HK1224649B - Container filling system and valve for same - Google Patents

Description

Container filling system and valve for container filling system

This application is a divisional application of the Chinese patent application with international application number PCT/US2014/031469, national application number 201480028914.7, application date March 21, 2014, and title “CONTAINER FILLING SYSTEM AND VALVE FOR CONTAINER FILLING SYSTEM”.

Cross-references to Related Patent Applications

This application claims priority to U.S. Provisional Patent Application No. 61/804,452, entitled “(Universal Filling System and Valve for a Universal Filling System),” filed on March 22, 2013. Patent Application No. 61/804,452 is incorporated herein by reference in its entirety.

Background Art

Beverage products are a category of products intended for human consumption, typically for drinking. Beverage products are typically placed in some type of primary packaging for distribution and sale. Primary packaging can include any of a variety of container types. Examples include bottles, glass bottles, aluminum bottles, cans, etc. made of PET (polyethylene terephthalate), HDPE (high-density polyethylene) or other plastics. Even for a single type of product, primary packaging can have a wide range of sizes and shapes.

The system for filling primary packaging containers with beverage products usually includes a filling valve, which starts and stops the product from flowing into the container being filled. The filling valve is usually connected to the can or other type of reservoir in order to keep a large amount of beverage products in question. The mode of filling the container changes with different types of beverage products. For certain types of beverage products, the container can be cold filled. In the cold filling process, the product is dispensed into the container while being in freezing or room temperature state. For certain types of beverage products, the container is warm filled or hot filled. In these types of filling processes, the product is dispensed into the container while being in heated state. Some other types of beverage products must be placed in the aseptic container under aseptic conditions, which is the process called aseptic filling.

The current system that is used to fill primary packaging container with beverage product is designed to process product type and the filling situation of narrower scope.For example, most filling systems are designed to be only used for a kind of in cold filling, warm/hot filling, extended shelf life filling, high acid aseptic filling or low acid aseptic filling.As another example, obtainable filling system is designed to fill container with the product in quite narrow viscosity range.Conventional system is also limited to type, size and the concentration of the inclusions that may be present in the product.When with not being low viscosity product (for example, if product viscosity is greater than about 20 centipoises) or comprising the product filling container of inclusion, many such conventional systems also must operate with the speed that significantly reduces.

These limitations severely restrict the product space that can be successfully packaged with a single filling system. This, in turn, limits the flexibility and effectiveness of expensive production facilities. If production volume drops significantly or if a product type is no longer required, converting to equipment that can be used to fill containers with different types of beverage products may be expensive and time-consuming. Manufacturers of beverage filling systems would rather provide a factory with several filling systems to fill a wide range of products (i.e., provide multiple beverage filling platforms) rather than providing a single filler that can handle a wide range of products.

Summary of the Invention

This summary is intended to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the present invention.

Embodiments include a container filling valve. The filling valve may include a magnetically coupled shuttle and a drive sleeve. Movement of the drive sleeve may move the shuttle from a position where the filling valve is closed to a position where the filling valve is open.

Embodiments also include a container-handling arm. The arm can include a distal end configured to hold a container and a proximal end including a load cell. The arm can be adjusted to change the ratio between the load applied by the container and the load applied to the load cell. In some embodiments, adjustment of the arm can be performed automatically.

Embodiments also include a low flow set point system. The system can be configured to prevent the fill valve from closing when the fill valve is partially closed. The system can be adjustable and can include a fluid actuator configured to prevent movement of the valve shuttle.

Embodiments also include a pressure control system. The system can be configured to maintain a desired pressure in the reservoir or a desired pressure in the flow path from the reservoir. The system can be configured to maintain a desired pressure that is a vacuum.

Embodiments additionally include a product recirculation system that can be used, for example, during hot fill operations. The system can be configured to regulate the flow rate in the product recirculation system. In some embodiments, the flow rate can be regulated by adjusting the flow rate of a variable speed pump. In other embodiments, the flow rate can be regulated in other ways.

Embodiments include filling systems that can be configured to fill various types of containers with a variety of products under various types of filling conditions. The viscosity of the product can range from 1 centipoise (cps) to 400 cps. The product can also contain inclusions. The inclusions can take the form of blocks or particles with a size up to 10 cubic millimeters and/or a volume up to 1000 cubic millimeters. Such inclusions can be as small as 1 millimeter, for example, inclusions fitted in a 1 mm x 1 mm x 1 mm block. Inclusions can also take the form of pulp sacs up to 10 mm in length and fibers up to 20 mm in length. The product can contain a variety of types of inclusions (particles, blocks, pulp and/or fibers). The volume percentage of inclusions in the product can be as high as 50%.

Embodiments include methods of using the devices and systems described herein.

Additional embodiments are described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

Certain embodiments are illustrated by way of example, and not limitation, in the accompanying figures in which like references indicate similar elements.

1A is a left side view of a filler unit and corresponding container handling arm.

1B is a front view of the filler unit and container handling arm of FIG. 1A .

2 is a partially schematic top view of a carousel-style beverage product container filling system including the filler unit and gripping arm of FIG. 1A .

3A to 3F are enlarged front, left, right, rear, left perspective, and right perspective views, respectively, of the filler unit of FIG. 1A .

3G is an enlarged left rear perspective view of the filler unit of FIG. 1A , but with certain components removed.

FIG. 4A is a partial cross-sectional view taken from the position shown in FIG. 3A .

4B is a cross-sectional view similar to FIG. 4A , with the fill valve in an open condition.

5A through 5C are enlarged top, top, and bottom perspective views, respectively, of a shuttle from the filler unit of FIG. 1A .

FIG5D is a cross-sectional view taken from the position shown in FIG5B .

5E is an enlarged side perspective view of the shuttle from FIGs. 5A-5C, but with certain components removed.

5F is an enlarged top view of a shuttle in the main tube of the filler unit from FIG. 1A .

FIG5G is an enlarged cross-sectional view taken from the position shown in FIG5F.

5H and 5I are enlarged top and bottom perspective views, respectively, of a shuttle according to certain other embodiments.

6A is an enlarged cross-sectional perspective view of a filling valve drive sleeve from the filler unit of FIG. 1A .

6B is a perspective view of the drive sleeve of FIG. 6A .

7A to 7C are left front perspective, right front perspective, and right side views, respectively, of the container handling arm of FIG. 1A .

7D is a right side view of the container handling arm of FIG. 1A in an alternative configuration.

8A through 8H are partially schematic diagrams of a rear view of the filler unit of FIG. 1A and further explain the operation of the low flow set point system according to some embodiments.

8I-8P are partially schematic rear views of a filler unit incorporating a low flow set point system according to another embodiment.

9A is a schematic diagram of a portion of a beverage container filling system including a pressure control system, according to at least some embodiments.

9B is a schematic diagram of a portion of a beverage container filling system including a product recycling system, according to at least some embodiments.

9C and 9D are schematic diagrams of a portion of a beverage container filling system incorporating a product recycling system according to additional embodiments.

10 is a block diagram of inputs and outputs of a filling system controller, according to some embodiments.

11A is a flow chart of an example of an algorithm that may be executed by a filling system controller in conjunction with the operations shown in FIGS. 8A-8H and 8I-8P.

11B is a flow chart of an example of an alternative algorithm that may be executed by the filling system controller in conjunction with operations similar to those shown in FIGs. 8A-8H and FIGs. 8I-8P.

11C is a flow chart of an example of an algorithm that may be executed by the filling system controller in conjunction with the pressure control system.

1 ID is a flow chart of an example of an algorithm that may be executed by a filling system controller in conjunction with a product recirculation system.

12A to 12D are block diagrams illustrating steps of methods according to certain embodiments.

DETAILED DESCRIPTION

In the following description of various embodiments, reference is made to the accompanying drawings, which form a part of the specification, and each embodiment is merely illustrative. It should be understood that other embodiments exist and that structural and functional modifications may be made. Embodiments of the present invention may take physical form in certain parts and steps, examples of which will be described in detail in the following description and shown in the accompanying drawings, which form a part of the specification.

As used in this application, including the claims, the following terms have the applicable meanings. "Configured to perform a function or operation" when used in connection with a specific component, device, or system means that the component, device, or system in question includes structure that places the component, device, or system in a state ready to perform the specified operation or function. Unless otherwise specified, a "fluid" can be a liquid, a gas, or a mixture of a liquid and a gas. "Comprising" is synonymous with "including." For example, the statement "X includes element Y" does not preclude X from also including other elements.

Beverage container filling systems according to at least some embodiments may include filling valves and/or other equipment as described herein. As further explained in detail below, these filling systems can fill different types of containers with various beverage products under multiple different filling situations. For example, during one time period, the filling system can be operated as a cold fill (CF) system and fill containers with frozen or room temperature beverage products. During another time period, the same filling system can be operated as a hot fill (HF) system and fill containers with heated beverage products. During another time period, the filling system can be operated as an extended shelf life (ESL) filling system. During other time periods, the filling system can be operated as a high acid aseptic (HAA) or low acid aseptic (LAA) filling system.

Filling systems according to some embodiments can also accommodate a wide range of beverage product types. At least some such systems can fill containers with beverage products having viscosities ranging from about 1 centipoise (cps) to about 400 cps. Non-limiting examples of beverage products within this viscosity range include water (1 cps), milk (3 cps), fruit juice (55 to 75 cps), tomato juice (180 cps), and drinkable yogurt (50 to 400 cps).

According to some embodiments, the system also fills a container with a multiphase beverage product containing hard or soft inclusions. The inclusions can take the form of blocks, particles, pulp, and/or fibers. Examples of soft inclusions include fruit pulp, vegetable chunks, gel chunks, cassava chunks, other types of soft food products, raw pulp sacs, and fruit fibers. Examples of hard inclusions include seeds, nut chunks, and grains. In at least some embodiments, the system can fill a container with a beverage product having a particle or block-shaped inclusion (hard or soft) that is as large as or can fit within a block of approximately 10 millimeters (mm) x approximately 10 mm x approximately 10 mm, a 10 mm long pulp sac, and a 20 mm long fiber inclusion. The product can contain a variety of types of inclusions (particles, blocks, pulp, and/or fibers). The percentage of inclusions in the product (by volume) can be as high as 50%, as low as 1% (or even 0%), or any percentage value therebetween. But as some examples, in various embodiments, the system can fill the container with a beverage product having a volume concentration of contents that is less than 1%, approximately 1%, from 1% to 5%, from 5% to 10%, from 10% to 15%, from 15% to 20%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, or at least 45%. In embodiments corresponding to each of these volumetric inclusion concentrations, the volume of at least a portion of the inclusions can be 1 cubic millimeter or less (e.g., each inclusion fits in a 1 mm x 1 mm x 1 mm block), at least 125 cubic millimeters (e.g., a 5 mm x 5 mm x 5 mm block), at least 216 cubic millimeters (e.g., a 6 mm x 6 mm x 6 mm block), at least 343 cubic millimeters (e.g., a 7 mm x 7 mm x 7 mm block), at least 400 cubic millimeters (e.g., a 7.37 mm x 7.37 mm x 7.37 mm block), at least 512 cubic millimeters (e.g., an 8 mm x 8 mm x 8 mm block), or at least 729 cubic millimeters (e.g., a 9 mm x 9 mm x 9 mm block). The inclusions can be spherical or can have any other shape.

FIG1A is a left side view of a filler unit 10 and an associated container gripping arm 20 according to at least some embodiments. FIG1B is a front view of the filler unit 10 and the gripping arm 20. FIG1A and FIG1B illustrate that the gripping arm 20 holds a beverage container C in a filling position below the filler unit 10. When the container C is in the filling position, the filling valve of the filler unit 10 can controllably allow the beverage product to flow into the opening in the neck of the container C. Additional components of the filler unit 10 and the container gripping arm 20, and their operation, will be described below. Furthermore, as described below, in some embodiments, a complete filling system can include multiple additional filler units identical to the filler unit 10 and multiple container gripping arms identical to the arm 20.

The filler unit 10 is mounted to a support rack 11. As explained in more detail below in conjunction with FIG. 2 , the support rack 11 can hold additional filler units that are arranged to form a circular pattern. The inlet pipe of the filler unit 10 is connected to a product reservoir (not shown in FIG. 1A and 1B) via a feed pipe 12. A recirculation conduit 13 is a part of the system that can be used to recirculate the product, as described in more detail herein.

The dotted line in Figure 1A schematically shows a portion of barrier 30. The space within barrier 30 forms a sterile area 31 below filler unit 10 and other filler units in the same filling system. Barrier 30 can be similar to the sterile area barrier of a conventional filling system and can include upper, inner, lower and outer separators 32, 33, 34 and 35 respectively. Sterile air can be pumped into sterile area 31. Then, sterile air flows out from the openings in or between separators 32 to 35 to prevent contaminants from entering sterile area 31. Gripping arm 20, recirculation pipe 13 and other equipment (not shown) can extend into sterile area 31 through such openings. Upper separator 32, inner separator 33 and lower separator 34 are shown in Figure 1B, with outer separator 35 omitted. As shown in the curves on the right and left sides of Figure 1B, barrier 30 can continue to exceed both sides of filler unit 10 so that sterile area 31 extends below other filler units. Although Figures 1A and 1B show barrier 30 in conjunction with shelf 11, this is not required. In some embodiments, for example, the upper spacer of the sterile field barrier can be located below the clamp that connects the cup of the fill valve to the rest of the valve (e.g., the clamp shown directly below shelf 11 in Figures 1A and 1B).

