CONTAINERS, CORRESPONDING FILLING DEVICE AND FILLING MACHINE

TECHNICAL FIELD

The present invention relates to a system for monitoring a process for filling containers, in particular with a carbonate food product, to a corresponding filling device and to a filling machine including the filling device.

In general, the present solution may be implemented in filling machines for any type of containers or receptacles, such as containers made of glass, plastics (PET), aluminum, steel and composites, and with any type of carbonated product, such as sparkling water, soft drinks, etc..

BACKGORUND OF THE INVENTION

Rotary-type filling machines are known, comprising a rotary conveyor (so called "carousel") rotatable around a vertical axis, a reservoir containing a pourable product and a plurality of filling devices (or "filling valves"). The filling devices are peripherally carried by the carousel, are connected to the reservoir by means of respective ducts and are carried by the carousel along a circumferential transfer path.

A typical filling machine also comprises input and output container conveying means, in particular an inlet conveyor for feeding a succession of empty containers to the carousel and an outlet conveyor receiving the filled containers from the carousel and configured to feed the filled containers to further processing devices, such as a capping device or a labeler device.

Each filling device is configured to feed a predetermined volume of pourable filling product into a respective container at a time, while being advanced along the transfer path due to the rotary motion imparted by the carousel.

For example, in case of a filling process for filling a container with a carbonated filling product, the filling process may include the following phases:

- a pressurization phase, during which a pressurization valve is open in order to raise the pressure within the container by means of a pressurization fluid, an evacuation valve is closed and a filling valve is closed; and

- a filling phase.

The filling phase may include the following substeps:

- a first filling substep (of a very short duration), during which the pressurization valve is closed, the evacuation valve is closed and the filling valve is opened to deliver the filling product in the container (the evacuation valve is closed so that the product starts to be directed towards the lateral walls of the container, as the pressurization fluid is opposing the entry of the filling product); and

- a second filling substep, during which the pressurization valve is closed, the evacuation valve is opened (for evacuating the pressurization fluid during delivery of the filling product) and the filling valve is opened to deliver the filling product in the container.

During the filling phase, there is a typical trend over time of the flow rate of the filling fluid towards the container.

With reference to Figure 1, the trend of the flow of filling product, denoted with Q, during the filling process typically includes: a first section SI, during which raising of the current flow rate from an initial, zero, value occurs;

- a second section S2, during which a stabilization of the current flow rate occurs around a stabilization value;

- a third section S3, during which a decreasing of the current flow rate occurs, e.g. up to the initial, zero, value.

This flow trend is caused by a typical time trend of the filling valve opening degree, which is controlled by a control unit of the filling machine, running a suitable control method.

With reference to Figure 2, the opening degree trend over time, denoted with OD, typically comprises an opening section OS (corresponding to the above first section SI of the flow rate trend), an intermediate section IS (corresponding to the above second section S2) and a closing section CS (corresponding to the above third section S3).

DISCLOSURE OF THE INVENTION

The Applicant has realized that problems of pressurization occurring in the pressurization phase preceding the current filling phase may affect the reliability of the filling process. These pressurization problems may be due for example to one or more of the following causes:

- a not correct pressurization time;

- a loss in a valve or in a seal;

- the evacuation valve not being correctly closed during the first filling substep.

It would therefore be desirable to monitor the filling process since this would allow to determine the occurrence of a possible problem of pressurization occurring before the filling phase.

In particular, the present Applicant has realized that it would be desirable to monitor the filling process in such a way to determine to what extent the flow rate trend is peaking in the first section SI. Indeed, the higher the peak is, the more likely it is that the above discussed problem of pressurization has occurred.

In this regard, Figure 3 shows the trend of the flow of filling product during a filling process where a pressurization problem occurs, as denoted by the high peak of the instant flow rate value in the first section SI (as compared to the "normal" or "regular" time trend shown in Figure 1).

