PILL DEVICE APPARATUS, SYSTEM AND METHODS FOR INTRUSION DETECTION
20210169741 ยท 2021-06-10
Inventors
- Grant Cook (Geneva, IL, US)
- Thomas Kohlert (St. Charles, IL, US)
- Scott Nicholson (South Elgin, IL, US)
Cpc classification
B67C3/2628
PERFORMING OPERATIONS; TRANSPORTING
B67C2003/2657
PERFORMING OPERATIONS; TRANSPORTING
A61J7/0436
HUMAN NECESSITIES
B67C3/262
PERFORMING OPERATIONS; TRANSPORTING
International classification
A61J7/00
HUMAN NECESSITIES
A61J7/04
HUMAN NECESSITIES
Abstract
The present disclosure is directed to a vent tube apparatus, system and methods incorporating a ball cage with a modified pill device design comprising a traceable material such as a Radio Frequency Identification (RFID) tag for use in conjunction with a filling machine during container filling operations for a quicker and more accurate detection of the location of the pill device to the extent it becomes detached from the ball cage during filling operations, and to increase the safety of the filling operation and reduce costs and time when a malfunction occurs.
Claims
1. A vent tube and ball cage apparatus for use in filling a container during a filling process in which the ball cage is attached to the vent tube, and the vent tube is attached to a filling machine, comprising: a vent tube body, said vent tube body being hollow and comprising a vent tube opening, said vent tube body configured to be attached to a filling machine and configured to vent a gas from the container during the filling process; a ball cage, said ball cage comprising an opening, said ball cage attached to said vent tube body at said vent tube opening; a pill device, said pill device having an oblong shape and having a bottom portion that is spherical, said pill device configured to be located inside said ball cage opening, said pill device further comprising a top portion, and a cylinder portion, said cylinder portion providing said oblong shape of said pill device; and an indicator, said indicator being housed in said pill device, such that if said pill device is removed from said filling machine, said pill device can be detected using an indicator detection system.
2. The vent tube and ball cage apparatus in claim 1, wherein said top portion comprises a beveled edge.
3. The vent tube and ball cage apparatus in claim 1, wherein said top portion comprises a flat bottom.
4. The vent tube and ball cage apparatus in claim 1, wherein said top portion comprises a spherical end.
5. The vent tube and ball cage apparatus in claim 1, wherein said indicator is a Radio Frequency Identification tag.
6. The vent tube and ball cage apparatus in claim 1, wherein said indicator detection system is a Radio Frequency Identification reader.
7. The vent tube and ball cage apparatus in claim 1, wherein said housed in said pill device means enclosed during an injection molded process.
8. The vent tube and ball cage apparatus in claim 1, wherein said housed in said pill device means attached during a machining process.
9. The vent tube and ball cage apparatus in claim 1, wherein said pill device is prevented from rotating in more than one axis due to said oblong shape.
10. The vent tube and ball cage apparatus in claim 1, wherein said indicator is a magnet.
11. A pill device for use with a vent tube and ball cage apparatus for filling a container in a filling machine in which the vent tube is configured to vent a gas from the container during a filling process, comprising: a top portion, a cylinder portion and a bottom portion, said pill device configured such that said cylinder portion creates an oblong shape; said pill device configured to be located in a ball cage opening in said ball cage, such that said ball cage prevents said pill device from rotating in more than one axis due to said oblong shape; said bottom portion configured in a spherical shape; an indicator, said indicator being housed in said pill device, such that if said pill device is removed from said ball cage opening, said removal from said ball cage opening can be detected using an indicator detector.
12. The pill device in claim 11, wherein said top portion comprises a beveled edge.
13. The pill device in claim 11, wherein said top portion comprises a flat bottom.
14. The pill device in claim 11, wherein said top portion comprises a spherical end.
15. The pill device in claim 11, wherein said indicator is a Radio Frequency Identification tag.
16. The pill device in claim 11, wherein said indicator detector is a Radio Frequency Identification reader.
17. The pill device in claim 11, wherein said housed in said pill device housing means enclosed during an injection molded process.
