VALVE BAG PLACING SYSTEM AND METHOD

Abstract

In one example embodiment, a system for opening a valve bag includes a bag separator assembly and a valve opening assembly. The bag separator assembly is rotatable about a rotation axis and is configured to move along a taxis toward a plurality of valve bags to obtain a valve bag. The bag separator assembly also is configured to move along the y-axis in an opposing direction to separate the valve bag from the plurality of valve bags. The rotation axis and y-axis are perpendicular to one another. The valve opening assembly is configured to open a valve end of the valve bag. The valve opening assembly also is configured to move along an x-axis to be inserted into and removed from the valve end of a valve bag being held by the bag separator assembly. The bag separator assembly avoids contact with the valve opening assembly by rotating about the rotation axis before moving along the y-axis toward the plurality of valve bags.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application relates and claims priority to copending U.S. Provisional Patent Application Ser. No. 60/925,796 (the “'796 application”). The '796 application was filed on Apr. 23, 2007, and is entitled “Valve Bag Placing System and Method.” The complete subject matter of the '796 application is incorporated by reference herein in its entirety.

BACKGROUND OF THE INVENTION

The subject matter herein generally relates to valve bags and, more particularly, to a system and method for filling valve bags.

Valve bags are used to store a variety of goods, such as grain and concrete mix. Valve bags include a valve end that is similar to a one-way valve. For example, the valve end is opened by squeezing on opposite sides of the valve end. The goods are inserted into the valve bag through the opened valve end. For example, a spout can be inserted into the opened valve end and pour the goods into the valve bag. The valve end closes as the goods fill the bag and push the valve end to close. At this point, the valve bag is filled and closed and ready for storage and/or shipment.

Known systems and methods used to fill valve bags typically rely on several components that move relative to one another. For example, known systems may use several components that each performs a single task in filling a valve bag. For example, one component may grab a valve bag, while another component opens the valve bag and yet another component moves the valve bag to a spout. The spout then fills the valve bag. Each of these components typically moves independently of one another. The components that grab a valve bag and that open the valve bag do not move at the same time. Similarly, the components that open the valve bag and that places the valve bag on a spout do not move at the same time. As a result, time is wasted as the various components may stand idle while other components complete their assigned tasks. These systems fill valve bags at an inefficient rate.

Thus a need exists for a more efficient valve bag placing and filling system and method.

BRIEF DESCRIPTION OF THE INVENTION

In one example embodiment, a system for opening a valve bag includes a bag separator assembly and a valve opening assembly. The bag separator assembly is rotatable about a rotation axis and is configured to move along a y-axis toward a plurality of valve bags to obtain a valve bag. The bag separator assembly also is configured to move along the y-axis in an opposing direction to separate the valve bag from the plurality of valve bags. The rotation axis and y-axis are perpendicular to one another. The valve opening assembly is configured to open a valve end of the valve bag. The valve opening assembly also is configured to move along an x-axis to be inserted into and removed from the valve end of a valve bag being held by the bag separator assembly. The bag separator assembly avoids contact with the valve opening assembly by rotating about the rotation axis before moving along the y-axis toward the plurality of valve bags.

In another example embodiment, a method for filling a valve bag includes lifting a first valve bag with a bag separator assembly along a y-axis to enable a valve opening assembly to be inserted into a valve end of the first valve bag, inserting the valve opening assembly into the valve end of the first valve bag by moving the valve opening assembly along an x-axis, returning the bag separator assembly to a group of valve bags by rotating the bag separator assembly about a rotation axis and moving the bag separator assembly along the y-axis towards the group of valve bags, obtaining a second valve bag from the group of valve bags, lifting the second valve bag with the bag separator assembly to enable the valve opening assembly to be inserted into a valve end of the second valve bag, and removing the valve opening assembly from the valve end of the first valve bag by moving the valve opening assembly along the x-axis so as to avoid contact with the bag separator assembly.

In another example embodiment, a system for obtaining, opening, placing and filling a valve bag includes a bag supply assembly, a valve opening assembly, a bag separator assembly, a grabbing assembly, and a placement assembly. The bag supply assembly is configured to supply a plurality of groups of valve bags. The valve opening assembly is configured to open a valve end of each of the valve bags. The bag separator assembly is configured to raise and lower along a first slot in a housing and to rotate towards and away from the housing in order to individually obtain each of the valve bags in the groups of valve bags while avoiding contact with the valve opening assembly. The bag separator assembly individually lifts each of the valve bags to the valve opening assembly. The grabbing assembly is configured to engage the valve end of each of the valve bags. The placement assembly is configured to move the valve end from a location that is proximate to the valve opening assembly and to place the valve end in a location that is proximate to a bag filling assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a bag placing system according to one example embodiment.

FIG. 2 is a perspective view of one example embodiment of a portion of the bag supply assembly shown in FIG. 1.

FIG. 3 is a perspective view of one example embodiment of a portion of the bag separator assembly shown in FIG. 1.

FIG. 4 is a schematic diagram of one example embodiment of the bag separator assembly shown in FIG. 1 as the bag separator assembly moves to obtain a valve bag.

FIG. 5 is a perspective view of one example embodiment of the valve opening assembly shown in FIG. 1.

FIG. 6 is a perspective view of one example embodiment of the grabbing assembly and a portion of the placement assembly, both shown in FIG. 1.

FIG. 7 is a flowchart of one example embodiment of a method for placing a plurality of valve bags on one or more spouts of the bag filling assembly shown in FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is a perspective view of a bag placing system 100 according to one example embodiment. The bag placing system 100 is configured to obtain a valve bag, open a valve end of the valve bag and place the valve end so that the valve bag may be filled. The bag placing system 100 includes a plurality of assemblies 102, 104, 106, 108, 110 that move relative to one another in a synchronized manner to separate a valve bag 112 from a group of valve bags 112, open the valve end 114 of the valve bag 112, place the valve end 114 on a spout 520 in a bag filling assembly 116, and fill the valve bag 112. The bag placing system 100 performs these actions for a group or series of valve bags 112. Two or more of these actions may occur simultaneously to increase the efficiency and speed of the bag placing system 100.