However, a flow rate value can be correctly detected by means of a flow meter sensor during the intermediate section IS of the filling process, and therefore during the second section S2 of the flow time trend, when the flow rate value is more or less stabilized. On the contrary, a flow meter sensor cannot provide a reliable measure during a current raising or decreasing of the same flow rate, so that it is not possible to accurately detect the instant flow rate value during the first and third sections SI, S3 of the flow rate time trend.

The need is therefore felt for a solution allowing to provide an indication of the correctness of the flow rate time trend even during the initial phase of the filling process, when use of a flow meter sensor is not feasible.

The aim of the present solution is to solve, at least in part, the problem previously highlighted, and in general to satisfy the above need. According to the present solution, a monitoring system, a filling device, and a filling machine are provided, as defined in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the present invention, preferred embodiments thereof are now described, purely by way of non-limiting examples, with reference to the attached drawings, wherein:

- Figures 1-3 are plots of time trends of quantities related to filling processes;

- Figure 4 is a schematic representation of a filling machine according to this description, the filling machine according to this description comprising a plurality of filling devices according to this description;

- Figures 5 is a flow chart of a first embodiment of a monitoring process which can be carried out by a monitoring system according to this description;

- Figures 6-7 are plots of time trends of quantities related to the monitoring process; and

- Figures 8 is a flow chart of a second embodiment of a monitoring process which can be carried out by a monitoring system according to this description;

- Figures 9 is a flow chart of a third embodiment of a monitoring process which can be carried out by a monitoring system according to this description.

DETAILED DESCRIPTION A system according to this description is configured for carrying out a monitoring method. A filling device 5 according to this description comprises the system.

The monitoring method is for monitoring a filling procedure. The filling procedure is for filling sequentially a plurality of containers 2 with a pourable product and by means of the filling device 5. The filling device comprises a filling valve. The filling procedure comprises a respective filling process for each container to be filled. The pourable product can be a carbonated pourable product. The pourable product can be a food product . The pourable product can be a carbonated food product.

Each filling process comprises a respective filling phase. Each filling phase is carried out by controlling the opening degree OD of the filling valve, so that the opening degree trend over time comprises an opening section OS, a closing section CS, and an intermediate section IS, which is interposed between said opening section OS and closing section CS. The intermediate section IS corresponds to an at least partial stabilization of a flow rate of the product. The opening section OS, the intermediate section IS and the closing section CS are shown in Figure 2.

Depending on the current conditions of the filling device 5, the flow rate trend over time of the filling product, during each filling phase, can be for example more similar to the graph of Figure 1 or more similar to the graph of Figure 3. However, typically the flow rate trend over time comprises a first section SI, during which raising of the current flow rate from an initial, zero, value occurs; a second section S2, during which a stabilization of the current flow rate occurs around a stabilization value; a third section S3, during which a decreasing of the current flow rate occurs, e.g. up to the initial, zero, value. The first section SI is mainly caused by or corresponds to the opening section OS, the second section S2 is mainly caused by or corresponds to the intermediate section IS, and the third section S3 is mainly caused by or corresponds to the closing section CS.

Each filling process comprises a respective pressurization phase, during which the container to be filled is pressurized. The pressurization phase precedes the filling phase.

The filling device comprises a pressurization valve for allowing a pressurization fluid to enter the container during the pressurization phase. The filling device comprises an evacuation valve for allowing the pressurization fluid to escape the container during the filling phase.

Each filling phase comprises a respective first substep, during which the pressurization valve is closed, the filling valve is opened, and the evacuation valve is closed. Each filling phase comprises, after the first substep, a respective second substep, during which the pressurization valve is closed, the filling valve is opened, and the evacuation valve is opened.

The system can comprise a flowmeter for monitoring the volume of filling product delivered to the container. The system can comprise a position sensor for monitoring or detecting the opening degree. The system can comprise a timer for monitoring or detecting the time during the filling process. The system can comprise an actuator for controlling said opening degree. The system can comprise an automatic monitoring unit. The monitoring unit is configured for obtaining data and/or information and/or signals. The monitoring unit is configured for processing data and/or information and/or signals. The monitoring unit is configured for sending data and/or information and/or signals.

