LEAK DETECTOR AND PACKAGE INTEGRITY TESTING MECHANISM AND TESTING METHOD FOR VACUUM-SEALED PACKAGES

Abstract

A seal testing apparatus for testing the integrity of a seal in the packaging of vacuum packed product and a method of testing seal integrity. The apparatus includes a mechanical gripper that grips a portion of the packaging and is urged away from the packaging. A sensor monitors the movement of the gripper relative to the vacuum packed product and an evaluator compares the sensed movement of the gripper with an acceptable profile and accepts or rejects the product based on the comparison.

Claims

1. A seal testing apparatus for testing the integrity of the seal in the packaging of a vacuum packed product, comprising: a mechanical gripper for gripping a portion of the packaging; a first actuator that urges the gripper away from the packaging; a sensor for monitoring the movement of the gripper relative to the vacuum packed product; and an evaluator that compares the sensed movement of the gripper with an acceptable profile and accepts or rejects the product based on the comparison.

2. A seal testing apparatus as claimed in claim 1 wherein the mechanical gripper is a clamp adapted to close and grip each side of a flap extending from the main body of the packaging.

3. A seal testing apparatus as claimed in claim 2 wherein the clamp has at least one moving portion which is driven by a second actuator.

4. A seal testing apparatus as claimed in claim 3 wherein the second actuator is a pneumatic cylinder with linear travel.

5. A seal testing apparatus as claimed in any one of claims 1 to 4 wherein the first actuator is a linear actuator.

6. A seal testing apparatus as claimed in any one of claims 1 to 5 wherein the first actuator is a pneumatic cylinder.

7. A seal testing apparatus as claimed in any one of claims 1 to 6 wherein the sensing means is an actuator position sensor or mounted position transmitter.

8. A seal testing apparatus as claimed in claim 7 wherein the sensing means is a linear variable differential transformer (LVDT) or similar inductive device.

9. A seal testing apparatus as claimed in any one of claims 1 to 8 wherein the seal testing apparatus further has a frame on which the vacuum-packed product rests in use, and the gripper is mounted on a sub-frame pivotally connected to the frame, the first actuator acting on the sub-frame to urge the gripper away from the frame.

10. A seal testing apparatus as claimed in any one of claims 1 to 9 wherein the seal testing apparatus further has a gusset manipulator, comprising at least one finger which is inserted into the gusset fold area to manipulate a gusset in the packaging associated with the flap.

11. A seal testing apparatus as claimed in claim 10 wherein the gusset manipulator is a pair of fingers that pivot into and out of engagement with the gusset fold, each of the fingers having a hook portion on the inner end which is inserted into the side of the gusset fold as the fingers engage.

12. A seal testing apparatus as claimed in claim 10 or claim 11 wherein the fingers are mounted on the sub-frame via vertically-aligned pivot points and are connected via intermeshing gear segments, a third linear actuator connecting between the frame and one of the gear segments to rotate the gear segment and move the fingers into engagement when activated.

13. A seal testing apparatus as claimed in any one of claims 10 to 12 wherein the gusset manipulator is moveably connected to the sub-frame via a fourth linear actuator which pushes the gusset manipulator away from the frame when activated.

14. A seal testing machine as claimed in any one of claims 9 to 13 wherein an endless linear belt is mounted on the frame, the package resting on and transported by the belt in operation.

15. A seal testing machine as claimed in claim 14 wherein the belt transports the package from one side of the frame to the other, past the sub-frame and gusset manipulator.

16. A seal testing machine as claimed in claim 15 further having a sensor which automatically detects when the package is aligned with the sub-frame and gusset manipulator, the evaluator controlling movement of the belt and stopping the belt when the package is correctly aligned.

17. A seal testing machine as claimed in any one of claims 1 to 16 wherein the evaluator receives input from the sensing means and assesses seal integrity by comparing actual displacement over time to a predefined acceptable profile of displacement and time.

18. A seal testing machine as claimed in claim 17 wherein the acceptable profile consists of an absolute displacement.

19. A seal testing machine as claimed in claim 17 wherein the acceptable profile consists of displacement over a time interval.

20. A seal testing machine as claimed in any one of the preceding claims including a suction testing mechanism including a suction cup that may be advanced to grip a portion of the packaging with reluctance to withdrawal of the suction cup being detected to provide a measure of seal integrity.

21. A method of testing seal integrity in the packaging of a vacuum packed product comprising the steps of: mechanically gripping a portion of the packaging; applying a force in a direction away from the packaging; monitoring the movement of the gripped portion relative to the vacuum packed product; comparing the monitored movement with an acceptable profile; and accepting or rejecting the product based on the comparison.

22. A method of testing seal integrity as claimed in claim 21 wherein in the step of comparing the monitored movement with an acceptable profile actual displacement over time is compared to a predefined acceptable profile of displacement and time.

