Torque transducer assembly
A torque transducer assembly includes a first shell having a threaded neck and a distal end. A second shell is also provided. A sensor module includes a first frame member, a second frame member, and a sensor. The first frame member is attached to the first shell and the second frame member is attached to the second shell such that the first and second shells are coupled to one another. A method of manufacturing a torque transducer assembly is also provided. A packaging system including a torque transducer assembly is additionally provided.
The present invention relates to a torque transducer assembly that can be introduced to a capping system for measuring the amount of torque applied during a capping process. The torque transducer assembly can include electronics for storing and/or transmitting the measured torque and/or other measured parameters.
BACKGROUND OF THE INVENTIONContainers (e.g., bottles) with screw-type caps or lids are commonly used for packaging of nearly an endless variety of consumer goods. After such containers are filled with their desired contents, they are typically presented to a capping system which presents and rotates a threaded cap onto a threaded neck of the container until the cap is sufficiently tightened for sealing the container. The amount of capping torque required to fully seal the cap upon a container varies depending upon many factors including, for example, the size and thread configuration of the container's threaded neck. As containers are typically designed for efficiency to include as little material as possible, threaded neck portions often can only withstand capping torques that slightly exceed the capping torque required to seal the container. Conversely, inherent variation in capping machinery may result in a capping application torque that is too low. A capping system must therefore be finely tuned so as to provide enough capping torque to seal the container, but not so much capping torque as to cause deformation of the container.
It can be desirable to assess performance of a capping system by monitoring the amount of torque applied by the capping system during the capping process. Knowing the amount of torque applied during the capping process can enable an operator to determine whether or not a cap has been adequately tightened upon a container. If the operator finds that this capping torque is insufficient or excessive, he or she can adjust the capping system as necessary to increase or decrease the amount of capping torque accordingly.
However, measuring the amount of capping torque applied by a capping system can be difficult, expensive, and time-consuming. For example, one common method by which to assess capping torque is to measure the amount of removal torque necessary to remove a cap from a capped container, wherein the measured removal torque is estimated to be proportional to the capping torque which had been applied. Other prior art methods and devices for measuring and/or approximating capping torque are also known. However, none of these methods or devices provides a simple, quick, effective, and relatively inexpensive solution for measuring the capping torque applied by a capping system.
Accordingly, there is a need for a simple, quick, effective, and relatively inexpensive solution for measuring the capping torque applied by a capping system.
SUMMARY OF THE INVENTIONIt is an aspect of the present invention to provide a simple, quick, effective, and relatively inexpensive solution for measuring the capping torque applied by a capping system.
In one aspect of the present invention, a torque transducer assembly is provided that comprises a first shell including a threaded neck having a longitudinal axis and a distal end opposite the threaded neck. A first frame member is attached to the first shell adjacent to the distal end, and the first frame member comprises a first engagement surface. A second shell is also provided. A second frame member is attached to the second shell and comprises a second engagement surface. The second frame member is rotatably coupled with the first frame member for rotation at least partially about the longitudinal axis. A load cell is positioned between the first and second engagement surfaces such that the load cell is compressed between the first and second engagement surfaces when the first shell is rotated with respect to the second shell. A monitoring circuit is electronically connected with the load cell.
In another aspect of the present invention, a method for manufacturing a torque transducer assembly is provided. The method comprises providing a container having a shell including a threaded neck and a base, wherein the shell extends from the threaded neck to the base along a longitudinal axis. The container is severed in a direction substantially perpendicular to the longitudinal axis, thereby separating the container into a first shell and a second shell. The first shell extends along the longitudinal axis from the threaded neck to a first severed end. The second shell extends along the longitudinal axis from a second severed end to the base. A sensor module is provided comprising a first frame member, a second frame member, and a sensor. The first frame member is attached to the first shell and the second frame member is attached to the second shell, such that the first and second shells are coupled to one another.
