COUPLING DEVICE FOR COUPLING A COMPONENT TO AN ARTICLE

Abstract

A coupling device for coupling a component to an article includes a first retaining member that retains the component, a second retaining member that retains the article, a movement system for moving the first retaining member and the second retaining member between a non-operating position where the component and the article are spaced apart from one another, and an operating position where the component and the article are in a coupling position, and a detection system for detecting the positioning of the component on the first retaining member. The detection system includes an image detector device for capturing at least one image of the component when the component is retained by the first retaining member, and a processing unit provided for analysing the image captured by the image detector device and verifying if the component is retained on the first retaining member in a predefined position.

Claims

1.-20. (canceled)

21. A coupling device for coupling a component to an article, comprising: a first retaining member for retaining said component, a second retaining member for retaining said article, a movement system for moving said first retaining member and said second retaining member between a non-operating position where said component and said article are spaced apart from one another, and an operating position where said component and said article are in a coupling position, and a detection system for detecting positioning of said component on said first retaining member, said detection system comprising: an image detector device for capturing at least one image of at least said component when said component is retained by said first retaining member, and a processing unit provided for analysing said at least one image captured by said image detector device and verifying if said component is retained on said first retaining member in a predefined position.

22. The coupling device according to claim 21, wherein said first retaining member comprises a retaining surface on which said component is retained.

23. The coupling device according to claim 22, further comprising a welding device associated with said first retaining member for heat-welding said component to said article, said welding device comprising a welding head arranged close to said retaining surface.

24. The coupling device according to claim 23, wherein said welding head is positioned, with respect to said retaining surface, on an opposite side of said image detector device.

25. The coupling device according to claim 21, wherein said image detector device is configured to capture images in the visible range.

26. The coupling device according to claim 25, wherein said component comprises a detection surface facing said image detector device and having a different colouring with respect to said retaining surface on which said component is retained.

27. The coupling device according to claim 23, wherein said welding head is configured to be heated to a temperature greater than a temperature of said component, and said image detector device is configured to detect images of said at least said component in an infrared range.

28. The coupling device according to claim 22, wherein said first retaining member comprises a suction device for generating vacuum on said retaining surface and retaining said component on said retaining surface.

29. The coupling device according to claim 21, wherein said image detector device is configured to capture at least one image of said component retained by said first retaining member when said first retaining member is moved into said non-operating position.

30. The coupling device according to claim 21, wherein said first retaining member comprises a first retaining element for retaining a first component and a second retaining element for retaining a second component.

31. The coupling device according to claim 21, wherein said second retaining member comprises a first retaining device for retaining a first article and a second retaining device for retaining a second article.

32. An article packaging apparatus, comprising a movement carousel comprising at least one coupling device according to claim 21 for coupling a component to an article, the at least one coupling device being positioned in a peripheral position on said carousel.

33. The article packaging apparatus according to claim 32, wherein said image detector device is on an outside of said carousel in a position facing said coupling device when the at least one coupling device is in said non-operating position.

34. A method for coupling a component to an article, comprising: retaining said component by a first retaining member, retaining said article by a second retaining member, controlling correct positioning of said component on said first retaining member, moving at least one of said first retaining member and said second retaining member in order to contact said component and said article, and coupling said component with said article.

35. The method according to claim 34, wherein said controlling comprises detecting a position of said component on said first retaining member by capturing an image of said component retained on said first retaining member and processing said image.

36. The method according to claim 34, wherein said detecting also comprises sending a signal for modifying said coupling step on the basis of said signal.

37. The method according to claim 34, wherein said coupling comprises heat-welding said component to said article.

38. The method according to claim 35, wherein said detecting comprises providing a welding head having a surface temperature greater than a temperature of said component such that the welding head is optically distinct from said component in an infrared range, and capturing an image of at least said component in the infrared range.

39. The method according to claim 36, wherein, on the basis of said signal, said component is welded to said article i) on a continuous welding surface for a shorter time or ii) to portions of said welding surface.

