An actuator for a flow control device in a packing system

Abstract

An actuator for a flow control device (104) in a material packing machine (100) comprised of a single cylinder pneumatic actuator (102) configured to operably vary position of the flow control device (104) between a first position and a second position, a sensor module (106) and a control module (108). The flow control device (104) is configured to control flow of material on a conveyor, wherein the sensor module (106) is configured to continuously determine position of the piston of the single cylinder pneumatic actuator (102), and the control module (108) is configured to be in communication with the single cylinder pneumatic actuator (102) and the sensor module (106). The control module (108) is configured to control the position of the piston by providing inputs to the single cylinder pneumatic actuator (102) thereby changing the position of the flow control device (104) between the first position and the second position.

Description

AN ACTUATOR FOR A FLOW CONTROL DEVICE IN A PACKING SYSTEMBACKGROUNDField of the invention

[0001] The present invention pertains to a packaging system, and more particularly to an enhanced actuator for a flow control device in a packing system.Brief statement of the prior art

[0002] Automatic packing machines are widely used in various industries for the efficient filling and dosing of products, particularly powdery materials, into bags. Machines available in the market are configured to typically handle quantities ranging from 5 kg to 50 kg per bag and are composed of one or multiple identical filling units, each of which receives the product from a central storage tank. Depending on the design and production requirements, these machines can be arranged in a rotating (carousel) configuration or in a linear, inline arrangement.

[0003] During the bag-filling process, the product is conveyed through a duct into each bag. A flow control device is installed along the duct, which regulates the cross-sectional area through which the product passes. By adjusting the passage section, the flow control device controls the rate at which the product is transferred, allowing for dosing and efficient bag filling. Accurate control of the product flow is critical to ensuring that the target weight for each bag is achieved while maintaining a high production throughput.

[0004] In a typical operation of a packing machine, the filling process is divided into several stages. First, an empty bag is placed onto the filling unit, followed by a tare measurement to account for the weight of the bag. The filling phase is then divided into two parts: a high- flow phase, in which the bulk of the product is transferred rapidly, and a low-flow phase, in which a smaller, more precise quantity of product is added to achieve the target weight. This division is necessary to minimize the variability in the amount of product "in flight" (i.e., product still moving through the duct) when the flow is stopped. After the flow is interrupted, a final weight check is performed, and the filled bag is ejected from the machine. This two- phase approach helps balance the goals of high-speed filling with precise weight control.

[0005] The flow control device used to regulate the filling process typically consists of a mechanical component such as a knife gate valve, ball valve, or pinch valve. This device is operated by a pneumatic actuator, which moves the valve into one of three configurations:fully open (for high-flow filling), partially open (for low-flow filling), or fully closed (to stop the flow).

[0006] However, the existing designs of pneumatic actuators present several challenges. First, the current systems rely on mechanical stops to transition between flow configurations. For example, when switching from high-flow to low-flow, the actuator or the valve component physically strikes a stop, which causes mechanical vibrations. These vibrations can interfere with the load cells or other sensors that measure the weight of the product, leading to inaccurate weight readings. To mitigate these inaccuracies, many systems introduce a "blind time" immediately after the transition, during which the PLC ignores sensor readings to allow the vibrations to subside. However, this solution reduces overall bagging speed, as the transition to the low-flow phase must occur earlier to compensate for the blind time.

[0007] In addition to the issue of vibrations, many packing machines require frequent manual adjustments to the flow control device to accommodate different types of products with varying physical characteristics, such as particle size and density. These manual adjustments are not only time-consuming but also introduce safety risks, as the operator must intervene inside the machine. Moreover, manual adjustments are difficult to standardize across multiple filling units, leading to inconsistencies in performance and suboptimal machine operation. Furthermore, frequent product changeovers necessitate repeated adjustments, which reduce the machine's availability and productivity.

[0008] To address these issues, some machines employ automatic adjustments using electric motors. While automatic adjustment eliminates the need for manual intervention and ensures uniformity across all filling units, it introduces additional challenges. The use of electric motors increases both the initial and operational costs of the system. Furthermore, electric motors are prone to reliability issues in dusty environments, where dust can accumulate and interfere with their function, leading to frequent maintenance and potential downtime.