For each filling phase, the system is configured for carrying out a respective monitoring process.

Figure 5 shows the flow diagram of a first embodiment of the monitoring process. Figure 8 show the flow diagram of a second embodiment of the monitoring process. Figure 9 show the flow diagram of a third embodiment of the monitoring process.

According to all the embodiments, the monitoring process comprises automatically detecting a flow rate value FR during said intermediate section IS, by means of the flow meter. This flow rate value FR is indicative of the flow rate of the filling product within said intermediate section IS. This step is shown in block 21.

The value of detected flow rate FR can be correlated to more than one or more instant actual values which are measured during the intermediate section IS, or to an instant value, e.g. measured at the end of the intermediate section IS, before the start of the closing section CS. A possible flow rate value is indicated in Figure 6. Figure 6 shows an example of the flow rate time trend of the filling process.

According to all the embodiments, the monitoring process comprises automatically obtaining a current preclosing time APT, corresponding to a current time elapsed before the closing section CS. This step is shown in block 23 for the first embodiment and the second embodiment, and in block 26 for the third embodiment. The mathematical explanation of the current preclosing time APT is shown in Figure 6.

According to all the embodiments, the monitoring process comprises automatically obtaining a current preclosing volume APV, corresponding to a current volume which is delivered to the container 2 before the closing section CS. This step is shown in block 20 for the first embodiment and the second embodiment, and in block 26 for the third embodiment. The mathematical explanation of the current preclosing volume APV is shown in Figure 6.

According to all the embodiments, the monitoring process comprises automatically calculating an ideal preclosing time IPT, as if the current preclosing volume APV had been delivered completely at the detected flow rate value FR. This step is shown in block 23 for the first embodiment and the second embodiment, and in block 26 for the third embodiment. The mathematical explanation of the ideal preclosing time IPT is shown in Figure 7. According to all the embodiments, calculating the ideal preclosing time ITP comprises calculating the ideal preclosing time ITP as corresponding to the ratio between the current preclosing volume APV and the detected flow rate value FR.

According to all the embodiments, the monitoring process comprises automatically determining a local correctness value LC, based on the current preclosing time APT and the ideal preclosing time IPT. The local correctness value LC is indicative of the correctness of the filling process. The local correctness value LC is associated to the filling device 5. This step is shown in block 23 for the first embodiment and the second embodiment, and in block 26 for the third embodiment.

The system can be configured for determining the local correctness value LC, as corresponding to the difference between the current preclosing time APT and the ideal preclosing time IPT.

The system is configured so that the higher is the local correctness value LC, the more correct is the filling process. The system is configured so that the lower is the local correctness value LC, the less correct is the filling process. The system is configured so that a negative value for the local correctness value LC is indicative of a possible anomaly in the filling process. A possible anomaly indication is shown in block 24.

In other words, as schematically shown in Figure 7, the value of the ideal preclosing time is an ideal time, which is calculated supposing that the current preclosing volume APV has been completely delivered at the detected flow rate FR.

In the first example of Figure 1, the peak in the initial part of the filling phase is lower than in the second example of Figure 2. The system is configured substantially for detecting the correctness of the filling process by indirectly detecting the height of the peak. The first example of Figure 1 is referred to a filling process which is more correct than the filling process to which Figure 3 refers.

The duration of the part of the filling phase before the closing section CS depends on the relative height of the peak with respect to the detected flow rate value FR, and the current preclosing time APT gives at least an indication of the duration of said part of the filling phase. The detected flow rate value FR can be considered a flow rate stabilization value. The higher is the ratio between the current preclosing volume APV and the flow rate stabilization value, the higher is the peak with respect to the flow rate stabilization value, and the higher is the ideal preclosing time IPT with respect to the current preclosing time APT. The higher is the ideal preclosing time IPT with respect to the current preclosing time APT, the less correct is the filling process, and the lower is the local correctness value LC. The system is configured so that lower is the current preclosing time APT and/or the lower is the detected flow rate FR and/or the higher is the current preclosing volume APV, the lower is the correctness value LC, and therefore the less correct is the filling process.

