WO2002098785A1

WO2002098785A1 - Precise filling method

Info

Publication number: WO2002098785A1
Application number: PCT/IL2002/000442
Authority: WO
Inventors: Yair Sadeh
Original assignee: NET-KIT Ltd
Current assignee: NET-KIT Ltd
Priority date: 2001-06-05
Filing date: 2002-06-05
Publication date: 2002-12-12
Anticipated expiration: 2003-12-05
Also published as: IL143585A0; WO2002098785A8; AU2002311584A1

Abstract

Method for filling receptacles of a wide volume range in a multi-channel machine, is disclosed. The machine is easy to manufacture, facile to maintain and comfortable for after-sale service (including remote-service and problem-prediction and solving via computer networks), simple and having small dimensions, fully automated and operator independent, reliable, fast, clean, having means for keeping appropriate gap between each nozzle outlet and the apex of the liquid within the receptacle during filling in order to minimize foaming even when working in extremely high filling speeds, accurate, having short setup time thus promptly aligned for new jobs, having automatic self regulation, having 100% quality check, having self learning and self correction attributes, digital flow-rate alignment, built-in check-weighing motionlessly checking out every container, automatic filling completion for under-filled containers, automatic rejection of over-filled containers, and capable of generating online production reports.

Description

PRECISE FILLING METHOD

Field ofthe invention:

The present invention relates to a method for fast and accurate filling of liquids into receptacles. The present invention further relates to a valve control unit (VCU) for use in liquid filling machines according to said method, and to a multi-channel liquid filling machine based on a plurality of VCUs and making use of said method.

Background ofthe invention:

There are many different apparatuses known in the art that are designed for providing filling of glass, metal, or plastic containers, with a liquid substance. The substances may include juice, oil, milk, beer, paints, soaps and gels, etc.. that differ from each other in their physical attributes like specific-weight, viscosity and foaming. As will be further explained in detail, the physical attributes of the liquid being filled are of an utmost importance in determining an appropriate filling process for each substance, with respect to its filling rate, to the volume and shape of the receptacle being filled, and to the means for the prevention of foaming which has to be taken.

The apparatuses work on different principles, that were developed while trying to comply with several basic requirements: They have to be reliable, fully automated and operator independent, fast, clean, accurate, suited to fill various types of liquid materials, capable of generating on-line production data reports, suited to fill receptacles of various sizes, having short setup time thus promptly aligned for various new jobs, having automatic self regulation, having 100% quality check, having small dimensions, simple and being easy to manufacture, facile to maintain and comfortable for after-sale service, and being low priced.

As will be further described, there was not found yet a way to include all these advantages in one machine. Unfortunately, an implementation of some of said requirements conflicts the implementation of others. For example, increasing the accuracy, is usually enabled by decreasing the filling speed, and vice versa. Increasing the filling speed may result in ungoverned foaming, that disables a clean and accurate filling process. Increasing the accuracy, e.g. by using a "Piston Filler" as hereinafter described, increases the machine price, restricts the variety of receptacle sizes that can be filled in one machine, and may rise other problems as will be further discussed.

As mentioned before, there are several methods known in the art for filling liquids into receptacles automatically.

One main well known method according which automatic liquid filling machine works, is based on identifying if a predetermined target-weight of liquid in the receptacle has been reached (actually the filling valves in such machine are commanded off when a "stop-filling weight", that is a function of the target-weight, is being identified). This identification is achieved by weighing the containers during the filling process. Machines of that type are hereinafter called "weight fillers". Since the filling stream flowing into the receptacle induces mechanical "noise" (i.e. vibrations) influencing the weighing, weight fillers are used to be operated in two successive filling phases; (a) an initial phase during which the containers are being filled with a fast liquid flow (known in the art as "fast-fill", which cause a significant mechanical noise), until they reach a temporal predetermined weight (e.g. 90% of the final target weight), and (b) a final filling phase at which the containers are being filled with a relatively fine flow (known in the art as "dribble fill", for reducing the mechanical noise) until they reach a predetermined "stop-filling weight" which automatically actuates a valve and stops the filling.

There are some problems with the above mentioned weight fillers; (a) although the fine-flow filling phase is used for filling only about 10% of the total weight, it is drastically prolongs the total filling time as a result of the "dribble-fill"; (b) since a certain amount of mechanical noise exists also during the fine-flow filling phase, the weighing is not quite accurate and therefore weight fillers are considered to be inaccurate for filling small volume containers (e.g. of 1 litter or less) in which the error generated by the mechanical noise is significant relatively to the container's total weight; (c) the weight filler is bulky, complicated and expensive because of the special three position valve assembly it has to use in each filling channel for the two phase filling process (requiring fully open, fully closed and selectable intermediate valve settings).

Another type of automatic liquid filling method is used in a filling machine known in the art in the name "Piston Filler". It is based on sucking a predetermined volume of liquid (which is the predetermined filling target volume or a rational fraction of it) into a hollow cylinder, by means of a piston, and injecting it into the container. One problem with piston fillers is that on the one hand the cost of cylinder-piston units grows exponentially with the growing of volume, thus it becomes very expensive for volumes such as 5 liters and up, while on the other hand the accuracy of filling by pistons is decreased as their volume grows (resulted from air bubbles being sucked and mixed with the liquid). Another problem with piston fillers is that it is impossible to cover a quite wide volume range such as between 200ml and 20 litters using one machine. Usually three machines of three different piston volumes have to be used for covering volume range such as mentioned above. Furthermore, in common filling jobs e.g. filling different colors of liquid paints into various volume containers, the three machines have to be rinsed before the filling cycle of each new color. In addition, there is an inescapable efficiency loss in the piston filler operation because of the filling idleness during the piston recharging mode. This time loss is multiplied from one up to several times per container (i.e. in case of using small piston repeatedly, for filling one large container). Furthermore - the wear of piston fillers is accelerated because of their constantly moving mechanism; the adjustment of piston fillers for each filling job is made manually thus reduces their reliability while increasing their dependency on the operator's dexterity and good willing. Furthermore, the piston's alignment has to be watched repeatedly (in about every 30 minutes) otherwise a deviation in the piston alignment may disqualify a large amount of filled containers; piston-fillers have no integral check-weigher at their output and the check-weighing is made manually as a sampling spot check, (adding an external check-weigher extremely increases the machine cost).

Another type of automatic liquid filling method is used in a machine based on a combination between a flow-meter (which measures the flow of liquid into the container) and a timer controlling a valve which automatically stops the filling in that moment when the multiplication of the filling time and filling flow-rate have reached the target volume value. The accuracy of flow meters is limited and is influenced from the attributes of the specific liquid in use. Therefor, flow-meter based fillers are not accurate and hence not so popular.

It has to be added that a filling machine (of any known type) is usually considered as the bottle neck of a production line. Many times the production rate of a whole plant is deriving from the capacity of the filling machines at the end of the production line. Therefor, down time of a filling machine is commonly highly expensive because it results in halting the production in several manufacturing and delivery compartments, losing costly working hours, and damaging sales. This is the reason why the reliability of a filling machine and the quality of its after-sale service, are of an utmost importance.

The present invention aims to comply with the disadvantages of the existing filling machines and to provide principles according which a filling process can be meaningfully enhanced, and according which the architecture of filling machines can be extremely facilitated, while increasing their reliability and reducing their service time to minimum.

More specifically, the present invention is directed towards an innovative method for filling receptacles of a wide volume range in one inexpensive multi-channel machine, which will be easy to manufacture, facile to maintain and comfortable for after-sale service (including remote-service via computer networks and problem-prediction and solving in-advance), simple and having small dimensions, fully automated and operator independent, reliable, fast, clean, accurate, having short setup time thus promptly aligned for new jobs, having automatic self regulation, having 100% quality check, having self learning and self correction attributes, digital flow-rate alignment, built-in check-weighing motionlessly checking out each individual container, automatic filling completion for under-filled containers, automatic rejection of over- filled containers, and capable of generating online production reports.

Terminology:

In the context ofthe present invention the term "receptacle" relates to any type of container to which the liquid is being filled. The receptacle can be made of any desired material, such as glass, plastic, cardboard or metal, and of any desired volume and shape.

In the context of the present invention the term "filling nozzle" relates to the machine member through which flows out the filled liquid into the receptacle.

In the context of the present invention the term "valve" relates to the assembly that controls the flow of the filled liquid on and off through the filling nozzle. The filling nozzle and the valve may either be separate parts or one unit having mutual or common components

In the context of the present invention the term "target weight" relates to the exact final liquid weight intended to be contained within an optimally filled receptacle.

In the context of the present invention the term "stop-filling weight" relates to a weight close to the target weight, that when indicated by a load cell of a weight filler, the weight filler controlling means sends a stop-filling command to the respective valve, such that during the delay between recognizing the stop-filling weight and the actual stop of filling, the target weight is expected to be reached.

In the context of the present invention the terms "filler", " filling machine", "filling apparatus", and "filling system", means the same unless specified else.

Summary ofthe invention:

The most accurate known way for determining the volume of liquid within a container is by measuring the weight of the liquid while the container and the liquid are in a "rest" position (motionless). The substance mass is constant and steady attribute, hence the force of gravity acting on the liquid mass can be determined very accurately, thus the volume of the contained liquid can be determined accurately. However, since increasing the speed of a filling machine is inescapably involved with increasing the stream of the filled liquid causing mechanical noise which requires increased relaxation interval, it becomes impossible to use weighing as an indicator upon which a high speed filling machine may rely as a basis for controlling the valves of its filling nozzles on and off.

Therefore, and because of other reasons as will be further discussed, weighing cannot be used as a basis for opening and closing the liquid flow through the filling nozzles, according to the present invention. However, since weighing is the most accurate way for determining a volume of substance, it will be smartly utilized according to the present invention in order to obtain highly accurate filling, as will be described in detail.

Another known way for determining the volume of liquid within a container in a given moment, is by multiplying the flow rate of the filled liquid, by the filling time. At optimal conditions, where the flow rate is fixed and exactly known, and where the filling time can be accurately measured, the determination of the liquid quantity within the filled receptacle may be calculated very accurately. In such ideal and theoretical conditions, the filling sequence may be highly accelerated if liquid will be filled by controlling the filling nozzle valves on and off on time basis. But this is only theoretically, and assuming that efficient means for preventing foaming and overflow of liquid within the receptacle are provided. Unfortunately, a flow rate of liquid through a filling nozzle of a filling machine is many times a very unstable variable, because it is subject to the specific attributes of the liquid substance in use (e.g. imperfect homogeneity, influence of temperature on viscosity) to the pressure ofthe liquid, to the specific features of each filling channel from a plurality of substantially identical channels within one machine, comprising the combination between each filling nozzle and its valve, their specific pre-fabricated characteristics, the valve response time, the sediments and dirt accommodated within along time, and so on variants that may be changed unexpectedly, even during a single filling sequence. Thus, using time as a basis for controlling the filling nozzles activity and in the mean time obtaining a clean and accurate fill, is impracticable, unless several innovative principles set out according to the method of the present invention are being implemented.

