CN118401461A - Method for monitoring cap application and cap retainer - Google Patents

Abstract

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

Description

Method for monitoring cap application and cap holder

Technical Field

The present invention relates to the field of packaging. More particularly, it relates to an apparatus and method for cap application.

Background technique

Today, packages with screw caps are becoming increasingly popular in the food packaging industry. One reason for this popularity is that this opening device is reclosable, which has the positive effect that the package can still be stored horizontally after opening. Another reason for this popularity is that the screw cap is easy to operate for most consumers. Although some screw caps may be difficult to operate for people with reduced physical strength, for most people it is usually easier to operate a screw cap than, for example, a tear-off opening.

There are different techniques for applying screw caps during production. One common method is to screw the cap onto the threaded neck of the package using a so-called cap applicator. The general principle of such a device is to grab the cap, place the cap on the neck and rotate the cap while holding the package still so that the internal threads of the cap mate with the external threads of the neck. In order to ensure that the cap and the neck are not damaged during the cap application process, the cap applicator is usually fine-tuned so that sufficient application is achieved without damaging the cap and the neck. It is known to use a camera-based system to monitor the cap application process.

Currently used cap applicators generally perform well, but increasing the level of customization on certain packaging lines has proven to be a challenge. For example, caps of different colors often have different material properties. For example, applying a white cap to a neck may require different cap applicator settings than applying a red cap because of the different material properties of the white and red plastic materials used in the two caps.

Another challenge in the field of cap application is the increasing desire to reduce the amount of plastic material used in the cap and neck, both from a cost and environmental perspective. The result of using less plastic material is that tolerances need to be held tighter when applying the cap. Therefore, a more reliable cap application is required due to the reduction in material.

Based on the examples provided above, there is a need to improve the cap application process so that more reliable packaging production can be achieved while also using packaging with less plastic material.

Summary of the invention

The object of the present invention is to at least partially overcome one or more limitations of the above-mentioned prior art. In particular, the object of the present invention is to provide a method for achieving a more reliable and flexible cap application control. In addition, the object is to provide a method for monitoring the cap application in a filling machine in order to generate data for achieving a more reliable and flexible cap application control.

According to a first aspect, there is provided a method of monitoring cap application in a filling machine using a data processing device, wherein the filling machine comprises a cap holder comprising:

- a peripheral element for surrounding the cap,

a gripping element connected to the peripheral element and arranged for preventing a movement of the cap relative to the peripheral element during a rotation of the peripheral element about the central axis A,

- a sensor device attached to a peripheral element, and

a communication module, which is linked to the peripheral element, is communicatively connected to the sensor device and is arranged to transmit the sensor data to the data processing device,

The method comprises:

receiving sensor data captured by a sensor device,

comparing the sensor data with sensor reference data stored in a reference database communicatively coupled to the data processing device,

In the event of a discrepancy between the sensor data and the sensor reference data, a check notification is transmitted from the data processing device to the control system.

The benefit of this method is that the cap application can be effectively monitored. The benefit of attaching the sensor device to the peripheral element of the cap holder (also called the chuck) is that deviations in the movement of the cap holder can be detected and acted upon accordingly. By obtaining an indication as early as possible and in a reliable manner that the cap application may need adjustment or is not working properly for any other reason, this in turn leads to the fact that the cap application can be checked and possibly adjusted to avoid filling machine downtime and quality problems. In addition, improved monitoring of the cap application process also makes it possible to have tighter tolerance levels, which in turn allows less plastic material to be used in the packaging.

The sensor data includes measured angular data of rotation about the central axis between a cap application start position and a cap application end position.

By knowing the angle data (i.e. the angle between the start position and the end position), reliable monitoring of the cap application can be achieved. In the event of significant deviations in the angle data, this indicates that the cap application process is not working properly.

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

In addition to or as an alternative to angle data, torque data provides relevant information about the cap application. In the event that the torque used during the cap application deviates from the historical torque data and/or the set torque data, this indicates that the cap application may need to be readjusted.

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

In the event that the cap holder rotates about the vertical axis, this is an indication that the cap application operation is not proceeding as planned and the operator will look to see why the cap applicator is not operating as expected.

