APPARATUS AND METHOD FOR FORMING PLASTIC PREFORMS INTO PLASTIC CONTAINERS WITH CHANGEOVER ROBOT

Abstract

Apparatus for forming plastic preforms into plastic containers has a transport device having a rotatable transport carrier on which a large number of forming stations are arranged. The forming stations each have blow molding devices, within which the plastic preforms can be formed into the plastic containers by applying a flowable medium, and the forming stations each have application devices for applying the flowable medium to the plastic preforms. The apparatus has a clean room within which the plastic preforms are expanded to form the plastic containers, and such clean room is delimited from a non-sterile environment by at least one wall. The apparatus also has an exchange device for exchanging blow molding devices.

Claims

1. An apparatus for forming plastic preforms into plastic containers, having a transport device, configured to transport the plastic preforms to be formed along a predefined transport path, wherein the transport device has a rotatable transport carrier on which a large number of forming stations are arranged, wherein such forming stations each have blow molding devices, within which the plastic preforms can be formed into the plastic containers by applying a flowable medium, and the forming stations each have application devices for applying the flowable medium to the plastic preforms, wherein the apparatus has a clean room within which the plastic preforms are expanded to form the plastic containers, and such clean room is delimited from a non-sterile environment by at least one wall, wherein the apparatus has an exchange device configured for exchanging blow molding devices and such exchange device is arranged outside the clean room.

2. The apparatus according to claim 1, wherein the apparatus has at least one actuating device configured for carrying out a exchange process of blow molding devices of the forming station and such actuating device is selected from a group of actuating devices comprising actuating devices configured for opening and closing blow mold carriers, actuating devices configured for releasing and activating a fastening device for releasing and fastening blow molding parts to blow mold carrier parts, actuating devices configured for centering the rotatable transport carrier, actuating devices configured for unlocking and locking blow mold carriers, actuating devices configured for tensioning and relaxing application devices, and actuating devices configured for opening and/or closing the clean room.

3. The apparatus according to claim 2, wherein at least one of the actuating devices is arranged outside the clean room.

4. The apparatus according to claim 1, wherein the apparatus has a magazine device configured for storing blow molding devices.

5. The apparatus according to claim 1, wherein the apparatus has an enclosure configured for enclosing the exchange device and such enclosure is divided into at least two regions.

6. The apparatus according to claim 5, wherein the two regions are separated from one another.

7. The apparatus according to claim 5, wherein the exchange device is arranged in one region and a magazine device configured for storing exchangeable parts is arranged in the other region.

8. The apparatus according to claim 1, wherein the apparatus has an openable interface, via which the exchange device can carry out exchange processes.

9. The apparatus according to claim 8, wherein the apparatus has an actuating device configured for opening the interface, wherein the interface can be opened manually or automatically or by the exchange device itself.

10. The apparatus according to claim 8, wherein the interface has a separating element configured to separate the clean room from the environment, wherein such separating element extends in a plane that is oblique with respect to a vertical direction.

11. The apparatus according to claim 1, wherein the apparatus has a detection device configured to detect an intervention of a user in predetermined regions of an enclosure for enclosing the exchange device, and a control device, which controls the exchange device taking into account a value detected by such detection device, is provided.

12. A method for operating an apparatus for forming plastic preforms into plastic containers, wherein, in a working operation of the apparatus, a transport device transports the plastic preforms to be formed along a predefined transport path, wherein the transport device has a rotatable transport carrier, on which a large number of forming stations is arranged, wherein such forming stations each have blow molding devices, within which the plastic preforms are formed into the plastic containers by applying a flowable medium, and the forming stations each have application devices that apply the flowable medium to the plastic preforms, wherein the apparatus has a clean room within which the plastic preforms are expanded to form the plastic containers, and such clean room is delimited from a non-sterile environment by means of at least one wall, wherein an exchange device exchanges and/or replaces blow molding devices in an exchange operation, wherein the exchange device is arranged outside the clean room.

13. The method according to claim 12, wherein the exchange device carries out a test run to check the occupancy state of a magazine device.

14. The method according to claim 12, further comprising carrying out a check as to whether a protective device in which the exchange device is located has been opened and/or carrying out a check as to whether a user has entered a region in which a magazine device for storing the blow molding devices is located.

15. The method according to claim 14, further comprising as a function of the check as to whether a protective device in which the exchange device is located has been opened and/or whether a user has entered a region in which a magazine device for storing the blow molding devices is located, a decision is made as to whether a test run is to be carried out.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0064] Further advantages and embodiments result from the accompanying drawings. These show:

[0065] FIG. 1 a schematic illustration of an apparatus according to the invention;

[0066] FIG. 2 an illustration of the apparatus with an exchange device;

[0067] FIG. 3 a top view of the apparatus shown in FIG. 2;

[0068] FIG. 4 an illustration with an open interface;

[0069] FIG. 5 a further view with an open interface;

[0070] FIG. 6 an illustration of an actuating device of the apparatus;

[0071] FIG. 7 an illustration of the actuating device shown in FIG. 6;

[0072] FIG. 8 an illustration of a further actuating device; and

[0073] FIG. 9 an illustration for the exchange of application devices.

