CONTROL METHOD IN A PRODUCTION PROCESS FOR ARTICLES AND A PRODUCTION APPARATUS FOR ARTICLES OPERATING ACCORDING TO THIS METHOD

Abstract

A method for controlling a production process for articles includes: feeding a plurality of articles to a first operating unit where the articles are subjected to a first processing operation; controlling at least one characteristic of the articles outgoing from the first operating unit; identifying among the outgoing articles a first group and a second group of articles, in which the at least one characteristic is respectively in accordance or not with predetermined quality parameters; transferring the articles outgoing from the first operating unit to at least one second operating unit, where the articles are subjected to at least one second processing operation; allowing the at least one second operating unit to perform the at least one second processing operation on the first group of articles; receiving the articles outgoing from the at least one second operating unit, and then discarding the second group of articles.

Claims

1.-18. (canceled)

19. A method for controlling a production process for articles, comprising: feeding a plurality of articles to a first operating unit configured to subject said articles to a first processing operation, controlling at least one characteristic of said articles outgoing from said first operating unit, identifying among said articles a first group of articles, in which said at least one characteristic is in accordance with predetermined quality parameters, and a second group of articles, in which said at least one characteristic is not in accordance with said predetermined quality parameters, transferring said articles outgoing from said first operating unit to at least one second operating unit configured to subject said articles to at least one second processing operation, allowing said at least one second operating unit to perform said at least one second processing operation on said first group of articles, preventing, at least partially, said at least one second operating unit from performing said at least one second processing operation on said second group of articles, receiving said articles outgoing from said at least one second operating unit, and discarding said second group of articles.

20. The method according to claim 19, wherein said articles, after said at least one characteristic has been controlled, are subjected to a plurality of processing operations in successive operating units, and each of said successive operating units is allowed to perform a respective processing operation on said first group of articles and is prevented, at least partially, from performing said respective processing operation on said second group of articles.

21. The method according to claim 19, wherein said second group of articles is discarded at the end of said production process.

22. The method according to claim 19, further comprising a control operations of said articles downstream of one or more operating units, wherein said second group is formed by all articles identified as not being in accordance with at least one of said control operations.

23. The method according to claim 19, wherein said first processing operation is performed by said first operating unit by a plurality of moving members, each moving member being configured to operate on a different article.

24. The method according to claim 19, wherein said first processing operation is performed in a continuous manner while said articles are moving.

25. The method according to claim 19, wherein said at least one second processing operation is performed by said at least one second operating unit by a plurality of moving members, each moving member being configured to operate on a different article.

26. The method according to claim 19, wherein said at least one second processing operation is performed in a continuous manner while said articles are moving.

27. The method according to claim 19, wherein a process index is defined, the process index being formed by the whole of all different operating configurations taken up successively in a cyclical manner by said operating units during introduction of successive articles in the production process, and each of said articles is uniquely associated with a step number of said process index.

28. The method according to claim 27, wherein the step number of said process index is printed on each article.

29. The method according to claim 28, wherein the step number of said process index is printed at the end of said process.

30. The method according to claim 27, wherein, when a moving member of an operating unit of said apparatus is disabled, disabling of all processing operations of the other operating units involving articles having a step number of said process index comprising the moving member being disabled occurs.

31. The method according to claim 19, wherein said at least one characteristic is controlled by an optical detection system.

32. The method according to claim 31, wherein said optical detection system comprises four cameras directed towards said article.

33. The method according to claim 19, wherein said at least one characteristic is controlled while said articles are moving.

34. A production apparatus for articles, comprising: a first operating unit configured to subject said articles to a first processing operation, at least one second operating unit configured to subject said articles to at least one second processing operation, a detection system configured to detect at least one characteristic of said articles between said first operating unit and said at least one second operating unit, a control unit for said apparatus, connected to said detection system and configured to: i) control conformity of said articles with predetermined quality parameters of said at least one characteristic, ii) identify among said articles a first group of articles, in which said at least one characteristic is in accordance with said predetermined quality parameters, and a second group of articles, in which said at least one characteristic is not in accordance with said predetermined quality parameters, and iii) control said at least one second operating unit to perform said at least one second processing operation on said first group of articles and to prevent, at least partially, said at least one second processing operation from being performed on said second group of articles, and a discarding station positioned downstream of said at least one second operating unit and configured to discard said second group of articles.