Several principle steps are to be implemented according to the method of the present invention, in order to overcome the above mentioned problems, for providing a unique high speed highly accurate filling machine, that have many other innovative and advantageous features, in addition.

Using time as a basis for controlling the on-off activity of a filling nozzle, is the first principle set out according to the present invention. The implementation of this first principle enables freeing the machine from the need of "dribble fill" phase as required in weight fillers for minimizing the mechanical noise prior to weighing, and cancels the need in a time-consuming weighing for determining the stop-filling weight. Hence, the machine according to the method of the present invention, uses time as a basis for opening and closing the liquid flow through the filling nozzles.

As mentioned above, using time as a basis for controlling the valves on and off for determining the quantity of liquid being filled, may be accurate only in optimal case. Thus, additional basic principles has to be implemented in order to make the filling on time basis not only fast, but accurate as well. The second basic principle set out by the method of the present invention is that a substantially fixed height of liquid post has to be kept between the outlet point of each filling nozzle and the upper liquid level within a main hopper from which the filling liquid is being consumed by the filling nozzles. A fixed liquid level within the hopper may be obtained by continuously compensating the main hopper with liquid quantity equivalent to the liquid quantity consumed into the receptacles. A fixed height of liquid post keeps the flow rates through the filling nozzles unchanged at least for small time periods along which the specific characteristics of each filling channel are not expected to be meaningfully changed. Due to the quite absolute repeatability of the gravity force, a fixed height liquid post (of a specific liquid substance) always exerts the same respective liquid pressure at the filling nozzle outlet (and at any respective point along the filling channel), thus a fixed liquid flow rate is obtained on each filling nozzle outlet, allowing to rely upon for determining a valve opening-time for each filling channel, suitable for filling the exact target-weight liquid dose into a respective receptacle. However, as mentioned above, changes resulting from sedimentation and dirt accumulation along the time, and so on variants that may be changed unexpectedly, even during a single filling sequence, still may defect the filling accuracy. Therefor, in order to eliminate the inaccuracy resulting from unforeseen changes, a third basic principle is set out by the method ofthe present invention.

The third basic principle set out according to the method of the present invention, is that an after-filling motionless weighing of each filled receptacle has to be executed, and the weighing data has to be used as a feedback to a computerized controlling means that modifys the opening time of each filling-nozzle valve for every filling sequence, according to the weighing feedback data of the previous filling sequences. Since the weighing is made after (and not during) the filling, it does not delay the current filling sequence, and may be sampled after a complete relaxation of filling stream vibrations and with minimum of mechanical noise.

By implementing said three basic principles: (a) opening the filling nozzle valves on a time basis; (b) obtaining a substantially constant flow-rate by means of keeping a fixed liquid level within the hopper; and (c) modifying the opening time of each filling-nozzle valve for each filling sequence according to a weighing data acquired on the previous filling sequence; a high speed highly accurate filling process may be achieved, yet additional principles are set out according to the method of the present invention in order to improve the filling process furthermore, in order to prevent foaming, and in order to enable the implementation of wide range filling machines that will be unlimitedly and quickly adaptable to extreme changes in the type of liquid substance selected for filling, and in the volume and shape of receptacles to be filled.

The fourth principle according to the method of the present invention relates to a computerized self learning system (that is a computer program for self learning, based on gathering filling information, processing it, and constructing an internal data base accordingly) to be coupled to each filling-nozzle, and to the liquid filling system as a whole. The aim of the self-learning system is to learn and record a profile of the particular alignments required in the filling machine for executing a filling process with the particular substance currently being consumed, such that the same profile can be put to use whenever a similar filling job takes place in future. A selection of profiles suited to various types of filling jobs consuming various types of liquid substances may be constructed. Then, by selecting an appropriate predetermined alignment profile for every incoming filling job, a new filling process can be always started without (or with minimal) delay.

The self learning system according to the present invention may support also the build of a moderate alignment profile, e.g. an average alignment profile based on the up to 5 (or up to 8, or the like) alignment profiles that were used successfully for the last 5 (or 8, or the like) similar filling jobs. According to one preferred embodiment of the method of the present invention, a typical alignment profile includes information about the constant liquid level that has to be kept within the hopper for the particular liquid substance being used, and about the initial opening-time of each filling-nozzle valve according to its particular on-off response time.

Preferably, according to the method of the present invention a new filling machine is being supplied to a customer (i.e. filling plant) with a basic list of alignment profiles suitable for various types of conventional filling jobs, wherein each such profile can be used as a starting point for the self learning system, to be moderated according to the final alignment profiles that were actually served in the customer place in actual filling jobs. The self learning computer program according to this fourth principle, may be developed and adapted to a filling apparatus by those who skill in the art, according to known practice.

The relation between liquid filling speed and foaming is a well known. As already mentioned above, foaming is one of the main preventives to increasing the filling speed of liquid filling apparatuses. Several improvements were developed, all of which directed to the design of the filling nozzle through which consumed the filling liquid into the target receptacle, in order to decrease or inhibit foaming, thus enable increasing the filling speed. All of those improvement may be implemented (subject to Intellectual Property licensing where required) into a filling apparatus using the method of the present invention, however, a fifth principle is set out according to the method of the present invention aiming to solve the foaming problem in a unique and innovative way. In contradiction to the foaming preventing solutions known in the art directed to the filling nozzle design, the fifth principle of the method according to the present invention is based on the computerized data accumulated and existing in a filling machine due to the implementation of previous principles of the method of the present invention as set out hereinbefore. According to the fifth principle of the method of the present invention, an appropriate gap (that may be either positive, negative or zero, as selected by the operator, or according to predetermined or pre-programmed preferences of the filling machine) useful for minimizing foaming is automatically being applied between the outlet of each filling nozzle and the upper level ofthe liquid within the respective receptacle. In the context of the present invention the term "appropriate gap" relates to a gap that is found useful for minimization of bubbling or foaming of the filled liquid when applied between the outlet of each filling nozzle and the upper level of the liquid within the respective receptacle. The appropriate gap may be positive (i.e. the nozzle outlet is above the liquid apex), zero (i.e. the nozzle outlet is substantially in the same level with the liquid apex), or negative (i.e. the nozzle outlet immersed inside the liquid). The appropriate gap may be changed during the same filling sequence, all according to the guideline, that says: minimization of bubbling or foaming in order to allow increased filling flow rate. It has to be clarified that immersing the nozzle inside the liquid may extremely effect the liquid flow rate, however, the system according to the present invention with the feature of check weighing feedback, and with its self learning feature, may deal with such sequential changes in the flow rate, and provide accurate opening time to the valve. As will be further explained, this appropriate gap being applied by dynamically changing the relative position of the nozzle to the receptacle. For some certain filling jobs, said appropriate gap may be fixed for most of the filling sequence. However, for other certain filling jobs said gap may be dynamically changed during a filling sequence, i.e. the gap may have a substantially predetermined plot according which it changes during each single filling sequence in order to optimally inhibit foaming. This gap plot changes from one filling job to another, depending on the particular filling details, such as the type of liquid being filled, the type and shape of the container, and any other specific attribute that reflects the foaming and/or the behavior of the inner streams of the liquid within the container during a filling sequence. The gap plot is predetermined for each filling job (either by the user, or by the filling machine manufacturer), according to accumulated data acquired through experiments and/or through self learning procedures. For some filling jobs the optimal gap plot may include a deep immersion of the filling nozzle within the liquid for most of the filling sequence, and a fast elevation of the nozzle close to the end of filling, such that the filling sequence ends with the nozzle close (either positively, negatively, or in zero distance) to the liquid apex. For other filling jobs, the optimal gap plot may be such that the nozzle outlet traces the liquid apex with a substantially constant gap from above, along the entire filling sequence.

It has to be appreciated that the essence ofthe fifth innovative principle of the present invention is the notion of determining and controlling the gap between apex of the liquid being filled and the respective nozzle outlet, according to the needs, in a case sensitive manner wherein one from a plurality possible gap plots is coupled to a particular filling job. Therefor, in any case that a description hereinafter relates to a "constant gap", it has to be interpreted only as a particular case of a gap plot wherein a constant gap is optimally applicable for the filling job discussed. The "constant gap" case is especially useful for demonstration purposes, however in no manner it intends to limit the scope of the fifth principle regarding other cases wherein a non constant gap is applied and dynamically controlled during a filling sequence according to the method of the present invention. It is the duty of the user or of the machine manufacturer to determine, obtain or adapt an appropriate gap plot to each particular filling job.

It has to be appreciated that due to the new innovative principles provided by the present invention, liquid filling processes can be extremely speed-up comparing to traditional filling speeds being used. Therefore, the fifth principle of the present invention should be used even when filling substances considered as none foaming (e.g. water), and also short phases of dribble fill should be incorporated into such accelerated filling process, especially in the start filling moment and close to the end of filling. This is because even plain water may significantly bubble while being filled in a powerful stream, even with the filling nozzle outlet immersed within the elevate contained liquid, and especially close to the end off filling, wherein most ofthe narrowing inner space ofthe container bottleneck is occupied by the body ofthe penetrating nozzle.

According to this fifth principle, and as a study case, relating to the "constant gap" case, the filling nozzle outlet tracks the level of the liquid either by means of automatic elevation of each filling nozzle or by automatic lowering of the respective receptacle, according to the progressing elevation of the liquid level within the receptacle. The filling nozzles are first inserted into the receptacles close to the bottom of the empty receptacles, then being elevated or the receptacles being lowered during filling, as mentioned before. This elevation of filling nozzles or lowering of receptacles, could be made by any acceptable known electro-mechanical means, or by the one of the unique and innovative means according to the present invention, as will be disclosed and described in detail below.

Due to the narrow gap that is constantly being kept between the filling nozzle outlet and the level of the filled liquid, a strong liquid stream may be allowed in order to provide high speed filling, without significant foaming problems.