For example, in one example embodiment, a bag supply assembly 102 moves a plurality of groups of valve bags 112 towards a bag separator assembly 104. The bag separator assembly 104 grabs one of the valve bags 112 supplied by the bag supply assembly 102. The bag separator assembly 104 then lifts the valve bag 112 upwards towards a valve opening assembly 106. The valve opening assembly 106 opens the valve end 114 of the valve bag 112 and holds the valve end 114 open. A placement assembly 108 is connected to a grabbing assembly 110. The placement assembly 108 moves the grabbing assembly 110 over to the valve opening assembly 106. The grabbing assembly 110 grasps the valve end 114 of the valve bag 112 and holds the valve end 114 open. The placement assembly 108 moves the grabbing assembly 110 and the valve bag 112 over to the bag filling assembly 116. The bag filling assembly 116 includes the spout 520 that then fills the valve bag 112 with goods through the open valve end 114 until the valve bag 112 is substantially full of the goods. For example, the spout 520 may fill the valve bag 112 with concrete mix or grain. Once the valve bag 112 is substantially full, the valve end 114 closes and the valve bag 112 falls off of the spout 520.

In some embodiments, the movements of the various assemblies 102, 104, 106, 108, 110 are spatially and temporally coordinated so that two or more assemblies 102, 104, 106, 108, 110 simultaneously perform related, sequential tasks in the process of filling several valve bags 112. For example, the bag separator assembly 104 and bag opener assembly 106 may move in spatially and temporally coordinated movements so that each of the bag separator assembly 104 and the bag opener assembly 106 can complete the tasks of opening the valve end 114 of the valve bag 112 and separating the next valve bag 112 from a group of valve bags 112 simultaneously. Similarly, the bag opener assembly 106 and the placement assembly 108 can move in spatially and temporally coordinated movements to place one valve bag 112 on the spout 520 while the valve end 114 on the next valve bag 112 is opened.

The bag supply assembly 102 includes a conveyor frame 210 having an elongated shape extending towards the bag separator assembly 104. The conveyor frame 210 is supported by four legs 220. While four legs 220 are shown in the illustrated embodiment, a different number of legs 220 may be used. Each of a pair of sides 250, 260 extends along the conveyor frame 210. The sides 250, 260 prevent the valve bags 112 from falling off of the conveyor frame 210. In some embodiments, one or more of the bag side guides 250, 260 can be fixed in position and incapable of being moved with respect to the conveyor frame 210. In one or more other embodiments, one or more of the bag side guides 250, 260 can be adjustable and capable of being moved with respect to the conveyor frame 210. For example, the side guide 260 can be capable of being moved towards and/or away from the other side guide 250 to enable the bag supply assembly 102 to accommodate larger sized bags 112.

FIG. 2 is a perspective view of one example embodiment of a portion of the bag supply assembly 102. The bag supply assembly 102 moves the valve bags 112 to a position where the valve bags 112 may be grabbed by the bag separator assembly 104. A plurality of bag supports 235 extend upwards from the conveyor frame 210. The bag supports 235 separate several groups of valve bags 112 from one another. The bag supports 235 are each connected to a conveyance mechanism 230. The conveyance mechanism 230 is operated by a motor 240 (shown in FIG. 1). The motor 240 causes the conveyance mechanism 230 to move along the conveyor frame 210 towards the bag separator assembly 104. For example, the motor 240 may include a table top chain drive motor that moves a chain. In some embodiments, the motor 240 moves the conveyance mechanism 230 in a manner that is similar to a conveyor belt. The bag supports 235 each move towards the bag separator assembly 104 as the motor 240 causes the conveyance mechanism 230 to move towards the bag separator assembly 104.

The valve bags 112 are moved towards the bag separator assembly 104 until a group (or magazine) of the valve bags 112 contacts a bag stop 270 (shown in FIG. 1). The bag stop 270 is connected to the magazine supply assembly 102 in a location that is proximate to the bag separator assembly 104. The bag stop 270 includes any object capable of preventing the valve bags 112 from falling off the end of the conveyor frame 210 that is in a location proximate to a housing 305. In some embodiments, the bag stop 270 includes a pressure sensitive switch that detects when a group of valve bags 112 contacts the bag stop 270. This switch may become closed when a group of valve bags 112 contacts the bag stop 270 and open when no valve bags 112 contact the bag stop 270. The motor 240 may be connected to the switch in the bag stop 270 so that when the switch is open, the motor 240 moves the conveyance mechanism 230 to cause the next group of valve bags 112 to move towards and contact the bag stop 270. Once the next group of valve bags 112 contacts the bag stop 270, the switch closes and the motor 240 stops moving the conveyance mechanism 230.

In operation, an operator or user of the bag placing system 100 places empty valve bags 112 on the conveyance mechanism 230 between adjacent ones of the bag supports 235. The motor 240 causes the conveyance mechanism 230 and the bag supports 235 to move the valve bags 112 along the conveyor frame 210 towards the bag stop 270. The valve bags 112 stop at the bag stop 270. When the valve bags 112 reach the bag stop 270, the valve bags 112 are in position for the bag separator assembly 104 to individually remove each of the valve bags 112 one at a time from the conveyor frame 210. After the bag separator assembly 104 removes all of the valve bags 112 that are in a location that is proximate to the bag stop 270, the motor 240 moves the conveyance mechanism 230 towards the bag stop 270 until the next group of valve bags 112 is adjacent to the bag stop 270. By only moving one group of valve bags 112 into position against the bag stop 270 at a time, an operator of the bag placing system 100 can refill or add to the groups of valve bags 110 between adjacent ones of the bag supports 235 at any time during operation of the bag placing system 100.