23. A method of testing seal integrity as claimed in claim 21 or claim 22 wherein in the step of comparing the monitored movement with an acceptable profile the acceptable profile consists of an absolute displacement.

24. A method of testing seal integrity as claimed in claim 21 or claim 22 wherein in the step of comparing the monitored movement with an acceptable profile the acceptable profile consists of displacement over a time interval.

25. A method of testing seal integrity as claimed in any one of claims 21 to 24 wherein after a predetermined time the mechanical grip is released and the displacement assessed.

26. A method of testing seal integrity as claimed in any one of claims 21 to 25 wherein in the step of mechanically gripping a portion of the packaging a flap or seal is gripped.

26. A method of testing seal integrity as claimed in claim 25 wherein in the step of mechanically gripping a portion of the packaging mechanical fingers are inserted into the gusset fold area to manipulate a gusset in the packaging associated with the flap.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0052] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0053] FIG. 1a shows a perspective view of an embodiment of the seal testing apparatus of the present invention;

[0054] FIG. 1b shows a plan view of the embodiment of the seal testing apparatus of the present invention shown in FIG. 1a;

[0055] FIG. 1c shows a view from the entry end of the embodiment of the seal testing apparatus of the present invention shown in FIG. 1a and FIG. 1b;

[0056] FIG. 1d shows a side view of the embodiment of the seal testing apparatus of the present invention shown in FIGS. 1a, 1b, and 1c;

[0057] FIG. 2 shows a perspective view of the seal testing apparatus of the present invention shown in FIGS. 1a-d mounted to a frame with a protective enclosure around the testing station;

[0058] FIG. 3a shows a plan view of a gusset manipulation station that forms part of the seal testing apparatus of the present invention;

[0059] FIG. 3b shows a cross-sectional view along line A-A in FIG. 3a; and

[0060] FIG. 3c shows a vacuum packed package of cheese with a flap/seal at one end.

DETAILED DESCRIPTION OF THE INVENTION

[0061] The preferred embodiments of the invention are described below. The preferred embodiments are described in relation to testing the seal integrity for a generally cuboidal block of cheese weighing 20 kilograms, vacuum-packed in film packaging, the cuboidal block several times wider and longer than it is high. However, the invention may also be applied to any other suitable vacuum-packed items of different sizes with the same or similar configurationfor example a bag of ground coffee or coffee beans which also has a sealed flapand the description should not be taken as limiting. Also, the preferred embodiment is described in relation to a vacuum-packed item where the item is sealed within a bag formed from film packaging which has a single open end, sealed during the packaging process and with a seal/flap extending from one side or end. The invention could be used with other forms of vacuum-packaging, or other configurations of packaging, for example where the seal or flap is at the top of the packete.g. as in a bag of ground coffee or coffee beans. If the seal flap is at the top of the bag, the testing would be carried out either with the bag lying on its side, or a modification of the preferred embodiment as described below would be used in order to test for a package with an upwardly-oriented flap.

[0062] A leak detector 1 is shown in the figures. FIG. 2 shows the leak detector 1 mounted to a support frame 2 with a protective housing 22 covering the testing station including a human machine interface 24. The other figures show the detail of the testing mechanisms. The leak detector 1 has a frame 2 which in use rests on a surface (a warehouse floor or similar) to hold the remainder of the apparatus away from the ground. The frame 2 also holds various parts of the remainder of the testing apparatus in position. The leak detector 1 has a central conveyor 3 which in the preferred embodiment is of the linear endless belt type, aligned horizontally to convey items from one (open) end or side of the leak detector 1 to the other, opposite (open) side. As shown in the figures, the conveyor 3 can be formed from a number of smaller sub-belts in parallel or a single wide belt.

[0063] A sub-frame 4 is pivotally connected to the frame 2 to one side of the conveyor 3. The sub-frame 4 is connected to the frame 2 via a hinge 5 located below the level of the central conveyor 3, the sub-frame 4 extending upwards above and to the side of the conveyor 3. A first actuator 6 is mounted on a second sub-frame (not shown) above the conveyor 3. The actuator 6 is, in the preferred embodiment, a pneumatic cylinder with linear travel. However, the actuator 6 could be a hydraulic cylinder, or any other suitable type of actuator: linear, rotary or otherwise. The active or moving end of the first pneumatic cylinder 6 is connected to the sub-frame 4. The body of the first cylinder 6 is connected and held rigidly in relation to the conveyor 3, via the second sub-frame. As the cylinder 6 activates, it pushes the sub-frame 4 so that the sub-frame 4 rotates outwards around the pivot point of the hinge 5 away from the conveyor 3.

Mechanical Gripper and Gusset/Flap Manipulation Station

[0064] A gusset manipulation station 10 is connected to the sub-frame 4, the station is connected so that it is just above and to the side of the surface of the conveyor 3. The gusset manipulation station 10 has a number of interlocking and moving elements which are activated by actuating cylinders as described below.