The system is configured so that a detected not complete correctness of the filling process can be related at least to: the duration of the pressurization phase; and/or the current condition of the evacuation valve during the first substep of the filling phase.

The filling procedure is carried out according to a filling recipe, the filling recipe comprising the duration of the pressurization phase.

The system is further configured, in response to the local correctness value LC, for automatically suggesting to a user an adjustment of the filling recipe or automatically carrying out an adjustment of the filling recipe. For example the adjustment can comprise a variation of the duration of the pressurization phase.

The system can be also configured for automatically predicting possible future anomalies.

According to all the embodiments, the monitoring process comprises automatically obtaining a pre-established total volume PTV, corresponding to a volume of filling product to be delivered to the container 2 during the whole filling phase. This step is shown in block 20.

According to all the embodiments, the monitoring process comprises automatically obtaining a pre-established lag volume PLV, corresponding to a volume to be delivered to the container 2 during the closing section CS. This step is shown in block 20.

According to all the embodiments, the monitoring process comprises automatically calculating a pre-established preclosing volume PPV, as the difference between the pre- established total volume PTV and the pre-established lag volume PLV.

According to all the embodiments, the monitoring process comprises automatically triggering the closing section CS upon detection that the volume delivered to the container 2 is equal or greater with respect to the pre-established preclosing volume PPV. These steps are shown in block 22 and block 23. The monitoring process can be considered a monitoring and controlling procedure. The monitoring method can be considered a monitoring and controlling method. The monitoring unit can be a monitoring and control unit.

According to all the embodiments, the monitoring process comprises automatically obtaining a current lag volume ALV, corresponding to the current volume which has been delivered to the container during the closing section CS. This step is shown in block 26. According to first embodiment and third embodiment, the current lag volume ALV is detected by means of the flow meter. According to second embodiment, the current lag volume is calculated. The mathematical explanation of the current lag volume ALV is shown in Figure 6.

According to all the embodiments, the monitoring process comprises automatically updating the pre-established lag volume PLV by means at least of the current lag volume ALV. This step is shown in block 27.Updating the pre-established lag volume PLV by means at least of the current lag volume ALV can comprise applying any mathematical operation involving at least the current lag volume ALV. The pre established lag volume PLV corresponds to a volume to be delivered to the container during the closing section CS.

In this way the current preclosing volume APV of the next filling process will be at least in part dependent upon the condition of one or more previous filling processes, so that the local correctness value LC will be more indicative of the conditions over more than one filling process, to improve the relevance of the local correctness value LC.

According to the first embodiment and the second embodiment, obtaining the current preclosing volume APV comprises determining the current preclosing volume APV as corresponding to the pre-established preclosing volume PPV. This step is shown in block 20. Therefore, according to the first embodiment and the second embodiment, the current preclosing volume APV is preestablished.

According to the first embodiment and the second embodiment, obtaining the current preclosing time APT comprises detecting the current preclosing time APT, as corresponding to the time at which the volume delivered to the container 2 begins to be greater or equal with respect to the pre-established preclosing volume PPV, or as corresponding to the time at which the closing section CS is triggered. This step is shown in block

23. Therefore, the current preclosing time ATP is an indication about how quickly the pre-established preclosing volume PPV is reached.

According to the first embodiment and the third embodiment, obtaining the current lag volume ALV comprises detecting the current lag volume ALV by means of the flowmeter. This step is shown in block 26. In this way, in the first embodiment and in the third embodiment, there is a better correlation of the new updated value of the pre-established lag volume PLV with the current conditions of the flow meter.

According to the first embodiment and the third embodiment, updating the pre-established lag volume PLV comprises updating the preestablished lag volume PLV by means at least of the detected current lag volume ALV. This step is shown in block 27.

According to the second embodiment and the third embodiment, the monitoring process comprises, upon detection of closing of the filling valve 7, automatically detecting the current total filling time ATT, corresponding to the total duration of the filling phase. These steps are shown in block 25 and in block 26.