FIG. 3 is a perspective view of one example embodiment of a portion of the bag separator assembly 104. The bag separator assembly 104 obtains one valve bag 112 from a group of valve bags 112 supplied by the bag supply assembly 102 and separates the valve bag 112 from the group. The bag separator assembly 104 lifts the valve bag 112 up from the group of valve bags 112 to the valve opening assembly 106. The valve opening assembly 106 is inserted into the valve end 114 of the valve bag 112, as described below, and the bag separator assembly 104 lowers to obtain the next valve bag 112 while avoiding a collision with the valve opening assembly 106.

The bag separator assembly 104 includes a pair of separator arms 330 that extend outward from the housing 305. The separator arms 330 are connected with one another by a crossbar 320 and by an axle 340.

The crossbar 320 is connected via one or more hoses 322 to a vacuum pump 310 (shown in FIG. 1). The hoses 322 may extend between the crossbar 320 and the vacuum pump 310 through the housing 305. The vacuum pump 310 may be located inside or connected to the housing 305. Alternatively, the vacuum pump 310 is separate from the housing 305. The vacuum pump 310 is capable of exhausting air from inside the hoses 322 and the crossbar 320 to create a vacuum. One or more suction cups 324 extend downwards from the crossbar 320. The suction cups 324 are interconnected with the vacuum pump 310 via the crossbar 320 and the hoses 322. The suction cups 324 may include a hole or other opening (not shown). The vacuum pump 310 exhausts air from the hoses 322 and the crossbar 320 to create a vacuum and enable the suction cups 324 to provide a suction force to the valve end 114 of a valve bag 112 when the suction cups 324 contact the valve bag 112. The suction force can be applied to the valve end 114 of a valve bag 112 to lift the valve bag 112 away from the bag supply assembly 102.

The separator arms 330 and crossbar 320 can move in two different directions. First, the separator arms 350 and crossbar 320 can move vertically upwards and downwards with respect to the bag supply assembly 102. The separator arms 330 and crossbar 320 move upwards and downwards along a y-axis 326 in a slot 307 in the housing 305. In the illustrated embodiment the y-axis 326 is perpendicular to the ground. The separator arms 330 may be connected to a vertical drive motor (not shown) that is located in the housing 305. The vertical drive motor may move the separator arms 330 and crossbar 320 up and down along the y-axis 326 in the slot 307.

Second, the separator arms 330 and the crossbar 320 can rotate towards and away from the housing 305. The axle 340 enables the separator arms 330 to rotate about the axle 340. The separator arms 330 and crossbar 320 move along an arc 328 as the separator arms 330 rotate about the axle 340. In some embodiments, the separator arms 330 rotate about the axle 340 along the arc 328 between substantially horizontal and vertical positions. For example, the separator arms 330 may flip between a horizontal position that is substantially perpendicular to the y-axis 326 and a vertical position that is substantially parallel to the y-axis 326. The axle 340 may thus define a rotation axis for the separator arms 330. In the illustrated embodiment, the rotation axis and the y-axis 326 are perpendicular to one another.

In some embodiments, the separator arms 330 partially rotate about the axle 340 along the arc 328 in a total angular displacement of less than 90 degrees. In one or more other embodiments, the total angular displacement of the separator arms 330 is less than 60 degrees. In one or more other embodiments, the total angular displacement of the separator arms 330 is less than 45 degrees. In one or more other embodiments, the total angular displacement of the separator arms 330 is less than 30 degrees.

FIG. 4 is a schematic diagram of one example embodiment of the bag separator assembly 104 as the bag separator assembly 104 moves to obtain a valve bag 112. In operation, once a group of valve bags 112 is located in a position that is proximate to the bag stop 270, the bag separator assembly 104 rotates to avoid a collision with an upper valve opening tool 380 and a lower valve opening tool 350 of the valve opening assembly 106. The bag separator assembly 104 initially is at a first orientation 300. At the first orientation 300, the separator arms 330 are substantially parallel with the valve bags 112 supplied by the bag supply assembly 102. The separator arms 330 then rotate about the axle 340 so that the separator arms 330 and the suction cups 324 flip back towards the housing 305 along the arc 328. The bag separator assembly 104 is now at a second orientation 301. The bag separator assembly 104 is now in a position to lower to obtain the next valve bag 112 while avoiding a collision with the upper and lower valve opening tools 350, 380 of the valve opening assembly 106. For example, the bag separator assembly 104 may move downwards along the y-axis 326 toward the group of valve bags 112 to a third orientation 302. As the bag separator assembly 104 moves downwards, the separator arms 330 and the suction cups 324 avoid contact with the upper and lower valve opening tools 350, 380. The bag separator assembly 104 then rotates the separator arms 330 about the axle 340 towards the valve bags 112. The suction cups 324 and separator arms 330 flip away from the housing 305 towards the valve bags 112 along the arc 328 to a fourth orientation 303. The suction cups 324 contact the valve end 114 of the top valve bag 112 when the bag separator assembly 104 is at the fourth orientation 303. When the suction cups 324 contact the top valve bag 112, the vacuum pump 310 applies a suction force to the valve end 114 of the valve bag 112. The suction force is applied to the valve end 114 through the suction cups 324.