Fig. 2 is the local schematic top view of turntable type beverage product container filling system 40, and this turntable type beverage product container filling system comprises filler unit 10 (symbolically shown as circle) and gripping arm 20 (symbolically shown as rectangle).Filling system 40 comprises 71 extra filler units 10 and 71 extra gripping arms 20.For convenience, only a filler unit 10 and a gripping arm 20 are marked with symbols.From the position of other symbols similar to the symbol of mark, the position of other filler units 10 and gripping arm 20 is obvious.Filling system 40 rotates in clockwise direction, as shown in the figure.Filler unit 10 is arranged near the outer periphery of system 40 rotating disks.The gripping arm 20 relevant with each in these filler units 10 extends radially inwardly towards the center of system 40 rotating disks.As mentioned above, shelf 11 can be the shape of annulus (perhaps can be a plurality of carriages, these carriages connect to form annulus), so that filler unit is remained as circular arrangement form. Additional brackets (not shown) can support the gripping arms and other components of the filling system 40. In addition, the boundaries of the barrier 30 are shown in Figure 2. Upper partitions 32, inner partitions 33, and lower partitions 34 can be attached to the rotating turntable portion of the filling system 40, wherein the outer partition 35 remains stationary. The outer partition 35 may include an opening for a conveyor to feed empty containers into the turntable and for another conveyor to transport filled containers from the turntable. The approximate locations for these conveyors are shown in Figure 2, where arrows show the direction in which empty containers travel to the turntable and the direction in which filled containers travel from the turntable.

Although not shown in Fig. 2, other parts of filling system 40 can be positioned at the center turntable area that is surrounded by filler unit 10 and its corresponding gripping arm 20.These parts can include but are not limited to product reservoir, product recirculation system, pressure control system and other parts as described herein.Fig. 2 only shows a kind of arrangement form of filler unit and gripping arm according to some embodiments.Other embodiments can comprise less or more filler unit and gripping arm pairs.Filling system need not be rotatable.In certain embodiments, for example, filler unit and/or container gripping arm (such as those described herein) can be arranged linearly.

FIG3A is an enlarged front view of filler unit 10. FIG3B is an enlarged left side view of filler unit 10. FIG3C is an enlarged right side view of filler unit 10. FIG3D is an enlarged rear view of filler unit 10. FIG3E is a left front perspective view of filler unit 10. FIG3F is a right front perspective view of filler unit 10.

The filler unit 10 includes a filling valve 50, which is closed in Figures 3A-3F. The filling valve 50 includes a housing formed by an inlet pipe 51, a main pipe 52 and a cup 53. The lower portion of the main pipe 52 extends through an opening in the support shelf 11 and is held in place by a retaining rod 54 and a screw 55. The main pipe 52 can be attached to the cup 53 and the inlet pipe 51 by conventional clamps 56 and 57, respectively. Each clamp 56 and 57 can be of the type commonly referred to as a "Tri-Clamp" in the art. Conventional sanitary gaskets (e.g., the type commonly used with Tri-Clamp type clamps) can be located between the inlet pipe 51 and the main pipe 52 and between the main pipe 52 and the cup 53, connected in a sealed manner. The product recirculation pipe 13 extends from the bottom of the cup 53 to the product recirculation system. The components and operation of the product recirculation system will be described below in conjunction with Figure 9B.

The filling valve 50 also includes a magnetic drive sleeve 60 surrounding the main tube 52. The drive sleeve 60 is movable along the main tube 52. As explained in more detail below, a shuttle located within the housing of the filling valve 50 is magnetically coupled to the drive sleeve 60. When the filling valve 50 is closed, a stopper on the bottom end of the shuttle is positioned to close the dispensing outlet in the bottom of the cup 53. Movement of the drive sleeve 60 toward the inlet tube 51 causes the shuttle to move upward, thereby dislodging the shuttle's stopper from the outlet and allowing product to flow from the outlet and into a container located in the filling position below the cup 53.

In addition to the valve 50, the filling unit 10 also includes two fluid actuators 70 and 80. The fluid actuator 70 includes a main housing 71. The rod 72 of the actuator 70 extends and retracts from the housing 71 and is connected to a movable piston inside the housing 71. Similarly, the fluid actuator 80 includes a main housing 81 and a rod 82, which extends and retracts from the housing 81 and is connected to a piston inside the housing 81. The lower ends of the actuators 70 and 80 are pivotally attached to the support shelf 11. The upper ends 73 and 83 of the rods 72 and 82 are connected to the drive sleeve 60 via additional components, as described below. The actuator 70 is configured to open and close the filling valve 50. To open the filling valve 50, pressurized air is introduced into the lower piston chamber of the housing 70 through the fitting 74, while air can escape from the upper piston chamber of the housing 71 through the fitting 75. To close fill valve 50, air can escape from the lower chamber through fitting 74 while pressurized air is introduced into the upper chamber through fitting 75. Air flow into and out of the chamber of actuator 70 may be controlled using a conventional solenoid-actuated air valve, not shown.

Actuator 80 is configured to stop the movement of drive sleeve 60. Specifically, and as described in more detail below in conjunction with Figures 8A to 8H, actuator 80 is part of an adjustable low flow set point system. Fluid enters and leaves the lower piston chamber of housing 81 through fitting 84. Fluid enters and leaves the upper piston chamber of housing 81 through fitting 85.

FIG3G is an enlarged left rear perspective view of the filler unit 10, wherein the actuators 70 and 80 and various other components are removed to better illustrate some of the underlying structures of the filler unit 10. As in FIG3A-3F, the filling valve 50 is closed in FIG3G. The lower end of the upright bracket 91 is attached to the drive sleeve 60. A crossbar 92 is attached to the upright bracket 91 near the upper end. A guide block 93 is also attached to the upright bracket 91 near the upper end. A guide rod 94 extends upward through a hole 95 in the guide block 93, wherein the bottom end of the guide rod 94 is attached to the support shelf 11. The size of the hole 95 is formed so that the guide block 93 can slide up and down along the rod 94. The upper ends 73 and 83 of the rods 72 and 82 of the actuators 70 and 80 are attached to the crossbar 92.

An adjustable rod 110 ( FIG. 3C ) limits the upward movement of the drive sleeve 60. When the drive sleeve 60 is at the top of its upward stroke, a stop 111 on the bottom of the rod 110 abuts against the underside of a plate 112. One or more coil springs 113 are located on the guide rod 94 and are constrained by a pin that passes through the guide rod 94. Another guide block 115 (visible in FIG. 3C ) is attached to the lower end of the upright bracket 91 and also slides on the guide rod 94 when the drive sleeve 60 is raised or lowered. When the drive sleeve 60 is raised, the spring 113 is compressed by the guide block 115 and the pin. Thus, the spring 113 biases the filling valve 50 into the closed position. This provides a fail-safe closing feature that automatically closes the valve 50 in the event of a power failure. An optical flag 120 can be attached to the crossbar 92 ( FIG. 3E ) and moves into and out of a slot in an optical sensor 121. Sensor 121 is discussed in more detail below in conjunction with Figures 8A to 8H.

FIG4A is a partial cross-sectional view taken from the position shown in FIG3A. Clamps 56 and 57 and other external components of filler unit 10 are omitted from FIG4A. Inlet tube 51, main housing 52, cup 53, and drive sleeve 60 are shown in the cross-sectional view of FIG4A. FIG4A shows shuttle 200 of filling valve 50. Shuttle 200 is not shown in the cross-sectional view of FIG4A.

Shuttle 200 includes a central rod 201 and four magnetic drive rings 210a, 210b, 210c, and 210d. Drive rings 210a-210d are collectively referred to as "rings 210," and any one of rings 210 is generally referred to as "ring 210." Similar conventions are used elsewhere in this specification, where multiple similar or identical components are designated by a common reference numeral followed by a letter.

As explained in further detail below, each ring 210 includes a plurality of magnets oriented to repel the magnets of the drive sleeve 60 and sealed within the stainless steel enclosure of the ring 210. The stem 201 is extended with a guide vane element 202 and an end element 203. The guide vane element 202 is attached to the stem 201 at a threaded connection 204 and to the end element 203 at a threaded connection 205. When the filling valve 50 is closed, as shown in FIG4A , a portion of the end element 203 rests on the inside edge and shoulder of the outlet 49 to prevent product from flowing through the outlet 49.

FIG4B is a cross-sectional view similar to FIG4A , with filling valve 40 in an open position. When filling valve 50 is opened, as shown in FIG4B , drive sleeve 60 rises. Because the magnets of drive sleeve 60 and drive ring 210 repel each other, ring 210 remains centered about the longitudinal centerline of main tube 52. As explained in more detail below, a "magnetic spring" is formed by the magnetic force of the magnets in ring 210 and sleeve 60. This spring is not shown as compressed in FIG4A . Because shuttle 200 is magnetically coupled to sleeve 60, it moves up and down with sleeve 60. As shuttle 200 moves upward, end element 203 retracts from opening 49, allowing product to flow from opening 49 to a container located below cup 53.

4A and 4B , the flow path through the interior of the housing of the filling valve 50 is substantially straight. In some embodiments, the width of the outlet 49 is approximately 0.625 inches. As used herein, when describing the size of an opening or other flow passage, if the opening or passage is circular, then the "width" may be the diameter.

FIG5A is a top perspective view of shuttle 200 removed from filling valve 50. Except as noted below, drive rings 210 are substantially identical to one another. Each ring 210b through 210d includes an inner wall 211 and an outer wall 212 similar to inner wall 211a and outer wall 212a of ring 210a. Each ring 210 also includes a sweeping ridge 232, discussed below. As discussed below in conjunction with FIG5D and 5E , magnets are enclosed within the space between the inner wall 211 and outer wall 212 of each ring 210. Rings 210 are connected to rod 201 via three radial blades 220. In the illustrated embodiment, each blade 220 is solid and extends the entire length of ring 210. Blades 220 may be equally spaced from one another, i.e., the angle between adjacent blades 220 may be 120°. Thus, blades 220 and the inner wall 212 of ring 210 form three equally sized 120° segments 221. 5B is a top view of shuttle 200. In at least some embodiments, segments 221 are sized to allow 10 mm cubic inclusions to pass therethrough.

FIG5C is a bottom perspective view of the shuttle 220. The guide blade element 202 includes three radially extending blades 208 that help straighten the flow of beverage product dispensed through the filling valve 50. The end element 203 includes a circular stopper 224 that seals the outlet 49 of the cup 53. The end 225 of the stopper element 203 is sized to extend through the outlet 49. During the closure of the valve 50, the end 225 provides a shear force to cut off contents that may be trapped in the throat of the outlet 49, thereby providing a clean break. This prevents debris from flowing out of the closed outlet 49, which is undesirable in hot filling or aseptic filling operations. As explained in more detail below, in low-flow operations, the end 225 can be partially located in the outlet 49 to reduce the flow of product, prevent overfilling, and improve filling accuracy.

FIG5D is a cross-sectional view of shuttle 200 from the position shown in FIG5B . As described above, as can be seen in FIG5D , blades 220 extend the length of all four drive rings 210. Each blade 220 includes a slight indentation in the space between two adjacent rings 210. As shown in FIG5D , and as further discussed below in conjunction with FIG5G , the inner wall 211 of each ring 210 includes an upper flange 228 and a lower flange 227. A swept ridge 232 of each ring 210 extends outwardly from its upper flange 228. Magnets 230 are positioned in the space between the inner wall 211, its associated flanges 227 and 228, and the outer wall 212.

The arrangement of magnets 230 in ring 210 is further illustrated in FIG5E . FIG5E is a side perspective view of shuttle 200 with certain components removed. Outer wall 212a and magnets 230 have been removed from ring 210a to reveal outer side 231 of inner wall 211a and the inner edge of lower flange 227a. Outer walls 212b and 212c of rings 210b and 210c have been removed to reveal magnets 230. Magnets 230 are similarly arranged in rings 210a and 210d.

FIG5F is a top view of shuttle 200 in main tube 52, with other elements of filling valve 50 omitted. FIG5G is an enlarged partial cross-sectional view taken from the position shown in FIG5F . Each drive ring 210 includes magnets 230 arranged in three bands. Each band includes four concentric sub-bands of individual magnets 230. As shown in FIG5E , each magnet 230 extends only over a small sector of the circumference of drive ring 210. The magnets 230 in the bands are arranged end to end to surround ring 210.

FIG5G also shows further details of the sweep ridge 232. The gap between the ring 210 and the inner wall of the main tube 52 is narrowed in the area of the sweep ridge 232 to prevent seeds or other inclusions from reaching the space between the main tube 52 and the ring 210. In some embodiments, the gap between the outer edge of the sweep ridge 232 and the inner wall of the main tube 52 is approximately 0.01 inches. The gap between the outer side of the ring 210 (at the outer side of the outer wall 212) and the inner wall of the main tube 52 can be sized to prevent seeds or other small inclusions from becoming lodged between the drive ring 210 and the inner wall of the main tube 52. In at least some embodiments, this gap can be approximately 0.049 inches.

The top surface of the sweep ridge 232 is angled downwardly toward the center of the ring 210 at an angle α. These downwardly sloping surfaces help guide the contents toward the center of the shuttle 200 during the upward stroke of the shuttle 200 and as the product flows through the main tube 52 and through the shuttle 200. In some embodiments, the bottom surface of the lower flange 227 can be angled upwardly toward the center of the ring at an angle β. These upwardly sloping surfaces help guide the contents toward the center of the shuttle 200 during the downward stroke of the shuttle 200. In some embodiments, both α and β can be approximately 6 degrees. The sweep ridge 232a of the topmost ring 210a can further include a lip 234. The top surface of the lip 234 can be angled downwardly at a significantly steeper angle toward the center shuttle 200.

As further shown in FIG5G , the outer wall 212 of the ring 210 is relatively thin. In some embodiments, the outer wall 212 is formed of 0.006-inch-thick, hardened 316L austenitic stainless steel with weak magnetic attraction. The sheet forming the wall 212 is used in the hardened state to facilitate assembly. The thinness of the wall 212 maximizes the gap between the wall 212 and the inner wall of the main tube 52, while minimizing the distance between the magnets 230 of the shuttle 60 and the magnets 230 of the sleeve 60. The outer wall 212 can be laser welded in place to seal the magnets 230 in the ring 210 and prevent these magnets 230 from contacting beverage products or cleaning solutions that may pass through the valve 50. The laser weld seam of the outer wall 212 can be polished to promote cleanliness.

In at least some embodiments, the inner wall 211 of each ring 210, including flanges 227 and 228, swept ridge 232, lip 234, blades 220, and rod 201, can be formed as a unitary unit from a single, monolithic piece of 316L austenitic stainless steel. The one-piece unit can be formed, for example, by electro-discharge machining (EDM). The guide vane element 202 and the barrier element 203 can also be machined from 316L austenitic stainless steel. The use of a soft austenitic material for the shuttle minimizes interaction between the shuttle 200 and the magnetic field of the magnet 230.