Yet it has to be noted that contrarily to the second principle ofthe method of the present invention, the elevation of the filling nozzles according to the elevation of the liquid level within the receptacles, reduces the height ofthe liquid post between the liquid level within the hopper and the outlet of each filling nozzle, resulting in a continuous reduction in the liquid pressure at the filling nozzle outlets hence in the flow rate through the filling nozzles. Therefor, if elevation of the filling nozzles is chosen as the means for preventing foaming according to the fifth principle, a compensation to the valve opening time calculation according to the second principle, has to be taken into account in order to obtain the liquid target weight within the receptacle. Furthermore, the filling nozzle elevation speed also has to be changed during the elevation in order to keep tracking the non linear elevation speed of the level of the filled liquid. If absolute correlation between the filling nozzle elevation and the advancing of liquid level within the receptacle is in demand, the calculation for determining the valve opening time and the varying speed of filling nozzle elevation may involve high mathematics formulas which takes all the variants into account. Practically however, the complicated calculation can be simplified by directing the valve opening time to an average value of the liquid flow rate, i.e. the flow rate value resulting from an average height liquid post, that is the situation at the middle point ofthe filling nozzle elevation. In case of using this simplification, the gap between the filling nozzle outlet and the level of the liquid within the filled receptacle can be designed accordingly, i.e. to be wider at the starting of filling, and narrower or nearly zero at the ending of filling, thus a constant elevation speed of the filling nozzles can be used. Other simplifying approximations may be used as well.

A choice between using high mathematics formulas and simplifying approximation can be made also for correlating between the filling nozzle elevation speed and the liquid level advancing speed within the receptacle being filled, in cases where the receptacle has contour changes along its height, causing respective changes in the elevation speed of the apex of liquid being filled.

Another way for keeping a substantially constant liquid post height during the elevation of the filling nozzles is by having the hopper elevated together with the filling nozzles. Unfortunately, this seems to be bulky and complicated solution, which, in addition, may be actual only for linear multi-channel filling apparatuses in which a batch of receptacles are served in parallel, all of which contain a similar liquid quantity along the filling sequence, hence all their respective filling nozzles have to be elevated in parallel. In rotary filling machines, however, each receptacle holds a different liquid quantity relatively to its respective angular location between the start-filling and the stop-filling positions. Therefor, the only acceptable method for keeping a constant height of liquid post between a hopper of a rotary filling apparatus and each of it filling nozzle outlets, is by having all the filling nozzles constantly arranged in the same level. As a result, the constant gap between the filling nozzle outlets and the apex of liquid within receptacles, can only be kept by appropriately lowering each receptacle according to its respective angular location from which deriving the temporal liquid quantity it contains.

At this point the general construction of a conventional rotary weight filler has to be understood. A conventional rotary weight filler comprises a central revolving hopper with a plurality of downwardly oriented filling nozzles angularly spaced around its outer circumference each filling nozzle is being in liquid communication with the hopper lower portion, each filling nozzle has and being aligned with a respective receptacle supporter adapted to receive a receptacle to be filled with a target-weight of liquid consumed from the hopper via the filling nozzle. A load cell is located as a part from each receptacle supporter, by which weighing of each receptacle is repeatedly being sampled and sent to a central control unit via appropriate wires connecting between the load cell unit and the central control unit. The central control unit processes the weighing data received from each filling channel, for identifying the stop-filling moment for each receptacle in order to control the respective filling nozzle valve off, for controlling and adapting between the liquid filling speed and the revolving speed ofthe filler, and for other purposes such as check-weighing an quality check. As already explained in the background section, Weight filler apparatuses work slowly, with quite modest liquid flow rate, in order to minimize the mechanical noise and vibration resulting from the filling liquid stream and affecting the weighing accuracy. Due to the weak liquid stream in rotary fillers, foaming problem almost does not rise.

As mentioned above, the method of the present invention provides means enabling the use of time as a basis for controlling the valves on and off, and therefor, when implementing the method of the present invention on a rotary filler, means for foaming inhibition are very essentially required, in order to enable extreme enlargement of the filling speed, relatively to the speed of conventional rotary weight-fillers.

As further explained above, the preferred foaming inhibition method in a time-based rotary machine according to the present invention is by lowering the receptacles in correlation with the elevation of the apex of the filled liquid.

As set out by the third principle of the method, an after- filling motionless weighing of each filled receptacle has to be executed. Thus, a rotary filler based on the method of the present invention comprises a load cell located below each filling nozzle as a part of a respective receptacle supporter.

On one hand, this configuration is similar to that of a conventional rotary weight-filler, but on the other hand and contrarily to a rotary weight-filler, the receptacle supporter units in a time-based filler using the method of the present invention have to continuously change their vertical position in order to comply with the fifth principle ofthe method, according which each receptacle has to be lowered in correlation with the elevation of the apex of the liquid being filled, and according to the respective angular location, then be elevated towards a new empty receptacle to be filled in the upcoming filling cycle. In a conventional rotary weight-filler, each receptacle filling unit is comprising the load cell, the filling nozzle valve, and their individual wiring connections with the central control unit. According to this conventional arrangement, the central control unit is connected to a number of N load cells by a number of N cables (each cable having 6 wires), and to a number of N respective valves by a number of N cables (each cable having between 2 and 4 wires). For example: in case of 48 channel filling machine, 96 cables are connected to the central control unit (48 cables arriving from the load cells, plus 48 cables arriving from the valves) . This wiring configuration is very bulky, and thus cannot be adopted in the high-speed time-based filler using the method of the present invention, in which this wiring configuration will have to be continuously fluctuated up and down with the movement of the receptacle supporter according to the fifth principle of the method, while increasing the wear and decreasing the reliability ofthe machine. In addition, in conventional rotary weight-fillers analog voltages are being transferred between each load cell and the central control unit (a reference voltage is constantly supplied via a pair of electrical wires from the central control unit to a Witston-Bridge of each load cell, a pair of wires is returning voltage excitation sense, and an analogue signal relative to the detected weight is returned by another pair of electrical wires to the central control unit, there which the weighing voltage is being sampled repeatedly for further processing as mentioned before), a matter that cannot be adopted by the high-speed time-based rotary filler, because the up and down fluctuation ofthe wiring will harmfully defect the reliability and repeatability of the analogue data being transferred via this wiring, as a result of inescapable and unpredictable changings in the concealing magnetic field. In addition, since the receptacle support units are in rotary motion, the central control unit has to be rotated accordingly, otherwise a significant number of golden contacts has to be used for connecting the 2N number of cables to the central control unit. Anyways, the transition of analogue voltages information (even through golden contacts) reduces the repeatability of weighings and the reliability ofthe system.

Since the conventional wiring configuration does not agree with the inquiries and goals of the present invention as set out hereinbefore, two additional principles will further be set out.

A sixth principle ofthe present invention is that any analog weighing data has to be digitized inherently by A/D converter being attached to or in a close proximity to the load cell, in order to insure that no sensitive analog data flows between the machine units. Preferably, and as will be further explained in detail, the load cell, the A/D converter, and an individual computerized controlling means, are all being enclosed in the same protecting box.

A seventh principle of the present invention is that a minimum of wiring has to be used for connecting between the central control unit, the load cells and the valves. Reducing to minimum the number of wires in a filling machine (including any type of filling machine, and especially a type wherein wiring is being fluctuated) will reduce to minimum the number of wiring failures.

In order to comply with said sixth and seventh principles of the present invention, and in order to reduce to minimum the number of wires in a filling machine, and particularly in a rotary time-based filling machine, a unique innovative device is to be preferably used in the filling machines using the method of the present invention. Thus present invention will further relate to a Valve Control Unit (hereinafter referred to also as VCU) that will be preferably used as a basic component of the liquid filling machine according to the present invention. Each Liquid Filling Channel (hereinafter referred to also as LFC) which based on the use of the VCU according to the present invention, may be interpreted as a complete single channel liquid filling machine, i.e. it has all the means required for fast and precisely measuring and filling a predetermined liquid quantity into every single receptacle from an unlimited series of receptacles.

An LFC according to the present invention is comprised of (a) a filling nozzle having a nozzle with an on-off valve; and (b) a Valve Control Unit (VCU), wherein the VCU includes; (bl) a load cell; (b2) conventional means for receiving and positioning on said load cell a receptacle to be filled (wherein the self- weight of said means is considered as a part of the load cell dead-weight thus not taken into account while sampling the receptacle's weight); (b3) a local computer means (such as a "smart card" with embedded software) having means for sampling and converting analog weighing data received from the load cell into digital data, processing said data, constructing a data base dedicated to the specific LFC, calculating an opening time required for obtaining a target weight to be filled into the receptacle through the nozzle, and controlling the valve on and off accordingly; (b4) communication means for communicating and exchanging data with a Central Supervision Unit (CSU), preferably by means of a conventional communication protocol (e.g. and preferably TCP/IP); and, optionally, (b5) hardware means for recognizing the position of the LFC (e.g. in a rotary filling machine - the respective angular location of the LFC, or e.g. in a linear filling machine, the stage ofthe LFC in a two stage linear filling machine). The hardware means for recognizing the location of the LFC are optional, because the location may be recognized also by means of calculation based on weighing data, and/or by means of identifying each VCU before the CSU in advance, according to a preset or pre-fabricated addressing code inherent to each VCU.

Although each LFC may be interpreted as an independent filling machine for a single channel, a central control unit is still required for regulating the operation of the plurality of LFCs configured in one multi-channel filling machine (e.g. optimizing between the liquid flow rate through the nozzles and the speed of carousel rotation in rotary filler), for supplying a preliminary operation conditions and working mode, for retrieving statistical filling information in order to construct a data base and/or for self-learning purposes, for obtaining a direct communication with each LFC for service, routine checkout, emergency control, and other general non real-time functions which relate to the CSU and the plurality of LFCs as a whole filling system. However, the use of a plurality of LFCs and a central supervision unit according to the present invention, can be defined by several significant advantages:

Since each LFC makes its own A/D conversion for the weighing, only digital data communication has to be exchanged between each LFC and the central control unit.

Since each LFC is having its own built-in valve control unit (hereinafter referred to also as VCU), including a micro-processor, memory, operation software, self-learning system, etc., as it was an independent single-channel filling apparatus. Thus each LFC may be replaced without any special adaptation and without affecting the machine operation.

Since each VCU calculates its own opening time and controls its filling valve independently, the central supervision unit according to the present invention does not have to deal with multi-channel real-time operations, nor have to accumulate and trace over individual behavior and characteristics of each of the plurality of valves, thus the central control unit according to the present invention, is defined by having a facile construction.

Furthermore, since no real time operations have to be made by the central supervision unit (according to the preferred embodiment according which each LFC has its own VCU computer means), there is definitely no need in a "star" shaped wiring configuration as in the traditional filling systems wherein each load cell or each valve has individual cable connection to the central control unit. According to the present invention, all the VCUs may be connected through one bus, in a network configuration, wherein each VCU has its unique local (Ethernet) address. This revolutionary concept (hereinafter will be referred to also as "the eighth principle"), leads extremely important advantages, as will be further explained in detail.

According to the eighth principle of the present invention, each VCU is connected to the other in a LAN concatenation manner, through one cable (the bus), and only one cable (the bus) connects between the central control unit and an unlimited number of VCUs.