The bag separator assembly 104 then moves upward along the y-axis 326 away from the group of valve bags 112. The suction force exerted on the valve end 114 of the top valve bag 112 in the group of valve bags 112 causes the top valve bag 112 to be lifted upwards in the y-axis 326 and separated from the group of valve bags 112. The bag separator assembly 104 returns to the first orientation 300. The bag separator assembly 104 stops moving upward when the valve end 114 of the valve bag 112 is at approximately the same height as the upper and lower valve opening tools 350, 380 of the valve opening assembly 106. The bag separator assembly 104 avoids a collision with the upper and lower valve opening tools 350, 380 when the bag separator assembly 104 moves upward to the first orientation 300 because the upper and lower valve opening tools 350, 380 have moved out of the way of the bag separator assembly 104, as described below.

FIG. 5 is a perspective view of one example embodiment of the valve opening assembly 106. The valve opening assembly 106 opens the valve end 114 of a valve bag 112. The valve opening assembly 106 includes upper and lower valve opening tools 350, 380. Each of the upper and lower valve opening tools 350, 380 includes an elongated, substantially flat blade that is capable of being inserted into an opening 332 of the valve end 114 of a valve bag 112 when the valve end 114 is closed. Each of the upper and lower valve opening tools 350, 380 are connected to a valve opener carriage 370 by an arm 360. The valve opener carriage 370 moves in two diametrically opposed directions along an x-axis 362. In the illustrated embodiment, the x-axis 362 is parallel to the ground. The x-axis 362 is substantially perpendicular to the y-axis 326 in which the separator arms 330 (shown in FIG. 3) move. The x-axis 362 is substantially parallel to the valve end 114 of a valve bag 112. The valve opener carriage 370 is located within the housing 305. A slot 372 in the housing 305 permits the arms 360 to move along the x-axis 362.

The valve opener carriage 370 moves along the x-axis 362 to move the valve opening assembly 106 to an inserted position or a retracted position. In the inserted position, the upper and louver valve opening tools 350, 380 are at least partially inserted into the valve end 114 of a valve bag 112. For example, the upper and lower valve opening tools 350, 380 may be inserted into the valve end 114 sufficiently far so that the upper and lower valve opening tools 350, 380 open the valve end 114 when the upper and lower valve opening tools 350, 380 move away from one another. In the retracted position, the upper and lower valve opening tools 350, 380 are moved in an opposing direction along the x-axis 362 so that the upper and lower valve opening tools 350, 380 are removed from the valve end 114. The valve opening assembly 106 is in the retracted position in the embodiment illustrated in FIG. 3. The valve opening assembly 106 is in the inserted position in the embodiment illustrated in FIG. 5.

The arms 360 move towards one another to move the upper and lower valve opening tools 350, 380 towards each other. In some embodiments, only one of the arms 360 moves towards the other arm 360 in order to move the upper and lower valve opening tools 350, 380 towards each other. The upper and lower valve opening tools 350, 380 move towards each other until the upper and lower valve opening tools 350, 380 contact one another. The upper and lower valve opening tools 350, 380 are in a closed position when the upper and lower valve opening tools 350, 380 contact one another. The upper and lower valve opening tools 350, 380 are shown in a closed position in FIGS. 3 and 4. The upper and lower valve opening tools 350, 380 may be inserted into a closed valve end 114 of a valve bag 112 when the upper and lower valve opening tools 350, 380 are in a closed position.

In some embodiments, the arms 360 move away from one another to move the upper and lower valve opening tools 350, 380 away from each other. In one or more other embodiments, only one of the arms 360 moves away from the other to move the upper and lower valve opening tools 350, 380 away from each other. The upper and lower valve opening tools 350, 380 move towards away from one other to separate die tipper and lower valve opening tools 350, 380 from one another and to open the valve end 114. The upper and lower valve opening tools 350, 380 are in an open position when the upper and lower valve opening tools 350, 380 do not contact one another. In some embodiments, the upper and lower opening tools 350, 380 are in the open position when the upper and lower valve opening tools 350, 380 are separated by a minimum distance. The minimum distance is the smallest distance the upper and lower valve opening tools 350, 380 must separate in order to open the valve end 114 of the valve bag 112 a sufficient amount to place the valve end 114 onto a spout 520 (shown in FIG. 1).

In operation, the upper and lower valve opening tools 350, 380 are initially in a closed position. The bag separator assembly 104 lifts a valve bag 112 with a closed valve end 114 upwards along the y-axis 326 until the valve end 114 is at approximately the same height as the upper and lower valve opening tools 350, 380. The bag separator assembly 104 remains in position while the upper and lower valve opening tools 350, 380 are moved along the x-axis 362 towards the valve end 114 of the valve bag 112 being held in place by the bag separator assembly 104. The upper and lower valve opening tools 350, 380 are inserted into the closed valve end 114. The upper and lower valve opening tools 350, 380 then open the valve end 114 by moving away from one another towards the open position (shown in FIG. 5).

Once the upper and lower valve opening tools 350, 380 are inserted into the closed valve end 114, the suction cups 324 (shown in FIG. 3) of the bag separator assembly 104 release the valve end 114. For example, the vacuum pump 310 (shown in FIG. 3) may release the suction force exerted on the valve end 114 by the suction cups 324. As described above, the bag separator assembly 104 then rotates to the second orientation 301 and lowers to the third orientation (shown in FIG. 4) so that the next valve bag 112 may be obtained by the bag separator assembly 104, while avoiding a collision with the upper and lower valve opening tools 350, 380.

In some embodiments, the movements of the bag separator assembly 104 and the valve opening assembly 106 occur simultaneously. For example, the valve opening assembly 106 may move out of the way along the x-axis 362 (or to the left as shown in FIG. 6) while the bag separator assembly 104 moves from the fourth orientation 303 to the first orientation 300 (shown in FIG. 5). By moving the valve opening assembly 106 out of the direction of travel of the bag separator assembly 104 while the bag separator assembly 104 simultaneously moves upwards, production time may be saved. For example, if the leftward movement of the valve opening assembly 106 and the upward movement of the bag separator assembly 104 occurred in a sequence, rather than occur simultaneously, production time could be wasted. The bag separator assembly 104 would have to wait for the valve opening assembly 106 to move out of the direction of travel of the bag separator assembly 104 before the bag separator assembly 104 could move upwards.