18. The pill device in claim 11, wherein said housed in said pill device housing means attached during a machining process.
19. The pill device in claim 11, wherein said indicator is a magnet.
Description
DRAWINGS
[0047] The preferred embodiments of the disclosure will be described in conjunction with the appended drawings provided to illustrate and not to the limit the disclosure, where like designations denote like elements, and in which:
[0048]
[0049]
[0050]
[0051]
[0052]
[0053]
[0054]
[0055]
[0056]
[0057]
[0058]
DETAILED DESCRIPTION
[0059] As described herein, product, such as cola or beer, is transferred from the production, brewing or fabrication stage to the packaging stage to be individually packaged for sale. This transfer process is known as the fill or filling process and utilizes automatic high-speed filling equipment to fill and seal thousands of containers each minute. Often, these automatic filling machines are of the rotary filler type, which may vary in size from 40, 60, 72, 100, 120 or 180 fill valves and vent tubes per machine, allowing for the filling of thousands of containers each minute that the machine is in use.
[0060]
[0061] For glass containers 14, the vent tube 12 is usually made of stainless steel, but can be made of a food grade plastic, stainless steel hybrid. For aluminum containers, the vent tube 12 is usually made of a food grade plastic material. In a vent tube ball cage, a food grade plastic ball is used to start and stop the flow of gas.
[0062] Due to the high speeds where thousands and tens of thousands of containers are filled each minute, and due to the constant use of these filling machines 10, occasionally a vent tube 12 or other device used in the filling process, may detach from the filling machine 10 and fall into the product container 14. If and when this event occurs, there are a few primitive systems in place to locate the vent tube 12 and halt the filling process before thousands of additional containers are filled, making it more difficult to locate the container 14 with the broken vent tube 12 (or other device).
[0063]
[0064] In accordance with the present disclosure, the vent tube (or other devices as shown in
[0065]
[0066] As described herein and in the preferred embodiment, the vent tube 16 incorporates an RFID tag 18 for detection when the vent tube detaches from the filling machine 10. The vent tube 16 can be manufactured from material that will be determined by the standards of the food and beverage industry for each application. The RFID tag 18 can be attached to, or housed or enclosed in, the vent tube 16 through a machining or injection molding process as understood by one having ordinary skill in the art, such that in the preferred embodiment the RFID tag 18 is attached to, or housed or enclosed in, the vent tube head 24.
[0067] The vent tube may also incorporate a magnet 22 for additional detection purposes. In some instances, the vent tube only uses a magnet 22 and not the RFID tag 18. In accordance with the present disclosure, an RFID tag or other traceable material 18 can be placed on any type of vent tube used in the filling process, including vent tube ball cages. Similar to the RFID tag above, the magnet 22 can be attached to the vent tube 16 in the same manner. The present disclosure can utilize the RFID tag 18 alone or in conjunction with the magnet 22.
[0068] RFID systems have several components, such as chips, tags, readers and antennas, which can be used to determine the location of an RFID tag (and any item that the tag is attached to) from a distance away. In its simplest form, a small silicon chip is attached to a small flexible antenna to create a tag. The chip is used to record and store information and when a tag is to be read, the RFID reader or scanner send out a radio signal. The tag absorbs some of the RF energy from the reader signal and reflects it back as a return signal delivering information from the tag's memory.
[0069] The RFID tags 18 do not require a battery, as the power is supplied by the identification gate as understood by one having ordinary skill in the art. Any type of RFID tag 18 can be used in the present disclosure, Ultra-High Frequency (UHF), High Frequency (HF), and Low Frequency (LF), each providing its own advantages and disadvantages. The higher the frequency, the longer the range for detection; while the lower the frequency, the less power that is needed for the tag to operate. Ranges of 20 to 30 feet are obtainable for the UHF RFID tags, while the HF and LF RFID tags operate at approximate distances of 1 meter and 1 foot, respectively.
