Apparatus and method for filling capsules

Abstract

An apparatus for filling capsules comprises a conveyor wheel, on the circumference of which a plurality of capsule holders is provided a conveyor wheel drive that alternately passes through stopping times and movement times, so that the capsule holders move along the conveying path in cycles, and a plurality of process stations disposed along the conveying path. The process stations comprise at least one supply station for supplying capsules to be filled to the conveyor wheel, at least one opening station for opening the capsules by separating the upper and lower capsule parts, at least one filling station for filling the lower capsule parts, at least one closing station for closing the filled capsules by connecting the upper and lower capsule parts, and at least one discharge station for discharging the filled capsules. A method for filling capsules is also described.

Claims

1. An apparatus for filling capsules having a respective upper capsule part and a respective lower capsule part, the apparatus comprising: a conveyor wheel, on a circumference of which a plurality of capsule holders is provided, wherein each capsule holder has a plurality of capsule receptacles for one capsule each; a conveyor wheel drive with which the conveyor wheel is rotatable to alternately pass through stopping times and movement times, so that the plurality of capsule holders move along a conveying path in cycles; and a plurality of process stations disposed along the conveying path, wherein the plurality of process stations comprise at least one supply station for supplying capsules to be filled to the capsule receptacles, at least one opening station for opening the capsules to be filled by separating the upper capsule parts from the lower capsule parts, at least one filling station for filling the lower capsule parts with material, at least one closing station for closing the filled capsules by connecting the upper capsule parts with the lower capsule parts, and at least one discharge station for discharging the filled capsules; wherein: a process station of the plurality of process stations has a process drive that is controlled independently of the conveyor wheel drive, wherein the process drive and the conveyor wheel drive move during cycled conveying of the plurality of capsule holders; and a controller device is configured for controlling the conveyor wheel drive for variable adjustment of associated conveying cycles by variably adjusting a ratio between the stopping times and the movement times of the conveyor wheel, and for controlling at least one of a drive speed or a stroke path of the process station having the process drive independently of the conveyor wheel drive, such that: during a first cycle along the conveying path through the plurality of process stations, the controller device controls the conveyor wheel according to a first stopping time and a first movement time and controls the process station according to a first drive speed and a first stroke path; and during a second cycle along the conveying path through the plurality of process stations, the controller device controls the conveyor wheel according to at least one of a second stopping time different from the first stopping time or a second movement time different from the first movement time, and controls the process station according to at least one of a second drive speed different from the first drive speed or a second stroke path different from the first stroke path.

2. The apparatus according to claim 1, wherein each of the plurality of process stations has a respective process drive, and wherein the controller device is configured for controlling the conveyor wheel drive for variable adjustment of the ratio between the stopping times and the movement times of the conveyor wheel, and for controlling at least one of the drive speed or the stroke path of each of the plurality of process stations independently of the conveyor wheel drive.

3. The apparatus according to claim 1, wherein the conveyor wheel drive is a servo drive comprising a servomotor that drives the conveyor wheel in rotation via a gear mechanism.

4. The apparatus according to claim 1, wherein the conveyor wheel drive is a torque drive.

5. The apparatus according to claim 1, wherein the process drive of the process station is a drive from a group of servo drives, direct drives, and linear drives.

6. The apparatus according to claim 1, wherein the at least one discharge station separates good capsules from bad capsules.

7. The apparatus according to claim 1, wherein the controller device is configured for, responsive to a change in production parameters relating to filling the capsules, at least one of changing the ratio between the stopping times and the movement times of the conveyor wheel and changing at least one of the drive speed or the stroke path of the process station having the process drive.

8. The apparatus according to claim 1, further comprising: multiple sets of production parameters relating to filling the capsules stored in the controller device, and wherein the controller device, after selection of a set of production parameters, at least one of sets the ratio between the stopping times and the movement times of the conveyor wheel and sets at least one of the drive speed or the stroke path of the process station having the process drive.

9. The apparatus according to claim 8, wherein the set of production parameters includes the material to be filled into the capsules.