DETAILED DESCRIPTION OF THE DRAWINGS

[0074] FIG. 1 shows an apparatus 1 for forming plastic preforms 10 into plastic containers 15. Such apparatus has a rotatable carrier 22 on which a large number of forming stations 4 is arranged. Such individual forming stations each have blow molds 82 that form a cavity inside them for expanding the plastic preforms.

[0075] Reference sign 84 denotes an application device, which is used to expand the plastic preforms 10. This can be a blow nozzle, for example, which can be applied to a mouth of the plastic preforms in order to expand the latter. Reference sign 90 denotes a valve arrangement, such as a valve block, which preferably has a large number of valves that control the application of different pressure levels to the plastic preforms.

[0076] In a preferred method, first a preblow pressure P1, subsequently at least one intermediate blow pressure Pi that is higher than the preblow pressure, and finally a final blow pressure P2 that is higher than the at least one intermediate blow pressure Pi are applied to the plastic preforms. After expansion of the plastic containers, the pressures or compressed air are preferably returned from the container to the individual pressure reservoirs.

[0077] Reference sign 88 denotes a stretching bar used to stretch the plastic preforms in their longitudinal direction. Preferably, all forming stations have such blow molds 82 along with stretching bars 88. Preferably, the number of such forming stations 4 is between 2 and 100, preferably between 4 and 60, more preferably between 6 and 40.

[0078] The plastic preforms 10 are fed to the apparatus via a first transport device 62, such as, in particular but not exclusively, a transport star. The plastic containers 15 are transported away via a second transport device 64.

[0079] Reference sign 7 denotes a pressure supply device, such as a compressor or also a compressed-air connection. The compressed air is conveyed via a connecting line 72 to a rotary distributor 74, which gives it via a further line 76 to the reservoir 2a, which in this case is an annular channel. Thus, preferably, such rotary distributor serves the purpose of feeding air from a stationary part of the apparatus into a rotating part of the apparatus.

[0080] In addition to such annular channel 2a shown, further annular channels are preferably provided, which are, however, concealed by, e.g., lie underneath, the annular channel 2a in the illustration shown in FIG. 1. Reference sign 98 denotes a connecting line that delivers the compressed air to a forming station 4 or the valve block 90 thereof. Preferably, each of the annular channels is connected to all forming stations via corresponding connecting lines. Such connecting line is preferably arranged in the rotating part of the apparatus.

[0081] Reference sign 8 schematically denotes a clean room, which is preferably annular here and surrounds the transport path of the plastic preforms 10. Preferably, a (geometric) axis of rotation with respect to which the transport carrier 22 is rotatable is arranged outside the clean room 8. Preferably, the clean room is sealed from the non-sterile environment by a sealing device, which preferably has at least two surge tanks.

[0082] FIG. 2 shows a side view of an apparatus according to the invention. Reference sign 12 refers to an exchange device, in particular an exchange robot (however, the use of a manipulator would also be conceivable), which is used to exchange, for example, blow molding devices or the like. Reference sign 8a denotes a wall, which at the same time forms a boundary of the clean room. Reference sign 14 denotes an interface via which, for example, the exchange of blow molding devices can be carried out. Such interface is, in particular, a releasable opening through which the exchange device can exchange exchangeable parts, such as blow molding devices.

[0083] Reference sign 30 denotes in its entirety an enclosure, which in particular also serves to enclose the exchange device 12. This enclosure has a wall (possibly in the form of a grid) and also a door 36 that can be opened. Such enclosure serves in particular to protect the operating personnel but also, conversely, to protect the exchange device 12.

[0084] A magazine device 32, in which, for example, blow molding devices but also other exchange parts can be deposited, is preferably provided inside the enclosure. Reference sign 34 denotes a carrier on which the enclosure 30 and preferably also the magazine device 32 and the exchange device 12 are arranged.

[0085] FIG. 3 shows a top view of the apparatus shown in FIG. 2. Here as well, the exchange device 12 and the magazine device 32 can be seen. The exchange device 12 can remove blow molding parts from the magazine device 32 and exchange them. Reference sign 14 in turn denotes the interface via which exchanges of blow molded parts, for example, are possible. Reference sign 12a denotes a gripping device of the exchange device. This gripping device 12a can be suitable and intended for gripping blow molding devices, for example.

[0086] Preferably, such gripping device is designed to be exchangeable and can, for example, be exchanged for other gripping devices (for example, for gripping application devices, such as blow nozzles).

[0087] When carrying out an exchange process, the interface 14 is initially opened, which can take place, for example, by opening an isolator window. This opening can take place manually, automatically or by the changeover device 12. This is followed by an exchange of exchangeable parts, such as the blow molding devices. In a further method step, the isolator window is closed again and the clean room is thus also closed. Finally, sterilization of the interior of the isolator or clean room preferably takes place.

[0088] Preferably, the apparatus described herein is capable of being operated in a working operation, or production operation, and in an exchange operation. Preferably, such operating modes are mutually exclusive and/or cannot be carried out simultaneously.