In another example of the simultaneous movements of the bag separator assembly 104 and the valve opening assembly 106, the bag separator assembly 104 rotates towards the housing 305 and moves downwards towards the bag supply assembly 102 at the same time that the valve opening assembly 106 opens a valve end 114 of a valve bag 112. For example, once the upper and lower valve opening tools 350, 380 are located in a closed valve end 114 of a valve bag 112, the bag separator assembly 104 releases the valve end 114, moves from the first orientation 300 to the second orientation 301, moves downward to the third orientation 302, and rotates to the fourth orientation 303 (shown in FIG. 5) to obtain the next valve bag 112 at the same time the upper and lower valve opening tools 350, 380 of the valve opening assembly 106 open the valve end 114 of the valve bag 112. The bag separator assembly 104 does not need to wait for the valve opening assembly 106 to move out of the direction of travel of the bag separator assembly 104 before the bag separator assembly 104 lowers to obtain the next valve bag 112.

FIG. 6 is a perspective view of one example embodiment of the grabbing assembly 110 and a portion of the placement assembly 108. The placement assembly 108 moves the grabbing assembly 110 to a location that is proximate to the valve opening assembly 106. The grabbing assembly 110 then grasps the valve end 114 of a valve bag 112. The placement assembly 108 then moves the grabbing assembly 110 to a location that is proximate to one of the spouts 520 (shown in FIG. 1). The placement assembly 108 then moves the grabbing assembly 110 so that the valve end 114 of the valve bag 112 is placed on the spout 520.

The grabbing assembly 110 includes a pair of arms 460 connected to a bracket 450. The bracket 450 interconnects the arms 460 with a robotic arm 410 of the placement assembly 108. Each of the arms 460 is connected to the bracket 450 with an axle 452. The arms 460 can each rotate about a respective axle 452 to move towards and away the other arm 460.

Each of a pair of piston actuators 438 is mounted to the bracket 450. Each of the piston actuators 438 moves a piston 436 towards and away from a contact plate 434 connected to each of the arms 460. In some embodiments, each of the piston actuators 438 includes a linear actuator that moves the piston 436 in a linear direction towards and away from the contact plate 434. For example, the piston actuators 438 may include hydraulic actuators, pneumatic actuators, or electro-mechanical actuators. In some embodiments, the piston actuators 438 may include a linear motor. Each of the pistons 436 may be connected to one of the contact plates 434. The piston actuators 438 each extend and retract the pistons 436 towards and away from the contact plates 434.

The contact plates 434 are mounted to the arms 460. When the piston actuators 438 extend the pistons 436 outwards in a linear direction towards the contact plates 434, the contact plates 434 are forced downward. The downward movement of the contact plates 434 causes the arms 460 to rotate about the axles 452 towards each other. Conversely, when the piston actuators 438 retract the pistons 436 inwards in a linear direction away from the contact plates 434, the contact plates 434 are pulled upwards. The upward movement of the contact plates 434 causes the arms 460 to rotate about the axles 452 away from each other.

The arms 460 rotate about the axles 452 to move towards each other in order to grasp an opened valve end 114 of a valve bag 112. The arms 460 also rotate about the axles 452 to move away from each other in order to release an opened valve end 114. Each of the arms 460 is connected to a valve support plate 430 and one or more anti-slip contacts 442. When the arms 460 move towards one another, the valve support plates 430 on the arms 460 engage the opened valve end 114 while the anti-slip contacts 442 engage the valve bag 112 in a position below the valve end 114. The valve support plates 430 engage the valve end 114 so as to keep the valve end 114 opened. The anti-slip contacts 442 engage the valve bag 112 so as to prevent the valve bag 112 from slipping out from the grasp of the grabbing assembly 110.

Each of the valve supports 430 includes a plurality of teeth 432. The teeth 432 connected to each valve support 430 are positioned to engage the valve end 114 of the valve bag 112. In one example embodiment, the teeth 432 are positioned to engage the valve end 114 on opposite sides of a fold 116 on each side of the valve end 114. By pressing the folds 116 on opposing sides of the valve end 114 towards one another, the valve end 114 may be kept open.

Each of the anti-slip contacts 442 of each arm 460 includes an extension that extends away from a bag support plate 440. Each of a pair of bag support plates 440 is mounted to one of the arms 460. The anti-slip contacts 442 physically contact the valve bag 112 below the valve end 114. The anti-slip contacts 442 may include a surface that prevents the valve bag 112 from moving relative to the bag support plates 440. For example, the anti-slip contacts 442 may each include a rubber surface.

The grabbing assembly 110 may grasp an opened valve end 114 of a valve bag 112 that is being held by the valve opening assembly 106. In order to grab the valve end 114, the piston actuators 438 retract the pistons 436 to cause the arms 460 to move away from one another. The placement assembly 108 moves the grabbing assembly 110 to a position where the valve end 114 is located between the valve supports 430 and the bag support plates 440. The piston actuators 438 then extend the pistons 436 to cause the arms 460 to move towards one another. As the arms 460 move towards one another, the teeth 432 of the valve support plates 430 and the anti-slip contacts 442 of the bag support plates 440 engage the valve end 114 and the valve bag 112.

The grabbing assembly 110 may release an opened valve end 114. In order to release the valve end 114, the piston actuators 438 retract the pistons 436 to cause the arms 460 to move away from one another. As the arms 460 move away from one another, the teeth 432 of the valve support plates 430 and the anti-slip contacts 442 of the bag support plates 440 disengage and release the valve end 114 and the valve bag 112.