10. A method for filling capsules including a respective upper capsule part and a respective lower capsule part, in which a conveyor wheel, on a circumference of which a plurality of capsule holders is provided, wherein each capsule holder has a plurality of capsule receptacles for one capsule each, is rotated in cycles, wherein the conveyor wheel alternately passes through stopping times and movement times, so that the plurality of capsule holders move in cycles along a plurality of process stations disposed along a conveying path, wherein the plurality of process stations comprise at least one supply station for supplying capsules to be filled to the capsule receptacles, at least one opening station for opening the capsules to be filled by separating the upper capsule parts from the lower capsule parts, at least one filling station for filling the lower capsule parts with material, at least one closing station for closing the filled capsules by connecting the upper capsule parts with the lower capsule parts, and at least one discharge station for discharging the filled capsules, the method comprising: responsive to a change in production parameters relating to filling the capsules, variably adjusting associated conveying cycles by changing a ratio between the stopping times and the movement times of the conveyor wheel using a conveyor wheel drive such that: during a first cycle along the conveying path through the plurality of process stations, the conveyor wheel moves according to a first stopping time and a first movement time, and during a second cycle along the conveying path through the plurality of process stations, the conveyor wheel moves according to at least one of a second stopping time different from the first stopping time or a second movement time different from the first movement time; and changing at least one of a drive speed or a stroke path of a process station of the plurality of process stations having a process drive independent of the conveyor wheel drive, such that: during the first cycle, the process station moves according to a first drive speed and a first stroke path; and during the second cycle, the process station moves according to at least one of a second drive speed different from the first drive speed or a second stroke path different from the first stroke path, wherein the process drive and the conveyor wheel drive move during cycled conveying of the plurality of capsule holders.

11. The method according to claim 10, wherein the change in production parameters comprises a change in the material to be filled into the capsules.

12. The method according to claim 10, wherein multiple sets of production parameters relating to filling the capsules are stored in a controller device, the method further comprising: after selection of a set of production parameters from the multiple sets of production parameters, using the controller device to at least one of set the ratio between the stopping times and the movement times of the conveyor wheel and set at least one of the drive speed or the stroke path of the process station of the plurality of process stations having the process drive according to the set of production parameters.

13. The method according to claim 10, further comprising: controlling the drive speed of the process station independent of the conveyor wheel drive.

14. The apparatus according to claim 1, wherein the controller device is configured for controlling the drive speed of the process station having the process drive independently of the conveyor wheel drive.

15. An apparatus for filling capsules having a respective upper capsule part and a respective lower capsule part, the apparatus comprising: a conveyor wheel, on a circumference of which a plurality of capsule holders is provided, wherein each capsule holder has a plurality of capsule receptacles for one capsule each and the conveyor wheel is rotatable to alternately pass through stopping times and movement times, so that the plurality of capsule holders move along a conveying path in cycles; and a plurality of process stations disposed along the conveying path, wherein the plurality of process stations comprise at least one supply station for supplying capsules to be filled to the capsule receptacles, at least one opening station for opening the capsules to be filled by separating the upper capsule parts from the lower capsule parts, at least one filling station for filling the lower capsule parts with material, at least one closing station for closing the filled capsules by connecting the upper capsule parts with the lower capsule parts, and at least one discharge station for discharging the filled capsules; wherein: a process station of the plurality of process stations is controlled independently of the conveyor wheel; the process station and the conveyor wheel are independently controlled during cycled conveying of the plurality of capsule holders; the conveyor wheel is controlled for variable adjustment of associated conveying cycles by variably adjusting a ratio between the stopping times and the movement times such that: during a first cycle along the conveying path through the plurality of process stations, the conveyor wheel moves according to a first stopping time and a first movement time; and during a second cycle along the conveying path through the plurality of process stations, the conveyor wheel moves according to at least one of a second stopping time different from the first stopping time or a second movement time different from the first movement time; and at least one of a drive speed and or a stroke path of a process station of the plurality of process stations is controlled independently of controlling the conveyor wheel, such that: during the first cycle, the process station moves according to a first drive speed and a first stroke path; and during the second cycle, the process station moves according to at least one of a second drive speed different from the first drive speed or a second stroke path different from the first stroke path.

16. The apparatus according to claim 15, wherein the stroke path of each of the plurality of process stations is controlled.

17. The apparatus according to claim 15, wherein the at least one discharge station separates good capsules from bad capsules.

18. The apparatus according to claim 15, further comprising: production parameters related to filling the capsules, wherein the at least one of the conveyor wheel is controlled for variable adjustment of the ratio between the stopping times and the movement times, and the drive speed and the stroke path of the process station of the plurality of process stations is controlled independently of controlling the conveyor wheel, responsive to a change in the production parameters.

19. The apparatus according to claim 15, further comprising: multiple sets of production parameters relating to filling the capsules, wherein at least one of the ratio between the stopping times and the movement times of the conveyor wheel, a drive speed of the process station of the plurality of process stations, and the drive speed and the stroke path of the process station of the plurality of process stations is set in accordance with selection of a set of production parameters of the multiple sets of production parameters.

20. The apparatus according to claim 19, wherein the set of production parameters includes identification of the material for filling the capsules.

21. The apparatus according to claim 15, wherein the drive speed of the process station is controlled independent of the conveyor wheel.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) One exemplary embodiment of the invention will be explained in greater detail below with reference to figures wherein:

(2) FIG. 1 is a schematic top view of an apparatus for filling capsules composed of an upper capsule part and a lower capsule part;

(3) FIG. 2 is an illustration of a production cycle in an apparatus for filling capsules composed of an upper capsule part and a lower capsule part;

(4) FIG. 3 is an explanation of a method according to the invention, with reference to a further illustration of a production cycle in an apparatus for filling capsules composed of an upper capsule part and a lower capsule part; and

(5) FIG. 4 is a further illustration of a production cycle in an apparatus for filling capsules composed of an upper capsule part and a lower capsule part.