In yet another aspect of the present invention, a packaging system is provided that comprises a conveyor system configured to transport containers. A capping system comprises at least one capping head disposed adjacent to the conveyor system. The capping head is configured to install caps upon containers transported by the conveyor system. At least one torque transducer assembly is configured to be periodically inserted upon the conveyor system for capping by the capping system. The torque transducer assembly comprises a first shell, a second shell coupled to the first shell, and a sensor module. The sensor module has a first frame member attached to the first shell, a second frame member attached to the second shell, and a sensor configured to generate electrical signals indicative of capping torque. The torque transducer assembly further comprises a transmitter configured to transmit data indicative of capping torque. A control system is electrically connected with the capping system and comprises a receiver configured to receive the capping torque data from the transmitter. The control system is configured to adjust the amount of rotational torque applied by the capping head in response to the capping torque data received by the receiver.
One advantage of the present invention is its provision of a simple, quick, effective, and relatively inexpensive solution for measuring the capping torque applied by a capping system. Additional aspects, advantages, and novel features of the invention will be set forth in part in the description that follows and in part will become apparent to those skilled in the art upon examination of the following, or may be learned with the practice of the invention. The aspects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGSWhile the specification concludes with claims particularly pointing out and distinctly claiming the present invention, it is believed that the same will be better understood from the following description taken in conjunction with the accompanying drawings in which:
The present invention and its operation is hereinafter described in detail in connection with the views and examples of
The torque transducer assembly 16 is shown in
Referring again to
A port 72 can be provided in the second shell 20. This port 72 can be used to facilitate transfer of data and/or power to and/or from internal components of the torque transducer assembly 16. For example, power might be provided to the torque transducer assembly through port 72, and/or data might be read from the torque transducer assembly through port 72. Although port 72 is depicted as being accessible through an aperture in the second shell 20, it should be appreciated that port 72 might alternatively be located through an aperture in the first shell 18, through an aperture in the base 24 of the second shell 20, or through an opening 21 in the threaded neck 22 of the first shell 18. Other embodiments of the present invention might involve a torque transducer assembly 16 having more than one such port 72, while other embodiments might not involve any such port 72 whatsoever.
Turning now to
Referring now to
The first and second filler materials 50, 52 can assist in providing a secure and solid connection between the sensor module 36 and the first and second shells 18, 20. Furthermore, through use of such filler materials 50, 52, a single sensor module 36 can be installed into containers having differing diameters and/or surface contours. The first and second filler materials can be formed (e.g., by casting or machining) from any of a variety of suitable materials, including for example, plastic, epoxy, wood, metal, and/or facsimile compound.
A wire 43 is shown to connect the first sensor 42 to the circuit boards 64 and/or 66. The circuit boards 64 and 66 can be electrically and mechanically connected together through use of connectors 68, and can be together supported upon a bracket 58 with respect to the sensor module 36. In one embodiment, the first circuit board 64 can generally contain conditioning circuitry (e.g., 95 and 97, discussed below), while the second circuit board 66 can generally contain data acquisition circuitry (e.g., including controller 98 and memory 99, as discussed below). The second circuit board 66 is shown to support a battery holder 71, which can hold a battery 70 (e.g. AA or AAA) battery. Although circuit boards 64 and 66 are shown as being mechanically connected with the sensor module 36 (i.e., with bracket 58), it should be appreciated that monitoring circuitry might alternatively not include this mechanical connection (other than with wires leading to sensors), but rather might be disposed elsewhere within a cavity formed by the first and/or second shell of a torque transducer assembly.
The transducer assembly 16 can be configured such that the first engagement surface 74 is urged toward the second engagement surface 76 when the first shell 18 is rotated with respect to the second shell 20. In particular, the first engagement surface 74 can be configured for movement toward the second engagement surface 76 when the first shell 18 is rotated in a direction (e.g., clockwise) about the longitudinal axis (L) with respect to the second shell 20. The sensor 42, being positioned between the first and second engagement surfaces 74, 76, can be compressed between the first and second engagement surfaces 74, 76 when the first shell 18 is rotated in that direction about the longitudinal axis (L) with respect to the second shell 20. Additionally, the first engagement surface 75 can be configured for movement toward the second engagement surface 77 when the first shell 18 is rotated in a direction (e.g., counter-clockwise) about the longitudinal axis (L) with respect to the second shell 20. The sensor 44 being positioned between the first and second engagement surfaces 75, 77 can be compressed between the first and second engagement surfaces 75, 77 when the first shell 18 is rotated in that direction about the longitudinal axis (L) with respect to the second shell 20. By having first and sensors 40, 42 arranged in this manner, data can be measured that is indicative of torque applied to the torque transducer assembly in both directions about the longitudinal axis (L). It should be appreciated that the amount of rotation between rotatably coupled first and second shells 18, 20 can be very small, and can in some circumstances amount to only a few radial degrees.