[0065] A fixed anvil 8 is connected to the sub-frame 4. The fixed anvil 8 has a horizontal upwards-facing anvil striking surface. A second linear actuatorflap clamp cylinder 7is connected to the sub-frame 4 between the body of the sub-frame 4 and the conveyor 3, above the fixed anvil 8. The preferred embodiment of flap clamp cylinder 7 is a pneumatic cylinder, with a moving piston that has a clamp anvil 9 on the lower end, the clamp anvil 9 having a downwards-facing anvil surface complimentary to and aligned with the upwardly-facing surface of the fixed anvil 8. When the flap clamp cylinder 7 activates, the downwards-facing anvil surface of the clamp anvil 9 is moved downwards to contact and press against the upwardly-facing surface of the anvil 8. These items form a mechanical gripper for a package, either by themselves or in combination with other items as described below. In the preferred embodiment, the position of the fixed anvil 8 is vertically adjustable, and most preferably horizontally adjustable also (towards and away from the conveyor 3). The position of the flap clamp cylinder 7 and in particular the clamp anvil 9 is adjustable in a complimentary manner, either by adjustment of the position of the flap clamp cylinder 7 in it's entirety, or by adjusting the stroke length to suit, so that contact is made at all positions between the flap clamp cylinder 7 and the clamp anvil 9. The linear pneumatic flap clamp cylinder 7 could be replaced by any suitable clamping mechanismfor example by a jaw rotating towards the anvil, or a pair of jaws rotating together towards one another, or clamping elements which screw towards one another.

[0066] A pair of mechanical fingers 11a, 11 b are located one on each side of the gusset manipulation station 10. Each finger 11 is formed from an elongate member extending towards the conveyor 3, the two fingers 11a, 11 b angled away from one another (that is, if the lines of the main portion of the bodies of the fingers were extended to convergence, this would occur at a point further away from the conveyor). The outer end (away from the conveyor) of each finger 11a and 11b is connected to a pivoting element 12a and 12b that pivots around a substantially vertical axis so that the fingers 11a and 11b rotate in a substantially horizontal plane. The inner ends of the fingers 11a and 11b are angled inwards to form hook portions 13a and 13b. In the preferred embodiment, the pivoting elements 12a and 12b are a pair of meshed, interlocking gear sections or arcs connected to the sub-frame 4, the interlocking portions located between the vertical rotation axes. A third linear actuator 14 is connected between a fixed point on the sub-frame 4, and a point on the perimeter of one of the pivoting elements 12a and 12b (i.e. at a distance from the vertical rotation axis of that pivoting element, and between the rotation axes). The third linear actuator 14 is aligned to activate horizontally away from the conveyor 3 (in the preferred embodiment, substantially perpendicular to the conveyor 3). As the third linear actuator 14 activates, it causes the connected one of the pivoting elements 12 to rotate around the vertical rotation axis, which causes the other pivot element to also rotate in the opposite direction due to the meshed gearing. This causes the fingers 11 to rotate inwards, or towards one another. The fingers 11 and the hook portions 13 are shaped and sized so that the inner ends arc towards one another and nearly contact each other just to the side and above the edge of the conveyor 3. In the preferred embodiment, the third linear actuator is a pneumatic cylinder. As before, this could alternatively be a hydraulic cylinder, a rotary screw, or a similar actuating mechanism. The fingers and their associated elements form another part of the mechanical gripper formed by flap clamp cylinder 7, clamp anvil 9 and anvil 8.

[0067] In the preferred embodiment, the gusset manipulation station 10 is mounted to the sub-frame 4 in such a manner that it can move relative to the sub-frame 4, substantially horizontally towards and away from the sub-frame 4 and conveyor 3.

Operation

[0068] Operation of the apparatus will now be described with reference to the structural elements described above, and further structural description as necessary.

[0069] A single specimen of the product to be testedi.e. a 20 kg block of vacuum packed cheese 16 in the preferred embodiment (or other similar vacuum packed product) is guided onto the belt of the central conveyor 3 at one end, and moves with the belt along and through the leak detector 1 to a point determined by a photo cell (not shown) mounted either on the frame 2, or an equally appropriate position. Another similar type of sensor could be used instead of the photo cell (for example a weight sensor placed under the belt at the appropriate position, which activates when the cheese or other product is above the sensor. The bagged cheese 16 is placed on the belt so that the flap/seal 17 extends generally horizontally out to one side of the conveyor, on the same side as the sub-frame 2. As the preferred embodiment of the apparatus will be used to test multiple specimens of identical size and packaging, the vertical position of the flap/seal is known, as each individual product item is substantially identical to the others. This allows an initial setup/location of items such as the position of the clamp anvil 9 and the fixed anvil 8. The block of cheese 16 travels along the conveyor 3 until the photo cell detects that the bagged cheese 16 is positioned and/or aligned opposite the gusset manipulation station 10. Linear actuator 23 may then push the bagged cheese 16 towards the gusset manipulation station 10 until the flap 17 is between the clamp anvil 9 and the fixed anvil 8. Linear actuator 23 may extend a predetermined distance each time for packages of consistent dimensions or a further sensor may be employed to detect that the flap 17 is correctly located between the anvils.