Figures 5H and 5I are enlarged top and bottom perspective views, respectively, of a shuttle 200' according to certain other embodiments. Shuttle 200' can be used in filling valve 50 as an alternative to shuttle 200. Shuttle 200' can be identical to shuttle 200 except for blades 220'. Specifically, shuttle 200' includes six radial blades 220' that connect rings 210a' to 210d' to a central rod. Blades 220' can be arranged to form a primary segment 221 and a secondary segment 222. Primary segment 221 can be sized to allow a 10 mm cube of contents to pass through.

As described above, the ring 210 travels up and down within the main tube 52. In some embodiments, the main tube 52 is also formed of 316L austenitic stainless steel. An exemplary wall thickness of the main tube 52 is approximately 0.044 inches, and an exemplary cylindricity is within 0.0025 inches.

In at least some embodiments, cup 53 is formed from PEEK (polyetheretherketone). Although PEEK is very rigid and durable, it is flexible enough to allow sealing between stopper 224 of end member 203 and the inner upper edge and shoulder of outlet 49, thereby avoiding the need for an additional gasket to seal outlet 49 when valve 50 is closed.

FIG6A is an enlarged cross-sectional perspective view of the drive sleeve 60. The cross-section in FIG6A is identical to the cross-section in FIG4A and FIG4B. FIG6B is a perspective view of the drive sleeve 60, wherein the rings of the sleeve 60 have been separated to further illustrate the internal structure details. In the illustrated embodiment, the drive sleeve 60 includes four magnet retaining rings 300a, 300b, 300c, and 300d. Each ring 300 includes two half rings. For example, ring 300d includes half rings 301d and 302d. The ends of half rings 301d and 302d meet at joints 303d and 304d. A second ring 300c includes half rings 301c and 302c that meet at joints 303c and 304c. A third ring 300b includes half rings 301b and 302b that meet at joints 303b and 304b. The fourth ring 300a comprises half rings 301a and 302a meeting at joints 303a and 304a. The cover plate 310 comprises two half plates 311 and 312 meeting at joints 313 and 314.

Each half ring can be machined from PEEK and can include seven channels 319 formed in the upper surface. Two rows of magnets 230 are then placed into each channel and held in place by set screws 320. The orientation of the magnets 230 in the sleeve 60 (discussed below) creates magnetic repulsion forces that push the magnets 230 radially outward. The set screws 320 resist these outward forces and secure the magnets 230. The magnets 230 and set screws 320 have been omitted from one channel 319 in the half ring 301c to show additional detail of the channel 319. Each channel 319 in the half rings 301a, 302a, 301b, 302b, 301c, 302c, 301d, and 302d includes a countersunk hole 321 through which a bolt is inserted and secured to a threaded hole 322 in the lower half ring. This is indicated by the uneven dashed lines for one hole 321 in half ring 301c and the corresponding hole 322 in half ring 301d.

Each ring 300 is oriented 90 degrees relative to the adjacent ring 300. For example, the line between joints 303d and 304d of ring 300d is perpendicular to the line between joints 303c and 304c of ring 300c. Similar designs are also used for rings 300c and 300b, and for rings 300b and 300a. The half rings of ring 300 are not directly bolted to each other. Instead, each half ring 300 is held in place by its attachment to the adjacent ring 300. For example, half ring 301d of ring 300d is attached to one end of half ring 301c and one end of half ring 302c. Similarly, half ring 302d is attached to the other ends of half rings 301c and 302c. Half rings 301c and 302c have similar designs to half rings 301b and 302b, and half rings 301b and 302b to half rings 301a and 302a.

Drive sleeve 60 can be assembled by loading magnets 230 into channels 319 of half-rings 301d and 302d, securing these magnets 230 with set screws 320, and then placing half-rings 301d and 302d in place around main tube 52. Half-rings 301c and 302c can then be placed in place around main tube 52 on top of half-rings 301d and 302d without magnets 230 installed. Fasteners are then passed through holes 321 in channels 319 of half-rings 301c and 302c and into holes 322 of half-rings 301d and 302d, and tightened. Magnets 230 can then be placed into channels 319 of half-rings 301c and 302c and secured with set screws 320. A similar process can be performed for rings 300b and 300a. Finally, half plates 311 and 312 are mounted on top of ring 300a by inserting bolts (not shown in FIG. 6B ) through countersunk holes in half plates 311 and 312 and holes 322 in half rings 301a and 302a. Also shown in FIG. 6B are holes 399a (ring 300a) and 399c (ring 300c) through which sleeve 60 can be attached to riser bracket 91 (see FIG. 3G ).

In at least some embodiments, the magnets 230 of the shuttle 200 and drive sleeve 60 can be curved neodymium iron boron (NDFeB) grade N45H. This grade (corresponding to an operating temperature of up to 248°F) allows the magnets 230 to withstand the temperatures associated with sterilizing the valve 50 during cleaning and/or sterilization cycles. Magnets with higher maximum operating temperatures are available and can be used in certain embodiments. The magnets 230 can be sized so that fourteen magnets, placed end to end, form a strip with an outer diameter of 43 mm, an inner diameter of 39 mm, and a height of 5 mm. The magnetization can be from the inner bend to the outer bend, with the north pole of each magnet on the outer side. The magnets 230 are placed in the sleeve 60 with the north pole facing inwardly toward the shuttle 200. The magnets 230 are placed in the shuttle 200 with the north pole facing outwardly toward the sleeve 60.

In some embodiments, the magnets 230 in certain channels 319 of the sleeve 60 can be replaced with PTFE (polytetrafluoroethylene) bearing elements. For example, all magnets 230 in the channels 319 of the ring 300a directly above the hole 399a (as indicated by arrow 398a), all magnets in the channels 319 on the other side of the ring 300a (as indicated by arrow 397a), all magnets 230 in the channels 319 of the ring 300d on either side of the joint 303d (as indicated by arrows 395d and 396d), and all magnets 230 in the channels 319 of the ring 300d on either side of the joint 304d (as indicated by arrows 393d and 394d) can be omitted. A PTFE bearing can then be inserted into each channel 319 from which the magnets 230 have been omitted. In some embodiments, these PTFE bearings can be manufactured by cutting approximately 9/16-inch-long pieces from raw PTFE rod having a diameter of 7/16-inch. These PTFE bearings extend from the set screws 320 of their corresponding channels 319 and slightly exceed the inner diameter of the rings 300a and 300d. These set screws 320 can then be used to adjust the compression on the PTFE bearings so that the inner ends of the PTFE bearings contact the outer wall of the main tube 52. Using such PTFE bearings smooths the travel of the sleeve 60 on the main tube 52 and can reduce wear on the main tube 52.

As can be understood from Figures 4A and 4B , and in accordance with the description of shuttle 200 in conjunction with Figures 5A-5G and the description of sleeve 60 in conjunction with Figures 6A and 6B , magnet 230 of drive ring 210a of shuttle 200 is straddled by magnets 230 of sleeve rings 300a and 300b. Magnets of rings 210b and 210c of shuttle 200 are straddled by magnets of rings 300b and 300c, and rings 300c and 300d, respectively. The repulsive force of magnets 230 prevents each ring 210 from moving beyond ring 300 of sleeve 60, which is immediately above or below it. This creates a coupling, whereby shuttle 200 can be moved upward or downward by moving sleeve 60 upward or downward.

The staggered arrangement of ring 210 relative to ring 300 provides additional advantages. For example, this arrangement allows the repulsive force between ring 300 and ring 210 to be precisely and repeatably aligned vertically. In addition, this staggered arrangement provides a certain degree of magnetic spring force. Specifically, when the stopper element 203 abuts against the inner edge and shoulder of outlet 49 (as shown in FIG4A ), an upward vertical force is applied to shuttle 200, while a downward vertical force is also applied to ring 60, causing rings 300 a to 300 d to move closer to rings 210 a to 210 d, respectively. As the spacing between ring 300 and ring 210 decreases, the magnetic repulsive force attempting to separate the two rings increases. When sleeve 60 is subsequently moved upward again, shuttle 200 elastically returns to its initial position relative to sleeve 60. This allows sleeve 60 to travel slightly beyond shuttle 200 when closing valve 50 , thereby compressing the magnetic spring and causing the shuttle to apply a constant force against the inner edge and shoulder of outlet 49 .

Additionally, as shown in FIG4A , rings 210 and 300 are staggered such that a ring 300 is located above each ring 210 , but only below rings 210 a , 210 b , and 210 c . This configuration allows for a greater magnetic coupling in the downward direction, thereby providing an increased downward force available on shuttle 200 to seal valve 50 when closed. In at least some embodiments, the coupling force in the downward direction between shuttle 200 and sleeve 60 is at least 30 pounds to provide sufficient closing force and a sufficiently fast closing time. This closing force also facilitates shearing of contents that may be lodged in outlet 49 when valve 50 is closed.

In some embodiments, a single ring magnet may replace the segmented assembly of magnets 230 in ring 210. Similarly, a single ring (or half ring) magnet may replace the segmented assembly of magnets 230 used in the ring of sleeve 60, but the diameter of the single ring magnet used for ring 300 is larger than the diameter of the single ring magnet used for ring 210. Such a single ring magnet may also be NDFeB grade N45H.

Referring back briefly to Figures 1A and 1B, in some embodiments, the filler unit 10 is used in conjunction with a container gripping arm 20. Except for slight movements of certain arm 20 components described below, the arm 20 is substantially fixed relative to the filling unit 10. At the start of or before the filling operation, an empty container C is received in the gripper of the arm 20. When the filling valve 50 of the filler unit 10 is opened, the beverage product is dispensed from the outlet 49 of the filling valve 50 and passes through the open top of the container C. The weight of the container C increases as it is filled. The load cell in the arm 20 sends a signal representing this weight. The controller can then determine when to close the filling valve 50 based on these signals.

Containers C can be placed onto the arms 20 in a conventional manner. For example, when the continuously rotating turntable causes one arm 20 ( FIG. 2 ) of the filling system 40 to rotate past a position (e.g., the 6 o'clock position in FIG. 2 ), the arm 20 can receive a container C, where the first conveyor delivers an empty container C for receipt by a passing gripping arm. Then, as the turntable continues to rotate toward the second conveyor, product is dispensed into the received container C by the filler unit 10 corresponding to the arm 20. When the turntable's rotation has caused the arm 20 to reach the second conveyor's position (e.g., the 12 o'clock position in FIG. 2 ), the now-filled container C is removed from the arm 20 and transported away by the second conveyor system. The turntable then returns the arm 20 to the first conveyor to receive a new empty container C.

7A is a left front perspective view of a container handling arm 20 according to at least some embodiments. The support beam 401 of the arm 20 includes a boom 402, an upright 403, and a load cell attachment extension 404. In at least some embodiments, the beam 401 is a single component. The beam 401 is rigid and remains fixed relative to the filling unit 10 to which the arm 20 corresponds. Specifically, the upright 403 can be bolted or otherwise attached to a turntable or other structure of the filling system incorporating the arm 20. When attached to the filling system structure, the boom 402 is cantilevered and oriented horizontally.

The components of arm 20 that are attached to boom 402 include a pair of fulcrum brackets 405, a load cell 406, and a load cell coupling 407. A counterbalance lever 408 is pivotally coupled to boom 402 via a fulcrum element 409, which is held in place by brackets 405. Fulcrum element 409 interacts with a mating feature of lever 408 at one of a plurality of pivot positions to permit rotational movement of lever 408 about fulcrum element 409. In embodiments of arm 20, fulcrum element 409 can be a bolt or pin, and the mating arm feature is one of holes 410a through 410f in lever 408. Holes 410e and 410f can be seen in FIG7D .

In some configurations, and as shown in Figures 7A and 7B, an anti-snake bracket 411 can be attached to the distal end of the boom 402. The bracket 411 includes a guide slot 412 that constrains movement of the lever 408 to the left or right side of the boom 402 and helps maintain alignment of the lever 408 with the boom 402 in a vertical plane. The guide slot 412 is sized so that the lever 408 can freely move upward and downward within the slot 412. In other configurations, as described below, the bracket 411 can be omitted.

Container gripper 415 is attached to the distal end of lever arm 408 via bracket 416 and bolt 417. In the configuration shown in Figures 7A-7D, gripper 415 is a conventional gripper having spring-loaded jaws 418 sized to receive and hold a portion of the neck of container C. In some embodiments, gripper 415 can be configured to hold bottles with a final neck size between 28 mm and 43 mm. The spring tension in jaws 418 can be overcome by the force of the container neck pushing horizontally against surface 419 (e.g., when receiving an empty container from the first conveyor system described above) and by the force of the container neck pushing outward from jaws 418 (e.g., when a filled container is removed by the second conveyor system described above). Gripper 415 can be removed and replaced with a different type of gripper to grip different types of containers. Other types of grippers can also be used. For example, in some embodiments, the holder may not have spring-loaded jaws and may simply be a bracket with a recess that corresponds to the shape of the neck of the container.

The proximal end of load cell 406 is fixedly attached to extension 404 of support beam 401 by bolt 421. The distal end of load cell 406 is coupled to the proximal end of lever 408 by coupling 407. The lower end of coupling 407 is pivotally attached to load cell 406 by pin 422. The upper end of coupling 407 is pivotally attached to lever 408 by pin 423. As shown in FIG7C , a container held in holder 415 applies a downward force F1. This generates an upward force F2 on coupling 407 by rotating lever 408 about fulcrum element 409. Force F2 is transmitted to load cell 406 via coupling 407, causing load cell 406 to deform slightly. The strain gauges and other elements within load cell 406 generate a signal SLC corresponding to the magnitude of the deformation, and thus the magnitude of force F2, and output signal SLC via cable 425. Based on signal SLC, the known dimensions of arm 20, and the configuration of bracket 405 (described below), a controller of a filling system incorporating arm 20 can determine the weight of a container held by arm 20. Because the volume of the container and the density of the dispensed beverage product are known, the controller can also use signal SLC to determine the extent to which the container has been filled.

In at least some embodiments, the load cell 406 has a range of 0 to 7.5 kilograms (kg). Load cells are well-known weight sensors that utilize strain gauges to detect deformation and output a signal representative of the force causing the deformation. Load cells and control software for processing the load cell signal output are commercially available from a variety of sources.