According to the eighth principle of the present invention, the central control unit becomes generic; always it has only one input/output (I/O) connection, no matter how many VCUs exist in the system. An unlimited number of VCUs may be connected to the central control unit through same I/O connection, without any physical change. This is contrarily to the traditional central control units, that are adapted and limited to a specific predetermined number of filling channels that are connected to a respective number of individual input circuits existing in the central control unit.

According to the eighth principle of the present invention, the same central control unit can be used for a four-channel apparatus as well as for filler of any other number of filling channels, such as 200-channel filling system.

According to the eighth principle of the present invention, a filling apparatus can be designed as a modular extendable system, enabling a facile adaptation ofthe number of LFCs to the current needs of a plant.

According to the eighth principle of the present invention, the filling system is significantly facilitated, the number of wires is extremely reduced, the concentration of circuits on the central control unit, and the number and essentialness of tasks is has to perform, are also extremely reduced, thus the chances to a cessation fault in the system are meaningfully reduced. In addition, and due to the facile and non-concentrated configuration of the system, the service-time is also reduced to minimum.

Furthermore, according to the eighth principle of the present invention, due to the modular attribute it provides, and because either the LFC and the central control system can be utilized by various filling systems of various capacities and types including linear and rotary apparatuses, they both will be worthwhile for mass-production manufacturing, lowering the cost of filling apparatuses and services rendered. Actually, according to the eighth principle, a conventional industrial PC computer may be utilized as a central control unit for controlling the VCUs network. The central control unit in a network configuration according to the eighth principle of the present invention will be hereinafter referred to as Central Supervision Unit or CSU (in order to define it relatively to a central control unit - CCU, of conventional filling systems).

Preferably, the network data according to the present invention is using a conventional communication standards, such as TCP/IP.

According to the eighth principle, the filling apparatus may be easily and naturally integrated into any conventional communication network such as the Internet, enabling not only remote data exchange between the CSU and the "outside" world, but also a direct access to each VCU (according to its specific LAN address) for remote alignments, checkout, or service purposes.

As mentioned above, according to the fifth principle of the method of the present invention each receptacle has to be lowered according to a predetermined gap plot (or in some cases in correlation with the elevation of the apex of the liquid being filled), then be elevated towards a new empty receptacle to be filled in the upcoming filling cycle.

According to a first preferred embodiment dynamically determining and applying the appropriate gap between each nozzle outlet and the apex of the liquid within a respective receptacle during filling is controlled and kept by means of computer controlled servo-mechanism adapted to allow vertical movement of each VCU such that any desired positive, negative or zero gap, between the nozzle outlet and the apex of the liquid may be designated and applied during filling. This is performed by using computerized gap plots predetermined for each filling job either by the user, or by the filling machine manufacturer, according to accumulated data acquired through experiments and/or through self learning procedures.

One example of servomechanism adapted to allow vertical movement of each VCU, is a pneumatic piston driven by a solenoid that is controlled by the VCU to reach any vertical position along the height range restricted by the piston attributes. The pneumatic piston is linked to a sensor that continuously measures its actual position and returns this position data as a feedback to the VCU which in turn transfers the information to the CSU and controls the piston to a further vertical movement, according to the gap plot to be kept. The VCU generates the control signals to the solenoid according to information received from the CSU that processes the feedback information regarding the piston actual position, together with the general information regarding the specific filling job being executed, in order to drive the piston according to the appropriate gap to be kept.

The present invention further relates to a formed track enabling another facile implementation of the fifth principle. According to this second embodiment ofthe present invention each LFC has a vertical rod movable vertically within a fixed level sleeve, a downwardly oriented wheel is connected to the lower edge of said rod, said wheel is riding upon a formed track. The track is formed such that each rod (and the respective LFC connected to the rod) is being elevated and lowered during each filling sequence such that a receptacle being placed on said LFC is firstly being elevated towards the filling nozzle until the filling nozzle outlet reaches a closed proximity to the receptacle bottom, then being lowered in correlation with the elevation ofthe liquid level within the receptacle. In rotary filling machines according to the preferred embodiment of the present invention, the formed track is stationary, and the carousel (i.e. the revolving portion of a rotary filling machine) and the fixed level sleeves (that are rigidly connected to the carousel) force the vertical rods to trace the contour of the formed track during their rotational motion, and to change their vertical position according to their respective location relatively to the stationary formed track.

In linear filling machines according to the present invention, the fixed level sleeves are stationary, and the formed track is rotatable, thus force the vertical rods to change their vertical position according to the contour ofthe rotatable formed track.

The formed track enables increasing the filling machine speed without foaming problem entanglement, due to the appropriate gap being kept continuously between the nozzle outlet and the apex of liquid within the receptacles. This is in contradiction to weight fillers and other conventional fillers, that fill while the nozzles outlets are quite above the receptacles opening. The formed-track solution enables acceleration of the rotation speed without inducing foaming problems and with minimal liquid vibrations affecting the weighing accuracy, even when the filling speed reaches extremely high rates, that are irrelevant for weight-fillers and other conventional fillers.

_The first mentioned embodiment, relating to a separate servo mechanism for each VCU is preferred, however, from the formed track embodiment, because it can be adapted to unlimited number of filling job types simply by means of pure computer software, without requiring to design and hold stocks of formed tracks. Furthermore, the servomechanism embodiment allows for independent operation of each filling channel, with no mechanical linkage between the height of a filling nozzle and its relative angular position in a rotary filler according to the present invention, for example. Thus, any abnormality that may occur in a single filling channel during run time can be treated separately, e.g. by shutting a problematic filling nozzle in the middle of a filling sequence, without affecting the operation ofthe other channels.

The operation of a time-based rotary filler according to various preferred embodiments of the present invention includes a three main operation modes; (a) set-up (alignment) mode; (b) current filling mode; (c) tail filling mode (wherein the remaining of liquid is consumed and the liquid level falls within the hopper, near the end of the filling job). However, in this specification, if nothing is specified relating the mode of operation, the description should be interpreted as relating to the current-filling mode.

One of two basic alignment procedures may be selected in the set-up mode ofthe time-based filler according to the present invention.

The first set-up type (hereinafter referred to also as full-setup procedure), takes place when a non-familiar filling job is to be performed, wherein no prior information, or wherein only a partial information, exists in the CSU memory relating to this job (e.g. when a new liquid substance is to be filled, or a new type of receptacle is intended to be used). In full-setup procedure, at least part of the following steps are required: (a) determining (by typing through a key-board or by writing into the CSU memory in any acceptable way) a target-weight; (b) determining (by typing through a key-board or by writing into the CSU memory in any acceptable way) initial values to at least part from the following: (bl) liquid level to be kept within the hopper, wherein a relatively low level may be firstly selected, in order to obtain a small flow rate through the filling nozzles; (b2) an initial carousel rotation speed; (b3) an initial opening time to the valves (to be supplied to the VCUs via communication); (c) (in case where no relevant data exists for executing step (b3)) operating the machine wherein the valves are being controlled off (either arbitrarily by the operator, or automatically in a weight-filler mode, according to weight) at least once during the filling of a first batch of receptacles, wherein the filling time is meanwhile being counted, and the flow rate through each filling nozzle is calculated accordingly; (d) optionally, repeating step "b", according to the results of step "c", in order to optimize the flow rate (while considering the foaming and/or other attributes of the specific liquid substance used, and other aspects of the specific filling - job); (e) running a few first filling sequences, starting with high speed of lowering the receptacles (in a rotary filler by starting with high speed rotation of the carousel, and in linear filler by starting with high speed rotation of the formed track) relatively to the expected liquid elevation speed inside the receptacles, in order to prevent a direct contact between the filling nozzle outlets and the liquid within the receptacles (in order to provide clean and accurate filling with no liquid drops staining the receptacles, and without affecting the weight sampling being taken during filling), and decreasing the lowering speed of the receptacles until reaching an optimal gap between the filling nozzle outlets and the liquid level within the receptacles; (f) making final adaptations between the settings taken during steps "b" to "d", and the rotation speed setting taken during step "e"; and passing into current-filling mode.

The second set-up type (hereinafter referred to also as prompt-setup procedure), takes place when a familiar filling job is to be performed, wherein prior information relating to this job exists in the CSU memory (either provided by the machine producer, obtained via Internet or the like, or acquired during previous filling jobs in the same plant). In this set-up mode, only the "code" of the job has to be marked or typed-in into the CSU, then only the steps "e" and "f ' of the full set-up procedure are commonly have to be taken.

However, whenever a problem occurs or a need rises, either during set-up, or during current-filling, any step of the full-setup procedure may be repeated.

In the current filling mode, the following steps are taken during each filling sequence: (a) empty receptacles are positioned one by one (in a rotary time-based filler) or in batches according to the number of LFCs (in a linear time-based filler), on the VCUs, wherein the opening of each receptacle is quite below the respective non-occupied filling nozzle (in linear fillers, a fast pre-filling operation may anticipate this step, thus a batch of half-filled receptacles enter this step) ; (b) the weight of each empty receptacle is sampled (in linear fillers with two stage filling operation, the weight of the partially filled receptacle is sampled); (c) the empty receptacle (in linear fillers having two stage filling, the partially filled receptacle) is being elevated to the max height wherein the receptacle's bottom (in linear fillers, the apex of the liquid within the partially filled receptacle) reaches a position quite below the outlet of the respective filling nozzle; (d) the VCU commands the respective valve "on", the liquid starts flowing into the receptacle; (e) the receptacle is being lowered in correlation with the elevation of the liquid level within; (f) the liquid quantity within the main hopper is compensated continuously, keeping its level constant; (g) the weight of the receptacle is being supervised during filling by sampling its weight in time intervals and accuracy sufficient for safety purposes, and in order to recognize abnormal and/or emergency conditions; (h) the VCU counts time until stop-filling time being reached, then commands the valve "off, thus stops the liquid flow; (i) the full receptacle is being lowered quite below the filling nozzle outlet, then, after a sufficient relaxation interval, being weighed; (j) the VCU checks the weighing information for being within the target weight accuracy range, then, in case that under-filling is recognized, calculates the supplemental filling-time required for top-up, and commands the respective valve "on" for the top-up filling-time; (k) a final check-weighing is sampled by the VCU, for quality check and in order to revise (if necessary) the filling-time for the following filling sequence via this LFC; (1) the full receptacle is removed from the LFC and conveyed to the filled receptacles station (or to rejected, if failed in the quality check-weighing), then the non occupied LFC starts a new sequence, and recurrently.

The tail-filling mode takes place when the filling job is close to end, and the main hopper does not receive additional liquid quantity as a compensation to the liquid being consumed into the receptacles. In this filling stage, the second principle of the invention is being fertilized, since the height of the liquid post is continuously being reduced. According to one concept, the time based filling machine changes its operation method at this stage, and the CSU communicates with the VCUs, controlling them to act like a conventional low speed weight-filler, and reduces the rotation speed of the carousel (or the conveying means, in a linear filler) accordingly. According to another concept, the CSU is provided with appropriate information tables and appropriate mathematics formulas relating to various liquid types and to their changing flow rates in the different liquid post heights, which enable to communicate with the VCUs, and calculate appropriate filling times, being changed appropriately, during this tail-filling mode.