[0009] Thus, there is a clear need for an improved actuator system that can minimize the mechanical vibrations caused by flow transitions, and reduce the reliance on manual or complex automatic adjustments, even in challenging industrial conditions. The present invention addresses these challenges by providing a novel pneumatic actuator that enables smoother transitions between flow configurations, eliminates the need for mechanical stops, and allows for automatic, continuous adjustment of the flow control device without the added cost and complexity of electric motors.OBJECT OF THE INVENTION

[0001] It is an object of the present invention to overcome or at least alleviate one or more of the above problems of the prior art and / or provide the user with a useful or commercial choice.

[0002] It is an object of the present invention to provide an actuator system for offering a smoother transition of a flow control device between two extreme positions, i.e. open position and closed position.

[0003] It is a further object of the present invention to provide an alternative to the prior art.SUMMARY OF THE INVENTION

[0004] In an embodiment, an actuator for a flow control device in a packing system is disclosed, wherein the actuator comprises of a single cylinder pneumatic actuator, a sensor module, and a control module. The single cylinder pneumatic actuator, the sensor module, and the control module are configured to be in communication with each other, wherein anyone of the above may be configured to receive inputs / feedback from the other.

[0005] In an embodiment, the single cylinder pneumatic actuator may be configured to be operably coupled to the flow control device, wherein the flow control device may be configured to control flow of material on a conveyor. The single cylinder pneumatic actuator may be configured to operably vary position of the flow control device between a first position and a second position.

[0006] In an embodiment, in the first position of the flow control device, the flow control device may be configured to allow maximum material to pass through the conveyor, and in the second position of the flow control device, the flow control device may be configured to restrict the flow of material on the conveyor by blocking the material.

[0007] In an embodiment, the single cylinder pneumatic actuator may be, but not limited to, a pneumatically operated piston and cylinder arrangement, wherein the piston of the single cylinder pneumatic actuator is configured be operated by adjusting volume of fluid within the cylinder of the single cylinder pneumatic actuator.

[0008] In an embodiment, the sensor module may be configured to continuously determine the position of the piston of the single cylinder pneumatic actuator. The sensor module may be, but not limited to, an inductive sensor which is configured to sense the magnetic field generated by the cylinder shaft is configured to continuously monitor the position of the piston of the single cylinder actuator, wherein the position of the piston of the single cylinderactuator monitored by the sensor module in high-resolution is communicated to the control module.

[0009] In an alternate embodiment, the sensor module may be a high-resolution camera sensor, which is configured to continuously monitor the position of the piston of the single cylinder actuator in high-resolution.

[0010] In an embodiment, the control module may be configured to be in communication with the single cylinder pneumatic actuator and the sensor module, wherein the control module may be configured to control the position of the piston by providing inputs to the single cylinder pneumatic actuator thereby varying the position of the flow control device at any position between the first position and the second position. The control module is configured to adjust position the flow control device at any position between the first position and the second position.

[0011] In an embodiment, the material packing machine comprises a load sensor, wherein the load sensor may be configured to be in communication with the control module, and the load sensor may be configured to continuously monitor weight of material exiting the flow control device on the conveyor.

[0012] In an embodiment, the control module may be configured to adjust the position of the flow control device at any position between the first position and the second position based on the inputs received from the sensor module and the load sensor, wherein the volume of fluid within the cylinder of the single cylinder pneumatic actuator may be configured to be gradually varied to enable smooth transition of the piston of the single cylinder pneumatic actuator, thereby enabling smooth transition of the flow control device between the first position and the second position.

[0013] In an embodiment, the single cylinder pneumatic actuator may be configured to be operated through, but not limited to, pneumatic electric valves.BRIEF DESCRIPTION OF DRAWINGS

[0014] Embodiments are illustrated, by way of example and not limitation, in the figures of the accompanying drawings, in which like references indicate similar elements and in which:

[0015] FIG. 1 illustrates a block diagram of a material packing machine 100 comprising of an actuator for a flow control device 104, in accordance with an embodiment.

[0016] FIG. 2 illustrates the actuator with the flow control device 104, in accordance with an embodiment.

[0017] FIG. 3 illustrates a flowchart of a process of material packing employing the material packing machine 100 comprising of the actuator for the flow control device 104, in accordance with an embodiment.DETAILED DESCRIPTION

[0018] Material packing machines 100 are widely used in industries such as food processing, pharmaceuticals, manufacturing, and logistics, where bulk materials need to be divided, controlled and packaged efficiently. These machines typically operate by moving materials along a conveyor system, where the flow of material must be regulated before being deposited into containers, bags or other packaging units.