Generally speaking, load cell accuracy increases if the larger range of a load cell's capacity is utilized. For example, assume container C holds 20 fluid ounces of product when filled, and the product in question is milk. 20 fluid ounces of milk weigh approximately 0.61 kg. Suppose load cell 406 is arranged so that the weight measured by load cell 406 increases by only 0.61 kg when container C is fully filled, and that the range accessible by load cell 406 is 7.5 kg. In this scenario, only approximately 8% of load cell 406's measuring capacity (0.61 kg/7.5 kg) is used to measure the difference between an empty and full container. Now assume that load cell 406 is arranged so that when the same container C is filled with milk, the load measured by load cell 406 increases by 2.58 kg (a factor of 4.227). In this scenario, approximately 34% of load cell 406's capacity is utilized, thereby improving weight measurement accuracy. In this second scenario, the deformation of load cell 406 will also increase. However, even at the maximum load, the magnitude of the load cell deformation is relatively small.

The relationship between the weight of the container and its contents and the weight experienced by load cell 406 varies depending on the position of fulcrum element 409 relative to gripper 415 and coupling 407. If the center of force exerted by the container and its contents is assumed to pass through the center of the gripping area of jaws 418, and if fulcrum element 409 is equidistant between the center of jaws 418 and pin 423 of coupling 407, then the ratio of the weight of the filled product to the weight exerted by the product on load cell 406 is 1:1. However, if fulcrum element 409 is closer to pin 423, this ratio increases. Generally speaking, if the distance between the center of force F1 acting on the gripped container and its contents and fulcrum element 409 is x, and the distance between fulcrum element 409 and pin 423 is y, then the force F2 exerted on load cell 406 by the weight of the container and its contents is (x/y)*F1.

In some embodiments, arm 20 can be reconfigured to better accommodate filling operations in which the filled containers have different weights. Specifically, bolts 430 holding bracket 405 and fulcrum element 406 can be removed, and bracket 405 can be repositioned so that fulcrum element 409 cooperates with a different one of holes 410. In Figures 7A-7C, bracket 405 is positioned so that bolts 430 pass through holes in boom 402 on either side of hole 410e, and so that fulcrum element 409 cooperates with hole 410e. In Figure 7D, anti-snake bracket 411 has been removed, and bracket 405 has been repositioned at the distal end of boom 402. In this position, bolts 430 pass through holes in boom 402 on either side of hole 410a, and fulcrum element 409 cooperates with hole 410a. Alternatively, the bracket 405 may be positioned so that the fulcrum element 409 mates with any one of the holes 410a to 410f.

In some embodiments, the lever 408 and other arm 20 components are sized so that the ratio of force F2 (the force exerted on the force sensor by the container and contents) to force F1 (container and contents) associated with the positioning of the fulcrum element 409 in each of the holes 410a to 410f is as listed in Table 1.

Table 1

In some embodiments, markings can be added to lever 408 near each hole 410. The markings can correspond to the settings input to the controller of the filling system when the filling system is set to fill a specific type of container. The markings can also or alternatively identify the container size associated with each hole 410. In addition or alternatively, such markings can also or alternatively be included in boom 402 to identify the position of bracket 405 for a specific container size.

In some embodiments, arm 20 may include one or more adjustable stops that limit the range of motion of lever 408. For example, upright 403 of support beam 401 may include a protrusion 431 extending from the proximal end of lever 408. A first bolt 432 may extend through a threaded hole in the end of protrusion 431 and may include a nut 433. Bolt 432 may be adjusted and secured with nut 433 so that the end of bolt 432 is spaced a predetermined distance above lever 408. If lever 408 is inadvertently subjected to excessive downward force at its distal end, the top of lever 408 will contact the end of bolt 432 and limit the upward force on coupling 407 and load cell 406. A second bolt 434 may extend through a threaded hole in the end of the proximal end of lever 408 and may include a nut 435. Bolt 434 may be adjusted and secured with nut 435 so that the end of bolt 434 is spaced a predetermined distance above the top of boom 402. If lever 408 is inadvertently subjected to excessive upward force at its distal end, the end of bolt 434 will contact the top of boom 402 and limit the downward force on link 407 and load cell 406 .

Arm 20 provides many advantages, conveniently using a single filling system to fill a wide range of beverage containers with a wide range of product types. When filling beverage containers, it may be important to monitor the amount of beverage placed in the container during the filling operation. Containers that are not fully filled may not be able to be sold. Overfilling containers leads to product waste and overflow, which may dirty production equipment. Conventionally, when filling containers, flow meters are utilized to monitor the amount of product flowing through the filling valve. However, when filling containers with beverages with large contents, existing flow meters are not able to monitor the fill level of the product in the container accurately enough. Using arm 20 to monitor the fill level of the container based on the weight of the container and its contents avoids using a flow meter to determine the fill level. The adjustability of arm 20 facilitates the use of the filling system for containers of a wide range of sizes and products with significantly different densities. In addition, the positioning of load cell 406 on arm 20 minimizes the number of components that must be located in the aseptic area.

The construction of arm 20 provides further advantages. Specifically, the arrangement of lever 408, coupling 407, support beam 401, and other components isolates load cell 406 from uncontrolled environmental forces, such as those caused by a container entering and exiting gripper 415. In the configuration shown in Figures 7A-7D, only forces in the vertical plane are transmitted to load cell 406. Because load cell 406 deflects only a limited amount under load, this effectively results in only pure vertical forces acting on load cell 406. Torque and side loads on load cell 406 are eliminated, thereby avoiding the potential loss of measurement accuracy caused by side loads or torque. The vertical force on load cell 406 is limited to a safe range by the stops of bolts 432 and 434. Coupling 408 remains under load, thereby eliminating backlash in the mechanism and reducing variations in weight measurements.

In some embodiments, a gripping arm similar to arm 20 can be modified so that the adjustment of the position of the fulcrum element is automatic. However, as an example of this embodiment, bracket 405 can be mounted on a slide or other linear motion device and can be moved by a servo mechanism or other type of actuator. Another servo mechanism can be used to move the fulcrum element into and out of position on lever 408 and to support lever 408 when adjusting the position of the fulcrum element.

To reduce the time required to fill a single container and thereby increase overall production speed, it is useful to fill the container at a higher flow rate. However, as the level of product in a container approaches its desired level, it is desirable to reduce the rate at which product flows into the container. Specifically, a slower flow rate allows more time to completely stop the flow of product, enabling more precise filling to the desired level.

Where the filling valve is part of a system designed to accommodate a wide variety of product types, reducing flow through the filling valve can be expected to be more complex. Flow through the filling valve can be reduced by partially closing the filling valve and thereby reducing the size of the opening through which the product flows from the filling valve to the container. The extent to which the filling valve must be partially closed may be affected by the viscosity of the product and the presence of inclusions. The time over which flow should be reduced may be affected by the size of the container.

In at least some embodiments, the filler unit includes a component that facilitates closing the filling valve to an adjustable low flow set point. For example, and as described above in conjunction with Figures 3A-3F, the filler unit 10 includes an actuator 80 that is part of a low flow set point system. An interruptible fluid circuit connects the two chambers of the actuator 80. When the container begins to fill, the actuator 70 pushes the cross bar 92 upward to open the filling valve 50. Pushing the cross bar 92 upward pulls the rod 82 of the actuator 80. If the fluid can flow between the chambers of the actuator 80, the piston in the actuator 80 can move, thereby allowing the rod 82 to be retracted from the housing 81. When the container is nearly full, the actuator 70 begins to close the filling valve 50 by pulling downward on the cross bar 92. The downward force on the cross bar 92 pushes the rod 82, which in turn pushes the piston of the actuator 80 downward. Initially, as the piston of actuator 80 moves downward in response to the push of rod 82, fluid can flow in opposite directions between the chambers of actuator 80. However, when fill valve 50 reaches a low flow set point for the product and the container being filled, fluid flow between the chambers of actuator 80 is interrupted. This stops the piston of actuator 80 and stops the downward movement of crossbar 92, thereby maintaining fill valve 50 at the low flow set point where valve 50 is only partially open. Once the weight of the container and its contents indicates that it is filled to the appropriate level, flow between the chambers of actuator 80 is again allowed, and fill valve 50 can be moved to the fully open position.

8A to 8H are partial schematic diagrams of filler unit 10, further explaining the operation of the low flow set point system. FIG8A to 8H show a rear view of filler unit 10. Shelf 11, drive sleeve 60, upright bracket 91, crossbar 92, optical marker 121, and optical sensor 120 are shown in simplified form. Additionally, housing 71 and rod 72 of actuator 80, as well as housing 81 and rod 82 of actuator 80, are shown in simplified form. For convenience, other elements of filler unit 10 shown in FIG8A to 8H are omitted from FIG8A to 8H.

As described above, and as can now be seen in Figures 8A to 8H, actuator 70 includes piston 501. Piston 501 acts as a barrier between chambers 502 and 503 in actuator 70. When piston 501 moves upward, the volume of chamber 502 increases, and the volume of chamber 503 decreases. The lower end of rod 72 is attached to piston 501. Rod 72 extends from housing 71 through a sealed opening in the top wall of housing 71. Piston 501 includes a seal that prevents fluid from passing through the edge of piston 501 between chambers 502 and 503. To extend rod 72 from housing 71, pressurized fluid can be introduced into chamber 502 while allowing fluid to exit chamber 503. To retract rod 72 into housing 71, pressurized fluid can be introduced into chamber 503 while allowing fluid to exit chamber 502. In some embodiments, actuator 70 can be a commercially available fluid actuator that operates using pressurized air as the working fluid. 8A-8H designate the working fluid of actuator 70 as air and use stippling to represent air. In other embodiments, different working fluids may be used.

Compressed air enters and leaves chamber 502 through port 505. Compressed air enters and leaves chamber 503 through port 506. Fittings 74 and 75 (Figure 3D) can be attached to ports 505 and 506, respectively. A two-position control valve 507 is connected to port 506. When the control valve 507 is in its first position, port 506 is in fluid communication with a source of compressed air. When the control valve 507 is in its second position, port 506 is in fluid communication with the atmospheric environment through a restricted exhaust port 508. The position of the control valve 507 is controlled by a solenoid 509. When the solenoid 509 is not activated, a spring biases the control valve 507 to its second position. When the solenoid 509 is activated, the control valve 507 moves to its first position. The solenoid 509 is activated in response to a control signal from a controller, as described below.

Another two-position control valve 517 is connected to port 505. When control valve 517 is in its first position, port 505 is in fluid communication with a source of compressed air. When control valve 517 is in its second position, port 505 is in fluid communication with the atmosphere via a restricted exhaust port 518. The position of control valve 517 is controlled by solenoid 519, which receives a control signal from a controller, as described below. When solenoid 519 is deactivated, a spring biases control valve 517 to its second position. Activating solenoid 519 moves control valve 517 to its first position.

As further shown in Figures 8A to 8H, actuator 80 also includes a piston 551. Piston 551 acts as a barrier between chambers 552 and 553 in actuator 80. When piston 551 moves upward, the volume of chamber 552 increases, and the volume of chamber 553 decreases. The lower end of rod 82 is attached to piston 551. Rod 82 extends from housing 81 through a sealed opening in the top wall of housing 81. Piston 551 includes a seal that prevents fluid from passing between chambers 552 and 553 past the edge of piston 551.

A two-position control valve 559 is inserted into a fluid circuit 560 that connects ports 555 and 556 of the actuator 80. Fittings 84 and 85 ( FIG. 3C ) can be attached to ports 555 and 556, respectively. When the control valve 557 is in its first position, the fluid circuit 560 is blocked, preventing oil from flowing between chambers 552 and 553. When the control valve 557 is in its second position, the fluid circuit 560 is unblocked, allowing oil to flow between chambers 552 and 553. The position of the control valve 557 is controlled by a solenoid 559 that receives a control signal from a controller, as described below. When the solenoid 559 is not activated, a spring biases the control valve 557 to its second position. Activating the solenoid 559 moves the control valve 557 to its first position. A spring-loaded supply valve 561 connects the fluid circuit 560 to a gravity-fed source 562 of oil to maintain the fluid level in the circuit 560 .

In order that rod 82 is retracted from housing 81, fluid is allowed to enter chamber 552 while allowing fluid to leave chamber 553. In order that rod 82 is pushed into housing 81, fluid is allowed to enter chamber 553 while allowing fluid to flow from chamber 552. In certain embodiments, actuator 80 can be a commercially available fluid actuator and utilizes liquid (e.g., food-grade silicone oil) to operate. For convenience, the remaining description parts of Figure 8A-8H designate the working fluid of actuator 80 as oil and utilize shading to represent oil. In other embodiments, different working fluids can be adopted. The fluid used in combination with actuator 80 can be selected according to viscosity so that control rod 82 can be pulled out from housing 81 or pushed into the speed in the housing.

FIG8A shows the filler unit 10 at time T1. At time T1, the filling valve 50 is closed and the shuttle 200 is at the bottom of its stroke (as shown in FIG4A). Time T1 can be the time after completing filling one container and before starting to fill the next container. Pistons 501 and 551 are at the bottom of their strokes in housings 71 and 81, respectively. Solenoids 509, 519, and 559 are not activated, so the respective control valves 507, 517, and 557 are in their second positions (chambers 502 and 503 are open to the atmosphere and fluid circuit 560 is not blocked). Optical sensor 121 generates a detection signal in response to a flag 120 located in sensor 121. However, at this stage of the operation of the filler unit 10, the controller does not take action based on the detection signal.

FIG8B shows filler unit 10 at time T2, after time T1. At time T2, filler unit 10 begins to open fill valve 50. Solenoid 519 is activated in response to a signal from the controller and moves control valve 517 to its first position (connecting chamber 502 to the compressed air source). Solenoid 509 is not activated, and control valve 507 remains in its second position (opening chamber 503 to atmosphere). Solenoid 559 is also not activated, and control valve 557 remains in its second position (fluid circuit 560 is unblocked). Compressed air begins to flow into chamber 502 and pushes piston 501 upward. This pushes rod 72 upward from housing 71, with rod 71 pushing crossbar 92 upward. Because crossbar 92 is coupled to shuttle 200 via upright bracket 91 and drive sleeve 60, the upward movement of crossbar 92 causes shuttle 200 to move upward and open fill valve 50. Because optical flag 120 is still within optical sensor 121, sensor 121 continues to output a detection signal. However, at this stage of filler unit 10 operation, the controller takes no action based on the detection signal.