40. A method for obtaining a contrasted image of two objects difficult to distinguish from one another in a visible range, comprising: differentiating temperatures of said two objects, and capturing an image of the two objects in an infrared range.

Description

[0166] The characteristics and advantages of the invention will become clearer from the detailed description of an embodiment illustrated, by way of non-limiting example, with reference to the appended drawings in which:

[0167] FIG. 1 represents a schematic view from above of an article packaging apparatus according to the present invention;

[0168] FIG. 2 is a schematic perspective view of a portion of the apparatus in FIG. 1;

[0169] FIG. 2A is an enlarged detail of FIG. 1;

[0170] FIG. 3 represents a schematic sectional view of a capsule according to the present invention;

[0171] FIG. 4 is a schematic perspective view of a coupling device from FIGS. 1 and 2 in a non-operating position;

[0172] FIG. 5 is a sectional view of the device in FIG. 4 in a non-operating position highlighting an image detecting device.

[0173] With initial reference to FIGS. 1 and 2, it is shown an article packaging apparatus 800 which is provided to produce a finished object 100 ready for packaging or use. The object 100, best visible in FIG. 3, is a coffee capsule and comprises a container 10 and a component 20 coupled to the container 10, as further described below.

[0174] The production apparatus 800 comprises a feeding station 801, a shaping station 802 for shaping a filter, a welding station 803 for welding the filter to the container 10, a filling station 804 for filling the container 10 in which a slideable product is introduced into the container 10 and a coupling station 805 for coupling the component 20 to the container 10. The coupling station 805 comprises a conveying device 200, best visible in FIGS. 2 and 2A, on which a plurality of coupling devices 1 are housed, each coupling device 1 being intended to couple at least one component 20 to a container 10.

[0175] The conveyor device 200 is configured to transport the components and the containers in the movement direction indicated by arrow F towards an unloading carousel 807 after coupling a component 20 to a container 10.

[0176] The conveying device 200 is a rotating carousel, best visible in FIG. 2, rotating in the direction of rotation F2. The carousel 200 comprises 32 coupling devices 1 and is intended to receive a plurality of components and a plurality of containers and to mutually couple a component and a corresponding container.

[0177] Preferably, the plurality of retaining devices 1 is constrained on the rotating carousel 200 at its maximum circumference in such a way that it can facilitate receiving and delivery of containers and lids on and respectively from the rotating carousel 200.

[0178] The conveying device 200 is configured to receive the components 20 from a component shaping device not visible in the Figures and to transport them along a first conveying segment T1 corresponding to a first rotation angle α1 of the carousel 200 equal to about 60°.

[0179] The conveying device 200 is configured to receive the containers 10 from an exchange wheel 806, placed downstream of the filling station 804, and to transport them along a second conveying segment T2 corresponding to a second rotation angle α2 of the carousel 200 equal to about 300°, in which the coupling device 1 moves both the components 20 and the containers 10.

[0180] The coupling device 1 further comprises a detection system 300 arranged to detect the position of the components on the rotating carousel 200, as further explained below.

[0181] The example embodiment described below refers to containers 10 in the form of capsules filled with a desired slideable product, to which a component 20 is coupled.

[0182] In the specific case described herein, the containers 10 are capsule elements for the preparation of infusion type beverages, in particular coffee capsules, and the slideable product is coffee powder “C”.

[0183] As better visible in FIG. 3, the container 10 is shaped to define a housing for a slideable product which is provided with a mouth 10′ through which the slideable product is introduced into the container.

[0184] Preferably, the container 10 may be made of multilayer material, for example materials that are composed of layers of PP (Polypropylene) and/or EVOH (Ethylene Vinyl Alcohol) in PET (Polyethylene Terephthalate) or PS (Polystyrene). Alternatively, the container 10 is made of multilayer material with at least one metal alloy layer, e.g. aluminium-based.