[0070] The first linear actuatorthe flap clamp pneumatic cylinder 7is then activated to push the clamp anvil 9 downwards and clamp the flap 17 between the clamp anvil 9 and the fixed anvil 8.

[0071] The second linear actuatorthe bag flap stressing pneumatic cylinder 6further has an associated sensing means (not shown). Once the flap 17 is clamped, the bag flap stressing cylinder 6 is then activated to apply a force to the sub-frame 4 and rotate this around the pivot point of the hinge 5 and away from the block of cheese. As the flap 17 is gripped between the clamp anvil 9 and the fixed anvil 8 it will pull away from and to the side of the block of cheese 16. The sensing means will start to measure the displacement of the sub-frame 4, which is indicative of a leak in the plastic packaging. In the preferred embodiment, the sensing means is an actuator position sensor or mounted position transmitter, most preferably a linear variable differential transformer (LVDT) or similar inductive device. The product movement is limited towards sub-frame 4 by a fence fitted to the frame of the testing unit and providing a measurement reference for the displacement of the gripped flap. For lighter products a clamp or holding system can be added to the apparatus to secure it in place during the testing sequence.

[0072] At the same time as the bag flap stressing cylinder 6 is activated, the third linear actuator 14 is activated. This causes the two mechanical fingers 11a, 11 b to rotate inwards towards one another. The hook portions 13a, 13b on the ends of the fingers 11a, 11 b will be inserted into the folded gussets on each side of the flap 17 of the plastic bag. This action is independent of the action of the bag flap stressing cylinder 6 and the flap clamp cylinder 7.

[0073] Once the fingers 11a, 11b are in position, the third linear actuatorpneumatic cylinder 14 continues to extend to apply an outwards force to push the fingers 11a and 11b away from the conveyor 3. This causes the hook portions to snag into and manipulate the gusset, and in particular the inside of the plastic gusset seal weld, and a pulling force is applied away from the block of cheese 16. This action will indicate any weakness in the heat sealed area, which will translate to further measurable movement in bag flap stressing cylinder 6 if a leak is present.

[0074] The preferred embodiment of the present invention includes an evaluator or evaluating means which receives signals relating to the sensed movement, and uses these to evaluate whether there is a leak or not. In the preferred embodiment, the leak evaluation is conducted using the sensed amount of movement from bag flap stressing cylinder 6. The amount of movement is compared with an acceptable or predefined profile, which is held in the memory of the evaluator. The results of this evaluation tags the product acceptable, or to be rejected.

[0075] An additional suction testing method may also be employed. A linear actuator in the form of pneumatic ram 25 may lower suction cup 26 down onto the top surface of the block of cheese 16. Suction may then be applied to the suction cup 26 and the pneumatic ram may be retracted with a set force. The distance travelled up by the pneumatic ram may be measured to provide an additional assessment as to whether the bag is leaking or not. A suction testing method may be used before, after or during the gusset flap testing method described above.

[0076] After a predetermined time all the actuatorsfirst cylinder 6, flap clamp cylinder 7, third cylinder 14 and fourth cylinder(s) 15will return to their resting position. This releases the block of cheese 16. Once the cylinders reach their initial or resting position, movement of the conveyor 3 resumes.

Advantages

[0077] The method (and associated apparatus) as outlined above is advantageous as outlined below:

[0078] Pulling the flap/seal 17 is an effective method of detecting large leaks, and pulling in this manner puts lower stress on the packaging.

[0079] Testing the gusset by manipulating and pulling from the inside (using the fingers) allows good detection of slow leaks, and requires the application of minimal force on the packaging.

[0080] Using a mechanical gripper provides a robust and reliable means of engagement with the packaging, and does not require a flat surface for use. The apparatus can therefore provide a useful alternative to an apparatus or method that uses only a suction cup.

[0081] Using a method where the flap/seal is pulled and also the gusset is manipulated or pulled from inside the folds provides both a primary and secondary method of determining leaks (the seal/flap pull and the gusset manipulation, respectively). The gusset manipulation also acts as a useful comparator to the physical manipulation.

[0082] While the present invention has been illustrated by the description of the embodiments thereof, and while the embodiments have been described in detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details, representative apparatus and method, and illustrative examples shown and described. Accordingly, departures may be made from such details without departure from the spirit or scope of the applicant's general inventive concept.