The method may also include harvesting energy using an energy harvesting device.

Using an energy harvesting device provides the following benefits: The interval between battery replacements can be extended, i.e. maintenance is more cost effective. In certain applications, if power backup is not deemed necessary, the battery can be eliminated when using an energy harvesting device. By placing the energy harvesting device on the peripheral component, there will be movement during cap application, which will make energy available for the energy harvesting device to capture.

The sensor data may also include data selected from the following groups, the groups including: translational movement data measured along the central axis, vibration data measured during the rotation from the cap application starting position to the cap application ending position, accelerometer data measured during the rotation from the cap application starting position to the cap application ending position, gyroscope data measured during the rotation from the cap application starting position to the cap application ending position; and/or temperature data.

The cap holder further comprises a memory storing cap holder type data, and the method may further comprise:

receiving cap holder type data from the memory via the communication module,

comparing the cap holder type data with the cap holder type reference data retrieved from the control system of the filling machine,

In the event that the cap holder type data differs from the cap holder type reference data, an incorrect cap holder type notification is transmitted to the control system.

Since different caps may use different cap holders, there is a risk of using the wrong cap holder. This risk is increased if several different caps are used and these have similar characteristics, which can cause the different cap holders to be similar. In this case, it may not be immediately apparent that the wrong cap holder has been used and a seemingly sound package may be produced, but a quality problem may be revealed upon closer inspection. By having a memory in the cap holder storing the data on the cap holder type, this risk is reduced or even completely eliminated.

The filling machine may comprise two parallel cap holders, wherein sensor data from the two parallel cap holders may be received in parallel and the sensor data from the two parallel cap holders may be compared between them to identify cap holder specific differences.

By having two cap holders operating in parallel, a relative comparison of the two can be made, which adds another possibility of identifying if the cap application work is not going as planned.

The memory may include identification data.

Providing identification data in the memory of the cap holder, i.e. setting a code for each cap holder so that they can be identified, has the benefit that cap application from many cap holders over time can be aggregated and tracked to obtain a reliable model to increase the understanding of the cap application process, for example by using artificial intelligence (AI). This in turn can lead to the ability to obtain improved sensor reference data.

According to a second aspect, there is provided a cap holder arranged to hold a cap during rotational application onto a package, the cap holder comprising:

- a peripheral element for surrounding the cap,

a gripping element connected to the peripheral element and arranged for preventing a movement of the cap relative to the peripheral element during a rotation of the peripheral element about the central axis,

- a sensor device attached to the peripheral element and arranged to generate sensor data, and

- A communication module linked to the peripheral element, communicatively connected to the sensor device and arranged to transmit sensor data.

The same benefits and features set out in relation to the first aspect also apply to this second aspect.

The sensor device and the communication module may share the same circuit board.

By placing the sensor means and the communication module and possibly also the energy harvesting means and/or memory on the same circuit board (ie the same unit), these can be easily attached to the cap holder. This has the benefit that existing filling machines can be easily upgraded.

The cap holder may include an energy harvesting device that is attached to the peripheral element to power the sensor device and/or the communication module.

The energy harvesting device may be selected from the group consisting of a moving coil device, a moving magnetic device, a free impact mass device, a suspended device, and a double spring mass device.

According to a third aspect, a filling machine is provided, comprising a cap applicator, which in turn comprises a cap holder according to the second aspect.

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

Other objects, features, aspects and advantages of the present invention will become apparent from the following detailed description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will now be described by way of example with reference to the accompanying drawings, in which

FIG. 1 shows an example of a cap holder.

FIG. 2 shows an example of a cap applicator comprising two cap holders.

FIG3 shows generally a filling machine and a data processing device.

FIG4 shows an example of a circuit board.

Figure 5 shows different principles of energy harvesting.

FIG. 6 is a flow chart illustrating a method for monitoring cap application.

Detailed ways

Referring to Fig. 1, a cap holder 100, sometimes also referred to as a chuck, is shown. As shown, the cap holder 100 can be annular so as to be placed above the cap 106. When placed above the cap 106, the peripheral element 102 of the cap holder 100 can surround the cap 100. In this position, in order to grasp the cap 106, a gripping element 104 contained in the peripheral element 102 can be used. After the gripping element 104 grasps the cap 106, the peripheral element 102 can be rotated around the central axis A so that the cap 106 is screwed onto the neck of the package.