Briefly, the present invention relates to a method for fast and accurate filling procedure of liquids into an unlimited number of receptacles, each receptacle intended to contain a predetermined target mass of liquid after filling, said method comprising the steps of;

(a) providing a hopper with a predetermined quantity of a liquid to be consumed into a plurality of receptacles, said quantity reaches (of course) a predetermined level within the hopper;

(b) consuming the liquid from the hopper through a plurality of filling nozzles, each nozzle is being aligned for a filling sequence with a respective receptacle to be filled, each nozzle is in liquid communication with the hopper and having a computer controlled on/off valve;

(c) compensating the volume of the liquid within the hopper during the filling in order to keep the predetermined level ofthe liquid within the hopper substantially constant, in order to obtain a known and substantially fixed flow rate of the liquid through each nozzle during filling;

(d) calculating, determining, and providing a precise individual opening time to each valve according to the known and substantially fixed flow rate of the liquid through the respective nozzle, wherein the precise individual opening time of each valve fits exactly for filling the target mass into the respective receptacle;

(e) recurrently positioning a receptacles to be filled below available respective nozzles, and controlling the valve of each nozzle on for its precise individual opening time, thus providing each receptacle filled with the target mass of liquid.

Preferably, and according to the preferred embodiment, the method of the present invention further comprises the step (k) of dynamically applying appropriate gap between each nozzle outlet and the apex of the liquid within a respective receptacle during filling in order to minimize bubbling or foaming.

According to various preferred embodiments the computer controlled on/off valve has at least two "on" states, one provides for a flow rate useful for a dribble fill and the other provides for a flow rate useful for a fast fill, and wherein the calculation and determination of a precise individual opening time to each valve according to step (d) further applies for time allotment between said two on states. Although two "on" states valves are more expensive and complicated than plain on/off valves, for certain filling jobs they may be essential for improving foaming inhibition, wherein according to the significantly speed-up filling process which becomes possible by implementing the principles of the present invention, even non foaming substances become bubbling and require incorporating short phases of dribble fill into the filling process, as already mentioned before. Furthermore, when integrated into the entire system according to the present invention, the advantages of using such two state valves significantly increase relatively to using them in conventional systems. One example for such a difference, is that due to the dynamically controlled gap according to the fifth principle of the present invention, the dribble fill state of the valve can be designed for a higher flow rate than can be allowed when a similar filling job is to be executed by a conventional filling system wherein the liquid flows from nearly above the receptacle opening. Another example for the advantage of using double flow rate valve in a system according to the present invention relatively to using it in conventional systems, is that due to the dynamically gap according to the present invention, a dribble fill phase can be utilized on start filling moment, wherein the receptacle bottom is elevated to max, almost touching the nozzle outlet. Such implementation was found very essential to minimize foaming when filling certain foaming substances, such as beer, wherein foaming extremely develops in the moment of the initial contact between the liquid and the container. Right after a relatively low predetermined level of liquid within the container was reached, the dribble fill phase can be changed to a fast fill phase, with the nozzle immersing within the liquid. In conventional systems wherein the nozzle outlet is positioned far away from above the bottom of the container the advantage in using dribble fill phase at start filling moment is very limited.

According to various preferred embodiments the method of the present invention further comprises at least one check weighing of each receptacle after filling, while its respective nozzle valve is closed and after the mechanical vibrations affecting the accuracy of weighing have naturally been reduced.

According to various preferred embodiments the method of the present invention further comprises top-up filling of those receptacles which their check-weighing result exceed a predetermined under-filling tolerance, by calculating and providing appropriate supplemental opening-time to the respective valve.

According to various preferred embodiments the method of the present invention further comprises using the result of at least one of the check weighings of each receptacle as a feedback to the computer controlling the respective nozzle valve, useful for optimizing the opening time of each valve for its following filling sequences.

According to various preferred embodiments the method of the present invention further comprises (g) adapting the speed of a filling sequence of a filling machine using the method and having a plurality of filling nozzles, to the filling sequence of a nozzle having the maximal opening time from all the nozzles.

According to various preferred embodiments the method of the present invention further comprises gathering filling information and constructing a data base comprising predetermined selected characteristics regarding each filling channel, useful for self learning for optimizing the filling, for decreasing the set-up time of a filler using the method in future filling works, or for predicting and preventing malfunction.

According to various preferred embodiments the method of the present invention further comprises the step of; (i) gathering filling information and constructing a data base comprising predetermined selected information regarding the operation characteristics of a filler using the method and its behavior with different liquid substances, useful for self learning for optimizing the filling, for decreasing the set-up time for similar filling works in future, or for predicting and preventing malfunction.

According to various preferred embodiments the method of the present invention further comprises the step of; (j) communicating and exchanging relevant data with a remote service provider.

According to various preferred embodiments the method of the present invention it is being used in a filling machine (preferably a rotary machine, however it may be implemented in linear fillers as well) comprising a CSU and plurality of LFUs, each of having a separate independent VCU, said VCU comprises in one casing a load cell for weighing a respective receptacle; an A/D converter for digitizing the analog weighing data supplied by the load cell; a microprocessor for determining the opening time ofthe respective valve and for controlling it on and off accordingly; and a LAN communication means for communicating with said CSU. According to the preferred embodiment, said caising (housing, or box) is stainless-steel RF protected one, and concealing from changes in the magnetic field, thus improving the accuracy of weighings.

The present invention further relates to a VCU for use in the method hereinbefor defined, comprising; (a) a load cell; (b) conventional means for receiving, positioning (and/or gripping) on said load cell a receptacle to be filled; (c) a local control unit having means for sampling and converting analog weighing data received from the load cell into digital data, processing said data, calculating an opening time required for obtaining a target weight to be filled into the receptacle through a nozzle having on/off valve, and controlling said valve on and off accordingly; (d) communication means for communicating and exchanging data with a CSU.

According to various preferred embodiments of the present invention, said computer controlled on/off valve has at least two on states, one provides for a flow rate useful for a dribble fill and the other provides for a flow rate useful for a fast fill and wherein controlling of said valve include time allotment between dribble fill and fast fill. The present invention further relates to a Liquid filling machine for use in the method hereinbefor defined, and comprising; (a) a CSU; (b) a plurality of VCUs in digital data communication with the CSU; (c) a plurality of downwardly oriented filling nozzles, each having an on/off valve controlled by one of the VCUs, all of said nozzles end along same horizontal line; (d) a main hopper in liquid communication with each of the nozzles, and having liquid level sensor, and liquid communication with a supplementer liquid supply, allowing for compensation of the liquid being consumed through said nozzles into receptacles during filling, wherein said compensation is controlled for keeping a substantially constant liquid level within the hopper; (e) means for dynamically determining and applying an appropriate gap between each nozzle outlet and the apex of the liquid within a respective receptacle during filling.

According to the preferred embodiment of the present invention, the means for dynamically determining and applying the appropriate gap between each nozzle outlet and the apex of the liquid within a respective receptacle during filling are comprised of (a) computer controlled servo-mechanism adapted to allow vertical movement of each VCU such that any desired positive, negative or zero gap between the nozzle outlet and the apex of the liquid may be designated and applied during filling.

The machine may include other accessories, for example, thermometers for tracing the liquid temperature in the hopper, or for tracing the environment temperature, which may be useful for predicting changes in the liquid flow rate relatively to previous similar filling jobs.

According to various preferred embodiments ofthe filling machine ofthe present invention, the means for keeping a substantially constant (either negative, positive or zero) gap between each nozzle outlet and the apex of the liquid within a respective receptacle during filling are comprised of

(a) a formed track having a contoured upper face portion matching an inverted plot of a liquid level elevation-speed relatively to time-scale of liquid being filled in a fixed flow-rate into an appropriate receptacle; (b) means for allowing vertical movement of each VCU according to the contour of the formed track during a rotational relative motion made between the formed track and each VCU.

According to various preferred embodiments the means for allowing vertical movement of the VCU is comprised of a vertical rod movable within a fixed height sleeve, wherein the VCU is connected on top of said vertical rod.

According to various preferred embodiments ofthe filling machine of the present invention, it has (a) a revolving carousel comprising the hopper, the plurality of filling nozzles, the plurality of VCUs wherein each VCU is vertically moveable and is aligned below a respective nozzle, and (b) a stationary formed track having a contoured upper face portion according which the VCUs change their vertical position during rotational motion of the carousel for keeping the substantially constant gap between each nozzle outlet and the apex of the liquid within a respective receptacle during filling.

According to other embodiments, the machine of the present invention is comprised of (a) a stationary part comprising the hopper, the plurality of filling nozzles, the plurality of VCUs each is aligned below a respective nozzle, wherein at least one group of VCUs is vertically moveable, and

(b) a revolving formed track having a contoured upper face portion according which the at least one vertically moveable group of VCUs change its vertical position during rotational motion of the formed track for keeping the substantially constant gap between the respective nozzle outlets and the apex of the liquid within respective receptacles during filling.

Preferably, the digital data communication between the CSU and the VCUs of the present invention is by means of a LAN configuration, wherein all the VCUs are catenated to the CSU via one bus.

According to the present invention the VCU may control its respective valve either via a pair of electrical wires, or by means of wireless remote control coupling (e.g. infra red coupling).

According to the present invention each VCU recognizes its angular location relatively to the stationary formed track (existing in a rotary filler according to various preferred embodiments), by means of measuring the time passed after sensing the positioning of an empty receptacle upon, and multiplying it by the carousel angular velocity indicated by or calculated according to relevant data received from the CSU.

Due to the simplicity of the wiring configuration of a filler according to the present invention, a conventional industrial PC may be used as a CSU, and there is no need in developing and adapting special types of control units to various types and sizes of filling systems, as used to be while using the conventional wiring method.

Furthermore, according to various preferred embodiments the CSU is comprising means for communicating and exchanging data with a remote service provider (e.g. through the internet or through point to point connection), useful for service, and for exchanging filling information tables. Detailed Description Of The Invention

The present invention will be further described in detail by Figures 1 - 6.

These Figures are solely intend to illustrate a few preferred embodiments ofthe present invention, and in no manner intend to limit its scope.

Brief description ofthe Figures:

Figure 1 illustrates a schematic diagram of the electrical connection configuration between the members from which comprised a conventional rotary filler.

Figure 2, illustrates a general diagram of an LFC according to the present invention.

Figure 3 illustrates a schematic diagram of the electrical connection configuration between the members from which comprised a rotary filler according to the present invention.