Because fluid circuit 560 is unobstructed, oil is able to flow between chambers 552 and 553 of actuator 80. The upward force applied to crossbar 92 from rod 72 of actuator 70 causes crossbar 92 to pull rod 82 of actuator 80. When rod 82 is pulled from housing 81, the pulling force on rod 82 causes upward movement of piston 551. The movement of piston 551 causes oil to flow from chamber 553 as the volume of chamber 553 decreases, and to flow into chamber 552 as the volume of chamber 552 increases.

For convenience, FIG8B includes arrows near ports 505 and 506 indicating the direction of air flow. Similarly, arrows near ports 555 and 556 indicate the direction of oil flow. Arrows located near the top of riser bracket 91 indicate the direction of movement of crossbar 92 and its coupled components (pistons 501 and 551, rods 72 and 82, optical flag 120, riser bracket 91, and drive sleeve 60 (and, therefore, shuttle 200)).

FIG8C shows the filler unit 10 at time T3 after time T2. At time T2, the filling valve 10 is fully open and the shuttle 200 is at the top of its stroke. Solenoid 519 remains activated in response to a signal from the controller and keeps control valve 517 in its first position (connecting chamber 502 to a compressed air source). Solenoid 509 remains unactivated and control valve 507 remains in its second position (opening chamber 503 to the atmosphere). Solenoid 559 also remains activated and control valve 557 is in its second position (fluid circuit 560 is not blocked). The upward movement of crossbar 92 and its coupled components is stopped by adjustable rod 110 ( FIG3D ). Because piston 501 no longer moves, the air flow through ports 505 and 506 has stopped, even though control valve 517 is in its first position and control valve 507 is in its second position. Similarly, even though fluid circuit 560 is unblocked, oil flow through ports 555 and 556 has ceased because piston 551 is no longer moving. Optical flag 120 has moved away from optical sensor 121, and sensor 121 no longer sends a detection signal.

8 D shows the filler unit 10 at time T4 after time T3. Between time T3 and time T4, one or more signals _SLC are output to the controller from the load cell 406 of the arm 20, indicating that the weight of the filled container and its contents has reached a level corresponding to the predetermined "nearly complete" fill level of the container. At time T4, and in response to the "nearly complete" representation, the controller sends a signal activating solenoid 509 and stops sending a signal activating solenoid 519. This causes control valve 507 to move to its first position (chamber 503 is connected to a compressed air source) and causes control valve 517 to return to its second position (chamber 502 is opened to the atmosphere). Solenoid 559 remains unactivated, and fluid circuit 560 remains unblocked.

As compressed air flows into chamber 503 and air flows out of chamber 502, and as oil is able to flow in fluid circuit 560, piston 501 moves downward. This pulls rod 72 and crossbar 92 downward. The downward movement of crossbar 92 causes downward movement of riser bracket 91, drive sleeve 60, and shuttle 200, as well as downward movement of rod 82 and piston 551. The arrows near ports 505 and 506 indicate the direction of air flow. The arrows near ports 555 and 556 indicate the direction of oil flow. The arrow located near the top of riser bracket 91 indicates the direction of movement of crossbar 92 and the components it connects.

Fig. 8E shows the filler unit 10 at time T5 after time T4. Crossbar 92 and its connected components continue to move downward. Solenoid 509 remains activated, and solenoids 519 and 559 remain deactivated. Air and oil continue to flow in the direction shown.

Fig. 8 F shows the filler unit 10 at time T6 after time T5. The downward movement of crossbar 92 has caused the optical mark 120 to arrive at the point detected by sensor 121. This causes the optical sensor 121 to send a detection signal to the controller. In response to the detection signal, the controller sends a signal to activate solenoid 559. This causes the control valve 557 to move to its first position (blocking fluid circuit 560). Solenoid 509 remains activated, and solenoid 519 remains unactivated. Because oil can no longer flow in fluid circuit 560, oil can no longer move between chambers 552 and 553. Therefore, the movement of piston 551 stops. This causes rod 82, crossbar 92 and other components connected with crossbar 92 to stop moving. Although control valve 507 is in its first position (connecting chamber 503 to a source of compressed air) and control valve 517 is in its second position (venting chamber 502 to atmosphere), piston 501 is held in place by virtue of its connection to crossbar 92 and air no longer flows into or out of actuator 70.

The position of shuttle 200 at time T6 corresponds to a low flow set point. When shuttle 200 is in this position, the flow of beverage product through opening 49 is partially blocked, and the rate of product flow from opening 49 to the container is reduced. The low flow set point will vary depending on the type of beverage and may also vary depending on the type of container. For example, a first low flow set point corresponding to a lower viscosity product without inclusions may place shuttle 200 in a first position that nearly completely closes opening 49. A second low flow set point corresponding to a product with a higher viscosity and/or inclusions may place shuttle 200 in a second position that partially blocks opening 49, but to a lesser extent than the first position.

The above system allows for simple adjustment of the low flow set point. Specifically, when the downward movement of the drive sleeve 60 is stopped, the position of the optical sensor 121 and the flag 120 are controlled. By moving the optical sensor 121 up or down (and/or adjusting the position of the flag 120 on the associated crossbar 92), the low flow set point can be changed.

In some embodiments, optical sensors are not used to control the low flow set point. On the contrary, when an indication of "nearly full" is obtained, the controller starts a timer. The value set by the timer represents the time required for sleeve 60 to advance downwards to the low flow set point position after sending the control signal activating solenoid 509 (and simultaneously stopping the control signal activating solenoid 519). By performing a test run of the filler unit 10 several times using the product in question and timing the time required to arrive at the low flow set point, the value of the timer can be easily determined. Then, this time value can be used for this filler unit and other filler units in the filling system.

FIG8G shows filler unit 10 at time T7, after time T6. One or more signals _SLC are output from load cell 406 of arm 20 to the controller, indicating that the weight of the filled container and its contents has reached a value corresponding to a fully filled container. In response to the "full" indication, the controller stops sending the signal activating solenoid 559. This causes control valve 557 to move to its second position (unblocking fluid circuit 560). The controller continues to send the signal activating solenoid 509, thereby maintaining control valve 507 in its first position (connecting chamber 503 to the compressed air source). Solenoid 519 is not activated, and control valve 517 is in its second position (opening chamber 502 to the atmosphere). Because oil is now able to flow from chamber 553 to chamber 552, pistons 501 and 551 and their connected components (including shuttle 200) continue to move downward.

Fig. 8 H shows the filler unit 10 at time T8 after time T7.At time T8, filling valve 50 is completely closed.The signal from the activation solenoid 509 of controller can be interrupted now, so that filler unit 10 is returned to the state shown in Fig. 8 A.Then, when the next container is in the filling position, the operation shown in Fig. 8 B to 8H can be repeated.In certain embodiments, controller continues to send the signal of activation solenoid 509, until the moment of opening filling valve 50 again.

8I to 8P are partial schematic rear views of a filler unit incorporating a low flow set point system according to another embodiment. The filler unit of FIG8I-8P is similar to the filler unit 10 shown in FIG8A-8H. However, in the embodiment of FIG8I-8P, cylinder 80 has been replaced with cylinder 81'. Cylinder 80' is similar to cylinder 80, wherein housing 81', rod 82', piston 551', ports 555' and 556', chamber 552', and chamber 553' are similar to housing 81, rod 82, piston 551, ports 555 and 556, chamber 552, and chamber 553 of cylinder 80, respectively.

However, fluid circuit 560 has been replaced. Chamber 552' is connected to oil reservoir 581 via port 555' through two paths. The first path includes a check valve 583. The second path includes a control valve 557', which is similar to control valve 557 and includes a flow-restricting orifice 582. Control valve 557' has a first position in which flow is blocked and a second position in which flow is unblocked. The position of control valve 557' is controlled by solenoid 559', which receives a control signal from a controller, as described below. When solenoid 559' is not activated, a spring biases control valve 557' to its second position. Activating solenoid 559' moves control valve 557' to its first position.

Chamber 553' is connected to the top of oil reservoir 581 via port 556'. In the embodiment of Figures 8I-8P, oil flows between lower chamber 552' and oil reservoir 581. Chamber 553' contains air and contains only a small amount of oil for sealing and lubrication. Chamber 553' is connected to oil reservoir 581 so that any oil that may be discharged through port 556' can return to oil reservoir 581. The upper portion of oil reservoir 581 is open to the atmosphere. The oil used in the embodiment of Figures 8I-8P can also be food grade silicone oil.

Check valve 583 allows flow from oil reservoir 581 to chamber 552' when piston 551' moves upward, and blocks flow in the other direction when piston 551' moves downward. Orifice 582 allows flow in either direction, but restricts it. Thus, orifice 582 slows the downward movement of piston 551'. This slows the downward movement of shuttle 200, preventing stopper 225 from slamming into outlet 49 and causing premature wear. When valve 50 is open, check valve 583 allows oil to bypass orifice 582, allowing the shuttle to rise more quickly.

The same control signals used in the embodiment of Figures 8A-8H can be used in the embodiment of Figures 8I-8P to achieve the same valve motion. In Figure 8I (time T1), filling valve 50 is closed, shuttle 200 is at the bottom of its stroke, pistons 501 and 551' are at the bottom of their stroke, and solenoids 509, 519, and 559' are not activated. Optical sensor 121 generates a detection signal in response to flag 120 located in sensor 121. However, at this stage of filler unit operation, the controller does not take any action based on the detection signal.

At time T2 ( FIG. 8J ), the filler unit begins to open the fill valve 50. Solenoid 519 is activated in response to a signal from the controller. Solenoid 509 is not activated. Solenoid 559′ is not activated, and control valve 557′ remains in its second position (unblocked). As piston 552′ moves upward, oil flows from reservoir 581 into chamber 552′ to increase the volume of the chamber. The oil flows through check valve 583 and, to a lesser extent, through orifice 582 and control valve 557′.

At time T3 ( FIG. 8K ), the fill valve is fully open and shuttle 200 is at the top of its travel. Solenoid 519 remains activated in response to a signal from the controller. Solenoid 509 remains deactivated. Solenoid 559′ also remains activated, and control valve 557′ is in its second position (unblocked). Because pistons 501 and 551′ are no longer moving, air and oil flow ceases. Optical flag 120 has moved out of the way of optical sensor 121, and sensor 121 no longer sends a detection signal.

At time T4 ( FIG. 8L ), in response to the “near full” indication, the controller sends a signal to activate solenoid 509 and stops sending a signal to activate solenoid 519. Solenoid 559′ remains deactivated, and control valve 557′ remains in its unblocked position. Oil flows from chamber 552′ to oil reservoir 581, but only through control valve 557′ and orifice 582.

At time T5 (FIG. 8M), solenoid 509 remains energized, and solenoids 519 and 559' remain deenergized. Air and oil continue to flow in the directions shown.

At time T6 ( FIG. 8N ), valve 50 has reached its low flow set point, and optical sensor 121 sends a detection signal to the controller. In response, the controller sends a signal to activate solenoid 559′. This causes control valve 557′ to move to its first position (blocking fluid flow). Solenoid 509 remains activated, and solenoid 519 remains deactivated. Because oil can no longer flow from chamber 552′ to oil reservoir 581, piston 551′ stops moving.

At time T7 ( FIG. 8O ), the controller has received the "full" indication and stops sending the signal to activate solenoid 559'. This causes control valve 557' to move to its second position (unblocked). The controller continues to send the signal to activate solenoid 509. Solenoid 519 is not activated. Because oil is now able to flow from chamber 552' to oil reservoir 581, pistons 501 and 551' continue to move downward.

At time T8 (FIG. 8P), fill valve 50 is fully closed. The signal from the controller to activate solenoid 509 can now be interrupted to return the filler unit to the state shown in FIG. 8I.

As mentioned above, in some embodiments, filler unit 10 is used for filling system, and this filling system can be filled container with various types of beverage products.These products can have the viscosity of a wide range, and may or may not include inclusions.In order to adapt to the product with larger inclusions, the size of the opening 49 of filling valve 50 is formed so that these inclusions can pass through.For example, the opening 49 of cup 53 can have a width of about 0.625 inch.However, the opening that is formed to size by larger inclusions (for example, 10mm square) may cause undesirably high flow rate for the product that lacks inclusions and/or viscosity is lower.In certain embodiments, the filling system that comprises filling valve 50 can also include a pressure control system, and this pressure control system maintains the desired pressure at the position in this filling system.This position can be in the product reservoir that supplies one or more filling valves, or it can be in the flow path from this reservoir.For some products, the desired pressure can be higher than atmospheric pressure, so that the product flows through the filling valve.For other products, the desired pressure can be lower than atmospheric pressure (i.e. vacuum), so that the product flows through the filling valve. As used herein, "atmosphere," "atmospheric pressure," and "ambient atmospheric pressure" all refer to the ambient pressure within the space surrounding the filling system, including the space at the outlet of the filling valve.

Fig. 9 A is a schematic diagram of a part of a beverage container filling system including a pressure control system 600 according to at least some embodiments. The filling system part shown in Fig. 9 A can be a part for a filling system (such as the filling system 40 shown in Fig. 2) and includes a filling valve 50. Because the filling valve 50 is symbolically shown as a rectangle in Fig. 9 A, the position of the recirculation conduit 13 is for the purpose of representing orientation. As shown in uneven dotted lines, additional filling valves 50 can be included in parallel. In the entire remaining description of Fig. 9 A and 9B, "filling valve 50" represents that there are 1 to n filling valves 50, wherein n is an arbitrary number (such as, 72 for the filling system 40 of Fig. 2). The recirculation conduit 13 of the filling valve 50 is connected to the product recirculation system. Further discuss the product recirculation system in conjunction with Fig. 9 B.