[0185] In the example embodiment described herein, the component 20 is a lid made of polyamide material. In particular, the lid 20 may be a multilayer polymer in which there is at least one aluminium layer.

[0186] Preferably, on the side of the lid 20 facing in use towards the inside of the container 10 there may be a layer of adhesive material intended to melt and be joined to the container at the time of welding.

[0187] Preferably, on the outer side there may be a layer of a higher-melting material rather than the material on the inner side, which must not melt when heat is supplied to melt the layer arranged on the inner side.

[0188] The lid 20 is coupled to the mouth 10′ of the container 10 and is shaped to close the mouth 10′ by sealing the container 10 to prevent the slideable product from escaping from the container 10.

[0189] The lid 20 comprises a couplable portion 25 which is effectively heat-weldable to the container 10 also made, for example, of polymeric material.

[0190] In the present example and as represented in FIG. 3, the container 10 has a substantially inverted truncated conical shape presenting a base 11 of substantially flat and circular shape from which a lateral wall 12 is transversely projected. This lateral wall 12 is inclined with respect to the vertical line, presenting the smaller diameter thereof at the base 11 and the larger diameter thereof at an upper opening 13 defining the mouth 10′ of the container 10.

[0191] The lateral wall 12 of the container 10 ends with an edge 14A radially projecting outwards from the container 10 itself and delimiting the mouth 10′ of the container 10.

[0192] An abutment surface 14B is identified on this edge 14A and which is configured to realise a coupling area with the couplable portion 25 of the lid 20.

[0193] Preferably, the lid 20 is circular in shape and can be superimposed to the upper opening 13 of the container 10, the couplable portion 25 of the lid 20 is an annular portion that can be superimposed with the abutment surface 14B so that, by coupling the lid 20 to the container 10, the mouth 10′ is closed and the container 10 is sealed.

[0194] With reference to FIGS. 4 and 5, a coupling device 1 for coupling the container 10 with the lid 20 provided on the carousel 200 is shown in greater detail.

[0195] The coupling device 1 comprises a frame 2 on which there is defined a first retaining member 3 for retaining at least one lid 20 and a second retaining member 6 for retaining at least one container 10.

[0196] The first retaining member 3 comprises a first retaining member 4 for retaining a first lid 20A and a second retaining member 5 for retaining a second lid 20B.

[0197] Similarly, in the version shown the second retaining member 6 comprises a first retaining device 7 for retaining a first container 10A and a second retaining device 8 for retaining a second container 10B.

[0198] Each of the first 7 and the second retaining device 8 is configured to define a seat 51 for housing the first 10A and the second container 10B, respectively.

[0199] The coupling device 1 further comprises a movement system 40, which is provided to move the first 3 and the second retaining member 6 between a non-operating position W in which the lids 20A and 20B and the containers 10A, 10B are respectively retained by the first 3 and the second retaining member 6 and are spaced apart from each other, and an operating position W′ in which the lids 20A and 20B and the containers 10A, 10B are respectively retained by the first 3 and the second retaining member 6 in a close coupling position to couple a lid 20A, 20B to the respective container 10A, 10B.

[0200] The first 4 and the second retaining element 5 are configured to retain the lids 20A, 20B in a substantially aligned position.

[0201] The first 4 and the second retaining element 5 are configured to retain the lids 20A, 20B in the non-operating position W aligned along an axis perpendicular to the transport direction F of the carousel 200 or, in the version shown, in the vertical direction Z.

[0202] The first 4 and the second retaining element 5 are configured to retain the lids 20A, 20B are both oriented parallel to a vertical plane, more preferably the first and second retaining elements are coplanar.

[0203] The first 4 and the second retaining element 5 are integral so that they can be moved together.

[0204] The first 7 and the second retaining device 8 are integral so that they can be moved together.