According to the second embodiment, the monitoring process comprises automatically calculating the current closure time ACT as the difference between the current total time ATT and the current preclosing time APT. The current closure time ACT corresponds to the current duration of the closing section CS. This step is shown in block 26. Figure 6 shows the mathematical explanation of this step of automatically calculating the current closure time ACT as the difference between the current total time ATT and the current preclosing time APT.

According to the second embodiment, obtaining the current lag volume ALV comprises calculating the current lag volume ALV, based on the detected flow rate value FR and the current closure time ACT. This step is shown in block 26.

The current lag volume ALV can be calculated by multiplying the current closure time ACT by the flow rate value FR, and dividing by two, with the following formula:

ALV=ACT•FR/2.

According to the second embodiment, updating the pre- established lag volume PLV comprises updating the pre- established lag volume PLV by means at least of the calculated current lag volume ALV. This step is shown in block 27.

The second embodiment allows to obtain a better correlation of the new updated value of the pre-established lag volume PLV with the flow rate value FR and the current closure time ACT, to improve the accuracy of the triggering of the closing section CS of the next filling process. Therefore there is also an increase of the accuracy of detection of actual preclosing time APT of the next filling process.

According to the third embodiment, the monitoring process comprises automatically obtaining a preestablished closure time PCT, corresponding to a preestablished duration of the closing section CS. This step is shown in block 20.

According to the third embodiment, obtaining the current preclosing time APT comprises calculating the current preclosing time APT as corresponding to the difference between the current total time ATT and the pre-established closure time PCT. This step is shown in block 26. In this way the obtained current preclosing time APT is more correlated to closure time of at least one previous filling process. In this way the part of local correctness value LC corresponding to the current preclosing time APT is dependent in part from the current conditions of the filling process for which the specific monitoring process is being carried out, and in part from the conditions of one or more previous filling processes. Therefore, the accuracy of the monitoring method is improved.

According to the third embodiment, the monitoring process comprises automatically detecting by means of the flow meter the current total volume ATV, corresponding to the current total volume which has been delivered to the container for the whole filling phase. This step is shown in block 26.

According to the third embodiment, obtaining the current preclosing volume APV comprises calculating the current preclosing volume APV as corresponding to the difference between the current total volume ATV and the preestablished lag volume PLV. This step is shown in block 26.In this way the part of local correctness value LC corresponding to the current preclosing volume APV is dependent in part from the current conditions of the filling process for which the specific monitoring process is being carried out, and in part from the conditions of one or more previous filling processes. Therefore, the accuracy of the monitoring method is improved.

According to the third embodiment, the monitoring process comprises automatically obtaining a current closure time ACT, which corresponds to a current duration of the closing section CS. This step is shown in block 26.

Automatically obtaining the current closure time ACT can comprise automatically detecting the current closure time ACT.

According to the third embodiment, the monitoring process comprises automatically updating the preestablished closure time PCT by means at least of the current closure time ACT. This step is shown in block 27.Updating the pre-established closure time PCT by means at least of the current closure time ACT can comprise applying any mathematical operation involving at least the current closure time ACT.

A filling machine according to present description comprises comprising a plurality of filling devices, each of which can have one or more of the features of a filling device 5 according to present description. Each filling device of the plurality can have all the features of the filling device 5 according to present description.

The machine 1 comprises a monitoring apparatus. The monitoring apparatus comprises a system according to present description. The monitoring apparatus is configured for automatically computing a global correctness value GC based on the respective local correctness values LC of the filling devices 5. The global correctness value GC can correspond to the sum of the local correctness values LC.

If the global correctness value GC is negative, it is more likely that there is a problem affecting the correct operation of the whole filling machine 1, instead of being due to a possible failure, e.g. due to a mechanical problem, of a single filling device 5 of the same filling machine 1. In other words, it is more likely that a problem in the pressurization time or in the first filling substep has indeed occurred.

