feedback are for instance electronic CAM values. It is clear that the machine position feedback can be achieved in alternative ways. Combining the measurements with the machine position feedback allows to synchronize the top and / or bottom opening measurements with the machine's operational cycle. This is beneficial to generate a detailed profile of the top and / or bottom opening. By taking measurements of the top and / or bottom opening at different times and combining this with the machine position feedback, a detailed profile of the top and / or bottom opening can be determined.

[0088] In a preferred embodiment the measurements are taken using one or more laser sensors. The use of laser sensors is highly advantageous due to their ability to provide accurate and consistent measurements, which are crucial for ensuring the proper functioning of the automated filling process. The laser sensors may be positioned at various strategic points around the pouch to measure the top and / or bottom openings. Preferably, the sensors are placed in such a manner that they can detect the exact position and alignment of the pouch films as they move through the machine. This precise detection is in particular beneficial for reconstructing the opening profile of the pouch in real-time. Overall, the use of laser sensors provides a highly precise and reliable method for measuring pouch openings, significantly enhancing the efficiency and accuracy of the automated filling process.

[0089] In a preferred embodiment the method comprises the additional step of stopping the machine if a pre-determined number of consecutive insufficient pouch openings are detected. Pouch opening can mean the top opening, bottom opening or top and bottom opening. Consecutive insufficient pouch openings indicates a problem with the automatic packaging machine or its settings, a quality problem with the pouches, or a combination of several causes. This embodiment is beneficial to reduce waste, preventing multiple defective pouches from being filled.

[0090] In a preferred embodiment the pouch opening is measured at multiple points, wherein the multiple measurement points are used to reconstruct a detailed profile of the pouch opening. Pouch opening can mean the top opening, bottom opening or top and bottom opening. The measurements are used to determine a relative position of the front film and back film of the pouch at the multiple points. The front film and back film bound an area. This area is used to determine if the top opening is sufficiently for entering a filling nozzle in the pouch or if the pouch is sufficiently expanded at the bottom opening.

[0091] In a preferred embodiment a relative position of a front film and a back film of the pouch are measured during measuring the opening of the pouch. This can be at the top, bottom or both. A relative position between the front film and the rear film is determined using the one or more sensors. This is advantageous to determine if the top opening and preferably also the bottom opening are sufficiently for entering a filling nozzle in the pouch and filling the pouch correctly. If the relative position between the front film and the rear film is too close, the pouch did not open completely and filling the pouch will most likely result in one of the following problems: creating waste, seal contamination, underfilled or empty pouches, improper seals, overfilling, and contamination of the automated packaging machine.

[0092] In an embodiment, the system generates adaptive feedback signals based on current measurements of the top and / or bottom opening to adjust components of the automated packaging machine. This adaptive feedback mechanism is designed to enhance the overall efficiency of the pouch filling process by minimizing the need for rework. Optionally, if the pouch opening measurements fall outside the acceptable range, feedback signals are generated to adjust for instance the grippers or filling nozzles of the automated packaging machine. This adjustment is preferably carried out in real-time, allowing the automated packaging machine to correct the pouch opening before the filling process begins. More preferably, the feedback signals are transmitted to control unit of the automated packaging machine, which then executes the necessary adjustments to the machine components. This approach ensures that each pouch is properly opened and aligned before filling, thereby reducing the likelihood of defects.

[0093] In a further embodiment, an adaptive feedback loop is used for generating the adaptive feedback signals, that continuously refines the machine's performance based on historical data and real-time measurements. This adaptive loop is preferably designed to learn from previous operations and make incremental adjustments to improve the accuracy and efficiency of the pouch filling process. For example, if a recurring issue with pouch openings is detected, the gripper tension or filling nozzle position may be automatically adjusted to address the problem.

[0094] In an embodiment the method comprises the additional step of calculating an area of the pouch opening. Pouch opening can mean the top opening, bottom opening or top and bottom opening. The area is the plain bounded by the front and back film at the pouch opening. When the area is smaller than a predefined threshold, the pouch opening is determined as insufficient. Subsequent steps can be as described in other embodiments of the method. This embodiment is especially beneficial for the bottom opening.

[0095] In an embodiment the method comprises the additional step of comparing a position of the front film and the back film of the pouch with a position of a filling nozzle. In this step it is verified that the filling nozzle is completely positioned inside the area bounded by the front and back film at the pouch opening. Preferably this step is executed before the filling nozzle is lowered in the pouch. It is clear that this step can be executed after the pouch is opened and even before the pouch is positioned under the filling nozzle. The relative position between the front film and the back film does normally not change while displacing the pouch to for instance a filling station of an automated packaging machine. Preferably the positions are compared at the filling station. Preferably a tolerance is used around the filling nozzle. The tolerance is a minimum distance between the filling nozzle and the front and back film. The tolerance is a minimum of 0 mm, preferably 1 mm, more preferably 2 mm and even more preferably 3 mm. This embodiment is especially beneficial for the top opening.