The filling valve 50 is connected to the product reservoir 601. The capacity of the interior of the reservoir 601 is used to hold a certain amount of beverage product, which is greater than the combined volume of the multiple containers being filled. For each filling valve 50, the interior of the housing is connected to the internal fluid of the product reservoir 601. A pressure transducer (PT) 602 is located in the fluid path between the reservoir 601 and the filling valve 50. In certain embodiments, the pressure transducer 602 can be located in the reservoir 601, for example, in the lower area of the reservoir 601 interior near the outlet leading to the filling valve 50. The pressure transducer 602 outputs a signal S _PT to the controller. Although not shown in Figure 9A, the controller forms a part of the pressure control subsystem 600 (and other systems described herein) and is described below in conjunction with Figure 10. The signal S _PT represents the pressure detected by the transducer 602 in the fluid path between the reservoir 601 and the filling valve 50 at each time. A level transducer (LT) 603 is located in the reservoir 601 and outputs a signal S _LT to the controller, wherein the signal S _LT represents the fluid level in the reservoir 601 at various times.

The reservoir 601 is filled with the beverage product through the supply inlet 606. The supply inlet 606 may receive the beverage product from a pasteurizer or sterilizer, as described in conjunction with Figure 9B.

The reservoir pressure control system 600 is connected to the interior of the reservoir 601 via a reservoir pressure control line 607. Line 607, as well as other lines described in connection with system 600, may include one or more pipes, tubes, or other types of conduits capable of containing a pressurized fluid and, for certain portions of the system 600, maintaining a vacuum without collapsing. The working fluid of the reservoir pressurization control system 600 may be a gas or a mixture of gases, such as air, nitrogen, carbon dioxide, etc. By regulating the pressure of the fluid in line 607, the pressure within the reservoir 601 (and at various locations in the flow path from the reservoir 601) may be controlled. Line 607 may include a vacuum breaker 608 to prevent the tank from collapsing due to an inadvertent high vacuum, and a safety valve 609 to prevent system damage due to an inadvertent overpressure within line 607.

The first branch of line 607 is connected to the output of pressure control valve 610. Pressure control valve 610 is selectively opened and closed by a current-to-pressure transducer (I/P) 611. The input side of pressure control valve 610 is connected to a pressurized air source 618 (or other pressurized working fluid source) via an additional line. The lines connecting pressure control valve 610 and source 618 may include an angle seat valve 614, filters 615 and 616, and a manual valve 617. Filters 615 and 616 may be 0.2 micron filters and may be used to prevent microorganisms or other contaminants from entering reservoir 601. For aseptic filling operations, filters 615 and 616 may be sterilizable HEPA ULPA filters. Manual valve 618 may be used to isolate system 600 from source 618. Angle seat valve 614 may also be used to isolate system 600 from source 618 while keeping filters 615 and 616 pressurized. An angle seat valve 612 connects the portion of the system 600 between the source 618 and the input side of the valve 610 to the drain 613 .

A second branch of the reservoir pressure control line 607 is connected to the input side of a vacuum pump 622. The outlet of the vacuum pump 622 is connected to a drain line 623. An angle seat valve 620 may be included in the line connecting the vacuum pump 622 to the line 607. An adjustable vacuum relief orifice 621 (e.g., a needle valve) is connected to the fluid path between the angle seat valve 620 and the vacuum pump 622.

Pressure transducer 602, liquid level transducer 603, vacuum breaker 608, safety valve 609, pressure control valve 610, current-pressure transducer 611, angle seat valves 612, 614, and 620, filters 615 and 616, manual valve 617, vacuum orifice 621, and vacuum pump 622 may be conventional, commercially available components. Therefore, additional details of these components are not provided except that they are used in the novel and inventive system described herein.

The pressure in line 607 is adjusted to maintain the pressure Piarget at or near Piarget (e.g., +/- 0.1 psi, +/- 0.05 psi, etc.) at the location corresponding to pressure transducer 602, which, as described above, is between reservoir 601 and filling valve 50 in FIG. 9A . In other embodiments, this location may be within reservoir 601 or elsewhere in the flow path from reservoir 601. The Piarget pressure may be subatmospheric (vacuum), atmospheric, or greater than atmospheric pressure. Due to head pressure from the contents of reservoir 601, the actual pressure in line 607 may be lower than the pressure measured by transducer 602. However, reducing the pressure in line 607 reduces the pressure between reservoir 601 and filling valve 50, and increasing the pressure in line 607 increases the pressure between reservoir 601 and filling valve 50.

Vacuum pump 622 draws fluid from line 607 to create a subatmospheric pressure (i.e., a vacuum) in the line. Valve 610 can be opened to allow pressurized fluid to flow from its input side to its output side. Depending on the degree to which valve 610 is opened, the output from valve 610 can reduce the subatmospheric pressure in line 607, neutralize the subatmospheric pressure in line 607 so that the pressure in line 607 becomes atmospheric pressure, or even overcome the subatmospheric pressure created in line 607 by vacuum pump 622 so that the pressure in line 607 exceeds atmospheric pressure. A controller receives a signal S _PT from pressure transducer 602. Utilizing a control algorithm described below in conjunction with FIG. 11C , and based on the received signal S _PT and previously set control parameters, the controller outputs a signal S _PC to transducer 611. In response to these signals S _PC , transducer 611 opens pressure control valve 610 to overcome the greater sub-atmospheric pressure generated by pump 622 (thereby increasing the pressure in line 607 ) or closes control valve 610 to overcome the less sub-atmospheric pressure generated by pump 622 (thereby decreasing the pressure in line 607 ).

Each angle seat valve 612, 614 and 620 is normally fully open or fully closed. Each of these angle seat valves can be actuated by a solenoid (or a solenoid-controlled pneumatic actuator) not shown in response to a signal from a controller. When the system 600 is running, the controller sends a signal to keep the angle seat valve 614 open, and stops sending this signal when the system 600 is not operating or when the high pressure flow needs to be cut off for some reason. When the system is running, the controller sends a signal to keep the angle seat valve 620 open, and stops sending this signal when the system is not operating or when the vacuum side needs to be isolated from the pressure side for some reason. The angle seat valve 612 remains closed during operation; the controller can send a signal to open the valve 612 in the event that air needs to be removed from the high pressure side.

Regulating the pressure using the compressed fluid source 618 and the vacuum pump 622 allows for better control, particularly when it is desired to maintain a vacuum in the line 607. In operation, valves 617, 614, and 620 can be open, valve 612 closed, and the vacuum pump 622 activated before opening any valve 50. With the pressure control valve 610 set in the middle of its optimal operating range, the orifice 621 can be adjusted so that the pressure sensed by the transducer 602 is Piarget, and the controller can then begin executing the pressure control algorithm described below and begin a filling operation using the valve 50.

The desired Piarget will depend on the beverage product under consideration, particularly the viscosity of the product. By performing a limited number of tests (e.g., between 14 psia and 15.5 psia in 0.1 psia intervals) to plot the input pressure of the filling valve 50 versus the flow rate through the outlet 49 of the filling valve 50 for the product under consideration, the desired Piarget for a particular beverage product can be determined. The desired flow rate can be selected, and the corresponding pressure can then be employed. A full system test can then be performed to adjust the pressure so that multiple filling valves 50 are able to accept product from the reservoir.

In the embodiment of system 600 shown in FIG9A , the output of pressure control valve 610 and the input of vacuum pump 622 are connected to pressure control line 607. As can be understood from FIG9A , line 607 and the interior of reservoir 601 form a common fluid space. In other embodiments, the output of the pressure control valve and the input of the vacuum pump (or other vacuum source) can be connected to lines of different configurations to form a common fluid space that includes the interior of the reservoir.

The reservoir 601 is sealed and can maintain a pressure above, equal to, or below atmospheric pressure. In some embodiments, the reservoir 601 can be vented to the atmosphere and the filling operation can be performed in a vented-to-atmosphere mode.

When performing a hot-fill operation, the temperature of the beverage product in the reservoir can be elevated to prevent microbial growth in the product and the container filled with the product. For example, the heated product can aid in sterilizing the interior of the container. In some filling operations, after the container has been filled with the heated product and sealed with a closure, the container is inverted. The heated product within the container then sterilizes the interior surface of the closure.

During hot filling operation, it is desirable to keep the temperature of filling valve 50 internal components close to the temperature of the rising of reservoir. If the temperature of filling valve drops too much, the temperature of the product dispensed in the container may be too low so. If product stops flowing completely when filling valve 50 is closed, the internal components of filling valve 50 may cool down as filling valve waits for the next container filling operation to begin so. For example and as explained above in conjunction with Fig. 2, filling valve 50 can be positioned on the turntable that rotates continuously, and when filling valve 50 moves between 6 o'clock position and 12 o'clock position, beverage product is dispensed in the container. When filling valve 50 moves between 12 o'clock position and 6 o'clock position to admit another container and start new filling operation, product does not flow from the outlet 49 of this filling valve 50.

To prevent excessive cooling of the filling valve when it is closed, it is known to recirculate a small amount of heated product through the filling valve and back to the product tank. However, for many types of products, excessive recirculation can reduce product quality. Therefore, the recirculation flow should be sufficient to keep the filling valve heated, but at a significantly reduced rate relative to the flow through the filling valve when it is open.

As mentioned above, the filling valve 50 can be used to fill containers with various beverage products. Some of these products can have larger inclusions. In order to recirculate products with large inclusions, a larger fluid path is required. For example, in order to recirculate beverage products with inclusions of 10mmx10mmx10mm, it is desirable that the width of the flow path be at least 0.625 inches (e.g., for a circular path, a diameter of 0.625 inches). However, for beverages with lower viscosities without inclusions, simply modifying a conventional product recycling system to include a path with this size will result in an undesirably high recycling flow rate for low-viscosity products with less (or no) inclusions.

In certain embodiments, the filling system may include a product recirculation system that recirculates large-content products, as well as other products, but not at undesirably high flow rates. A flow meter may be used to monitor the flow rate through the recirculation system. Based on the output of the flow meter, the flow rate within the recirculation system may be adjusted and maintained at a predetermined level.

Figure 9B is a schematic diagram of a portion of a beverage container filling system including a product recycling system 650, according to at least some embodiments. Figure 9B is an extension of Figure 9A and shows another portion of the same beverage container filling system.

The flow path of the product recirculation system 650 includes a variable speed positive displacement pump 651 equipped with a variable frequency drive (VFD) 652. The input of the pump 651 is connected to the recirculation line 13 of the filling valve 50. The output of the pump 651 leads to a balancing tank 655. A flow meter 653 is located in the portion of the flow path between the output of the pump 651 and the balancing tank 655. The flow meter 653 may include a mass flow meter, a flow sensor, or other type of transducer. The signal S _RFM output by the flow meter represents the flow rate through the flow meter 653 and, therefore, the flow rate through the flow path of the product recirculation system 650. A flash chiller or other heat exchanger 654 may be located in the flow path of the product recirculation system 650 and can cool the beverage product to prevent damage caused by prolonged heating. The pump 651, the variable frequency drive 652, the flow meter 653, and the heat exchanger 654 may be conventional, commercially available components. Therefore, no additional details of these components are provided except that they are used in the novel and inventive system described herein.

The controller receives a signal S _RFM from the flow meter 653. Although not shown in FIG9B , the controller forms part of the product recirculation system 650 and is discussed in conjunction with FIG10 . Utilizing a control algorithm described below in conjunction with FIG11D , and based on the received signal S _RFM and previously set control parameters, the controller outputs a signal S _RFC to the driver 652. In response to this signal S _RFC , the driver 652 increases or decreases the speed of the pump 651 to regulate the flow rate on the output side of the pump 651.

The output of the balance tank 655 is fed into the input of a second variable-speed positive displacement pump 656 driven by a variable frequency drive 657. A level transducer 659 outputs signals S _LTB representing the product level in the tank 655 to a controller. Based on these signals S _LTB , the controller generates signals S _FBC to increase or decrease the speed (and thus the flow rate) of the pump 656. The level transducer 659, pump 656, and variable frequency drive 657 can be conventional, commercially available components.

The output of pump 656 is connected to the input of a buffer tank 658. The output of buffer tank 658 is connected to the input of a third variable-speed positive displacement pump 660 driven by a variable frequency drive. The output of pump 660 is connected to a processor 661. Processor 661 can be a pasteurizer or other sterilizer. The output of processor 661 is connected to reservoir 601. Flow from processor 661 to reservoir 601 is controlled by a butterfly valve 664 (connected to a current-to-pressure transducer 665). The controller generates a signal S _LL that controls the position of valve 664 based on a signal S _LT from level transducer 603 ( FIG. 9A ). The recirculation loop at the output of processor 661 includes another butterfly valve 662 connected to current-to-pressure transducer 663. A signal from the controller (not shown) controls the position of valve 662. If, for example, flow to reservoir 601 slows or is interrupted, valve 662 can be opened. Flow from valve 662 returns the beverage product through a second rapid cooler 669 to the buffer tank 658. The portion of the system shown in FIG9B after pump 656 (i.e., buffer tank 658, pump and driver 660, processor 661, valve 662 and transducer 663, valve 664, rapid cooler 669, and transducer 665) can be similar to a conventional system for supplying heated product to a tank of a filling system that supplies a fill valve. In some embodiments, the passageway in the product recirculation system 650 has a minimum width of 0.625 inches.

FIG9C is a schematic diagram of a portion of a beverage container filling system including a product recirculation system 650′, according to at least some embodiments. With respect to such embodiments, FIG9C is an extension of FIG9A , rather than FIG9B . The embodiment shown in FIG9C is similar in several respects to the embodiment of FIG9B , wherein elements in FIG9C are similar to elements with the same reference numerals in FIG8B and operate in a similar manner to those with the same reference numerals in FIG8B . However, in recirculation system 650′, a variable flow valve 671 has been added. Valve 671 can be a conventional diaphragm valve or other type of flow-reducing valve. A variable speed pump 670 and its associated variable frequency drive are similar to pump 651 and drive 652. In system 650′, valve 671 is used to regulate flow. A controller sends a signal _SRFCv (e.g., to a current-to-pressure transducer connected to valve 671) that causes valve 671 to increase or decrease the flow of product through the flow path of system 650′. The controller can generate signal _SRFCv based on signal _SRFM received from flow meter 653. In some embodiments, the passageway of the product recirculation system 650' has a minimum width of 0.625 inches, except for valve 671 at certain settings. However, the controller can periodically trip valve 671 to an open position sufficient to allow flushing of any accumulated contents in valve 671.