[0019] A key component of any material packing machine 100 is flow control device 104, which is responsible for managing the amount of material that passes through the conveyor at any given time. The flow control device 104 may be of various forms, such as a gate, valve, or chute, and it serves the critical function of opening, closing, or modulating the flow of materials in a controlled manner. Effective regulation of this flow may be essential to ensure the right amount of material is dispensed into each package, avoiding overfilling, underfilling, or material waste.

[0020] The present invention relates to an improved actuator system designed for material packing machines 100, specifically addressing the need for precise control over the flow of materials on a conveyor system.

[0021] Referring to FIG. 1, a block diagram of a material packing machine 100 comprising of multiple filling spouts, wherein each filling spout comprising an actuator for a flow control device 104 is disclosed, in accordance with an embodiment. Each filling spout of the material packing machine 100 is comprised of, but not limited to, an actuator for a flow control device 104, a sensor module 106, a control module 108 and a load sensor 110.

[0022] In an embodiment, the single cylinder pneumatic actuator 102, the sensor module 106, and the control module 108 may be configured to be in communication with each other, wherein anyone of the above may be configured to receive inputs / feedback from the other.

[0023] In an embodiment, the single cylinder pneumatic actuator 102 may be configured to be operably coupled to the flow control device 104, wherein the flow control device 104 may be configured to control flow of material on a conveyor. The single cylinder pneumatic actuator 102 may be configured to operably vary the position of the flow control device 104 between a first position and a second position.

[0024] In an embodiment, in the first position of the flow control device 104, the flow control device 104 may be configured to allow maximum material to pass through the conveyor, and in the second position of the flow control device 104, the flow control device 104 may be configured to restrict the flow of material on the conveyor by blocking the material.

[0025] In an embodiment, the single cylinder pneumatic actuator 102 may be, but not limited to, a pneumatically operated piston and cylinder arrangement, wherein the piston of the single cylinder pneumatic actuator 102 is configured be operated by adjusting volume of fluid within the cylinder of the single cylinder pneumatic actuator 102.

[0026] In an embodiment, the sensor module 106 may be configured to continuously determine the position of the piston of the single cylinder pneumatic actuator 102. The sensor module 106 may be, but not limited to, an inductive sensor which is configured to sense the magnetic field generated by the cylinder shaft is configured to continuously monitor the position of the piston of the single cylinder actuator, wherein the position of the piston of the single cylinder actuator monitored by the sensor module 106 is communicated to the control module 108.

[0027] In an alternate embodiment, the sensor module may be a high-resolution camera sensor, which is configured to continuously monitor the position of the piston of the single cylinder actuator in high-resolution.

[0028] In an embodiment, the control module 108 may be configured to be in communication with the single cylinder pneumatic actuator 102 and the sensor module 106, wherein the control module 108 may be configured to control the position of the piston by providing inputs to the single cylinder pneumatic actuator 102 thereby varying the position of the flow control device 104 between the first position and the second position. The control module 108 is configured to adjust position the flow control device 104 at any position between the first position and the second position. The sensor module 106 continuously monitors the piston's position, while the control module 108 adjusts the actuator’s behavior based on this feedback, ensuring smooth and accurate transitions. In addition, the system can operate at any intermediate position between the first position (gate of the flow control device 104 fully open) and the second position (gate of the flow control device 104 fully closed), allowing the flow control device 104 to regulate the amount of material passing through the conveyor with a high degree of flexibility.

[0029] In an embodiment, the material packing machine 100 comprises a load sensor 110,wherein the load sensor 110 may be configured to be in communication with the control module 108, and the load sensor 110 may be configured to continuously monitor weight of material exiting the flow control device 104 on the conveyor.

[0030] In an embodiment, the control module 108 may be configured to adjust the position the flow control device 104 at any position between the first position and the second position based on the inputs received from the sensor module 106 and the load sensor 110, wherein the volume of fluid within the cylinder of the single cylinder pneumatic actuator 102 may be configured to be gradually varied to enable smooth transition of the piston of the single cylinder pneumatic actuator 102, thereby enabling smooth transition of the flow control device 104 between the first position and the second position.

[0031] In an embodiment, the single cylinder pneumatic actuator 102 may be configured to be operated through, but not limited to, pneumatic electric valves 202. The provision of pneumatic electric valves 202 enables for precise control of fluid to the cylinder, which in turn controls the piston's movement. This integration ensures high responsiveness and reliability, making the system suitable for high-speed packing applications that require consistent and repeatable results.