The placement assembly 108 includes a robotic arm 410. The robotic arm 410 may include a six axis robotic arm. For example, the robotic arm 410 may be a robotic arm that has six degrees of freedom. A first axis of the robotic arm 410 may be located at a base end 530 (shown in FIG. 1) of the robotic arm 410, the base end 530 may be mounted on a frame 420. The first axis allows the robotic arm 410 to rotate about the base end 530. In some embodiments, the robotic arm 410 can rotate 180 degrees about the base end 530. The robotic arm 410 can rotate about the base end 530 to move the grabbing assembly 110 between the spout 520 and the valve opening assembly 106, for example.

A second axis of the robotic arm 410 allows the robotic arm 410 to rotate about a first elbow 540. The robotic arm 410 can rotate along an arc 542 (shown in FIG. 1) to raise and lower the grabbing assembly 110.

A third axis of the robotic arm 410 allows the robotic arm 410 to rotate about a second elbow 550 (shown in FIG. 1). The robotic arm 410 can rotate along a second arc 552 (shown in FIG. 1). Rotation along the second arc 552 can extend the reach of the robotic arm 410. For example, rotation along the second arc 552 can allow the grabbing assembly 108 to move towards and away from the valve opening assembly 106.

A fourth axis of the robotic arm 410 allows the robotic arm 410 to rotate along a third arc 554 (shown in FIG. 1). The third arc 554 at least partially surrounds the robotic arm 410. Rotation along the third arc 554 assists in positioning the grabbing assembly 110 with respect to the valve opening assembly 106 and with respect to the spout 520.

A fifth axis of the robotic arm 410 allows the robotic arm 410 to rotate about a third elbow 560 (shown in FIG. 1). The robotic arm 410 can rotate along a fourth arc 562. Rotation along the fourth arc 562 allows the grabbing assembly 110 to be tilted up and down. Rotation along the fourth arc 562 also may allow for pitch and yaw motion of the grabbing assembly 110.

A sixth axis of the robotic arm 410 allows the robotic arm 410 to rotate about an axis 570 (shown in FIG. 5). The robotic arm 410 can rotate along a fifth arc 572. Rotation along the fifth arc 572 allows the grabbing assembly 110 to be twisted about the axis 570. In one example embodiment, the robotic arm 410 can twist the grabbing assembly 110 360 degrees along the axis 570.

In operation, the placement assembly 108 moves the grabbing assembly 110 towards the valve opening assembly 106. The grabbing assembly 110 grasps the valve end 114 of a valve bag 112. The placement assembly 108 then moves the grabbing assembly 110 towards one of the spouts 520 (shown in FIG. 1).

The placement assembly 108 moves and rotates the grabbing assembly 110 so that the opened valve end 114 is aligned with one of the spouts 520. For example, in one example embodiment the spout 520 elongated in a direction that is approximately 90 degrees to the valve end 114 of a valve bag 112 that is held by the valve opening assembly 106. The placement assembly 108 may rotate the valve end 114 approximately 90 degrees so that the valve end 114 is aligned with the spout 520. The placement assembly 108 may rotate the valve end 114 and valve bag 112 while simultaneously moving the grabbing assembly 110 towards the spout 520.

Once the valve end 114 is aligned with the spout 520, the valve end 114 is placed on the spout 520. The grabbing assembly 110 then releases the valve end 114 and the valve bag 112. The placement assembly 108 then moves the grabbing assembly 110 back towards the valve opening assembly 106 in order to grasp the next valve bag 112.

In some embodiments, the placement assembly 108 determines whether the valve end 114 is properly placed on a spout 520. For example, the placement assembly 108 can include one or more feedback sensors to determine if the valve end 114 is properly placed on the spout 520. The feedback sensors can include one or more pressure sensors or collision detection sensors. If the valve end 114 of a valve bag 112 is not aligned with the spout 520, the valve end 114 may resist being placed on the spout 520. The feedback sensors can detect if the valve end 114 resists being placed on the spout 520. For example, if the feedback sensors detect a resistance force to placing the valve end 114 on a spout 520 that is greater than a maximum threshold, the placement assembly 108 determines that the valve end 114 was not properly aligned with the spout 520 and that the valve end 114 was not properly placed on the spout 520. If the placement assembly 108 determines that the valve end 114 was not properly placed on the spout 520, then the grabbing assembly 110 can continue to grasp the valve end 114 while the placement assembly 108 removes the valve end 114 from the spout 520. The placement assembly 108 may then move the valve end 114 away from the spout 520. The grabbing assembly 110 can then release the valve end 114 so that the valve bag 112 is discarded.

Once the valve end 114 is placed on the spout 520, the placement assembly 108 returns towards the valve opening assembly 106 to obtain another valve bag 112. In some embodiments, the bag placing system 100 includes the bag filling assembly 116. The bag filling assembly 116 includes a plurality of spouts 520 and one or more reservoirs 510. Each spout 520 is connected to one or more reservoirs 510. The reservoirs 510 include the materials or goods to be placed inside the valve bag 112. The reservoirs 510 direct the materials or goods through the spouts 520 and the opened valve ends 114 located on the spouts 114 into the valve bags 112. Once a valve bag 112 is filled with the materials or goods, the valve end 114 closes and the valve bag 112 drops from the spout 520. For example, the spouts 520 can be angled slightly downward so that the mass of a filled valve bag 112 causes the valve bag 112 to slip off of and drop from the spout 520. While one example embodiment of the spout 520 is illustrated in FIG. 1, the spout 520 includes an device capable of being inserted into a valve end 114 of a valve bag 112 to fill the valve end 114 with a material or volume of goods.