FIG9D is a schematic diagram of a portion of a beverage container filling system including a product recirculation system 650″, according to at least some additional embodiments. With respect to such embodiments, FIG9D is an extension of FIG9A rather than FIG9B . Several aspects of the embodiment shown in FIG9D are similar to the embodiment of FIG9B , wherein elements in FIG9D are similar to and operate in a manner similar to elements with the same reference numerals in FIG8B . However, in recirculation system 650″, balancing tank 655 is replaced with a pressurized balancing tank 680 . Tank 680 is connected to a source of compressed air via a pressure control valve 673 , wherein valve 673 is connected to the flow of a pressure transducer 672 . A variable speed pump 670 and its associated variable frequency drive are similar to pump 651 and drive 652 . However, in system 650″, valve 673 is used to regulate flow by increasing or decreasing the pressure in tank 680 , thereby increasing or decreasing backpressure in the flow path of system 650″. The controller sends a signal S _RFCp to the current-to-pressure transducer 672, causing the valve 673 to increase or decrease the flow of compressed air into the tank 680. The controller can generate the signal S _RFCp based on the signal S _RFM received from the flow meter 653. In some embodiments, the passageway in the product recirculation system 650" has a minimum width of 0.625 inches.

FIG10 is a block diagram of the inputs and outputs of a controller 1000 of a filling system according to some embodiments. The controller 1000 can be a microprocessor, a programmable integrated circuit (IC), a special purpose IC, a programmable logic controller (PLC), a field programmable gate array (FPGA), or other type of device capable of receiving signals, executing instructions, and outputting signals based on received signals and instructions. The controller 1000 can include a memory for storing instructions and data and/or can access a separate storage component (not shown). Although FIG10 shows a single controller 1000, in some embodiments, the filling system can include multiple controllers, wherein the controller operations as described herein are distributed between these multiple controllers.

Controller 1000 is connected to one or more input signal lines on which it receives signals from various filling system components. Some of these input signal lines carry signals _SLC from load cells 406 (FIGS. 7A-7D) of arm 20. As shown in FIG10 , controller 1000 can receive separate inputs from each of multiple load cells 406. Each of these inputs can be a signal _SLC from load cells 406 of arm 20 corresponding to a single filler unit 10. Controller 1000 is also connected to input signal lines on which it receives signals _SPT from pressure transducer 602 (FIG. 9A), _SRFM from flow meter 653 (FIG. 9B), _SLTB from level transducer 659, and _SLT from level transducer 603 (FIG. 9A). Controller 1000 may include additional signal lines to receive signals from other transducers, programming instructions, and the like. For example, and as described above, when fill valve 50 is at a low flow set point, controller 1000 receives a signal from optical sensor 121 .

Controller 1000 is also connected to one or more output signal pipelines, and controller 1000 outputs control signal to each filling system component on these output signal pipelines.Some in these output signal pipelines are with the signal of the solenoid of the actuator of each in a plurality of filler units 10.As shown in Figure 10, for each filler unit 10, this can comprise the independent signal pipeline (Fig. 8 A to 8H) of each solenoid 509,519 and 559 (or the signal pipeline of solenoid 509,519 and 559 ' in the embodiment of Fig. 8I-8P).Controller 1000 will be associated with the input signal pipeline with the signal S LC from the force sensor 406 corresponding to the arm 20 of filler unit 10 to each group of output signal pipelines of one group of solenoid 509,519 and 559 in filler unit ₁₀ . Controller 1000 is also connected to output signal lines on which it transmits signal S _PC to transducer 611 ( FIG. 9A ), signal S _RFc to variable frequency drive 652 ( FIG. 9B ), signal S _FBC to driver 657, and signal S _LL to transducer 665 ( FIG. 9B ). Controller 1000 may include additional signal lines on which it transmits signals to other filling system components. These signals may include, but are not limited to, signals for angle seat valves 612 , 614 , and 620 , signals for current-to-pressure transducers 663 and 665 , a signal for valve 671 (in the embodiment of FIG. 9C ), a signal for transducer 672 (in the embodiment of FIG. 9D ), a signal for the driver of pump 660 , a signal for the driver of pump 670 (in the embodiments of FIG. 9C and 9D ), and an on/off signal for vacuum pump 622.

FIG11A is an example of an algorithm executed by the controller 1000 in conjunction with the operations shown in FIG8A-8H or FIG8I-8P. The algorithm of FIG11A relates to a single filler unit and its corresponding arm 20 and will be described with reference to the single filler unit and its corresponding arm 20. However, the controller 1000 may simultaneously execute separate instances of the algorithm of FIG11A for each filler unit and its corresponding arm 20.

At step 1101 (which may correspond to the state of the filler unit shown in FIG. 8A or FIG. 8I ), the controller 1000 determines whether an empty container has been placed in the gripper 415 of the arm 20. In some embodiments, the controller 1000 may make this determination based on a separate optical or contact sensor positioned on the gripper 415 to detect the container. In other embodiments, the controller 1000 makes this determination based on whether the signal S _LC currently received from the load cell 406 corresponds to the weight of the empty container. As indicated by the "no" loop, the controller 1000 continues to make the determination in step 1101 until an empty container is placed in the arm 20. At this point, the algorithm proceeds on the "yes" branch to step 1102. In step 1102 (which may correspond to the state of the filler unit shown in FIG. 8B (or FIG. 8J )), the controller 1000 sends a signal to activate the solenoid 519.

Then, the controller 1000 proceeds to step 1103, in which the controller 1000 determines whether the filled container is "nearly full," for example, 90% full. Step 1103 may correspond to the state of the filler unit shown in FIG. 8C (or FIG. 8K ). In some embodiments, the determination in step 1103 is based on whether the signal S _LC from the load cell 406 indicates a weight corresponding to a nearly full container. As shown by the "no" ring, step 1103 is repeated until the container is determined to be nearly full. Once this determination is made, the controller 1000 proceeds to step 1104 on the "yes" branch. In step 1104 (which may correspond to the state of the filler unit shown in FIG. 8D (or FIG. 8L )), the controller 1000 stops sending a signal to the solenoid 519 and starts sending a signal to the solenoid 509.

Then, the controller 1000 proceeds to step 1105, where the controller 1000 determines whether a signal from the optical sensor 121 has been received. Step 1105 may correspond to the state of the filler unit shown in FIG. 8E (or FIG. 8M ). As shown by the "No" ring, step 1105 is repeated until a signal from the optical sensor 121 has been received. Once the signal from the optical sensor is received, the controller proceeds to step 1106 on the "Yes" branch. In step 1106 (which may correspond to the state of the filler unit shown in FIG. 8F (or FIG. 8N )), the controller 1000 sends a signal to activate the solenoid 559 (or solenoid 559 '). Then, the controller 1000 proceeds to step 1107 and determines whether the filled container is completely filled. The controller 1000 makes this determination in step 1107 based on whether the signal S _LC received from the load cell 406 indicates the weight of a full container. Step 1107 is repeated (“no” loop) until a definitive full container determination is made, at which point the controller 1000 proceeds to step 1108 .

In step 1108 (which may correspond to the state of the filler unit shown in FIG. 8G (or FIG. 8O )), the controller 1000 stops sending the signal to activate solenoid 559 (or solenoid 559 ′). The controller 1000 then proceeds to step 1109 and determines whether the arm 20 is empty, that is, whether the filled container has been removed. In some embodiments, the controller 1000 makes the determination in step 1109 based on a signal from an optical or contact sensor on the arm 20. In other embodiments, the controller 1000 makes the determination in step 1109 based on whether the signal S _LC from the load cell 406 corresponds to the weight of the unloaded arm 20. Step 1109 is repeated (“no” loop) until a definitive empty arm determination is made, at which point the controller 1000 proceeds to step 1110. In step 1110, the controller 1000 stops sending the signal to activate solenoid 509. The controller 1000 then returns to step 1101 and waits for a signal indicating that the next empty container is in position in the arm 20 .

FIG11B illustrates an example of an alternative algorithm that may be executed by controller 1000 in conjunction with operations similar to those shown in FIG8A-8H and FIG8I-8P , but without the use of optical sensor 120. Steps 1121, 1122, 1123, 1126, 1127, 1128, 1129, and 1130 are similar to steps 1101, 1102, 1103, 1106, 1107, 1108, 1109, and 1110, respectively, of FIG11A and are not further described. In step 1124, controller 1000 performs operations similar to step 1104 of FIG11A , but also starts a timer. The timer has a value representing the time required for the fill valve to go from a fully open condition to a partially open condition, corresponding to a desired low flow set point. In step 1125, controller 1000 determines whether the timer has expired. The controller 1000 repeats step 1125 (“no” loop) until the timer has expired, at which point the controller 1000 proceeds on the “yes” branch to step 1126 .

As described above, the controller 1000 also controls the pressure in the reservoir 601 (or the flow path from the reservoir 601) by sending a signal S _PC ( FIG. 9A ) to adjust the position of the pressure control valve 610. In some embodiments, the controller 1000 executes instructions to control the setting of the pressure valve 610 using a PID (proportional-integral-derivative) control loop algorithm. FIG11C is a flow chart of an example of such an algorithm. At clock cycle t of the controller 1000, the algorithm receives two inputs. The first input is data corresponding to the value of the desired target pressure (P arget ) to be maintained in the reservoir 601 (or the flow path from the reservoir 601). This value can be a constant value stored in memory as a program parameter. The second input is S _PT (t), the value of the signal S _PT from the pressure transducer 602 received at clock cycle t. The adder 1151 subtracts one input from the other and outputs the resulting difference, E _Pr (t), the pressure error value at time t. The E _Pr (t) value is received by a proportional calculator block 1152, an integral calculator block 1153, and a derivative calculator block 1154. The values P(1), P(2), and P(3) are adjustment parameters, and "T" is the integration time interval (e.g., the total time elapsed since the start of the algorithm execution). The outputs of blocks 1152, 1153, and 1154 are received by a second adder block 1155, which sums the output of S _PC (t), the control signal S _PC (to the current/pressure transducer 611) for clock cycle t. At the next clock cycle (t+1) of the controller 1000, the algorithm of FIG. 11C is executed again, but using S _PT (t+1) instead of S _PT (t) as the second input to obtain E _Pr (t+1), the pressure error value at time t+1, which is provided to _blocks 1152-1154, etc. Signal S _PT (t+1) will be the value of signal S _PT received at period t+1 after pressure valve 610 has adjusted in response to S _PC (t).The algorithm of FIG 11C is repeated in a similar manner for subsequent clock cycles.

As also described above, controller 1000 controls the speed of positive displacement pump 651 by sending signal _SRFC ( FIG. 9B ) to adjust the speed of pump 651. In some embodiments, controller 1000 executes instructions to control the settings of pump 651 using another PID control loop algorithm. FIG11D is a flow chart of an example of such an algorithm. At clock cycle t of controller 1000, the algorithm receives two inputs. The first input is data corresponding to the desired flow rate through the flow path of product recirculation system 650. In some embodiments, this value (FL _Target ) is between 5% and 15% of the total flow rate entering reservoir 601. By calculating the percentage of flow rate entering reservoir 601, controller 1000 can calculate the value of FL _Target . The flow rate entering reservoir 601 can be determined by controller 1000 based on continuous data from level transducer 603 over time. For example, the flow rate based on the values S _LT (t) and S _LT (tn) can be calculated as [[the volume of the reservoir 601 corresponding to S _LT (t)] - [the volume of the reservoir 601 corresponding to S _LT (tn)] / [(t) - (tn)]]), where n is the number of clock cycles, corresponding to a time period long enough to detect a change in product level. The second input is S _RFM (t), the value of the signal S _RFM from the flow meter 653 received at clock cycle t. Adder 1161 subtracts one input from the other and outputs the resulting difference E _FL (t), the flow rate error value at time t. The _{E FL} (t) value is received by proportional calculator block 1162, integral calculator block 1163, and differential calculator block 1164. The values P(4), P(5), and P(6) are adjustment parameters, and "T" is the integration time interval (e.g., the total time elapsed since the start of the algorithm execution). The outputs of blocks 1162, 1163, and 1164 are received by a second adder block 1165, which sums the output of S _RFC (t), the control signal S _RFC (to the variable frequency drive 652) for clock cycle t. At the next clock cycle (t+1) of the controller 1000, the algorithm of FIG. 11D is executed again, but using S _RFM (t+1) instead of S _RFM (t) as the second input to obtain E _FL (t+1), the flow error value at time t+1, which is then provided to blocks 1162-1164, etc. Signal S _RFM (t+1) will be the value of signal S _RFM received at cycle t+ ₁ after the speed of the pump 651 has been adjusted in response to S _RFC (t). The algorithm of FIG. 11D is repeated in a similar manner for subsequent clock cycles. The values of the tuning parameters P(4), P(5) and P(6) may be determined using conventional techniques for initializing and tuning PID controllers for existing types of flow systems.

In the embodiment of FIG9C , the controller 1000 controls the flow rate through the flow path of the system 650 ′ by sending a signal S _RFVc to adjust the valve 671. In some embodiments, the controller generates the signal S _RFVc using a PID control loop algorithm similar to that of FIG11D , but with S _RFCv as the output instead of S _RFC . In the embodiment of FIG9D , the controller 1000 controls the flow rate through the flow path of the system 650 ″ by sending a signal S _RFVp to adjust the valve 673. In some embodiments, the controller generates the signal S _RFVp using a PID control loop algorithm similar to that of FIG11D , but with S _RFCp as the output instead of S _RFc .

As also described above, controller 1000 controls the speed of pump 656 by generating signal S _FBC . In some embodiments, controller 1000 generates signal S _FBC using another PID control loop algorithm based on signal S _LTB from level transducer 659 as an input. For example, a target value (ΔL _Target ) for balancing product level variations in tank 655 can be set to zero. Input ΔL(t) can be calculated based on the value of S _LTB over time. The algorithm can then be adjusted to maintain a constant product level in tank 655. Alternatively, the algorithm used to generate signal S _FBC can be simpler. For example, whenever the level in tank 655 reaches a certain value (e.g., 80% full), the controller can generate signal S _FBC , causing pump 656 to operate at a preset speed until the level in tank 655 reaches another level (e.g., 20% full).