35. The apparatus according to claim 34, wherein said first operating unit comprises a first transport member on which first moving members are mounted, and said articles are subjected to said first processing operation by said first moving members while said moving members are being moved by said first transport member.

36. The apparatus according to claim 34, wherein said at least one second operating unit comprises at least one second transport member on which respective second moving members are mounted, and said articles are subjected to said at least one second processing operation by said respective second moving members while said respective second moving members are being moved by said at least one second transport member.

Description

[0138] 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 wherein:

[0139] FIG. 1 is a schematic plan view from above of an article production apparatus operating according to the method of the present invention;

[0140] FIG. 2 is a schematic view in perspective from above and on an enlarged scale of a first section of the production apparatus in FIG. 1;

[0141] FIG. 3 is a schematic side elevation view of a second section of the production apparatus in FIG. 1.

[0142] With reference to the accompanying figures, 1 indicated an apparatus for articles 2 made to operate in accordance with the control method of the present invention.

[0143] In the embodiment example described herein, the production apparatus 1 is provided for the preparation of capsules for infusion type beverages, in particular coffee.

[0144] In this embodiment example, therefore, the articles 2 are formed by capsules, also indicated in the following with the same numerical reference, which in the development of the production process are gradually processed until they become, at the end of apparatus 1, capsules ready for packaging, packing and final dispatch.

[0145] In general terms, the apparatus 1 comprises an inlet unit 10 in which empty capsules 2 are fed, a filter shaping unit 20 in which a specially formed filter is inserted into each empty capsule 2, a coupling unit 30 in which the filters are coupled to respective capsules 2, a filling unit 40 in which the empty capsules 2 provided with a filter are filled with coffee powder, a closing unit 50 in which the capsules 2 filled with coffee are closed again by a membrane, as well as an outlet unit 60, in which the capsules are suitably selected and then sent to a packaging apparatus (not shown).

[0146] In the embodiment described herein, an auxiliary unit 11 is also provided between the inlet unit 10 and the filter forming unit 20, which is provided to deposit respective protection discs at the bottom of the empty capsules 2.

[0147] The capsules 2 are formed by a rigid casing, with a truncated conical shape, comprising a bottom from which a flared lateral wall extends towards a mouth opposite to the bottom. The bottom has a smaller cross-section than the mouth and, overall, the capsules have a diameter of between 20 and 60 mm and a height of between 15 and 60 mm.

[0148] Each of the units 10, 11, 20, 30, 40, 50, 60 listed above represents a respective operating unit of the production apparatus 1, and each of them is arranged to carry out one or more specific processing operations on the capsules 2 or components thereof.

[0149] The apparatus 1 operates continuously, so that the capsules 2 within the different operating units are subjected to the respective processing while being transported by a transporter member, which may be of the conveyor or carousel type, and are then transferred between successive operating units by means of transfer devices.

[0150] Advantageously, each article 2 is always retained, moved and processed individually, so that at any given time the position of an article 2 within the production apparatus 1 is always uniquely determined by the position of an operating unit or transfer device.

[0151] In other words, this means, for example, that in the production apparatus 1 there are no operating units in which processing operations are carried out on a random number of articles and that there are no random groupings or transfers of articles from one operating unit to another.

[0152] Therefore, all operating units are also synchronised with each other in order to enable the correct processing of the articles.

[0153] The inlet unit 10 comprises a singling device 12 which provides for extracting the single capsules from a pair of nested stacks of capsules and depositing them on a conveyor belt 13 where, during their path, they are provided, if envisaged by the process, with a protection disc deposited on their bottom at the auxiliary unit 11.

[0154] The empty capsules 2, possibly provided with a protection disc, are then transferred in a continuous row to the filter forming unit 20, where a filter is formed and positioned inside each empty capsule 2 thanks to the provision of special moving members 21 mounted on a rotating carousel 22.

[0155] The filter formed by the filter forming unit 20 is similar in shape to the capsule 2 into which it is inserted, except for its height. In particular, the filter has a truncated conical shape, comprising a substantially horizontal and smooth bottom, from which a flared lateral wall extends towards a mouth opposite to the bottom. The lateral wall is entirely pleated, with regular folds extending longitudinally from the mouth up to the bottom.