[0070] As an example, UHF tags operate within the 800 and 900 MHz band and provide a response from a range of 20-30 ft. RFID tags operating in the UHF range can transfer data much faster than RFID tags operating in the HF and LF bands. However, UHF RFID tags require more power than those operating at the HF and LF bands, and are suited more for applications when sensing through low-density materials.
[0071] RFID tags operating in the HF range primarily operate at 13.56 MHz. These tags require a read distance typically of about 1 meter, and work well when sensing through metal and liquids. RFID tags operating in the LF band have an operating frequency of 125 kHz and work well sensing through product or materials with a high concentration of water. These LF tags must be read with equipment within about a one-foot range. However, these LF RFID tags require the least amount of power of the three RFID tags described herein.
[0072] RFID readers or scanners are generally composed of a computer and a radio. The computer manages communications with the network or through the Programmable Logic Controller (PLC). The radio controls communication with the RFID tag, typically using a language dictated by a published protocol, such as the EPC Class 1 specification.
[0073] When the vent tube 16, or other devices, of the present disclosure, containing the RFID tag 18, is used in the filling process, an inspection system, such as an RFID reader, can be incorporated into the filling line or in numerous other locations to continuously check for vent tubes 16 that have detached from the filling machine 10. As soon as a vent tube 16 containing an RFID tag 18 detaches from the filling machine 10, the RFID reader determines that the vent tube 16 is no longer in the correct location and can be used to find the container 14 in which the vent tube 16 is located. This entire inspection and determination procedure takes seconds and can be incorporated into the filling system to immediately shut down the filling process as understood by one having ordinary skill in the art before many more containers are filled.
[0074] In an embodiment, the system and methods of the present disclosure comprise incorporating or housing an RFID tag or transponder in a stainless steel vent tube, for use in glass bottle filling for example, and a plastic vent tube, for use in aluminum can filling for example. The vent tube may also incorporate a magnet along with the RFID transponder. Using an additional traceable material, such as a magnet, increases the detection of the vent tube in certain situations such as when the vent tube falls into an aluminum can and is sealed attenuating the signal.
[0075] The embodiment of the system 40 and method is shown in
[0076] The second point of detection 46 takes place on the line after the container 14 has been seamed or sealed. This section 46 of the system 40 utilizes magnetic and inductive sensor technologies to detect the imbedded magnet 22 in the vent tube 16 (or the stainless steel vent tube). This section 46 of the system 40 provides an output to the operator that can be used in an auto reject system or at the operator's discretion.
[0077] The third point of detection utilizes a handheld RFID reader 48. After the first 42 or second 46 detection process has identified a vent tube detachment, the operator can now scan the specific can or bottle with the handheld scanner 48 in order to verify the location of the detached vent tube 16.
[0078] The present disclosure does not have to incorporate each of these detection points, and the system can use one or any combination of these detection points to detect and locate a malfunctioning vent tube or a vent tube that has broken off the filling machine.
[0079] The first point of detection, the RFID reader 42, which incorporates an antenna, can be integrated (i.e., through an RFID hardware and/or software integrator) into a local network at the filling site, or it can be connected through a global communications network, such as the Internet, to a remote site as understood by one having ordinary skill in the art. As such, the information received by the reader 42 at the antenna can be transmitted to a number of locations for informational purposes such as record keeping.
[0080] Further, the second 46 and third 48 points can also be integrated into the system as a whole. Additionally, the system is not limited to three detection points, as the system is scalable and additional detection points can be added for other filling lines and for other scanning purposes, such as to make sure that none of the filled containers being loaded onto a truck have a broken vent tube located inside.
[0081] Also, each of the detection points can utilize one or more of the detection methodologies. So for example, the first point of detection 42 may only read RFID tags, while the handheld scanner 48 may be configured to scan for both RFID tags and the magnet.