(6) Unless otherwise indicated, the same reference symbols in the figures refer to the same object.

DETAILED DESCRIPTION

(7) The apparatus according to an embodiment of the invention shown in FIG. 1 comprises a conveyor wheel 20, structured as a circular turntable in the example shown. A plurality of capsule holders 22 is disposed along the circumference of the conveyor wheel 20 and held by the conveyor wheel 20. The capsule holders 22 each possess two rows of capsule receptacles for one capsule each. By means of a conveyor wheel drive 24, not shown in greater detail, the conveyor wheel 20 is rotated in cycles. For example, a torque drive may rotate the conveyor wheel 20 clockwise as illustrated in FIG. 1 by the arrow. In this connection, the capsule holders 22 are moved in cycles along a conveying path through different process stations, as is basically known.

(8) The process stations are numbered with the numbers 01 to 12 in FIG. 1, and are shown only in part. The stations 01 and 02 are supply stations, in which pre-closed capsules 26 to be filled are passed to the first or second row of the capsule receptacles. The station 03 is an opening station, in which the capsules to be filled are opened by separating the upper capsule parts 26a from the lower capsule parts 26b. In this case, the station 04 is an unused station. However, it is also possible that the opening station is formed by the process station 04, and the process station 03 is an unused station. The process stations 05, 06 and 07 can be filling stations, in which the lower capsule parts 26b are filled with the material to be filled in. This is shown as an example by the filling wheel 28 in FIG. 1. It is also possible that one or two of the process stations 05, 06 and 07 is/are unused stations. The process station 08 can be an unused station, or capsules not opened in the opening station can be discharged in the process station 08. In the process stations 05, 06, 07 and 08, along with the capsule holders 22 that carry the lower capsule parts 26b in the open state of the capsules 26, capsule holders 30 for holding the upper capsule parts 26a are shown. Capsule holders 30 are disposed further radially inwardly than capsule holders 22. The process station 09 is a closing station, in which the filled capsules are closed by connecting the upper capsule parts 26a with the lower capsule parts 26b. The process stations 10 and 11 are each discharge stations. For example, bad capsules can be discharged in the process station 10, and good capsules can be discharged in the process station 11. The distinction is made using one or more testing devices. The process station 12 can be an unused station or, for example, a cleaning station in which the capsule holders 22 are cleaned to remove any product residues that might be present.

(9) According to embodiments of the invention, each of the process stations has at least one separate drive 32. Furthermore, a controller device 34 is provided, via which at least the drive speed and the displacement path of the drives of the process stations can be controlled independently of the conveyor wheel drive.

(10) Variants of the controller according to the invention will be explained with reference to FIGS. 2 to 4. A production cycle over time for a capsule to be filled is shown in FIG. 2. The white fields each show holding times, during which the conveyor wheel 20 stands still and the process stations are driven to perform their respective activities. The black fields each show indexing times, during which the conveyor wheel 20 is rotated further in order to move the capsule holders 22 from one process station to the next process station. In FIG. 2, the holding times and indexing times are shown as examples for the following process steps: supplying and opening (Supply/Opening), filling the capsules (Filling), closing the capsules (Closing), and discharging the capsules (Discharge). The indexing times are indicated by t.sub.T, while the holding time for filling the capsule, for example, is indicated by t.sub.F. In conventional apparatuses, the holding and indexing times are set in a fixed manner once for a process, and then are always the same in terms of their ratio.

(11) With reference to the filling process, it is shown in FIG. 3 how the uncoupling of the holding and indexing times according to the invention can shorten the production time. In the Fixed transmission correlation section, the fixed ratio between filling time t.sub.F and indexing time t.sub.T illustrated in FIG. 2 is shown. In the Variable transmission correlation area, it is shown how a shortened indexing time t.sub.T* for further transport from the filling station to the closing station is set while the filling time t.sub.F remains the same. This can take place, for example, due to a change in the product to be filled in. Using this example, a time savings in filling results, which is indicated by .sub.Filling in FIG. 3. Analogously, of course, it would also be possible to change the filling time t.sub.F as a function of the respective production parameters, for example to even lengthen it independently of the indexing time.

(12) FIG. 4 shows the uncoupling of the indexing and holding times as an example of a further variant of the invention. Once again, the production cycle shown in FIG. 2 is shown in the Fixed transmission correlation section. In the Variable transmission correlation section, the indexing time between the process stations has been changed in a suitable manner, in particular shortened, with the holding times for the individual process stations remaining the same. As a result, a time savings in the production cycle results, which is shown by .sub.Total in FIG. 4.