Figure 4 illustrates a formed track in a rotary time-based liquid filling machine according to the present invention.

Figure 5 illustrates a spreading view of the formed track illustrated in Figure 4, cut in its mid portion for combining an illustration of two filling channels according to the servomechanism embodiment.

Figure 6 illustrates a partial view of a time-based linear filler using the method ofthe present invention.

Figure 7 illustrates a general schematic view of a servomechanism embodiment with a plurality of LFCs (two are illustrated) each comprised of the LFCs illustrated in Figure 2 mounted on the servomechanism cylinders presented in the mid portion of Figure 5 .

Detailed description ofthe Figures:

Figure 1 illustrates a schematic diagram of the electrical connection configuration between the members from which comprised a conventional rotary filler. The conventional rotary filler has a plurality of filling nozzles (21), each has an on/off valve (21a) controlled by means of a central control unit (CCU) (22). The CCU generates the on and off commands for each nozzle's valve (21a), according to the weight of the receptacle being filled, wherein the weight is measured by means of a load cell (21b) upon which the receptacle is positioned during the filling sequence. The CCU (22) is preset by the user to a predetermined target weight of the liquid to be filled for the current filling job, into each one from a line of receptacles. The empty receptacle are being fed by means of a feeder placing them in turn on a load cell, below a respective filling nozzle. The load cells generate an analog electrical signal respective to the load they carry. Each load cell output is connected by a 6 wires (21c) to an individual A/D conversion circuit on the CCU, through which the weight of the empty receptacle is being sampled by the CCU right after positioning, thereafter a start-filling command ("on") is being generated and sent to the respective nozzle. The load cell analog data is continuously being sampled by the CCU, until a stop-filling weight is being sampled and recognized, resulting in an "off command being sent to the respective nozzle. According to this conventional filling apparatus, each nozzle's valve (21a) is connected to the CCU (22) individually, and each load cell (21b) is connected to the CCU individually as well. Hence, in case of 8 filling nozzle machine, an eight pointed "star" shaped wiring configuration should make the connection between the machine members, wherein 8 cables (2 Id) (each comprises between 2 and 4 wires) are required for connecting between the 8 valves (21a) and the CCU (22), and 8 additional cables (21c) (each cable comprises six wires) are required for connecting between the CCU (22) and the 8 load cells (21b). Accordingly, several tens of connection points and associate circuitry (22a) are required in the CCU (22) for receiving all the system wiring, and tens of electronic components are involved in receiving and processing the multi-channel data, all of which are being localized in the CCU, turning it into a complicated and bulky unit. Furthermore according to this traditional configuration, each CCU is restricted to deal with a predetermined and an inexpandable number of filling channels, thus each filling machine requires a specific CCU model, designed according to the specific number of filling channels to be controlled.

In addition, and as already mentioned, the sensitive analog data transmitted between the load cells and the CCU is affected by RF noise and by occasional changes in the concealing magnetic field during their rotational motion with the carousel, which defect the weighing accuracy. This inaccuracy is worsening if the cables have to continuously change their relative positioning, due to vertical motion of the load cells, as required for complying with the fifth principle ofthe method according to the present invention.

All of those disadvantages reflect the complexity and the cost of CCUs in particular, and increase the costs of filling machines and their maintenance, as a whole. This is besides the other problems that were discussed above, such as that of low speed, exposure to RF and magnetic influences, increased service-time in case of malfunction (due to the complicated configuration), and failure in complying with the fifth principle.

In contradiction to the traditional wiring configuration illustrated by Figure 1, the unique and innovative wiring configuration of a filling machine according to the present invention is illustrated by Figure 3.

The unique and innovative liquid filling machine wiring configuration illustrated in Figure 3, is based on the use of a plurality of the LFC illustrated in Figure 2.

Figure 2, illustrates a general diagram of an LFC. Each LFC according to the present invention may be interpreted as a complete single channel liquid filling machine, in that it has all the means required for fast and precisely measuring and filling a predetermined liquid quantity into every single receptacle from an unlimited series of receptacles. The LFC (31) is comprised of two main parts; a filling nozzle (37) capable of conducting liquid from a main liquid reservoir into a receptacle to be filled, and a valve control unit (VCU) (40) capable of controlling the filling.

The filling nozzle (37) is in liquid communication with a main liquid reservoir (41) (in the context of the present invention referred to also as "hopper") and thus it is capable of supplying liquid from the hopper to a receptacle, wherein the flow ofthe liquid may be controlled on and off by means of an inherent on/off valve (38) (comprised of a solenoid (38a), and a movable lance (38b)) of the filling nozzle. The valve (38) is controlled by means of the VCU (40). The connection between the VCU (40) and the valve (38) for the transmission of the on/off command could be implemented in any acceptable way, such as by a wire cormection (not illustrated in this Figure) through which electrical on/off signal is directed from the VCU and actuates the valve, or by a wireless (remote control) connection, wherein the filling nozzle further comprises a remote control receiver (33) controlling its valve, and a wire connection for powering, and wherein the VCU has a matching remote control transmitter (33 a) having a wireless communication with said remote control receiver (the remote control is not essentially required, and a conventional electrical wire can be used for transmitting the control signals from the VCU to the valve, as well).

The VCU is comprised of a load cell (18); conventional means (not illustrated) for receiving and positioning a receptacle to be filled on said load cell; a local control unit (19) for sampling and converting analog weighing data received from the load cell (18) into digital data, processing said data, calculating the opening time required for obtaining a target weight to be filled into the receptacle, and controlling the valve on and off accordingly. According to the servomechanism embodiment, the local control unit controls also the servomechanism for vertical movement in order to apply appropriate gap between the outlet of its nozzle (37) and the apex of the liquid within the receptacle (see Figure 7 for more details); communication means (39) for communicating and exchanging data with a central control unit by means of a conventional communication protocol (e.g. and preferably TCP/IP); and optionally, sensor means (17) for recognizing the position ofthe LFC (e.g. in a rotary filling machine - the temporal respective angular location of the LFC, or e.g. in the stage ofthe LFC in a two stage linear filling machine).

The means for recognizing the temporal respective position of the LFC in a rotary machine may be a calculation made by the VCU according to the time which have passed after the initial position was left, wherein the initial position can be recognized by sensing the positioning of an empty receptacle upon the load cell. Thus, no physical "navigation" means are required. The means for recognizing the LFC stage in two stage linear filler may be a manual pre-set, thus, physical sensor means may be redundant according to various preferred embodiments.

Figure 3 illustrates a schematic diagram of the electrical connection configuration between the members from which comprised a rotary filler according to the present invention. This could be a re-configured rotary weight-filler, however, this new wiring configuration enables the development of, and therefor is preferably implemented in a high-speed time-based rotary filling machine.

The time-based rotary liquid filling machine is comprised of a plurality of LFCs (30), each comprises a valved nozzle (30a) and a VCU (30b), wherein the VCUs are connected to each other and to a CSU (50) in a LAN configuration by means of Ethernet bus (55). As can be clearly seen, no matter how many filling channels exist in a system, only one bus cable (55) is connecting between the CSU (50) and the LFCs (30). The same CSU (50), which actually can be a conventional PC, and the same software, can be used for any type and size of filling machine who makes use of VCU based filling channels, either if it is a four channel machine or a 200 channel system. In comparison, according to the conventional connection configuration depicted in Fig. 1, 400 (!) cables should be connected to the CCU in case of 200 channel system, and thousands of I/O electrical connections of hundreds of electrical circuits should be connected to the thousands of wires included in the 400 cables, wherein the CCU cannot be the same type using for four channel machine. Furthermore, a machine using the method of the present invention can be expanded by adding filling channel according to needs, without any physical change done to the CSU. Due to this modular attribute, and because either the LFC and the central supervision system can be utilized by various filling systems of various capacities and types including linear and rotary apparatuses, they both will be worthwhile for mass-production manufacturing, lowering the cost of filling apparatuses and services rendered.

The CSU (50) regulates the operation of the plurality of LFCs (30), supply a preliminary operation conditions and working mode, for retrieving statistical filling information in order to construct a data base and/or for self-learning purposes. Furthermore the CSU enables a direct communication between a service office and each individual LFC, for remote service, routine checkout, emergency control, carousel rotation speed, and other acceptable purposes.

The filling machine according to this embodiment may be easily and naturally integrated into any conventional communication network such as the Internet, enabling not only remote data exchange with the CSU, but also a direct access to each VCU via the LAN (and according to its local address) for remote alignments, checkout, or service purposes.

Figure 4 illustrates the operation method of a formed track (9) in a rotary time-based liquid filling machine (hereinafter referred to also as "time-based filler" or shortly - TBF; partially illustrated in this Figure) according to the present invention. The TBF is having a plurality of LFCs (1) each comprised of a filling nozzle (7), VCU (3), a vertical rod (la), a sleeve (lb) through which the rod (la) is movable vertically, a wheel (lc) connected to the lower edge ofthe rod (la). The sleeves (lb) ofthe LFCs are being connected rigidly to a metal belt (2; only a portion of the complete metal belt is illustrated in this Figure) being a part of the carousel (i.e. the revolving portion of the rotary TBF). All the sleeves are fixed in the same height along one horizontal line (i.e. the belt (2) is oriented horizontally). During a typical filling process the carousel is being rotated in the direction D, continuously. Thus, the metal belt that is rigidly connected to the carousel, is being rotated also, in the direction A. The formed track (9) is immovable, and therefor, the rotation of the carousel and the metal belt (2) cause the wheel (lc) of each LFC to roll on the top portion (i.e. the formed portion) of the formed track (9) and to trace its contour, resulting in vertical movements of the respective rod (la), wherein said vertical movements trace the contour of the formed track. The contour of the formed track is designed and adapted to the specific shape of a receptacle to be filled. Hence, the formed track (9) is a replaceable part, to be selected from a plurality of designs and mounted into the rotary TBF, according to the shape and size ofthe receptacle type currently intended to be filled. The receptacle type being filled according to this Figure, is a bottle (6). A receptacle feeder (not illustrated) is feeding a plurality of empty bottles one by one in the direction B, placing each on an unoccupied LFC, marked "I". The lower portion of the VCU marked "I", is leaning on the apex of the respective sleeve, due to the lowest portion "E" of the formed track (9), which is designed to be lower enough in order to prevent any contact between the wheel and the track. Accordingly, the bottle being placed, is found in the lowest height in the filling sequence. When the bottle is in this position, the respective filling nozzle (10) is being aligned quite above the bottle opening. Right after placement, the wheel of the LFC "I" is contacting the track and being forced (by the rotation in the direction A) to climb the inclined portion (9a) of the formed track (9), until arriving to the start-filling position in which placed the LFC "S". In case that the tare weight of the receptacles is not accurate and may vary from one receptacle to another, a sampling of the tare weight is taken before starting the filling, right after placement of an empty receptacle wherein the VCU is above the track lowest portion "E", and before its wheel contacting the track incline (9a). as will be further explained, all the critical weighings are taken when the VCU leans on the sleeve and the wheel is disconnected from the track (which is the situation of each VCU reaching the lowest portion "E"), thus eliminating the mechanical noise resulting from the rolling ofthe wheel on the track.