The first and second sensors 42 and 44 can comprise load cells that are configured to generate output signals in proportion to the amount of force to which they are subjected. This force can be presented to these load cells by the engagement surfaces (e.g., 74, 75, 76, 77) of the first and second frame members 38, 40. Because the radial distance between the center of the load cells and the central rotational axis of the sensor module (i.e., longitudinal axis (L)) is known and held constant, torque can be determined by multiplying this radial distance by the amount of compressive force measured by a load cell.
The circuit boards 64 and 66 can include any of a variety of components. For example, as illustrated in part by the functional block diagram of
The conditioning circuitry 95 is shown in
As shown in
The monitoring circuit can further include at least one of a clock and a timer, either or both of which might be integrally provided within the controller 98. The controller 98 is shown to interface memory 99 for transmission and receipt of data therebetween. The port 72 can be provided in communication with the controller 98 to facilitate the transmission/receipt of data and/or instructions to/from external equipment, and might also or alternatively be connected with the battery 70 to enable charging of the battery 70. The port 72 can support such communication protocols as USB, RS232, RS485, Ethernet, Firewire, DeviceNet, Interbus-S, Profibus, Data Highway, and/or any of a variety of other communications protocols. A transmitter 100 might also be provided in communication with the controller 98 to facilitate infrared or radio frequency transmission of measured and/or processed data to equipment external to the torque transducer assembly 16. In one exemplary embodiment of the present invention, the transmitter 100 can be configured to transmit capping torque data. A receiver 91 might also be provided in communication with the controller 98 to facilitate reception of data relating, for example, to the position of the torque transducer assembly 16 with respect to a packaging system or components thereof (e.g., a capping head). Other exemplary uses for this transmitter 100 and receiver 91 are discussed below.
Exemplary conditioning circuitry 95 is depicted in
The use of strain gauge sensors in the manner illustrated in
A torque transducer assembly of the present invention can also be used as part of a packaging system. An exemplary packaging system 202 is depicted in
In some embodiments, a torque transducer assembly (e.g., 226, 228, 230, 232, 234, 236, 238 and 240) may include components (e.g., receiver 91 in
There are many manners in which a torque transducer assembly in accordance with the teachings of the present invention can be used in conjunction with the capping system 202 of
A torque transducer assembly in accordance with the teachings of the present invention might have a monitoring circuit including a clock in order that any measured data can be associated with a particular time. Therefore, an operator who later evaluates data can determine the time of day in which the data was obtained. Likewise, a torque transducer assembly might include a monitoring circuit that is configured to provide data indicative of a capping torque profile as a function of time. Such a monitoring circuit can include a clock or a timer in order that an entire torque profile as a function of time can be recorded, which necessarily would also include peak torque. This torque profile can be particularly beneficial to determine whether the capping heads 206, 208, 210, 212 are properly performing the capping process. A torque transducer assembly in accordance with the teachings of the present invention might even be configured to store multiple capping torque profiles as a function of time (e.g., by repeated presentation of a torque transducer assembly to a capping system before data is offloaded therefrom).
As opposed to manual calibration of the control system 246 in response to data read from one or more torque transducer assemblies, the torque transducer assemblies can be configured to include a transmitter 100 to facilitate transmission of this data. Such a transmitter might, in some embodiments, be configured only to transmit this information upon docking of a self-contained torque transducer assembly in a particular area or bay. However, in alternate embodiments, the transmitter might be configured to operate continuously or automatically upon measurement of data to facilitate transmission of that data to the receiver 248 of the control system 246.