[0032] Furthermore, combining the actuator with the sensor module 106 and the control module 108, the invention provides a system capable of continuously monitoring and adjusting the position of the flow control device 104 in real-time. This enables precise and smooth control over material flow, improving the overall performance of the packing machine.

[0033] The provision of the load sensor 110, which is configured to monitor the weight of the material being processed by the packing machine allows the control module 108 to adjust the position of the flow control device 104 dynamically based on the actual material weight being conveyed, ensuring optimal material flow for different packaging requirements. For instance, when a lighter load is detected, the system can increase the material flow, and when a heavier load is detected, the system can decrease the material flow by adjusting the position of the flow control device 104 between the first position and the second position, providing an adaptive control solution.

[0034] An important innovation of this system is its ability to handle gradual transitions between the first position (gate of the flow control device 104 fully open) and the second position (gate of the flow control device 104 fully closed). Instead of abrupt movements, which can cause sudden changes in material flow that may result in spills or damage tosensitive products, the single cylinder pneumatic actuator 102 disclosed in this invention is configured to control the volume of fluid within the cylinder, enabling the piston to move smoothly. This smooth motion translates into a controlled adjustment of the flow control device 104, reducing the risk of material handling errors. This actuator system offers a significant improvement over conventional methods, enhancing the accuracy, efficiency, and flexibility of material flow control in packing machines, ultimately improving productivity and reducing material waste. A key advantage of this invention is the significantly smoother movement it offers compared to traditional systems, which often experience mechanical shock due to abrupt position changes. By minimizing or eliminating these shocks, the system ensures that load cell data can be utilized immediately following a transition, without the need for a settling period. This improvement reduces the overall duration of the filling cycle and enhances the machine’s efficiency and throughput, contributing to a more streamlined and reliable operation.

[0035] In an alternate embodiment, the material packing machine 100 may be provided with linear encoder, wherein the linear encoder may be configured to determine and change the position of the piston of the single cylinder pneumatic actuator 102 based on the relevant inputs / feedback the linear encoder receives.

[0036] FIG. 3 illustrates a flowchart of a process of material packing employing the material packing machine 100 comprising of the actuator for the flow control device 104.

[0037] At step 302, the material to be packed is received on the conveyor. The packing machine comprises a conveyor followed by a dispensing unit, wherein empty bags or bottles or boxes may be positioned at the dispensing unit to be filled, wherein the material to be filled in the empty bags or bottles or boxes may be conveyed via the conveyor to the dispensing unit. The flow control device 104 as described in the foregoing may be provided, wherein the flow control device 104 may be configured to control the flow of material on the conveyor.

[0038] At step 304, weight of the material exiting the conveyor is determined by the load sensor 110. The material to be packed is fed to the dispensing unit, wherein the material from the dispensing unit is then received by the empty bags or bottles or boxes. The load sensor 110 is configured to continuously monitor the weight of the bags or bottles or boxes receiving the material from the dispensing unit.

[0039] At step 306, position of the piston of the single cylinder pneumatic actuator 102 is determined by the sensor module 106. The sensor module 106 is configured to continuouslymonitor the position of the piston of the single cylinder pneumatic actuator 102 during the packing process.

[0040] At step 308, position of the piston of the single cylinder pneumatic actuator 102 is changed / altered by the control module 108 based on the inputs / feedback received from the sensor module 106 regarding the position of the piston at a given instant, and the inputs / feedback received by the load sensor 110 regarding the weight of the material received by the bags or bottles or boxes. For example, when a lighter load is detected, the system is configured to increase the material flow, and when a heavier load is detected, the system is configured to decrease the material flow by adjusting the position of piston of the single cylinder pneumatic actuator 102 which in turn results in adjusting the position of the flow control device 104 between the first position and the second position, thereby providing an adaptive control solution. This change in position of the piston is achieved by gradually varying the volume of fluid introduced or discharged into / from the cylinder. The functioning of the single cylinder pneumatic actuator 102 is described in detail in the foregoing, and therefore not repeated for the sake of brevity.