[0096] A person skilled in the art will appreciate that a method according to the second aspect is preferably performed with an in-line measurement system according to the first aspect and that in-line measurement system according to the first aspect is preferably configured to perform a method according to the second aspect. Each feature described in this document, both above and below, may therefore relate to any of the two aspects of the present invention.

[0097] The invention is further described by the following non-limiting figures which further illustrate the invention, and are not intended to, nor should they be interpreted to, limit the scope of the invention.DESCRIPTION OF FIGURES

[0098] FIG. 1 shows a schematic representation of an automated packaging machine.

[0099] The automated packaging machine (1) comprises a supply station (2) for delivering empty pouches (3). The pouches (3) follow a circular path through the automated packaging machine (1). The automated packaging machine (1) comprises grippers (4) for opening the pouches (3). The grippers (4) are in this embodiment suction cups. After opening, the pouch (3) continues its path towards a filling station (5). An in-line measurement system according to an embodiment of the current invention is installed at the grippers (4) at the earliest and at the filling station (5) at the latest. After filling, the pouch (3) is sealed at a sealing station (6). The sealing station (6) comprises a sealing bar (7) for sealing the pouch (3). The filled and sealed pouch (3) is removed from the automated packaging machine (1) at the discharge station (8).

[0100] It is clear to the skilled person that several different embodiments of the automated packaging machine (1) can be envisaged.

[0101] FIG. 2A shows a schematic representation of the measurement of a top opening of a pouch using a laser line scanner.

[0102] The pouch (3) is gripped by two grippers (4), one at each side of the pouch (3). The two grippers (4) are in this embodiment mechanical fingers. The pouch (3) is opened by bringing the grippers (4) closer to each other. The in-line measurement system comprises a laser line scanner (9) to measure a top opening (10) of the pouch (3). The top opening (10) is open to allow a filling nozzle to enter the pouch (3). The laser line scanner (9) projects a laser beam (11) onto a top portion of the pouch (3). This results in lines (12) on the front (14) and back film (15) of the pouch (3). The in-line measurement systems determines intersections (13) of the laser beam (11) with the top edge of the pouch (3). The laser beam (11) is projected on the pouch (3) while the pouch (3) follows it path through an automated packaging machine (1). The solid line (12) is at the current position of the laser beam (11), while the dashed lines (12) are at previous and future positions of the laser beam (11). A detailed profile of the top opening (10) can be determined by combining the intersections (13) with machine position feedback of the automated packaging machine (1). The top opening (10) is in this embodiment measured at the top of the pouch (3).

[0103] FIG. 2B shows a schematic representation of the measurement of a bottom opening of a pouch using a laser line scanner.

[0104] Measuring a bottom opening (16) of the pouch (3) is very similar to measuring the top opening (10) of the pouch, as described in FIG. 2A. FIG. 2A and 2B are comparable and the description of FIG. 2A applies mutatis mutandis to FIG. 2B. A first difference is that the bottom opening (16) is already sealed with a bottom film (17) during filling. A second difference is that the laser line scanner (9) is now positioned at the bottom of the pouch (3). It is clear that when the in-line measurement system measures both the top opening (10) and the bottom opening (16), the in-line system comprises a laser line scanner (9) at the top and a laser line scanner (9) at the bottom of the pouch (3). The laser line scanner (9) projects in this case a laser beam (11) onto a bottom portion of the pouch (3). This results again in lines (12) on the front (14) and back film (15) of the pouch (3). The lines on the back film (15) are represented as thinner dashed and solid lines (12). The solid lines (12) are again at the current position. As described for FIG. 2A, the intersections (13) are determined and combined with machine position feedback to obtain a detailed profile of the bottom opening (16). The bottom opening (16) is in this embodiment measured at the bottom of the pouch (3).

[0105] FIG. 3A shows a schematic representation of the measurement of a top opening of a pouch using a laser pointer.