A circuit board 108 may be attached to the peripheral components 102, the circuit board comprising a sensor device 110, a communication module 112, an optional energy harvesting device 114 and a memory 116. To ensure that the circuit board 108 is resistant to moisture, liquids, etc., the circuit board may be encapsulated or in any other way isolated from the environment inside the filling machine. In this context, the term "circuit board" should be interpreted broadly and understood to cover any device that combines different arrangements together so that an operator can handle them as a unit.

A benefit of attaching the circuit board 108 to the peripheral element 102 is that the circuit board 108 can be attached to an existing cap holder 100. In other words, having the sensor device 110, the communication module 112, the optional energy harvesting device 114 and the optional memory 116 contained as one unit that can be easily attached to the peripheral element 102 has the benefit that the existing base of the cap applicator can be easily upgraded, which in turn allows the sensor data to be easily provided to the food manufacturer.

Fig. 2 shows by way of example a portion of a cap applicator 200 comprising two cap application holders 100 operating in parallel. One reason for providing parallel cap application holders in the cap applicator 200 is that the capacity can be increased.

In the example shown in Fig. 2, a translational moving element 202 is provided. By using this element, two cap holders 100 can be adjusted in translation so that a suitable fit with packaging can be achieved. In order to achieve the rotation of the cap holder 100, a rotational moving element 204 can be used. In the example shown, the rotational moving element 204 includes a belt connected to the cap holder 100 so that the cap holder 100 can be rotated around the central axis A via the belt. Other alternatives can also be adopted, such as directly connecting the cap holder 100 to a servo motor without using a belt.

The cap can be applied after the package is filled with the food. This is the case with PET bottles. Another alternative is to apply the cap before filling the product. This alternative can be used when the package is made of a carton-based material. In this case, the packaging material web can be fed into the filling machine, cut into sheets, folded into sleeves, sealed longitudinally, the plastic top (i.e., shoulders and neck) is set in the forming station, the cap is applied, the food is filled, and the bottom is sealed to close the package. The benefit of applying the cap first and then filling is that the package can be positioned in any way when the cap is applied.

In order that the cap application is performed correctly, e.g. without misalignment, the sensor device 110 may be arranged to also measure vertical angle data about a vertical axis B that is perpendicular to the central axis A. In case rotation occurs about the vertical axis B during the cap application, i.e. the cap application start position and the cap application end position, this may prove an indication to check the adjustment of the cap applicator 200.

Figure 3 schematically shows an example of a filling machine 300. As ^mentioned above, different types of packaging are produced in different ways. Although the filling machine 300 demonstrated herein is a filling machine for producing cardboard packaging such as TetraTop ^™ , its principles may also be applicable to other types of packaging provided with screw caps.

As shown, the filling machine 300 may include a sleeve former 302, which is arranged to receive a web of packaging material and form it into a sleeve of packaging material. As described above, this may involve cutting the web into pieces and sealing the pieces longitudinally into sleeves. Another option is to feed the filling machine with blanks (i.e., finished sleeves that are folded flat and erected by the sleeve former 302).

After the sleeves are formed, they are provided with a top by a top former 304. As described above, the top can be formed by injection molding the top onto the sleeve so that the upper end of the sleeve is closed, but other alternatives are possible. For example, although not commonly used, a pre-formed top can be used and sealed to the upper end of the sleeve.

Once the top is formed, the cap 106 is applied to the top in a cap applicator 200. The cap applicator 200 may be embodied in different ways, and the example shown in FIG2 is one of several possible alternatives.

Next, the food is filled into the package through the open bottom of the package when the cap 106 is applied. After filling, the bottom is sealed and possibly folded into the bottom of the package. This is done in a bottom former, which in turn can be divided into multiple sub-units, such as a bottom sealer and a final former.

To ensure that the cap is applied correctly, sensor data 314 can be fed from the cap applicator 200 (more specifically the cap holder 100) to a data processing device 312. As shown, the data processing device 312 can be a server, or a server farm, but can also be a computer placed locally at the filling machine 300.