[0089] As shown in FIGS. 2 and 3, the exchange device 12, or the robot, is located outside the clean room, or not in the aseptic region. In this manner, it is possible that the exchange device 12 itself does not have to be sterile.

[0090] Reference sign 50 in FIG. 3 refers to a sterilization device, which is used to sterilize the plastic preforms.

[0091] In a preferred design, whether or not the door 36 of the enclosure 30 has been opened can be recognized. If the door has not been opened, it is possible that the exchange device will not carry out a further test run, since it has been ensured that no exchangeable parts have been removed from the enclosure by the user, for example. Such design is possible for the aseptic forming device described here and for non-aseptic applications. In this manner, it would also be preferably possible for maintenance work to be carried out in the front region A (see FIG. 3), for example, but not in the region of the magazine device B. In this case as well, it can be specified that no further test run of the robot device or exchange device 12 is carried out.

[0092] Between the region A and the region B, a detection device can be provided, such as a large number of light barriers and/or a light barrier curtain (not shown), by means of which it is possible to check whether a user has passed from the region A into the region B.

[0093] FIG. 4 shows a further illustration of the apparatus according to the invention. A door, or sliding door 38, is shown here. Next to it, the forming station 4, which is arranged within the clean room 8, can be seen. In addition, the station carrier 22, or the transport carrier 22, can also be seen. Reference sign 52 denotes a valve arrangement, or valve terminal, which is used to control pressures. This can preferably be arranged below the individual forming stations.

[0094] FIG. 5 shows a further view of an apparatus according to the invention. The actuating unit 54 for locking the mold carriers can also be seen here. It is preferably arranged partially outside the clean room and partially inside the clean room. Reference sign 18 refers to a centering unit along with the mold carrier actuator.

[0095] With reference to FIGS. 6 and 7, the actuating device 54 for locking the mold carriers is explained.

[0096] Particularly preferably, the actuating device 18 for locking (in particular a locking mechanism of the blow mold carriers) is arranged directly on a base plate 56 of the clean room. As can be seen from FIG. 7, such actuating device 18 has a double-acting cylinder device that is intended to open and close the locking flap of the mold carrier, in particular by means of a lever arrangement 184.

[0097] In particular, the double cylinder arrangement 182 is a pneumatic cylinder. Reference signs 182a and 182b indicate query positions for the cylinder device. In the position 182a, the cylinder device is retracted, and in the position 182b, the cylinder device is extended. Preferably, the apparatus therefore comprises a position determining device that detects a position of the cylinder device 182.

[0098] Reference sign 186 denotes a transmission element and reference sign 188 denotes a transmission rod via which rotational movements can be transmitted to a lever element 190. In this manner, the cylinder device can open or close a lock on the blow molding parts. Reference sign 192 denotes a cam follower that rolls relative to a guide cam (not shown) during working operation, in order to guide the blow mold carriers into a locked or unlocked state.

[0099] For the purpose of exchanging the blow mold, such locking mechanism can be actuated by the actuating device 18.

[0100] FIG. 8 shows a further actuating device 17 for opening and closing for the blow mold carriers and preferably also for centering. Preferably, a mold carrier actuator 176 is provided, along with a centering part 162 that is used to center the forming stations. Preferably, such actuating device 17 is also mounted on a base frame of the apparatus. Preferably, the actuating device 17 is arranged in such a manner that it can be subsequently mounted or dismounted, in particular without removing a forming station.

[0101] Preferably, the actuating device 17 has a rest position when a mold carrier cam is extended. In this manner, it is ensured that no collisions occur with a running machine or a machine in working operation.

[0102] As mentioned, reference signs 176 refer to pneumatic cylinders for controlling the centering block 175. Reference signs 163 refer to control cylinders for the mold carriers.

[0103] In the position shown with reference sign 166, the pneumatic cylinder for the centering block is retracted, and in the situation shown with reference sign 164, the cylinder for the centering block is extended.

[0104] In the situation marked with reference sign 174, the cylinder for the mold carrier is retracted, and in the situation marked with reference sign 168, the cylinder for the mold carrier is fully extended and thus in a rest position. In the position marked with reference sign 172, the cylinder is extended such that a mold exchange is possible.

[0105] Finally, FIG. 9 shows the actuating device for the blow nozzle 82 or, in a preferred design, a pneumatic spring, in particular in the form of a pneumatic cylinder 165, is used instead of a mechanical spring. Such pneumatic cylinder can actively actuate and/or advance the blow nozzle 82. The pneumatic cylinder is used in particular to clamp the blow nozzle in the direction of the plastic preform so that the blow nozzle does not lift off. Furthermore, a query device that detects a position of the roller 167 can be provided. For example, a central query of such roller position can be used by a proximity initiator, for example.

[0106] The applicant reserves the right to claim all features disclosed in the application documents as essential to the invention, provided that they are novel over the prior art individually or in combination. It is also pointed out that features which can be advantageous in themselves are also described in the individual figures. The person skilled in the art will immediately recognize that a particular feature described in a figure can be advantageous even without the adoption of further features from this figure. Furthermore, the person skilled in the art will recognize that advantages can also result from a combination of several features shown in individual or in different figures.