The system is configured so that a user can carry out an initialization phase, which occurs before the filling process. During the initialization phase the user inserts in the system an initialization value for any of the preestablished total volume PTV, the preestablished lag volume PLA, the preestablished preclosing volume PPV, and/or the preestablished closure time PCT.

Filling machine 1 comprises a conveying device, including a rotating conveyor (or carousel) 4, which is mounted to rotate continuously (e.g. anticlockwise in Figure 1) about a substantially vertical longitudinal axis A.

The carousel 4 receives a succession of empty containers 2 from an input wheel W (or other suitable input conveyor), which is coupled thereto at a first transfer station and is mounted to rotate continuously about a respective vertical longitudinal axis A', parallel to axis A. The carousel 4 releases a succession of filled containers

2 to an output conveyor 8 (a linear belt conveyor, as shown in Figure 1, or another suitable output conveyor), which is coupled thereto at a second transfer station and is configured to transfer the filled containers 2 towards a capping machine configured to cap the same filled containers 2 (or towards another processing machine).

Filling machine 1 comprises a number of filling devices 5, which are equally spaced about axis A, are mounted along a peripheral edge of the carousel 4, and are moved by the same carousel 4 along a path P extending about axis A and through the above transfer stations.

Each filling device 5 is designed to receive at least one container 2 to be filled, and to perform, during its rotation along path P, the respective filling process according to the filling recipe.

In a manner not shown in detail, each filling device 5 includes a main body, for example with a tubular configuration, having a vertical extension along a longitudinal axis that is substantially parallel to axis A of carousel 4, and mechanically coupled to the same carousel 4. The main body includes, at a bottom portion thereof, a container receiving part, designed to engage a top portion of a respective container 2 that is to be filled during the filling operations, and generally includes one or more fluidic conduits and flow regulators (here not shown), including at least a filling valve 7 (shown schematically), that are designed to selectively couple the container 2 to one or more feed devices or product tanks (also not shown), of the filling machine 1, via respective filling ducts 6.

Operation of the filling devices 5 is controlled by a machine control unit 12 (shown schematically), generally including an industrial PLC (Programmable Logic Controller) or any other suitable digital processing unit, for example a computer running a PLC software application, designed to control general operation of the filling machine 1 according to the desired filling recipe.

Each filling device 5 may be provided with its own intelligence, i.e. with a respective local control unit 12' (shown schematically), e.g. a processor or similar computing unit, programmed to manage the filling operations of the same filling device 5 according to the filling recipe and operatively coupled to the machine control unit 12.

Local control units 12' are communicatively coupled to the machine control unit 12 of the filling machine 1, e.g. via a data communication bus 14, so as to receive control signals from the machine control unit 12 and provide feedback signals to the same machine control unit 12, while filling operations are performed. Data communication bus 14 may be a real-time bus, in particular an Ethernet-based real-time communication bus, such as the Powerlink bus, Ethercat, Ethernet Realtime, or Profinet, or any other bus capable to offer data communication capability, even not in real time (e.g. a RS-485 bus).

The machine control unit 12 may moreover be coupled to a central supervising unit (here not shown), including a respective PLC or any other suitable computing and processing unit, e.g. located remotely with respect to the filling machine 1, via a cabled or remote wireless link; central supervising unit may supervise and manage operation of various processing machines in a same processing plant, in addition to filling machine 1 (e.g. a capping machine, a labelling machine and so on, all cooperating in processing of the containers 2), and may receive feedback information from the various machines of the processing plant.

The monitoring unit of the monitoring system can comprise at least a part of any local control unit 12' or at least a part of the machine control unit 12. The monitoring apparatus of the filling machine can comprise at least a part of any local control unit 12' or at least a part of the machine control unit 12.

In particular, it is again underlined that the proposed solution allows to improve the efficiency of the filling machine 1, allowing to obtain monitoring indications of the flow rate time trend even during the initial phase of the filling process, so as to detect possible anomalies in the pressurization phase or in the first filling substep of the filling process.

Finally, it is clear that modifications and variations may be applied to the solution described and shown, without departing from the scope of the appended claims.