The sensor data 314 may be continuously fed to the data processing device 312 from the cap applicator 200, but it may also be fed to the data processing device 312 upon request. In the latter case, a request 316 may be transmitted from the data processing device 312 to the cap applicator 200. The request 316 may be sent periodically, but may also be triggered by other events that may indicate that the cap application should be checked. For example, such a trigger may be generated by a vision-based quality system.

In order to evaluate the sensor data 314, the sensor reference data 320 can be retrieved from the database 318. The database 318 can be dedicated to the filling machine, but it can also be shared by multiple filling machines. One benefit of sharing between many filling machines is that more reliable models can be established, whether statistical models or artificial intelligence models. This is especially true when considering a large number of parameters such as translational movement data, accelerometer data, gyroscope data, temperature data, torque data, plastic material type data (providing information on the material used for the cap and/or neck). In addition, by measuring over time, the model can be further improved, and the sensor reference data 320 generated by the model can also be further improved. One benefit of measuring over time is that historical data can be used as a basis for making predictions (such as predictive maintenance). In other words, in the case where the comparison of sensor data 314 and reference sensor data 320 does not match (i.e., sensor data 314 indicates that something in the cap application work is not carried out as planned), this may indicate that the cap application work is currently in progress, but may face the risk of being unable to proceed in the future.

In the event that there is a discrepancy between the sensor data 314 and the sensor reference data 320 (i.e., the current value and the expected value do not match), a check notification 322 may be issued and transmitted to a control system 324 of the filling machine 300. This in turn may trigger a notification message to be sent to an operator or schedule a maintenance event. Although the control system 324 is shown as part of the filling machine 300, the control system may also be independent or form part of another device.

4 shows an example of a circuit board 108. In this particular example, a battery is provided at the left end of the board 108 to ensure power supply even if the energy harvesting device 114 does not generate power. A microphone is provided at the right end. By providing a microphone, the sensor data 314 can also include audio data.

To further facilitate mounting of the circuit board 108 on the peripheral component 102 , the communication between the circuit board 108 and the data processing device 312 may be wireless, at least in part making it possible to avoid wires that risk obstructing the rotation of the cap holder 100 .

By providing the energy harvesting device 114, fewer battery changes are required, which in turn reduces the need for frequent maintenance intervals for the circuit board 108. As shown in FIG4, to ensure reliable operation, the circuit board 108 may be provided with a battery as a supplement to the energy harvesting device 114.

The use of the energy harvesting device 114 is beneficial in this case because the peripheral component 102 of the cap holder 100 will move during the operation of the filling machine 300. In other words, the positive effect of placing the circuit board 108 provided with the energy harvesting device 114 on the peripheral component 102 is that movement will be provided so that the energy harvesting device 114 can generate electricity for the circuit board. In addition to generating electricity, the energy harvesting device 114 can also be used as a wake-up device and a closing device, that is, the circuit board can be set to an idle mode or a low power mode by using input from the energy harvesting device 114.

As shown in FIG. 5 , the energy collection device 114 may use different principles to collect energy, for example, a moving coil device (A), a moving magnetic device (B), a free impact mass device (C), a suspension device (D), and a double spring mass device (E).

6 is a flow chart showing a method 600 for monitoring cap application in a filling machine 300. In a first step 602, sensor data 314 may be received. In a second step 604, the sensor data 314 may be compared with sensor reference data 320. In case of a difference 606 between the two, in a third step 608, an inspection notification 322 may be transmitted.

Optionally, in order to reduce maintenance requirements and improve energy efficiency, in a fourth step 610, energy harvesting device 114 may be used to harvest energy.

Optionally, to avoid using the wrong type of cap holder (also called chuck), in a fifth step 612, cap holder type data may be received from the memory 116. In a sixth step 614, the cap holder type data may be compared with the cap holder type reference data. In case of a discrepancy 616, in a seventh step 618, an incorrect cap holder type notification may be transmitted.

From the above it emerges that, although various embodiments of the invention have been described and shown, the invention is not restricted thereto but may also be embodied in other ways within the scope of the subject-matter defined in the following claims.