In some embodiments, the bag placing system 100 includes a control panel 390 (shown in FIG. 1). The control panel 390 includes controls or input devices to control, start and/or stop each of the bag supply assembly 102, the bag separator assembly 104, the valve opening assembly 106, the placement assembly 108 and the grabbing assembly 110. For example, the control panel 390 can include switches, buttons and/or other input devices for controlling the bag supply assembly 102, the bag separator assembly 104, the valve opening assembly 106, the placement assembly 108 and/or the grabbing assembly 110.

In some embodiments, the movements of two or more of the valve opening assembly 106, the placement assembly 108 and the grabbing assembly 110 occur simultaneously. For example, the valve opening assembly 106 may move away from the grabbing assembly 110 (in the x-axis 362 shown in FIG. 4) at the same time that the grabbing assembly 110 grasps the valve end 114 of the valve bag 112 (that was opened by the valve opening assembly 106) and at the same time that the placement assembly 108 moves the grabbing assembly 110 away from the valve opening assembly 106.

In some embodiments, the movements of two or more of the valve opening assembly 106, the placement assembly 108 and the grabbing assembly 110 occur simultaneously with the movements of the bag separator assembly 104 and the valve opening assembly 106. For example, the grabbing assembly 110 may grasp a valve bag 112 from the valve opening assembly 106 while the valve opening assembly 106 moves away from the grabbing assembly 110. As the grabbing assembly 110 grasps the valve bag 112 and the valve opening assembly 106 moves away from the grabbing assembly 110, the bag separator assembly 104 may rotate towards the housing 305 and lower towards the bag supply assembly 102.

In some embodiments, the placement assembly 108 may move the grabbing assembly 110 away from the valve opening assembly 106 and towards a spout 520 at the same time that the valve opening assembly 106 moves away from the grabbing assembly 110 and at the same time that the bag separator assembly 104 lowers towards the bag supply assembly 102.

By performing several of the actions described above simultaneously, the throughput efficiency of the bag placing system 100 can increase over known bag placement systems. For example, the bag placing system 100 may separate the valve bags 112, open the valve ends 114 of the valve bags 112, and move the valve ends 114 onto the spouts 520 for more valve bags 112 in a given time period than known bag placing systems.

FIG. 7 is a flowchart of one example embodiment of a method 600 for placing a plurality of valve bags 112 on one or more spouts 520 of the bag filling assembly 116. First, at step 602, one or more groups of valve bags 112 are moved towards the bag separator assembly 104. For example, the bag supply assembly 102 may move one or more groups of valve bags 112 towards the bag separator assembly 104, as described above.

At step 604, the bag separator assembly 104 lowers to the top valve bag 112 in the group of valve bags 112 that are in a location that is proximate to the bag separator assembly 104. In some embodiments, the bag separator 104 lowers to the top valve bag 112 in the bag supply assembly 102 by rotating towards the housing 305 and then lowering along the y-axis 326 towards the bag supply assembly 102.

At step 606, the bag separator assembly 104 separates the top valve bag 112 from the group of valve bags 112. For example, the bag separator assembly 104 may rotate away from the housing 305, exert a suction force on the top valve bag 112, and then move upwards away from the bag supply assembly 102.

At step 608, a determination is made as to whether any additional valve bags 112 remain in the group of valve bags 112. For example, a determination is made as to whether the valve bag 112 that was separated and removed at step 606 was the last valve bag 112 in a group of valve bags 112. If the valve bag 112 removed at step 606 was the last valve bag 112 in the group, then the method 600 proceeds from step 608 to step 610. At step 610, the next group of valve bags 112 is advanced towards the bag separator assembly 104. In one embodiment, the method 600 proceeds from step 610 to step 640.

Alternatively, if the valve bag 112 removed at step 606 was not the last valve bag 112 in the group, then the method 600 proceeds from step 608 to step 612.

At step 612, at least a portion of the valve opener assembly 106 is inserted into the valve end 114 of the valve bag 112 that was removed at step 606. For example, the upper and lower valve opening tools 350, 380 are inserted into the valve end 114.

At step 613, the valve end 114 is released by the bag separator assembly 104 and the bag separator assembly 104 lowers to separate the next valve bag 112 from the group of valve bags 112. For example, the bag separator assembly 104 may rotate towards the housing 305 and lower towards the bag supply assembly 102.

At step 614, the valve end 114 is opened. For example, the upper and lower valve opening tools 350, 380 are separated from one another to open the valve end 114.

At step 616, the opened valve end 114 is grasped by the grabbing assembly 110. For example, the placement assembly 108 moves the grabbing assembly 110 towards the valve opening assembly 106 so the grabbing assembly 110 can grasp the valve end 114.

At step 617, the valve opener assembly 106 is removed from the opened valve end 114. For example, the upper and lower valve opening tools 350, 380 are moved away and out of the valve end 114. The upper and lower valve opening tools 350, 380 may be returned to a closed before or after the upper and lower tools 350, 380 are removed from the valve end 114.

At step 618, the opened valve end 114 is moved to a spout 520. For example, the placement assembly 108 moves the grabbing assembly 110 from a location that is proximate to the valve opening assembly 106 towards a spout 520. The placement assembly 108 then moves the grabbing assembly 110 and the valve end 114 so the valve end 114 is placed onto the spout 520.

At step 620, a determination is made as to whether the valve end 114 was properly placed on the spout 520. For example, a determination is made as to whether the valve end 114 was aligned with the spout 520 when the valve end 114 was placed on the spout 520. If the valve end 114 was not aligned with the spout 520, then the valve end 114 may not have been placed on the spout 520 or the valve end 114 may have been misaligned with the spout 520.