[0156] The capsules 2 and the relative filters are then transferred by an exchange wheel 23 to the coupling unit 30, where, on another rotating carousel 31 equipped with positioning and welding moving members 32, the filters are correctly positioned and welded inside the capsules 2. Specifically, the filter is welded at the upper crown of its lateral wall to the corresponding lateral wall of the capsule, near the respective mouth.

[0157] The capsules 2 provided with a filter are then removed from an exchange wheel 33 by means of special gripping elements 34, of the pincer type, and transferred to the filling unit 40, where they are filled with coffee powder thanks to special moving members 41 equipped with delivery devices, continuously transported on a rotating carousel 42.

[0158] After a series of further exchange wheels, the capsules 2 are brought to the closing unit 50 where they are closed with a lid at special welding moving members 51 arranged uniformly on a rotating carousel 52.

[0159] Downstream of the closure unit 50, the capsules 2, filled and duly closed, are transferred to the outlet unit 60, where the capsules 2 are marked, sampled and sorted before being transferred to the packaging apparatus.

[0160] Along the production apparatus 1 there are also provided several detection systems which are provided to acquire information regarding the capsules 2 or the components thereof which are useful to verify the quality of the processing carried out in one or more of the immediately preceding operating units.

[0161] In particular, each detection system is provided to control one or more characteristics of the articles or the components in order to verify their conformity with predetermined quality parameters.

[0162] Of course, the characteristics to be controlled depend on the specific processes carried out in the upstream operating units and can be very diverse, depending on the processes, articles and quality parameters to be met.

[0163] By way of example, in the production apparatus 1 there is provided a first detection system 35 between the coupling unit 30 and the filling unit 40, a second detection system 45 downstream of the filling unit 40 and a third detection system 55 positioned at the closing unit 50.

[0164] In particular, the first detection system 35 is provided to acquire the information necessary to verify both the integrity of the filter and its correct coupling inside the capsule 2, the second detection system 45 is provided to acquire the information necessary to verify the correct filling of the capsule with the coffee powder and the third detection system 55 is provided to acquire the information necessary to verify the correct positioning of the lid on a welding moving member 51 before welding it onto the respective capsule.

[0165] These detection systems are chosen according to the characteristic to be controlled and may therefore be based on different operating principles. For example, the first and third detection system 35 and 55 are of the optical type and are based on an analysis of images captured by special cameras, while the second detection system 45 can be of the gravimetric or microwave type.

[0166] The production apparatus 1 also comprises a control unit 100, which is provided to control the entire production process as well as each single operating unit and, of course, the associated detection systems.

[0167] First of all, a process index is defined in control unit 100 by the cyclic succession of all the different operating configurations assumed by the operating units as successive articles enter the production process. Each configuration assumed by the different operating units when a new article enters the process forms a step in the process index.

[0168] Since all operating units operate in synchrony with each other and there is no intermediate accumulation of articles, each article entering an operating unit corresponds to one article leaving the same operating unit and one article entering the next operating unit.

[0169] Furthermore, since each operating unit comprises one or more moving members that carry out the planned operations in a cyclic manner (thanks to the fact that they operate on a rotary carousel), each operating unit has the same configuration (i.e. the same arrangement of moving members) after a defined number of operations (corresponding to one complete turn of the carousel).

[0170] Therefore, it is always possible to identify a process cycle number, represented by the lowest common multiple between the moving member numbers of the single operating units, after which all the operating units re-present the same configuration (having each performed one or more complete cycles).

[0171] In other words, the configuration of all operating units of the production apparatus 1 will be the same for every number of process index steps equal to the aforesaid process cycle number.

[0172] In addition, each process index step can in turn be further subdivided into a number of sub-steps required for a more precise control of processings or events that take place in smaller time intervals than the process index step. For example, each process index step can be further subdivided into 360 sub-steps. The subsequent sub-steps and, consequently, each step of the process index is marked by an encoder.

[0173] In addition, a scroll register is defined in the operating unit 100, where all events and information deemed significant relating to each article from the entry thereof into the apparatus 1 until the exit the from the apparatus 1 are recorded.