[0106] FIG. 3A shows an alternative way of measuring the top opening (10), using two laser pointers (18), instead of a laser line scanner (9) as in FIG. 2A. A first laser pointer (18) projects a laser beam (11) on the front film (14). A second laser pointer (18) projects a laser beam (11) on the back film (15). The first and second laser pointer (18) have both a known position. The first laser pointer (18) measures a distance between the front film (14) and its known position. The second laser pointer (18) measures a distance between the back film (15) and its known position. A relative position between the front film (14) and the back film (15) can be determined from these distances and known positions. The laser beam (11) is projected on the pouch (3) while the pouch (3) follows it path through an automated packaging machine (1). Multiple measurement points are obtained along a path (19) on the front film (14) and the back film (15). The path (19) on the back film (15) is represented with a thinner dashed line than the path (19) on the front film (14). A detailed profile of the top opening (10) can be determined by combining the multiple measurements with machine position feedback of the automated packaging machine (1). The top opening (10) is measured in this embodiment at a distance from the top of the pouch (3) that is about 10% of a total distance from top to bottom of the pouch (3).

[0107] FIG. 3B shows a schematic representation of the measurement of a bottom opening of a pouch using a laser pointer.

[0108] FIG. 3B shows how in a similar way as described for FIG. 3A the bottom opening (16) of the pouch (3) can be measured with two laser pointers (19). The description of FIG. 3A applies mutatis mutandis to FIG. 3B. It is clear that when the in-line measurement system measures both the top opening (10) and the bottom opening (16), the in-line system comprises a first and a second laser line pointer (18) at the top and a first and a second laser line pointer (18) at the bottom of the pouch (3). The bottom opening (16) is measured in this embodiment at a distance from the bottom of the pouch (3) that is about 10% of a total distance from top to bottom of the pouch (3).

[0109] FIGS. 4A-E show different cases wherein a pouch opening is tested against predefined tolerances.

[0110] In these examples two different tolerances are illustrated, being a tolerance (21) around a filling nozzle (20), represented by a dashed line, and a calculated area (22) of a pouch opening (10, 16), represented by diagonal hatching. When the tolerance (21) around the filling nozzle (20) is completely positioned inside the area bounded by the front (14) and back film (15) at the pouch opening (10, 16), the pouch opening (10, 16) is considered sufficient. When the calculated area (22) is lower than a predefined threshold, the pouch opening (10, 16) is considered insufficient. The first predefined tolerance is especially beneficial for the top opening (10) and the second predefined tolerance for the bottom opening (16). Nevertheless, it is clear that both predefined tolerances are suited for the top opening (10) and the bottom opening (16). It is also clear that both predefined tolerances can be used simultaneously for a single pouch opening (10, 16). In that case, preferably both predefined tolerances must be met before the pouch opening (10, 16) is considered sufficient.

[0111] FIG. 4A shows an example wherein the calculated area (22) is above the predefined threshold and wherein the tolerance (21) around the nozzle (20) is completely positioned inside the area bounded by the front (14) and back film (15) at the pouch opening (10, 16). The pouch opening (10, 16) is considered sufficient.

[0112] In FIG. 4B the calculated area (22) is still above the predefined threshold, but the tolerance (21) around the nozzle (20) is not completely positioned inside the area bounded by the front (14) and back film (15) at the pouch opening (10, 16). When using the latter, the pouch opening (10, 16) would be insufficient.

[0113] FIG. 4C shows an example wherein the calculated area (22) is, despite its odd shape, still above the predefined threshold, but the tolerance (21) around the nozzle (20) is again not completely positioned inside the area bounded by the front (14) and back film (15) at the pouch opening (10, 16). When using the latter, the pouch opening (10, 16) would be insufficient.

[0114] FIG. 4D shows an example wherein the calculated area (22) is below the predefined threshold, and the tolerance (21) around the nozzle (20) is also not completely positioned inside the area bounded by the front (14) and back film (15) at the pouch opening (10, 16). No matter which predefined tolerance is used, the pouch opening (10, 16) would be insufficient.

[0115] FIG. 4E shows an example wherein the tolerance (21) around the nozzle (20) is completely positioned inside the area bounded by the front (14) and back film (15) at the pouch opening (10, 16), but in this case the calculated area (22) is below the predefined threshold. When using the calculated area (22) as the predefined tolerance, the pouch opening (10, 16) would be insufficient.

[0116] FIGS. 5A-B show the determination of a detailed profile of a pouch opening.

[0117] The detailed profile of the pouch opening (10, 16) is in this embodiment based on measurements obtained with laser pointers (18) as previously described. Multiple measurements of the distance (24) from a first laser pointer (18) to the front film (14) and of the distance (25) from a second laser pointer (18) to the back film (15) are made while a pouch (3) follows its path through an automated packaging machine (1). The distances (24, 25) are combined with machine position feedback (23). The machine position feedback (23) allows to calculate a distance the pouch (3) has moved between two measurements. The measured distances (24, 25) and the machine position feedback (23) are represented in FIG. 5A. Because the relative positions of the laser pointers (18) are known, a relative position of the front film (14) and the back film (15) can be calculated. This is represented on FIG. 5B. Graphically this corresponds to shifting the curves (24, 25) until the front film (14) and the back film (15) touch each other at edges of the pouch (3). It is now also possible to calculate the area (22) and to verify if the tolerance (21) around the filling nozzle (20) is completely positioned inside the area bounded by the front (14) and back film (15) at the pouch opening (10, 16).