For example, the packaging system 202 of
In another embodiment, the control system 246 can automatically adjust the control signals to the capping actuators 214, 216, 218, 220 quickly enough in response to transmissions from recently capped torque transducer assemblies 226, 228, 230 and 232, such that the next containers to be capped will be capped using an appropriate torque. Additional torque transducer assemblies 234, 236, 238, 240 can then be inserted along the conveyor system 222 in order to verify that the appropriate torque calibrations have been made by the control system 246 in response to data received from the torque transducer assemblies 228, 230, 232 via the receiver 248. In response to data received from torque transducer assemblies 234, 236, 238 and 240 by receiver 248, the control system 246 can implement further adjustments to torque as appropriate. Torque transducer assemblies can be inserted into and taken from the conveyor system 222 by hand or through some automatic arrangement. A conveyor system 222 might be provided with an auto-eject system which recognizes the presence of a torque transducer assembly and ejects it from the normal flow of containers so that data can either be offloaded from this torque transducer assembly and/or this torque transducer assembly can either be manually or automatically reinserted onto the conveyor line for recapping.
The battery 70 discussed above may be provided as an alkaline, rechargeable, or other type of battery. Although the torque transducer assembly may be configured such that its battery is easily replaceable, the battery might alternatively be configured to be rechargeable while present within the torque transducer assembly. In such a circumstance, the monitoring circuit might be configured so that power received through port 72 can be passed to the battery 70 to facilitate its charging, as shown for example in the exemplary block diagram of
The monitoring circuit of an exemplary torque transducer assembly might also include one or more LED's or other such indicia which might be viewable through one or more apertures in the first shell and/or the second shell. Such indicia can provide an onlooker of the torque transducer assembly with immediate diagnostic information regarding status of the torque transducer assembly. For example, one or more LED's might be capable of displaying (e.g., in blinking patterns and/or colors) diagnostic information such as battery level, sensor activation status, memory capacity level, peak torque value measured, transmitter activation status, receiver status, data transfer status, charging status, and/or any of a variety of other such information.
An exemplary torque transducer assembly might also include an activation device, such as a switch, to prevent drainage of the battery 70 during periods of non-use. Although this switch might be accessible through an aperture in the first shell and/or second shell (e.g., 18, 20 in
The foregoing description of exemplary embodiments and examples of the invention has been presented for purposes of illustration and description. These examples and descriptions are not intended to be exhaustive or to limit the invention to the forms described. Numerous modifications are possible in light of the above teachings. Some of those modifications have been discussed, and others will be understood by those skilled in the art. It is hereby intended that the scope of the invention be defined by the claims appended hereto.
Claims
1. A torque transducer assembly comprising:
- a first shell comprising a threaded neck having a longitudinal axis and a distal end opposite the threaded neck;
- a first frame member attached to the first shell adjacent to the distal end, the first frame member comprising a first engagement surface;
- a second shell;
- a second frame member attached to the second shell and comprising a second engagement surface, the second frame member rotatably coupled with the first frame member for rotation at least partially about the longitudinal axis;
- a load cell positioned between the first and second engagement surfaces such that the load cell is compressed between the first and second engagement surfaces when the first shell is rotated with respect to the second shell; and
- a monitoring circuit electronically connected with the load cell.
2. The transducer assembly of claim 1 wherein the monitoring circuit is disposed at least partially within at least one of the first and second shells.
3. The transducer assembly of claim 1 wherein the first frame member is disposed at least partially within a cavity in the first shell, and wherein the second frame member is disposed at least partially within a cavity in the second shell.
4. The transducer assembly of claim 1 further comprising a first filler material disposed at least partially between the first shell and the first frame member.
5. The transducer assembly of claim 1 further comprising a second filler material disposed at least partially between the second shell and the second frame member.
6. The transducer assembly of claim 1 wherein the monitoring circuit comprises a conditioning circuit in electrical communication with the load cell, a controller, and memory.
7. The transducer assembly of claim 6 wherein the monitoring circuit further comprises at least one of a clock and a timer, and the monitoring circuit is configured to provide data indicative of a capping torque profile as a function of time.
8. The transducer assembly of claim 7 wherein the monitoring circuit is configured to store multiple capping torque profiles as a function of time.
9. The transducer assembly of claim 1 wherein the monitoring circuit comprises a transmitter configured to transmit capping torque data.
10. The transducer assembly of claim 1 wherein the monitoring circuit is configured to provide data relating to at least one of:
- a capping head which operates upon the torque transducer assembly; and
- a time of day at which the torque transducer assembly is capped.
11. The transducer assembly of claim 1 wherein the transducer assembly is configured such that the first engagement surface is urged toward the second engagement surface when the first shell is rotated with respect to the second shell.