Claims (15)

1. A method (600) for monitoring cap application in a filling machine (300) using a data processing device (312), wherein the filling machine (300) comprises a cap holder (100), the cap holder (100) comprising: - a peripheral element (102) for surrounding the cap (106), a gripping element (104) connected to the peripheral element (102) and arranged to prevent movement of the cap (106) relative to the peripheral element (102) during rotation of the peripheral element (102) about the central axis (A), - a sensor device (110) attached to said peripheral element (102), and a communication module (112) linked to the peripheral element (102), communicatively connected to the sensor device (110) and arranged to transmit sensor data to the data processing apparatus (312), The method comprises: receiving (602) the sensor data (314) captured by the sensor device (110), comparing (604) the sensor data (314) with sensor reference data (320) stored in a reference database (318) communicatively coupled to the data processing device (312), In the event of a difference (606) between the sensor data (314) and the sensor reference data (320), a check notification (322) is transmitted (608) from the data processing device (312) to a control system (324). 2. The method of claim 1, wherein the sensor data (314) comprises measured angular data of a rotation about the central axis (A) between a cap application start position and a cap application end position. 3. A method according to any one of the preceding claims, wherein the sensor data (314) includes torque data measured during rotation of the cap around the central axis (A) from the cap application starting position to the cap application ending position. 4. A method according to any one of the preceding claims, wherein the sensor data (314) includes measured vertical angle data rotated around a vertical axis (B) between the cap application starting position and the cap application ending position, wherein the vertical axis (B) is perpendicular to the center axis (A). 5. The method according to any one of the preceding claims, further comprising: Energy is harvested (610) using an energy harvesting device (114). 6. A method according to any one of the preceding claims, wherein the sensor data (314) also includes data selected from the following groups, the group including: translational movement data measured along the central axis (A), vibration data measured during the rotation from the cap application starting position to the cap application end position, accelerometer data measured during the rotation from the cap application starting position to the cap application end position, gyroscope data measured during the rotation from the cap application starting position to the cap application end position; and/or temperature data. 7. The method according to any of the preceding claims, wherein the cap holder further comprises a memory (116) storing cap holder type data, the method further comprising: receiving (612) the cap holder type data from the memory (116) via the communication module (112), comparing (614) the cap holder type data with cap holder type reference data retrieved from the control system (324) of the filling machine (300), In the event of a discrepancy (616) between the cap holder type data and the cap holder type reference data, an incorrect cap holder type notification is transmitted (618) to the control system (324). 8. A method according to any of the preceding claims, wherein the filling machine comprises two parallel cap holders (100), wherein the sensor data (314) from the two parallel cap holders (100) are received in parallel, and the sensor data (314) from the two parallel cap holders (100) are compared between them to identify cap holder-specific differences. 9. The method of claim 7, wherein the memory (116) includes identification data. 10. A cap holder (100) arranged to hold a cap (106) when rotationally applied to a package, the cap holder comprising: - a peripheral element (102) for surrounding the cap (106), a gripping element (104) connected to the peripheral element (102) and arranged to prevent the cap (106) from moving relative to the peripheral element (102) during rotation of the peripheral element (102) about the central axis (A), - a sensor device (110) attached to the peripheral element (102) and arranged to generate sensor data (314); and A communication module (112) linked to the peripheral element (102), communicatively connected to the sensor device (110) and arranged to transmit the sensor data (314). 11. The cap holder (100) according to claim 10, wherein the sensor device (110) and the communication module (112) share a same circuit board. 12. The cap holder (100) according to claim 10 or 11, further comprising an energy harvesting device (114) attached to the peripheral element (102) in order to power the sensor device (110) and/or the communication module (112). 13. The cap holder (100) according to claim 12, wherein the energy collection device (114) is selected from the group consisting of a moving coil device, a moving magnetic device, a free impact mass device, a suspension device and a double spring mass device. 14. A filling machine (300) comprising a cap applicator (306) comprising a cap holder (100) according to any one of claims 10 to 13. 15. A computer program product comprising instructions which, when said program is executed by a data processing device (312), cause said data processing device (312) to perform a method according to any one of claims 1 to 9.