[0082] Other embodiments for determining a malfunction in the filling process 10, such as a vent tube 16 detaching from a filling machine 10 and falling into a container 14 include determining the temperature variant in the bottle as the temperature will change quickly when a vent tube 16 falls into the container 14 filled with product. This embodiment employs measuring the temperature variant in the bottle 14 to detect if a vent tube 16 is present. In a similar manner, determining the change in bottle 14 capacitance, whereby the system measures the capacitance and/or change in capacitance in the bottle 14, can be used to detect an inadvertent vent tube 16. In this embodiment, a charge is applied to the bottle 14 and the system measures charge or discharge time.
[0083] Another embodiment for detecting a detached vent tube 16 include utilizing an inductive sensor, where a ferrous material 22 is injection molded inside or into the vent tube 16, or a Hall Effect sensor, where a magnet 22 is injected molded inside or into a vent tube 16. Additional sensors can be used to detect a modified vent tube 16 using Ultra Sonic, Infrasonic or Infrared sensors, or with the use of vision sensors.
[0084]
[0085] The vent tube cap 50 can be attached to existing vent tubes in order to retrofit the vent tube to become traceable in accordance with the monitoring system described herein. The vent tube cap 50 can be configured with screw threads, a slot or slots, a snap-in configuration, or some other manner, as understood by one having ordinary skill in the art, to be attached to the existing non-traceable vent tube. Other configuration, as described in the prior art references disclosed above, can be incorporated to allow the vent tube cap 50 to be attached to the existing vent tube.
[0086] As detailed above, the scanning system 40 and/or method can then be incorporated to check for malfunctions in the filling process, and to determine in which container a malfunctioning vent tube containing a traceable vent tube cap 50 has inadvertently fallen into the filled bottle, for example. By using the traceable vent tube cap 50 with an existing non-traceable vent tube, the retrofit vent tube can now be tracked by the scanning system 40.
[0087]
[0088]
[0089] Because the captured polypropylene ball 70 is spherical, it can move or rotate around in the vent tube 64. To the extent that the ball 70 can move on the z-axis, it will function properly. To the extent that the ball rotates and makes continuous contact with the insides 76 of the vent tube ball cage 66, the ball 70 may become deformed or reduced in size over time, which will lead to the ball falling out of or detach from the vent tube ball cage 66, creating the problems described herein.
[0090]
[0091] The pill device 78 has a top portion 80 and a bottom portion 82. The top portion 80 is designed with a top end 84 having a diameter larger than the vent tube opening, such that when the pill device 78 moves up the z-axis to the top of the ball cage 74, the pill device 78 will likewise block the vent tube opening thereby preventing gases from leaking into the vent tube 64.
[0092]
[0093] In the example, the top portion 80 comprises the top end 84 and a cylinder portion 88, which lies below the top end 84. It is the cylinder portion 88, which is configured to keep the pill device 78 from rotating in an unwanted direction during the filling process. In the preferred embodiment, the top end 84 has a diameter of 0.385 inches, and the cylinder portion 88 has a cylinder height of 0.06 inches, although other sizes and configurations can be incorporated to keep the RFID tag properly oriented for reading functionality. The top portion 80 and the cylinder portion 88 can be two separate pieces or integrated as a single piece. Likewise, the entire pill device can be molded as a single piece, including the encapsulation of the RFID tag 86.
[0094]
[0095] Similar to the pill device 78, the flat bottom pill device 90 has a top portion 92 and a bottom portion 94. The top portion 92 is designed with a top end 96 having a beveled and/or flat portion 98. The bottom portion 94 is oval, curved or spherical with a radius that is larger than the vent tube opening (not shown), such that when the flat bottom pill device 90 moves up the z-axis to the top of the ball cage 74, the bottom portion 94 of the flat bottom pill device 90 will likewise block the vent tube opening, thereby preventing gases from leaking into the vent tube 64. In an exemplary embodiment, the flat bottom pill device 90 has a diameter of 0.385 inches, with the bottom portion 94 being 0.192 inches high and having a radius of 0.193. The cylinder portion 88 is 0.134 inches high, and the beveled or flat bottom portion 96 is 0.059 inches high with a beveled edge 98 at 30 degrees, and a bottom edge diameter of 0.317 inches.