12. A method for manufacturing a torque transducer assembly, the method comprising:
- providing a container having a shell including a threaded neck and a base, the shell extending from the threaded neck to the base along a longitudinal axis;
- severing the container in a direction substantially perpendicular to the longitudinal axis, thereby separating the container into a first shell and a second shell, the first shell extending along the longitudinal axis from the threaded neck to a first severed end, and the second shell extending along the longitudinal axis from a second severed end to the base;
- providing a sensor module comprising a first frame member, a second frame member, and a sensor; and
- attaching the first frame member to the first shell and attaching the second frame member to the second shell, such that the first and second shells are coupled to one another.
13. The method of claim 12 wherein the sensor comprises a load cell, the load cell being positioned between the first and second frame members such that the load cell is compressed between the first and second frame members when the first shell is rotated with respect to the second shell.
14. The method of claim 12 wherein the sensor module is configured such that the first frame member is rigidly connected by at least one strut to the second frame member, and wherein the sensor comprises at least one strain gauge attached to said at least one strut.
15. The method of claim 12 wherein the first frame member is attached to the first shell and the second frame member is attached to the second shell using at least one of an adhesive and a fastener.
16. The method of claim 12 further comprising inserting a first filler material between the first frame member and the first shell, and inserting a second filler material between the second frame member and the second shell.
17. The method of claim 12 wherein the first frame member is attached to the first shell such that the first frame member is disposed at least partially within a cavity in the first shell, and the second frame member is attached to the second shell such that the second frame member is disposed at least partially within a cavity in the second shell.
18. A packaging system comprising:
- a conveyor system configured to transport containers;
- a capping system comprising at least one capping head disposed adjacent to the conveyor system, said capping head configured to install caps upon containers transported by the conveyor system;
- at least one torque transducer assembly configured to be periodically inserted into the conveyor system for capping by the capping system, the torque transducer assembly comprising a first shell, a second shell coupled to the first shell, and a sensor module, the sensor module having a first frame member attached to the first shell, a second frame member attached to the second shell, and a sensor configured to generate electrical signals indicative of capping torque, the torque transducer assembly further comprising a transmitter configured to transmit data indicative of capping torque; and
- a control system electrically connected with the capping system and comprising a receiver configured to receive the capping torque data from the transmitter, the control system being configured to adjust the amount of rotational torque applied by said capping head in response to the capping torque data received by the receiver.
19. The packaging system of claim 18 wherein the first frame member comprises a first engagement surface, the second frame member comprises a second engagement surface, and the sensor comprises a load cell positioned between the first and second engagement surfaces such that the load cell will be compressed between the first and second engagement surfaces when the first shell is rotated with respect to the second shell.
20. The packaging system of claim 18 wherein the first frame member is rigidly connected by at least one strut to the second frame member, and wherein the sensor comprises at least one strain gauge attached to said at least one strut.
21. The packaging system of claim 18 wherein the control system is configured to automatically adjust in real time the amount of rotational torque applied by said capping head in response to the data received by the receiver.
22. The packaging system of claim 18 wherein said packaging system comprises a plurality of said torque transducer assemblies, the receiver being configured to receive data from each of said transducer assemblies, and the control system being configured to automatically adjust the amount of rotational torque applied by said capping head in response to the data received by the receiver.
23. The packaging system of claim 18 wherein the capping system comprises a plurality of capping heads each being respectively disposed adjacent to the conveyor system, wherein said torque transducer assembly is configured to identify a particular capping head associated with capping torque data and is further configured to transmit the identity of the particular capping head, wherein the receiver is further configured to receive the identity of the particular capping head, and wherein the control system is configured to automatically adjust the amount of rotational torque applied by the particular capping head in response to capping torque data associated therewith.
Type: Application
Filed: Jan 21, 2005
Publication Date: Jul 27, 2006
Inventors: Clinton Haynes (Mason, OH), Douglas Marriott (South Lebanon, OH), Todd Buchholz (Hermitage, TN), William Miller (Houston, TX), Rande Johnson (Edwardsville, IL), Eric Robbins (Cincinnati, OH)
Application Number: 11/040,155
International Classification: B65B 7/28 (20060101);