[0205] The first retaining member 3 is movable between a non-operating position W, shown in greater detail in FIGS. 4 and 5, in which the retaining member 3 is oriented so that the first 4 and the second retaining member 5 can receive a respective lid 20A, 20B to be retained. Preferably, the non-operating position W is identified by a substantially vertical orientation of the retaining member 3.

[0206] From this non-operating position W, the coupling device 1 and in particular the first retaining member 3 is movable into an operating position W′ in which the first retaining member 3 is rotated towards the second retaining member 6 so as to close the seats 51 and to bring the lid 20A, 20B into contact with the edge 14 of the respective container 10A, 10B.

[0207] The movement system 40 is configured such that the first retaining member 3 is rotatable about a rotation pin 33 along both directions of the rotation trajectory indicated by the arrow F1 in FIG. 5 to be moved between the non-operating position W′ and the operating position W. The first retaining member 3 performs a curved trajectory Cl to reversibly move between the non-operating position W and the operating position W.

[0208] In the cases shown in the Figure such a curved trajectory Cl is preferably an arc of circumference substantially equal to 90°.

[0209] Alternatively, such a curved trajectory Cl can be an arc of an ellipse, or parabola, or further curved paths that can be achieved by means of linkages or cam mechanisms.

[0210] The movement system 40 is configured to move the first 4 and the second retaining element 5 simultaneously.

[0211] The movement system 40 is configured to rotate the first 4 and second retaining element 5 by about 90° between the non-operating position W and the operating position W′.

[0212] The first 7 and the second retaining device 8 are substantially identical, so they will be described together. Each retaining device 7, 8 is shaped to define a seat 51 constrained to the frame 2 and shaped to stably house the container 10A and the container 10B, respectively.

[0213] Each seat 51 comprises a cylindrical recess in which the container 10A, 10B is housed. The two seats 50 of the first 7 and the second retaining device 8 are preferably aligned according to a sagittal straight line of the coupling device 1.

[0214] In one embodiment, each retaining device 7, 8 may selectively retain the container 10A, 10B for example by means of a suction cup or similar systems in reduced pressure.

[0215] The first 4 and the second retaining element 5 are substantially identical, so they will be described together. Each retaining element 4, 5 of the first retaining element 3 is configured to selectively retain a lid 20A, 20B. Each retaining element 4, 5 comprises a retaining surface 4A, 5A arranged to receive and retain a respective lid 20A, 20B.

[0216] The first retaining member 3 is shaped so that the retaining surfaces 4A, 5A are aligned along a substantially vertical direction when the coupling device 1 is in the non-operating position W.

[0217] The first retaining member 3 is shaped so that the retaining surfaces 4A, 5A are substantially coplanar.

[0218] The retaining surfaces 4A, 5A have a shape dependent on the shape of the component to be coupled to the container. In the present case where the component to be coupled is a circular shaped lid 20A, 20B, the retaining surfaces 4A, 5A are substantially circular in shape.

[0219] Each retaining surface 4A, 5A preferably has a maximum diameter smaller than the maximum diameter of the lied 20A, 20B.

[0220] The first 4 and the second retaining element 5 are configured such that the lid 20A, 20B is retained by the retaining surfaces 4A, 5A at a central portion thereof.

[0221] Therefore, a peripheral portion not in contact with the retaining surface 4A, 5A is defined on each lied 20A, 20B.

[0222] Preferably, such a retaining surface 4A, 5A is a surface of a suction cup or similar retaining device.

[0223] The first 4 and the second retaining element 5 are operatively connected to a suction device, schematically indicated by 30, and shaped to create a desired reduced pressure on the retaining surfaces 4A, 5A to pick up and retain the lid 20A, 20B.

[0224] The coupling device 1 comprises a coupling element 70 which is a thermal welder intended to thermally weld the lid 20A, 20B to the respective container 10A, 10B.

[0225] Such a thermal welder 70 is intended to couple the lid 20A, 20B to the respective container 10A, 10B by heating the lid 20A, 20B so that it adheres to the edge 14A of the respective container 10A, 10B.