During the elevation along the incline (9a), the filling nozzle penetrates into the bottle (the filling nozzles ends in one horizontal line, and they are all in the same constant unchanged height). In the start-filling position S, the bottle is being found at its highest location during the filling sequence, wherein the filling-nozzle outlet is being aligned quite above the bottle bottom. When the S position is being sensed by the VCU navigation means, the VCU commands the respective valve "on", and starts counting its pre-calculated filling time. During the filling time, the LFC "S" keeps moving in the rotation direction A, while being lowered continuously according to the respective location of its wheel along the incline (9b) of the formed track (9), and while the outlet of the respective filling nozzle tracks the liquid level within the container with a substantially constant small gap in between. The incline (9b) becoming somewhat extreme in the portion (9c), in order to adapt the lowering of the bottle, to the fast liquid elevation within, occurring when the liquid reaches the narrowing portion of the bottle. Near the end point of the inclined portion (9c), the filling-time is intending to end, and the VCU commands the respective valve "off. Thereafter, the formed track becomes to its lowest portion E wherein the bottle is being lowered to the lowest position, the filling-nozzle taken off from the opening of the full bottle (location "F"), wherein, after a relaxation of the mechanical noise caused by the roll ofthe wheel on the track and the "landing" ofthe VCU upon the respective sleeve, and after the relaxation ofthe liquid vibrations caused by the filling stream, the VCU samples the bottle's weight, calculates a supplemental-filling-time for top-up (location T) and commands the valve "on", accordingly, in case that under-fill was detected, in order to reach the exact target weight, samples the bottle's weight as a final quality checkout, calculates the filling time for the next filling sequence, and communicates with the CCU for reporting the filling data, or for rejecting an over-filled bottle. Then, the filled bottle is being fed out in the direction C, by means of a out-feeder (not illustrated). Thereafter, the LFC reaches the initial position "I", being ready to receive a new empty bottle.

As already mentioned, during the filling process the carousel is being rotated in the direction D, continuously. The rotation can be stopped in several cases, for example, during the set-up process, when initiated by the operator from any reason, or in emergency (i.e. when identifying malfunction or any other abnormality such as overflow in any of the LFCs, unwanted immersion of a nozzle within the filled liquid) which could be recognized, either by a VCU, by the CSU, by means of any type of internal or external sensor (e.g. over-temperature sensor), or by a remote service office.

As already mentioned before, according to the preferred embodiment of the present invention, the vertical motion ofthe VCUs is not by means of a formed track but by means of servo mechanism. According to the servomechanism embodiment, the formed track (9) does not exist, the rods (la) have no wheels (lc) on their lower end, thus each of the rods (la) serves as a piston (or has a piston on its lower end) movable within a pneumatic cylinder wherein the cylinder body is rigidly connected to the metal belt (2). Each such pneumatic servomechanism is computer controlled for elevating and lowering the corresponding VCU according to a preprogrammed filling job data, together with real time feedback data received from a vertical location sensor. According to the servomechanism embodiment, adaptations of the filling machine for the entire various types of filling jobs are completely controlled through the computer software, which mean there is no need in replacement between different designs of formed tracks for different types of filling jobs. Furthermore, according to the servomechanism embodiment, there is no mechanical linkage between the temporal vertical position of a specific VCU and between its temporal angular position around the carousel, which improves operation continuity by allowing individual channel troubleshooting with individual elevation and/or lowering of a problematic receptacle without reflecting the normal operation of the other filling channels. An illustration of a servomechanism embodiment is given in the following figure wherein two filling channels having servomechanism means for vertical movement of their VCUs are shown between the plurality of filling channel of the formed track embodiment. Of course this mixture between the two embodiments is not realistic, they are only combined here into a single illustration to enable a visual brief comparison between their similarities and differences.

Figure 5 illustrates a spreading view of the formed track (9) illustrated in Figure 4. The track is cut in the location "E" depicted in Figure 4, between the input LFC marked "I" (seen on the right side of Figure 5), and the output LFC marked "O" (seen on the left of Figure 5), hence location "E" is divided into two extents on Figure 5, one on the right side and the other on the left. As explained in Figure 4, the TBF has a plurality of LFCs (1) (in this Figure, 16 LFC machine is illustrated, however the 16 illustrated LFCs may be interpreted also as 16 different "pictures" of a single LFC, taken at 16 different positions during one of its typical filling sequences) each comprised of a filling nozzle (7) (in this figure it can be seen that all the filling nozzles are fixed in one height), VCU (3), a vertical rod (la), a sleeve (lb) (in this figure it can be seen that all the sleeves are fixed in one height) through which the rod (la) is movable vertically, a wheel (lc) connected to the lower edge of the rod (la). The sleeves (lb) of the LFCs are being connected rigidly to a metal belt (2) being a part ofthe carousel (i.e. the revolving portion ofthe rotary TBF).

In order to enable a visual brief comparison between a formed track embodiment and a servomechanism embodiment, two filling channels according to the servomechanism embodiment are illustrated here, combined into this figure in place of two of the 16 filling channels of the formed track. As already mentioned above, the mixture between the two different embodiments is not realistic, it is only made here, in this figure, to enable a visual brief comparison between their similarities and differences. According to the servomechanism embodiment, two LFCs marked (Wl, W2) are shown. As can be seen, there is no formed track below these filling channels wherein the vertical movement of the VCUs is by means of computer controlled pneumatic cylinders (81a, for Wl, and 81c for W2) shown in a general view, rigidly connected to the metal belt (2), each having a movable piston that is the lower portion of the respective rods (81b) and (8 Id), that support the VCUs upon which positioned the containers being filed. In the complete servomechanism embodiment (not illustrated), all the sleeves (lb) are replaced with computer controlled pneumatic cylinders similar to (81a) and (81c). The pneumatic cylinders is only one example for servomechanism useful for providing vertical elevation and lowering of the VCUs according to the present invention. As can be appreciated, implementation of other servomechanisms types, configurations, and arrangements, is only a matter of design, thus falls within the scope ofthe present invention.

During the filling process the carousel is being rotated in the direction D, continuously. Thus, the metal belt that is rigidly connected to the carousel, is being rotated also, in the direction A. The formed track (9) is immovable, and therefor, the rotation of the carousel and the metal belt (2) cause the wheel (lc) of each LFC to roll on the top portion (i.e. the formed portion) of the formed track (9) and to trace its contour, resulting in vertical movements of the respective rod (la), wherein said vertical movements trace the contour of the formed track. The contour of the formed track is designed and adapted to the specific shape of a receptacle to be filled, except along the lowest portion E wherein the VCU leans on the respective sleeve while the wheel at the lower end of the rod is taken off from the track, in order to enable accurate receptacle weighing, with a minimum of mechanical noise. In the servomechanism embodiment wherein there is no formed track, the operation of the formed track and the interaction between the formed track and the wheels is implemented virtually by means of the computer software and the computer controlled pneumatic cylinders (81a)(81c). The formed track (9) is a replaceable part, to be selected from a plurality of designs and mounted into the rotary TBF, according to the shape and size of the receptacle type currently intended to be filled. The receptacle type being filled according to this Figure, is a bottle (6). A receptacle feeder (not illustrated) is feeding a plurality of empty bottles one by one in the direction B, placing each on an unoccupied LFC, marked "I". The lower portion of the VCU marked "I", is leaning on the apex of the respective sleeve, due to the lowest portion "E" of the formed track (9), which is designed to be lower enough in order to prevent any contact between the wheel and the track. Accordingly, the bottle being placed, is found in the lowest height in the filling sequence. When the bottle is in this position, the respective filling nozzle is being aligned quite above the bottle opening. Right after placement, the wheel of the LFC "I" is contacting the track and being forced (by the rotation in the direction A) to climb the inclined portion (9a) of the formed track (9), until arriving to the start-filling position in which placed the LFC "S". In the start-filling position S, the bottle is being found at its highest location during the filling sequence, wherein the filling-nozzle outlet is being aligned quite above the bottle bottom. When the S position is being sensed by the VCU navigation means (that may be either hardware sensor, or pure software means, or a combination thereof), the VCU commands the respective valve "on", and starts counting its pre-calculated filling time. During the filling time, the LFC "S" keeps moving in the rotation direction A, while being lowered continuously according to the respective location of its wheel along the incline (9b) of the formed track (9), and while the outlet of the respective filling nozzle tracks the liquid level within the container with a substantially constant small gap in between. The incline (9b) becoming somewhat extreme in the portion (9c), in order to adapt the lowering of the bottle, to the fast liquid elevation within, occurring when the liquid reaches the narrowing portion of the bottle. Near the end point of the inclined portion (9c), the filling-time is intending to end, and the VCU commands the respective valve "off. Thereafter, the formed track becomes to its lowest portion E wherein the bottle is being lowered to the lowest position, the filling-nozzle taken off from the opening of the full bottle (location "F"), wherein, after a relaxation of the mechanical noise caused by the roll ofthe wheel on the track and the "landing" of the VCU upon the respective sleeve, and after the relaxation ofthe liquid vibrations caused by the filling stream, the VCU samples the bottle's weight, calculates a supplemental-filling-time for top-up (location T) and commands the valve "on", accordingly, in case that under-fill was detected, in order to reach the exact target weight, samples the bottle's weight as a final quality checkout, calculates the filling time for the next filling sequence, and communicates with the CCU for reporting the filling data, or for rejecting an over-filled bottle. Then, the filled bottle is being fed out in the direction C, by means of a out-feeder (not illustrated). Thereafter, the LFC reaches the initial position "I", being ready to receive a new empty bottle.

Preferably, the sleeves (lb) have a cushioning means on their apex upon which the VCU housing leans during its rotational motion hovering above the E portion of the formed track. It is also possible to have the cushioning means on the underneath of the VCU box. The cushioning arrangement reduces to minimum the mechanical noise caused by the carousel rotation, making the end portion "E" of the formed track ideal for check weighing sampling, for feed back, and in case that the tare weight of the receptacles is not accurate and may vary from one receptacle to another, for sampling the tare weight of a receptacle before starting the filling, right after placement of an empty receptacle in the "I" position, and before the wheel contacts the track for climbing the incline (9a).