[0174] Starting from these assumptions, to each new capsule 2 entering the production apparatus 1, for example when removed from the singling unit 12, the control unit 100 assigns a step number of the process index, which will uniquely define its path within the production apparatus 1 and, in particular, by which moving member of each operating unit it will be processed.

[0175] In the event that the singling unit 12 removes more than one capsule at the same time, an order of numerical succession will be established according to the position of the removed articles.

[0176] In the following, in order to describe the present invention in detail, specific reference will be made to the first detection system 35 interposed between the coupling unit 30, which thus represents a generic first operating unit of the production apparatus 1, and the filling unit 40, which thus represents a generic second operating unit of the production apparatus 1. Accordingly, the rotary carousel 31 thus represents a generic first transport member, the positioning and welding moving members 32 represent a generic plurality of first moving members, while the rotary carousel 42 represents a generic second transport member and the moving members 41 represent a generic plurality of second moving members.

[0177] It is understood that what is stated with respect to the first detection system 35 and the respective coupling units 30 and filling units 40 will, however, be similarly reproducible in the other detection systems mentioned above.

[0178] As better visible in FIG. 2, the detection system 35 is positioned at the exchange wheel 33, which is interposed between the coupling unit 30 and the filling unit 40, and comprises four cameras 36 capable of acquiring one or more images of the capsules 2 being transferred between the two operating units.

[0179] The cameras 36 of the detection system 35 are arranged coplanar to the vertices of a square and, in particular, are mounted on a support plate 37, which is horizontal and has a large central hole through which the cameras are pointed.

[0180] The cameras 36 are placed at a height of about 150 mm from the mouth of the capsules 2 and are tilted downwards in such a way that their optical axis is inclined by about 55° to 60° with respect to the horizontal plane.

[0181] An annular-shaped lighting device 38 is also positioned at the hole of the plate 37, facing downwards and synchronised with the cameras 36 to illuminate the capsule 2 and the filter inside it from above with diffuse light.

[0182] The cameras 36 are pointed in a fixed manner towards a point on the path of the exchange wheel 33, where the capsules 2 pass continuously.

[0183] In particular, the cameras 36 are oriented so as to capture images of the bottom and the pleated lateral wall of the filter, with special attention to the welding area between the filter and the capsule, which together form the surface to be controlled by the optical control system.

[0184] Advantageously, the optical axis of the cameras 36 is pointed towards the lateral wall of the filter, at a median height between the mouth and the bottom. The cameras 36 have a suitable focal distance, for example 16 mm, which allows them to frame the capsule 2 and the filter coupled thereto from above with a framing of about 70 mm×50 mm.

[0185] Within this frame, a central region is defined, substantially corresponding to a region proximal to the optical axis, in which the focus can be considered optimal, and a peripheral region, in which the image is slightly blurred.

[0186] Thanks to the characteristics of the cameras 36 and their specific arrangement, the central region of each camera 36 covers a lateral wall sector of the filter developed over an angle of about 90°, centred on the respective optical axis.

[0187] In this way, the entire lateral wall of the filter, which due to pleating is more difficult to analyse precisely, is part of a central region of a camera 36. In addition, a large part of the lateral wall is also part of a peripheral region of a camera 36.

[0188] As for the bottom of the filter, in turn, it may be part of a central region of an image of a camera 36, or, for example its most central portion, may be part of the peripheral region of several cameras 36, preferably all four cameras 36.

[0189] The images captured by the cameras 36 are immediately analysed by the control unit 100, by means of a special algorithm, in order to verify the integrity of the filter, its correct shaping, its correct positioning inside the capsule, and the correct coupling between filter and capsule.

[0190] This analysis is carried out in real time (a few tens of milliseconds) and makes it possible to identify the conformity of these characteristics with the required quality parameters.

[0191] On the basis of this analysis, a first group of capsules that meet these quality parameters and a second group of capsules that do not meet these quality parameters are identified.

[0192] In particular, all capsules 2 of the second group are uniquely identified by recording this non-conformity on the slide register at their specific process index step number.

[0193] The capsules 2 of both the first and second groups are carried by the exchange wheel 33 to the subsequent operating unit, namely the filling unit 40, where each capsule is picked up by a respective moving member 41.