[0226] The welder 70 is preferably kept active and is translatable with respect to the first retaining device 3. When the coupling device 1 is in the non-operating configuration W, the welder 70 is placed at a desired distance from the lids 20A, 20B and in particular from their couplable portion 25 so as to avoid the possibility of overheating the lids 20A, 20B when they are secured to the respective retaining element 4, 5, before they are brought into contact with the respective container 10A, 10B.

[0227] Preferably, this predefined distance is between 1 mm and 10 mm.

[0228] When the coupling device 1 is brought into the operating position W′, the welder 70 is displaced with respect to the lids 20A, 20B coming close, or in contact with, the coupling portion 25 of the lid 20A, 20B.

[0229] Alternatively, the welder 70 may be translated so as to protrude in the operating position W′ externally from the retaining surface 4A, 5A so as to exert additional pressure on the coupling portion 25 during the coupling step.

[0230] The welder 70 is provided with a pair of welding heads 7A, 7B having a substantially circular crown shape and configured to be arranged in the operating position W radially external to each retaining surface 4A, 5A.

[0231] Each welding head 7A, 7B is shaped in such a way that it can be at least partially superimposed with the abutment surface 14B of the container 10 when the coupling device 1 is brought into the operating position W′.

[0232] Each welding head 7A, 7B is shaped in such a way that it can be at least partially superimposed with the coupling portion 25 of the lid 20A, 20B.

[0233] Each welding head 7A, 7B can also be moved and controlled independently of the other welding head of the thermal welder 70.

[0234] Preferably each welding head 7A, 7B and each retaining surface 4A, 5A are configured so that the welding head 7A, 7B surrounds the respective retaining surface 4A, 5A.

[0235] Preferably, the welder 70 is configured to apply a coupling temperature between 150° C. and 300° C. for a predetermined coupling time that is between 0.2 seconds and 0.8 seconds, preferably equal to 0.4 seconds.

[0236] Still preferably, the welder 70 exerts an even pressure on the coupling portion 25 between 45 and 85 Psi.

[0237] In operation, the first 4 and the second retaining element 5 of a coupling device 1 of the carousel 200 pick up two lids 20A and 20B from a lid shaping device to transport them, by means of the carousel 200, along the first conveying segment T1.

[0238] The first 7 and the second retaining device 8 of a coupling device 1 of the carousel 200 pick up two containers 10A 10B coming from the exchange wheel 806 to transport them, by means of the carousel 200, along the second conveying segment T2, together with the lids 20A, 20B.

[0239] In this joint conveying segment T2 the coupling device 1 is moved from the non-operating position W to the coupling operating position W′, where the lids 20A, 20B are coupled to the respective containers 10A, 10B.

[0240] The coupling device 1 further comprises a detection system 300 arranged to detect the position of the lids 20A, 20B on the respective retaining surface 4A, 5A of the first retaining member 3.

[0241] The detection system 300 comprises an image detector device 301, schematically shown in FIGS. 2 and 5, arranged to capture at least one image of the lid 20A, 20B when it is retained on the respective retaining element 4, 5.

[0242] The detection system 300 further comprises a processing unit not visible in the Figures and arranged to analyse the image of the lid 20A, 20B captured by the image detector 301 and verify whether the lid 20A, 20B is retained on the respective retaining surface 4A, 5A in a predefined position.

[0243] The processing unit is configured to send a signal dependent on the processing of the detected position of the lied 20A, 20B.

[0244] Depending on the signal sent by the processing unit, it may be possible to modify the coupling step, as explained in more detail below.

[0245] The image detector device 301 is positioned to capture at least one image of the lid 20A, 20B when the coupling device 1 is in the non-operating position W.

[0246] The image detector device 301 is configured to simultaneously detect the position of the lids 20A, 20B which are retained on the first 4 and the second retaining element 5.