[0096] Similar to the pill device 78, the flat bottom pill device 90 comprises an RFID tag 86 that is located between the top portion 92 and the bottom portion 94. In the exemplary embodiment, the RFID tag 86 of the flat bottom pill device 90 is 0.060 inches high. The location of the RFID tag 86 in between the top portion 92 and the bottom portion 94, and keeps the RFID tag 86 in a consistent and predetermined plane related to the direction of travel (for example, along the z-axis) of the flat bottom pill device 90 inside the ball cage 66 and attached to the vent tube 64. In doing so, the antenna of the reader 42 will be able to determine if the flat bottom pill device 90 is still located in the vent tube ball cage 66.
[0097] In the design of the exemplary flat bottom pill device 90, the top portion 92 comprises the top end 96 and the cylinder portion 88, which lies at the bottom of the top end 96. It is the cylinder portion 88 that is configured to keep the flat bottom pill device 90 from rotating in an unwanted direction inside the ball cage 66 during the filling process.
[0098] In the exemplary embodiment of the flat bottom pill device design 90, the top end 96 of the top portion 92 has a diameter of 0.385 inches at its wide end (the same diameter as the flat bottom pill device design), and 0.317 inches at its narrow end, and a top end height from top of the top portion to the bottom of the top portion of 0.059 inches. This configuration creates a 30 degree beveled edge 98, although other beveled edge configurations will suffice.
[0099] The top end 96 and the cylinder portion 88 can be two separate pieces or integrated as a single piece. The bottom portion 94 and the RFID tag 86 can also be two separate pieces or integrated as a single piece. Likewise, the entire flat bottom pill device (or any of the individual portions) can be molded as a single piece, including the encapsulation of the RFID tag 86. Other sizes and configurations can be incorporated for these designs and measurements to keep the RFID tag or other indicator properly oriented for reading functionality during the fill process.
[0100]
[0101] The vent tube 100 further comprises a vent tube body 108, a steam resistant O-ring 110, a hex adaptor 112 and a threaded washer 114. Other parts can be incorporated into the vent tube 100 as necessary, and the ball cage 102 can be designed longer than a standard ball cage to provide enough room to allow the flat bottom pill device 90 (or the other devices described herein) to move properly in the ball cage 102. Additionally, the lower portion of the ball cage 102, where the bottom 96 of the flat bottom pill device 90 rests against it, can be designed or configured to more closely adapt to the beveled edge 98 of the flat bottom pill device 90. In use, the ball cage is threaded onto the vent tube body 108 after the O-ring 110 has been properly located. The threaded washer is likewise threaded onto the end opposite the ball cage 102 to the proper location. Now the vent tube 100 with the flat bottom pill device 90 can be attached to the filling machine.
[0102] When in use, the spherical end 94 of the flat bottom pill device 90 is designed with a diameter larger than the vent tube opening 116, such that when the flat bottom pill device 90 moves up the z-axis to the top of the ball cage 102, the pill device 90 will block the vent tube opening thereby preventing gases from leaking into the vent tube 100.
[0103] It will be understood that the embodiments of the present disclosure, which have been described, are illustrative of some of the applications of the principles of the present disclosure. Although numerous embodiments of this disclosure have been described above with a certain degree of particularity, those skilled in the art could alter the disclosed embodiments without departing from the spirit or scope of this disclosure.
[0104] All directional references (e.g., upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of the disclosed system and methods.
[0105] Additionally, joinder references (e.g., attached, coupled, connected, and the like) are to be construed broadly and may include intermediate members between a connection of elements and relative movement between elements. As such, joinder references do not necessarily infer that two elements are directly connected and in fixed relation to each other. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure may be made without departing from the spirit of the disclosed apparatus, system and methods as disclosed herein.