[0194] However, the moving members 41 taking over a capsule 2 belonging to the second group, i.e. a capsule identified as non-conforming, are substantially disabled, so that they are moved along the filling unit 40 without, however, being filled with coffee powder.

[0195] Similarly, all capsules 2, both those identified at the first detection system 35 as conforming and those identified as non-conforming, are fed to the closure unit 50.

[0196] The capsules 2 identified as non-conforming, however, even though they are received by the respective welding moving members 51 and moved by the rotating carousel 52 are not closed by a corresponding lid, saving both the lid and the corresponding welding operation.

[0197] Downstream of the closure unit 50, the capsules 2 are then transferred to the outlet unit 60.

[0198] Here, as is better visible in FIG. 3, the capsules 2 are transported by a conveyor 61 to a marking station 62, where certain data relating to the product, such as the batch number, the expiry date, and other data relating to the production process, including, in particular, the step number of the process index associated with each single capsule, are printed by laser.

[0199] In this way, it is possible to precisely identify the moving members that have carried out each individual processing on each individual capsule 2, even when the capsules have already left the production apparatus 1, for example during packaging, packing steps or even later when they are placed on the market.

[0200] The outlet unit 60 further comprises a sampling station 63, wherein some capsules 2 are picked up for possible statistical quality sampling and, finally, a discard station 64, wherein the capsules 2 of the first group (i.e. the capsules found to be conforming as a result of the analysis derived from each detection system) are separated from the capsules 2 of the second group (i.e. the capsules found to be non-conforming as a result of the analysis derived from at least one detection system).

[0201] In particular, the discard station 64 comprises an exchange wheel 65 which selectively picks up the capsules 2 of the first group to take them to a transport device 66 intended for the packaging apparatus, leaving instead on the conveyor 61 the capsules 2 of the second group intended to fall into a waste collection container (not illustrated) provided at the end of the conveyor 61.

[0202] All the actions of enabling and disabling the moving members of the various operating units up to the final selection of the exchange wheel 65 of the discard station 64 are easily managed by the control unit 100 thanks to the recording of any non-conformities on the scroll register as well as the provision of the process index and the unique association of each step with each capsule that enters and is processed in the production apparatus 1.

[0203] The control unit 100 also manages in a substantially similar manner the quality controls carried out on the capsules 2 by the second detection system 45 and the third detection system 55.

[0204] In particular, the second detection system 45 verifies, downstream of the filling unit 40, that the quantity of coffee powder fed into each capsule 2 is in accordance with the required weight values.

[0205] If, as a result of this control, a capsule 2 is found with non-conforming values, 20 this capsule is also identified as belonging to the second group and its non-conformity is recorded in the slide register.

[0206] In this case, however, it is envisaged that the welding moving member 51 taking charge of a capsule 2 identified as non-conforming following the analysis resulting from the second detection system 45 will only be partially disabled.

[0207] In particular, it is envisaged that such a capsule will still be closed by a lid, even if it is not completely sealed or only partially sealed.

[0208] This prevents the coffee powder in the capsule from being dispersed into the environment and at least ensures that the capsule remains closed at least until the capsules discarded from the production process are disposed of.

[0209] Similarly, the capsules 2 that are found to be non-conforming following analysis by the third detection system 55 which verifies, by means of optical analysis, the correct positioning of the capsule and lid before welding them, are treated. Also in this case, in fact, it is envisaged that the sealing moving member 51 intended to operate the sealing operation of the lid and of the capsule 2 identified as non-conforming is only partially disabled, so as to still close the capsule, already filled with coffee powder, with a lid only partially sealed or with a minimum level of sealing.

[0210] Should statistical sampling of the capsules 2 picked up at sampling station 62 show any additional non-conforming capsules, all moving members which processed these additional capsules would be easily identified by the process index step number printed on them.

[0211] All step numbers of the capsules identified as non-conforming as a result of statistical sampling or as a result of controls carried out during the process are also advantageously recorded and statistically verified, so as to identify any anomalies attributable to some specific moving member of an operating unit and to allow any targeted interventions.

[0212] Thanks to the features of the present invention, it is therefore possible to manage the production process of articles efficiently, guaranteeing the highest standards of quality control of the articles during their production without, however, placing limits on the production capacity and without increasing the costs and space requirements of the production apparatus.

[0213] 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.