[0041] The detailed description described in the foregoing includes references to the accompanying drawings, which form a part of the detailed description. The drawings show illustrations in accordance with example embodiments. These example embodiments, which may be herein also referred to as “examples” are described in enough detail to enable those skilled in the art to practice the present subject matter. However, it may be apparent to one with ordinary skill in the art, that the present invention may be practiced without these specific details. In other instances, well-known methods, procedures and components have not been described in detail so as not to unnecessarily obscure aspects of the embodiments. The embodiments can be combined, other embodiments can be utilized, or structural, logical, and design changes can be made without departing from the scope of the claims. The foregoing detailed description is, therefore, not to be taken in a limiting sense, and the scope is defined by the appended claims and their equivalents.

[0042] In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one. In this document, the term “or” is used to refer to a nonexclusive “or,” such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated.

[0043] Furthermore, the processes described above is described as a sequence of steps, this was done solely for the sake of illustration. Accordingly, it is contemplated that some stepsmay be added, some steps may be omitted, the order of the steps may be re-arranged, or some steps may be performed simultaneously.

[0044] Although embodiments have been described with reference to specific example embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the system and process or method described herein. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense.Many alterations and modifications of the present invention will no doubt become apparent to a person of ordinary skill in the art after having read the foregoing description. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. It is to be understood that the description above contains many specifications, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the personally preferred embodiments of this invention.Reference numeral list:100 - Material packing machine102 - Single cylinder pneumatic actuator104 - Flow control device106 - Sensor module108 - Control module110 - Load sensor202 - Pneumatic electric valve

Claims

CLAIMS1. An actuator for a flow control device (104) in a material packing machine (100) comprising: a single cylinder pneumatic actuator (102) configured to operably vary the position of the flow control device (104) between a first position and a second position; a sensor module (106); and a control module (108), wherein: the flow control device (104) is configured to control flow of material on a conveyor; the single cylinder pneumatic actuator (102) is configured to be operably coupled to the flow control device (104); the single cylinder pneumatic actuator (102) is a pneumatically operated piston and cylinder arrangement; the sensor module (106) is configured to continuously determine the position of the piston of the single cylinder pneumatic actuator (102); the control module (108) is configured to be in communication with the single cylinder pneumatic actuator (102) and the sensor module (106); and the control module (108) is configured to control the position of the piston by providing inputs to the single cylinder pneumatic actuator (102) thereby changing the position of the flow control device (104) between the first position and the second position.

2. The actuator for the flow control device (104) in the material packing machine (100) according to claim 1, wherein: in the first position of the flow control device (104), the flow control device (104) is configured to allow maximum material to pass through the conveyor; in the second position of the flow control device (104), the flow control device (104) is configured to restrict the flow of material on the conveyor by blocking the material; and the control module (108) is configured to adjust position the flow control device (104) at any position between the first position and the second position.

3. The actuator for the flow control device (104) in the material packing machine (100) according to claim 2, wherein: the sensor module (106) is an inductive sensor configured to continuously monitor the position of the piston of the single cylinder actuator; and the position of the piston of the single cylinder actuator monitored by the sensor module (106) is communicated to the control module (108).

4. The actuator for the flow control device (104) in the material packing machine (100) according to claim 3, wherein: the piston of the single cylinder pneumatic actuator (102) is configured to be operated by adjusting volume of fluid within the cylinder of the single cylinder pneumatic actuator (102); the volume of fluid within the cylinder of the single cylinder pneumatic actuator (102) is configured to be gradually varied to enable smooth transition of the piston of the single cylinder pneumatic actuator (102), thereby enabling smooth transition of the flow control device (104) between the first position and the second position.

5. The packing machine (100) comprising the actuator for the flow control device (104) according to claim 4 is comprised of a load sensor (110), wherein: the load sensor (110) is configured to be in communication with the control module (108); the load sensor (110) is configured to monitor weight of material exiting the flow control device (104); and the control module (108) is configured to adjust the position of the flow control device (104) at any position between the first position and the second position based on the inputs received from the sensor module (106) and the load sensor (110).

6. The actuator for the flow control device (104) in the material packing machine (100) according to claim 1, wherein the single cylinder pneumatic actuator (102) is configured to be operated through pneumatic electric valves (202).

7. A method of material packing using the single cylinder pneumatic actuator (102) for the flow control device (104) in the material packing machine (100) according to the preceding claims, the method comprises: receiving material on conveyor; determining weight of material exiting flow control device (104); determining position of piston; and changing position of piston to thereby change position of flow control device (104) between the first position and the second position.

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