[0118] The numbers in the figures refer to:

[0119] 1. Automated packaging machine

[0120] 2. Supply station

[0121] 3. Pouch

[0122] 4. Gripper

[0123] 5. Filling station

[0124] 6. Sealing station

[0125] 7. Sealing bar

[0126] 8. Discharge station

[0127] 9. Laser line scanner

[0128] 10. Top opening

[0129] 11. Laser beam

[0130] 12. Lines

[0131] 13. Intersection

[0132] 14. Front film

[0133] 15. Back film

[0134] 16. Bottom opening

[0135] 17. Bottom film

[0136] 18. Laser pointer

[0137] 19. Path of multiple measurement points

[0138] 20. Filling nozzle

[0139] 21. Tolerance around filling nozzle

[0140] 22. Area of pouch opening

[0141] 23. Machine position feedback

[0142] 24. Distance to front film

[0143] 25. Distance to back film

Examples

Embodiment Construction

Definitions

[0017]Unless otherwise defined, all terms used in disclosing the invention, including technical and scientific terms, have the meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. By means of further guidance, term definitions are included to better appreciate the teaching of the present invention.

[0018]As used herein, the following terms have the following meanings:

[0019]“A”, “an”, and “the” as used herein refers to both singular and plural referents unless the context clearly dictates otherwise. By way of example, “a compartment” refers to one or more than one compartment.

[0020]“Comprise”, “comprising”, and “comprises” and “comprised of” as used herein are synonymous with “include”, “including”, “includes” or “contain”, “containing”, “contains” and are inclusive or open-ended terms that specifies the presence of what follows e.g. component and do not exclude or preclude the presence of additional, non-recited components, fe...

Claims

1. An automated packaging machine comprising an in-line measurement system for monitoring pouch openings, characterized in that the in-line measurement system comprises one or more sensors configured to measure a top opening of a pouch, and a processing unit configured to determine from the measurements of the one or more sensors whether the pouch is sufficiently open for filling by a filling station and to control the filling process based on the measurements.

2. The automated packaging machine according to claim 1, wherein the in-line measurement system further comprises one or more sensors configured to measure a bottom opening of a pouch.

3. The automated packaging machine according to claim 1, wherein the one or more sensors are configured to measure a relative position of a front film and a back film of the pouch.

4. The automated packaging machine according to claim 1, wherein the one or more sensors are laser sensors.

5. The automated packaging machine according to claim 1, wherein the in-line measurement system further comprises optical elements configured to modify the light path of the one or more sensors.

6. The automated packaging machine according to claim 1, wherein the processing unit is configured to generate a stop signal for the filling process if an insufficient pouch opening is detected.

7. The automated packaging machine according to claim 1, wherein the processing unit is configured to generate a stop signal for the automated packaging machine if a pre-determined number of consecutive insufficient pouch openings are detected.

8. The automated packaging machine according to claim 1, wherein the processing unit is configured to process the measurements of the one or more sensors in real-time.

9. The automated packaging machine according to claim 1, wherein the processing unit comprises an interface for receiving machine position feedback from the automated packaging machine.

10. A method for monitoring pouch openings in an automated packaging machine, characterized in that the method comprises measuring a top opening of a pouch in real-time, determining whether the pouch is sufficiently open for filling, and controlling the filling process based on the measurements.

11. The method according to claim 10, wherein the method further comprises measuring a bottom opening of a pouch in real-time.

12. The method according to claim 10, wherein the measurements are combined with machine position feedback from the automated packaging machine.

13. The method according to claim 10, wherein the measurements are taken using one or more laser sensors.

14. The method according to claim 10, wherein the method further comprises stopping the filling process if an insufficient pouch opening is detected.

15. The method according to claim 10, wherein the method further comprises stopping the machine if a pre-determined number of consecutive insufficient pouch openings are detected.

16. The method according to claim 10, wherein the pouch opening is measured at multiple points, wherein the multiple measurement points are used to reconstruct a detailed profile of the pouch opening.

17. The method according to claim 10, wherein during measuring the opening of the pouch, a relative position of a front film and a back film of the pouch are measured.

Images