Figure 12A is a block diagram of the steps in the method according to some embodiments. In the first step 1201, a filling system reservoir is supplied with a first beverage product. The filling system can be a filling system such as described herein and can include one or more filling valves 50 and/or other components such as described herein. In step 1202, the filling system is used to hot-fill a container from the reservoir with the first beverage product. Specifically, the container is placed in a filling position relative to the one or more filling valves, and the heated product is distributed among these containers. After step 1202, in step 1203, the filling system is supplied with a second beverage product. Then, in step 1204, the filling system is used to aseptically fill a container from the reservoir with the second beverage product. After step 1204, in step 1205, the filling system is supplied with a third beverage product. Then, in step 1206, the filling system is used to fill a container from the reservoir with the third beverage product. When the third product is frozen or at room temperature and without maintaining aseptic conditions, the filling operation of step 1206 can be performed. Although not shown in FIG. 12A , additional setup, cleaning, and/or sterilization operations may be performed before step 1201 , between steps 1202 and 1203 , between steps 1204 and 1205 , and after step 1206 .

Any of the first, second, or third beverage products can have a viscosity between 1 cps and 400 cps. Any of the first, second, or third beverage products can contain inclusions (whose size is within the above range and whose concentration is within the above range), or can be free of inclusions. However, as an example, in some embodiments, one of the first, second, or third beverage products has no inclusions, and the other of the first, second, or third beverage products has an inclusion whose volume percentage is at least 10% and has a volume between 125 cubic millimeters and 1000 cubic millimeters (e.g., 25%, 400 cubic millimeters). In some embodiments, one of the first, second, or third beverage products has a viscosity between about 1 cps and about 50 cps, the other of the first, second, or third beverage products has a viscosity between about 50 cps and about 100 cps, and the other of the first, second, or third beverage products has a viscosity between about 100 cps and about 200 cps. In some embodiments, one of the first, second, or third beverage products has a viscosity between about 1 cps and about 50 cps, and the other of the first, second, or third beverage products has a viscosity between about 100 cps and about 200 cps. In some embodiments, one of the first, second, or third beverage products has a viscosity between about 1 cps and about 100 cps, and the other of the first, second, or third beverage products has a viscosity between about 200 cps and about 400 cps.

12A need not be performed in the order shown. For example, the order in which the filling system hot-fills the container with the first beverage product, aseptically fills the container with the second beverage product, and cold-fills the container with the third beverage product may be changed.

Figure 12B is a block diagram of steps in another method according to some embodiments. In step 1211, a container handling arm is placed in a first configuration for filling a first type of container. The container handling arm includes a load cell that outputs a signal representing a force F2 applied to the load cell in response to a force F1 exerted by the arm on the container and its contents. In the first configuration, force F2 is a first ratio of force F1. In step 1212, the container handling arm in the first configuration is used to hold the first type of container when filling with a beverage product from a filling valve. In step 1213, the container handling arm is placed in a second configuration for filling a second type of container. In the second configuration, force F2 is a second ratio of force F1, which is different from the first ratio. In step 1214, the container handling arm in the second configuration is used to hold the second type of container when filling with a beverage product from the filling valve. In other embodiments, the method of FIG12B can include additional steps in which the container handling arm is placed in additional configurations for filling additional types of containers, each additional configuration corresponding to a different F2:F1 ratio, and the container handling arm is used to hold these additional types of containers during filling with the beverage product and when in these additional configurations. Although not shown in FIG12B , additional setup, cleaning, and/or sterilization operations can be performed, for example, between steps 1212 and 1213 or between steps 1213 and 1214.

Figure 12 C is a block diagram of the step in another method according to some embodiments. In step 1221, the filling system reservoir is supplied with a first beverage product. This filling system can be a filling system such as described herein, and can include one or more filling valves 50 and/or other components such as described herein. In step 1222, the filling system is used to fill a container from the reservoir with the first beverage product. Specifically, the container is placed in the filling position relative to the one or more filling valves, and the product is distributed in these containers. In step 1222, the pressure at the position in the reservoir inside (or from the flow path inside the reservoir) remains at a first level. In step 1223, the filling system reservoir is supplied with a second beverage product. In step 1224, the filling system is used to fill a container from the reservoir with the second beverage product. In step 1224, the pressure at the same position remains at a second level different from the first level. At least one of the first and second levels is a subatmospheric pressure. Can carry out other step, wherein filling system is used for from the reservoir filling container with other beverage products, simultaneously the pressure at this position is maintained to one or more other levels.In certain embodiments, by by pressure being maintained in the +/-0.1psi of desired level, pressure is maintained to desired level.This tolerance can have other value (for example, +/-0.05psi).In certain embodiments, the first pressure level is subatmospheric pressure, and the second pressure level is atmospheric pressure or higher pressure, and the viscosity of the first beverage is less than the viscosity of the second beverage.In certain embodiments, the first pressure level is atmospheric pressure or higher pressure, and the second pressure level is subatmospheric pressure, and the viscosity of the first beverage is greater than the viscosity of the second beverage.Although not shown in Figure 12 C, can, for example, between step 1222 and 1223, perform extra setting, cleaning and/or sterilizing operation.In certain embodiments, the method for Figure 12 C may comprise other step: fill reservoir with the 3rd beverage product, then from the reservoir filling container with this 3rd beverage product, reservoir leads to atmospheric environment simultaneously.

Figure 12 D is a block diagram of the steps in the additional method according to some embodiments. In first step 1231, the filling system reservoir is supplied with the first beverage product. This filling system can be a filling system such as described herein, and can include one or more filling valves 50 and/or other components such as described herein. At step 1232, and during the first time period, the filling system is used to carry out the hot filling of beverage container from the reservoir with the first beverage product. Specifically, the container is placed in the filling position relative to one or more filling valves, and the product is distributed in these containers. During the first time period, the filling system automatically keeps the flow (for example, in the embodiment of Fig. 9 B by regulating the speed of the variable flow pump in this flow path, in the embodiment of Fig. 9 C by regulating the setting of the variable flow valve, in the embodiment of Fig. 9 D by regulating the pressure control valve) through the product recirculation flow path. In step 1233, the filling system reservoir is supplied with the second beverage product. At step 1234, and during the second time period, the filling system is used to carry out the hot filling of beverage container from the reservoir with the second beverage product. During the second time period, the filling system again automatically maintains flow through the product recirculation flow path.Although not shown in the figure 12D, additional setup, cleaning and/or sterilization operations may be performed between, for example, filling a container with one product and subsequently loading the reservoir with a different product.

One of the first and second beverage products has inclusions (within the above-mentioned ranges and within the above-mentioned ranges in concentration), while the other of the first and second beverage products lacks inclusions. However, as an example, the volume percentage of inclusions that one of the first and second beverage products has can be at least 25%. Each of at least a portion of these inclusions can have a single volume of at least 400 cubic millimeters. Additional or optional steps can be performed in which the reservoir is filled with other products having inclusions of other sizes and/or other concentrations (e.g., inclusions sized to fit within a 1 mm square at a concentration of approximately 1%), whereupon the filling system is used to perform heated filling of these other products into the container while also automatically maintaining flow through the product recirculation flow path.

Systems according to various embodiments are capable of filling containers with a much wider range of product types than can be achieved using conventional systems. When the viscosity of the product is greater than about 20 cps, or when the product has inclusions, systems according to various embodiments are capable of filling containers at a higher rate than can be achieved using conventional systems.

In addition to the variations and embodiments described so far, further embodiments may include different features and/or different combinations of features. Examples include, but are not limited to, the following:

Other types, shapes, and configurations of magnets can be used for the filling valve. The shuttle and/or drive sleeve can have other configurations. The shuttle can lack flow straightening blades, such as blade 208, and/or can have flow straightening blades of different configurations. Different types of end elements can be attached to the shuttle (e.g., for cups with openings of different sizes). In some embodiments, the filling valve cup (e.g., cup 53) can be replaced with another type of cup. As can be understood from Figures 1A, 1B, and 3A-4B, cup 53 can be easily replaced by loosening clamp 56, removing cup 53, placing a new cup in place, and re-tightening clamp 56. In one case, the beverage product to be filled with the container may lack contents, or may have smaller contents, which may not require the cup's outlet to be sized to allow large contents to pass through. In this case, the replacement cup may have a smaller opening to achieve greater accuracy during filling and/or to fill a container with a smaller opening. In another case, it may not be necessary to perform hot filling, and therefore it may not be necessary to recirculate the product. In this case, the replacement cup may not include a recirculation conduit, such as recirculation conduit 13.

The container handling arm may include a lever, a support beam, and a load cell arranged and/or coupled in alternative configurations.

The low flow set point system may include alternative arrangements of control valves and/or alternative positioning of various components.

The components of the reservoir pressure control system may be arranged in alternative ways. Alternative types of fluid control valves, transducers and other components may be employed.

The components of the product recirculation system may be arranged in alternative ways. Alternative types of components may be employed.

A filling valve having some or all of the features of filling valve 50 can be used in a filling system that does not include a container handling arm such as container handling arm 20, a low flow set point control system such as described in conjunction with Figures 8A-8H (or Figures 8I-8P), a pressure control system such as described in conjunction with Figure 9A, or a product recycling system such as described in conjunction with 9B-9D.

A container handling arm having some or all of the features of arm 20 may be used in a filling system that does not include a filling valve such as filling valve 50, a container handling arm such as container handling arm 20, a low flow set point control system such as described in conjunction with Figures 8A-8H (or Figures 8I-8P), a pressure control system such as described in conjunction with Figure 9A, or a product recycling system such as described in conjunction with 9B-9D.

A low flow set point system such as that described in conjunction with Figures 8A-8H (or Figures 8I-8P) can be used in conjunction with other types of filling valves and/or can be used in a system that does not include a container handling arm such as container handling arm 20, a pressure control system such as that described in conjunction with Figure 9A, or a product recirculation system such as that described in conjunction with 9B-9D.

A pressure control system such as that described in conjunction with FIG. 9A may be used in conjunction with other types of filling valves and/or may be used in a system that does not include a container handling arm such as container handling arm 20, a low flow set point control system such as that described in conjunction with FIG. 8A-8H (or FIG. 8I-8P), or a product recirculation system such as that described in conjunction with FIG. 9B-9D.

A product recirculation system such as that described in conjunction with Figures 9B-9D can be used in conjunction with other types of filling valves and/or can be used in a system that does not include a container handling arm such as container handling arm 20, a low flow set point control system such as that described in conjunction with Figures 8A-8H (or Figures 8I-8P), or a pressure control system such as that described in conjunction with Figure 9A.

Systems such as those described herein can also be used to fill containers with other types of liquids. These products can include, but are not limited to, foods, paints, inks, and other liquids. Such other products can also have viscosities and contents within the ranges described above for beverage products.

The above description of the embodiments has been provided for the purposes of illustration and description. The foregoing description is not exhaustive, nor is it intended to limit the embodiments of the invention to the precise form disclosed, and modifications and variations may be made in accordance with the above teachings, or as required by the practice of the various embodiments. The embodiments described herein are selected and described to explain the principles and characteristics of the various embodiments and their applications, so that those skilled in the art can use the invention in various embodiments, and with various modifications suitable for conceivable specific uses. Any and all combinations, subcombinations, and permutations of the features derived from the above embodiments are within the scope of the present invention.

Claims (12)

1. A container gripping arm, characterized in that the container gripping arm comprises: A gripper located at the distal end of a container gripping arm and configured to hold a beverage container. A force sensor is positioned at the proximal end of the container gripper arm and is configured to output a signal indicating the weight of the container and its contents when the container is held by the gripper. Pivot element; A support beam having a discrete plurality of bracket positions adapted to receive a bracket, wherein each of the discrete plurality of bracket positions includes a hole in the support beam; and A lever, connected to a gripper and a force sensor, includes a pivot position and is configured to rotate about a fulcrum element at the pivot position, wherein the pivot position is one of a plurality of discrete pivot positions located along the length of the lever. The bracket includes holes and can be repositioned along the length of the container gripping arm by passing a fastener through the holes in the bracket and through one of the holes at a discrete plurality of bracket locations. 2. The container gripping arm of claim 1, wherein the container gripping arm is adjustable to change the ratio between the weight applied to the gripper and the weight obtained from the force sensor. 3. The container gripping arm according to claim 1 or 2, further comprising a mark on a lever corresponding to the construction of the container gripping arm for use with a container having a size corresponding to the mark. 4. The container gripping arm of claim 1, further comprising a marking on a support beam corresponding to the construction of the container gripping arm for a container having a size corresponding to the marking. 5. The container gripping arm according to claim 1, 2 or 4, further comprising an adjustable stop configured to limit the force applied to the force sensor. 6. The container gripping arm according to claim 1, 2 or 4, wherein the container gripping arm is part of a container filling system including a filling valve, and wherein the gripper is positioned below the filling valve. 7. The container gripping arm of claim 6, wherein the container gripping arm is generally horizontal. 8. The container gripping arm of claim 6, wherein the force sensor is not located below the filling valve. 9. The container gripping arm of claim 6, wherein the filling system further includes a barrier that separates the area below the filling valve from the surrounding space, and wherein the container gripping arm extends through the barrier into the area. 10. The container gripping arm of claim 9, wherein the force sensor is located outside the region. 11. The container gripping arm of claim 1, wherein the container gripping arm is configured such that the force applied to the force sensor is in a vertical plane. 12. A container gripping arm, characterized in that the container gripping arm comprises: A gripper located at the distal end of a container gripping arm and configured to hold a beverage container. A force sensor is positioned at the proximal end of the container gripper arm and is configured to output a signal indicating the weight of the container and its contents when the container is held by the gripper. An anti-snake bracket, which is removably attached to the container gripping arm and configured to reduce the transmission of non-vertical forces from the gripper; fulcrum elements; and A lever, which is coupled to a gripper and a force sensor, includes a pivot position and is configured to rotate about a fulcrum element at the pivot position, wherein the fulcrum element is part of a bracket, and wherein the bracket is repositionable along the length of the container gripping arm to increase or decrease the distance between the fulcrum element and the force sensor.