[0247] The image detector device 301 is positioned on the outside of the carousel 200, at the segment T1, in a fixed position facing the first retaining member 3 when the coupling device is in non-operating position W with the lids 20A, 20B already picked up by the first retaining member 3.

[0248] The image detecting device 301 obtains an image of the lids 20A, 20B positioned on the first retaining element 4 and the second retaining element 5.

[0249] In the preferred embodiment described herein, the image detector device 301 is an image detector configured to detect images in the infrared range.

[0250] In an alternative embodiment, the image detector device 301 can be configured to capture images in the visible range. In the latter case, each lid 20A, 20B may be provided with a detection surface Sr facing the image detector device 301 having a different colouring than the colouring of the corresponding retaining surface 4A, 5A on which the lid 20A, 20B and the welding head 7A, 7B are retained.

[0251] The relative positioning of the welding head 7A, 7B, the respective lids 20A, 20B and the image detecting device 301 is such that when the lid 20A, 20B is retained in the correct position on the respective retaining surface 4A, 5A, the respective welding head 7A, 7B is hidden from the image detecting device 301 by the lid 20A, 20B. Thus, in this case, no surfaces with a temperature particularly different from the lid temperature will be present in the image detected by the image detecting device 301, so that no regions with a brightness particularly different from the lid brightness will be present in the image.

[0252] Conversely, in the event that the lid 20A, 20B is improperly retained on the respective retaining surface 4A, 5A, a portion of the respective welding head 7A, 7B will protrude from the lid 20A, 20B resulting visible by the image detecting device 301. Thus, in this case, a high brightness region will be present in the image detected by the image detecting device 301 with respect to that corresponding to the lid (corresponding to the portion of the welding head that is at a much higher temperature than the lid). This makes it easy to identify the non-alignment of the lid with the welding head and, consequently, of the lid with the respective retaining element.

[0253] Of course, if, for any reason, the component 20A, 20B were not present on the retaining surface 4A, 5A at the time of image acquisition, the welding head would be fully visible and, therefore, the position of the component would be identified as incorrect.

[0254] This image analysis is carried out by the processing unit of the detection system 300. The processing unit emits a signal dependent on the result of the image analysis.

[0255] If the lid is correctly positioned, the signal sent by the processing unit includes accepting the final capsule obtained from the packaging apparatus 800.

[0256] If instead the lid is not correctly positioned, the processing unit sends a corresponding signal which envisages discarding the corresponding capsule at the end of the packaging operation.

[0257] In addition, if the lid is not correctly positioned, the processing unit may send a signal to change the coupling step.

[0258] In particular, it is possible to carry out a less precise welding for the lid which is not correctly positioned on the corresponding container, for example a spot welding or a welding with a shorter than normally expected application time.

[0259] In addition or as an alternative, welding at a lower temperature than the intended welding temperature may be envisaged.

[0260] At the end of the segment T2, the capsules 100 are unloaded from the carousel 200 and loaded onto an unloading carousel 807 through which they are transported to further processing stations provided in the apparatus 800.

[0261] In an alternative version of the image detector device not shown, the image detector device is configured to detect the image of the lid on the first retaining element and the image of the lid on the second retaining element in a sequence one after the other.

[0262] In an alternative version not shown in the Figures, the coupling device comprises a first image detector device and a second image detector device separate from the first image detector device. The first and second image detector devices are intended to detect the position of the lid on the first and second retaining element, respectively.

[0263] Alternatively, in a version not shown, the image detector device is provided on the carousel and is arranged to face the coupling device when the coupling device is in the non-operating position.

[0264] In an alternative version, the image detector device is positioned on a movement member in such a way that it can be moved relative to the coupling device, preferably in a manner concordant with the direction of transport of the coupling device.

[0265] It goes without saying that a person skilled in the art may, in order to meet specific and contingent application requirements, make further modifications and variants of the above-described invention within the scope of protection as defined by the following claims.