Figure 6 illustrates a partial view of a time-based linear filler using the method ofthe present invention. A four channel filling stage is illustrated. The four channel filling stage comprises 4 VCUs marked (K), (L), (M), (N), connected on top of 4 respective rods (71a) movable vertically within 4 respective immovable sleeves (71b) fixed to a horizontal metal bar (72). The rods are rigidly connected to each other and through a metal member (71c) to a main rod (71), ending at its lower edge with a wheel (7 Id). A formed track (79) having contoured upper face, is in rotational motion in the direction F, by means of a vertically oriented motor-driven axle (74) which revolves clockwise (G). The formed track is made from a semi rigid material, which provides vertical resistance to the track together with lateral resiliency, such that the track can be stretched laterally and be held by an auxiliary vertical axis (73). The rotational motion of the track forces the wheel (7 Id) and thus the (K), (L), (M), (N) VCUs to change their height according to the contour of the track, firstly to climb the incline (79a) until the nozzles (77) reaches near the bottom of the bottles, then to move downwardly according to the incline (79b), wherein the bottles are being filled simultaneously and the liquid level inside the bottles elevates in correlation with the downward movement thus wherein a substantially constant small gap is kept between the nozzles outlets and the liquid level within the bottles. When the incline (79c) reaches the wheel (7 Id), the downwards movement is being accelerated in order to track the increase in the liquid elevation speed within the narrowing portion of the bottles, thereafter the lowest portion "E" of the track arrives below the wheel, the wheel is disconnected from the track and the VCUs rest upon the sleeves, for check-weighing and for top-up fill, as described in figures 4 and 5 concerning rotary time-based filler.

Figure 7 illustrates a general schematic view of a servomechanism embodiment with a plurality of LFUs (two are illustrated) each comprised ofthe LFUs (31) illustrated in Figure 2 mounted on the servomechanism cylinders (81a)(81c), presented in the mid portion of Figure 5. The two LFUs are illustrated with a bottle positioned on their load cells (18), wherein each bottle is shown in a different height. The left one is lower, and filled with a greater amount of liquid, the outlet of the nozzle (37), located however with a substantially zero gap from the liquid apex, similar to the gap between the nozzle of the right side LFU and the apex of the right bottle liquid content. The zero gap is kept in both LFUs although there is a different liquid amount within the bottles, due to the vertical motion of the VCUs (33a) obtained by the pneumatic pistons (81b)(81d) that moves within the respective cylinders (81a)(81bc). The cylinders are rigidly fixed in one height to a metal belt (see (2) of Figure 5), and the pistons moves vertically with the VCUs upon, by means of appropriate accurate differential pneumatic pressure supplied to both piston ends via pipes (84a)(84b) from a solenoid (84). The solenoid (84) receive a pneumatic pressure via input (85) from the same air pressure supply using for the activation ofthe LFU on/off valve. The solenoid (84) is electrically controlled by the VCU local control unit (19) which supply accurate controlling signals generated according to the gap plot of the current filling job, and according to real time feedback signals it receives continuously from the piston height sensor (82) that measures the exact vertical position of the receptacle and reports it back to the local control unit (19) as an electrical signals, or as light, according to the type of sensor being used. Thus, the gap plot of the current filling job can be traced and applied to the receptacle being filled, very accurately, wherein the piston moves exactly in the required speed, and timely reaches the exact required vertical positions according to the outline design of the receptacle being filled and according to the foaming inhibition requirements ofthe current filling job.

Claims

Claims:

1. The present invention relates to a method for fast and accurate filling procedure of liquids into an unlimited number of receptacles, each receptacle intended to contain a predetermined target mass of liquid after filling, said method comprising the steps of;

(a) providing a hopper with a predetermined quantity of a liquid to be consumed into a plurality of receptacles, said quantity reaches a predetermined level within the hopper;

(b)consuming the liquid from the hopper through a plurality of filling nozzles, each nozzle is being aligned for a filling sequence with a respective receptacle to be filled, each nozzle is in liquid communication with the hopper and having a computer controlled on/off valve;

(c) compensating the volume of the liquid within the hopper during the filling in order to keep the predetermined level of the liquid within the hopper substantially constant, in order to obtain a known and substantially fixed flow rate of the liquid through each nozzle during filling;

2. A method according to claim 1, wherein the computer controlled on/off valve has at least two on states, one provides for a flow rate useful for a dribble fill and the other provides for a flow rate useful for a fast fill, and wherein the calculation and determination of a precise individual opening time to each valve according to step (d) further applies for time allotment between said two on states.

3. A method according to claim 1, further comprising at least one check weighing of each receptacle after filling, while its respective nozzle valve is closed and after the mechanical vibrations affecting the accuracy of weighing have naturally been reduced.

3. A method according to claim 3, further comprising top-up filling of those receptacles which their check-weighing result exceed a predetermined under-filling tolerance, by calculating and providing appropriate supplemental opening-time to the respective valve.

4. A method according to claim 3, further comprising; (f) using the result of at least one of the check weighings of each receptacle as a feedback to the computer controlling the respective nozzle valve, useful for optimizing the opening time of each valve for its following filling sequences.

5. A method according to claim 1, further comprising the step of; (g) adapting the speed of a filling sequence of a filling machine using the method and having a plurality of filling nozzles, to the filling sequence of a nozzle having the maximal opening time from all the nozzles.

6. A method according to claim 1, further comprising the step of; (h) gathering filling information and constructing a data base comprising predetermined selected characteristics regarding each filling channel, useful for self learning for optimizing the filling, for decreasing the set-up time of a filler using the method in future filling works, or for predicting and preventing malfunction.

7. A method according to claim 1, further comprising the step of; (i) gathering filling information and constructing a data base comprising predetermined selected information regarding the operation characteristics of a filler using the method and its behavior with different liquid substances, useful for self learning for optimizing the filling, for decreasing the set-up time for similar filling works in future, or for predicting and preventing malfunction.

8. A method according to claim 1, further comprising the step of; (j) communicating and exchanging relevant data with a remote service provider.

9. A method according to claim 1, being used in a filling machine comprising a CSU and plurality of LFUs, each of having a separate independent VCU, said VCU comprises in one casing a load cell for weighing a respective receptacle; an A/D converter for digitizing the analog weighing data supplied by the load cell; a microprocessor for determining the opening time of the respective valve and for controlling it on and off accordingly; and a LAN communication means for communicating with said CSU.

10. A method according to claim 1, being used in a rotary filling machine.

11. A method according to claim 1 , being used in a linear filling machine.

12. Method according to claim 1, further comprising the step (k) of dynamically applying appropriate gap between each nozzle outlet and the apex of the liquid within a respective receptacle during filling in order to minimize bubbling or foaming.

13. VCU for use in the method according to claim 1, comprising; (a) a load cell; (b) conventional means for receiving and positioning on said load cell a receptacle to be filled; (c) a local control unit having means for sampling and converting analog weighing data received from the load cell into digital data, processing said data, calculating any appropriate opening times required for obtaining a target weight to be filled into the receptacle through a nozzle having on/off valve, and controlling said valve on and off accordingly; (d) communication means for communicating and exchanging data with a CSU.

14. VCU according to claim 13, wherein the computer controlled on/off valve has at least two on states, one provides for a flow rate useful for a dribble fill and the other provides for a flow rate useful for a fast fill and wherein controlling of said valve include time allotment between dribble fill and fast fill.

15. Liquid filling machine using the method of claim 1, and comprising; (a) a CSU; (b) a plurality of VCUs in digital data communication with the CSU; (c) a plurality of downwardly oriented filling nozzles, each having an on/off valve controlled by one of the VCUs, all of said nozzles end along same horizontal line; (d) a main hopper in liquid communication with each of the nozzles, and having liquid level sensor, and liquid communication with a supplementer liquid supply, allowing for compensation of the liquid being consumed through said nozzles into receptacles during filling, wherein said compensation is controlled for keeping a substantially constant liquid level within the hopper; (e) means for dynamically determining and applying an appropriate gap between each nozzle outlet and the apex of the liquid within a respective receptacle during filling.

16. Liquid filling machine according to claim 15, wherein the means for dynamically determining and applying the appropriate gap between each nozzle outlet and the apex of the liquid within a respective receptacle during filling are comprised of (a) computer controlled servo-mechanism adapted to allow vertical movement of each VCU such that any desired positive, negative or zero gap between the nozzle outlet and the apex of the liquid may be designated and applied during filling.

17. Liquid filling machine according to claim 15, wherein the means for dynamically determining and applying the appropriate gap between each nozzle outlet and the apex of the liquid within a respective receptacle during filling are comprised of (a) a formed track having a contoured upper face portion matching a combination between an inverted plot of a liquid level elevation-speed relatively to time-scale of liquid being filled in a fixed flow-rate into an appropriate receptacle, and between a gap plot of the designated gap to be kept between each nozzle outlet and the apex ofthe liquid at a given moment throughout a filling sequence; (b) means for allowing vertical movement of each VCU according to the contour of the formed track during a rotational relative motion made between the formed track and each VCU.

18. Liquid filling machine according to claim 15, wherein the means for allowing vertical movement of the VCU is comprised of a vertical rod movable within a fixed height sleeve, wherein the VCU is connected on top of said vertical rod.

19. Liquid filling machine according to claim 15, having; (a) a revolving carousel comprising the hopper, the plurality of filling nozzles, the plurality of VCUs wherein each VCU is vertically moveable and is aligned below a respective nozzle, and (b) a stationary formed track having a contoured upper face portion according which the VCUs change their vertical position during rotational motion of the carousel for dynamically applying the appropriate gap between each nozzle outlet and the apex ofthe liquid within a respective receptacle.

20. Liquid filling machine according to claim 15, having; (a) a stationary part comprising the hopper, the plurality of filling nozzles, the plurality of VCUs each is aligned below a respective nozzle, wherein at least one group of VCUs is vertically moveable, and (b) a revolving formed track having a contoured upper face portion according which the at least one vertically moveable group of VCUs change its vertical position during rotational motion of the formed track for dynamically applying the appropriate gap between the respective nozzle outlets and the apex ofthe liquid within respective receptacles during filling.

21. Liquid filling machine according to claim 15, wherein the digital data communication between the CSU and the VCUs is by means of a LAN configuration, wherein all the VCUs are catenated to the CSU via one bus.

22. Liquid filling machine according to claim 15, wherein each VCU controls the respective valve via a pair of electrical wires.

23. Liquid filling machine according to claim 15, wherein each VCU controls the respective valve by means of wireless remote control coupling.

24. Liquid filling machine according to claim 19, wherein each VCU recognizes its angular location relatively to the stationary formed track by means of measuring the time passed after sensing the positioning of an empty receptacle upon, and multiplying it by the carousel angular velocity indicated by or calculated according to relevant data received

25. Liquid filling machine according to claim 15, wherein the CSU is a conventional industrial PC.

26. Liquid filling machine according to claim 15, wherein the CSU is comprising means for communicating and exchanging data with a remote service provider.