If the valve end 114 was not properly placed on the spout 520, the method 600 proceeds from step 620 to step 622. At step 622, the valve end 114 is removed from the spout 520. For example, the placement assembly 108 removes the valve end 114 from the spout 520 before the grabbing assembly 110 releases the valve end 114. The method 600 then proceeds to step 624.

If the valve end 114 was properly placed on the spout 520, the method 600 proceeds from step 620 to step 624. At step 624, the valve end 114 is released. For example, the grabbing assembly 110 releases the valve end 114. If the valve end 114 was removed from the spout 520 at step 622, then the valve end 114 and the valve bag 112 is discarded once released at step 624. If the valve end 114 was properly placed on the spout 520 at step 618, then the valve end 114 is released at step 624 and left on the spout 520.

At step 626, the grabbing assembly 110 is returned towards the valve opening assembly 106 by the placement assembly 108. The grabbing assembly 110 is returned towards the valve opening assembly 106 to grasp the next valve bag 108.

In some embodiments, one or more of the steps of method 600 occur simultaneously. For example, steps 612 and 613 can occur simultaneously. As the upper and lower valve opening tools 350, 380 of the valve opening assembly 106 is inserted into the valve end 114 of one valve bag 112, the bag separator assembly 104 may rotate towards the housing 305 and lower towards the bag supply assembly 102 to obtain the next valve bag 112.

In another example, steps 614 and steps 616 occur simultaneously. For example, the valve end 114 of a valve bag 112 can be opened by the valve opening assembly 106 while the grabbing assembly 110 grasps the valve end 114.

In another example, steps 617 and steps 618 occur simultaneously. For example, the upper and lower valve opening tools 350, 380 are removed from the valve end 114 while the placement assembly 108 moves the grabbing assembly 110 and the valve end 114 towards a spout 520.

In some embodiments, step 614 is performed prior to step 613. For example, the valve end 114 of a valve bag 112 is opened by the valve opening assembly 106 before the bag separator assembly 104 releases the valve end 114.

It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and merely are example embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means—plus-function format and are not intended to be interpreted based on 35 U.S.C. §112, sixth paragraph, unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.

Claims

1. A system for opening a valve bag, the system comprising:

a bag separator assembly being rotatable about a rotation axis, the bag separator assembly configured to move along a y-axis toward a plurality of valve bags to obtain the valve bag and to move in an opposing direction along the y-axis to separate the valve bag from the plurality of valve bags, the y-axis and rotation axis being perpendicular to one another; and

a valve opening assembly configured to open a valve end of the valve bag, the valve opening assembly being configured to move along an x-axis to be inserted into and removed from the valve end of a valve bag being held by the bag separator assembly, wherein the bag separator assembly avoids contact with the valve opening assembly by rotating about the rotation axis before moving along the y-axis toward the plurality of valve bags.

2. The system according to claim 1, wherein the valve opening assembly avoids contact with the bag separator assembly by moving along the x-axis as the bag separator assembly moves along the y-axis to lift a valve bag up to the valve opening assembly.

3. The system according to claim 1, wherein the bag separator assembly moves along the y-axis towards the plurality of valve bags as the valve opening assembly opens the valve end of a valve bag.

4. The system according to claim 1, wherein the valve opening assembly moves along the x-axis between inserted and retracted positions, the valve opening assembly being partially inserted into the valve end when in the inserted position and the valve opening assembly being removed from the valve end when in the retracted position.

5. The system according to claim 1, wherein the valve opening assembly moves towards the retracted position as the bag separator assembly moves along the y-axis away from the plurality of valve bags.

6. The system according to claim 1, further comprising a grabbing assembly having a plurality of arms configured to engage the valve bag and the valve end of the valve bag, the grabbing assembly engaging the valve bag before the valve opening assembly is removed from the valve end by moving along the x-axis away from the valve end.

7. The system according to claim 1, further comprising a grabbing assembly and a placement assembly, the grabbing assembly engaging the valve end of the valve bag that has been opened by the valve opening assembly, the placement assembly moving the grabbing assembly away from the valve opening assembly as the valve opening assembly is removed from the valve end by moving along the x-axis away from the valve end.

8. A method for filling a valve bag, the method comprising:

lifting a first valve bag with a bag separator assembly along a y-axis to enable a valve opening assembly to be inserted into a valve end of the first valve bag;

inserting the valve opening assembly into the valve end of the first valve bag by moving the valve opening assembly along an x-axis;

returning the bag separator assembly to a group of valve bags by rotating the bag separator assembly about a rotation axis and moving the bag separator assembly along the y-axis towards the group of valve bags;

obtaining a second valve bag from the group of valve bags;

lifting the second valve bag with the bag separator assembly to enable the valve opening assembly to be inserted into a valve end of the second valve bag; and

removing the valve opening assembly from the valve end of the first valve bag by moving the valve opening assembly along the x-axis so as to avoid contact with the bag separator assembly.

9. The method according to claim 8, wherein the returning step comprises rotating the bag separator assembly about the rotation axis and away from the valve opening assembly before the bag separator assembly is moved along the y-axis toward the group of valve bags.

10. The method according to claim 8, wherein the obtaining step comprises rotating the bag separator assembly about the rotation axis and towards the group of valve bags and engaging the second valve bag.

11. The method according to claim 8, wherein the rotation axis and y-axis are perpendicular.

12. The method according to claim 8, wherein removing step comprises moving the valve opening assembly along the x-axis so as to avoid contact with the bag separator assembly as the bag separator assembly moves away from the group of valve bags.

13. The method according to claim 8, further comprising opening the valve end of the first valve bag, wherein the opening and returning steps occur simultaneously.

14. The method according to claim 8, further comprising:

grasping the valve end of the first valve bag and the first valve bag; and

moving the valve end and the first valve bag away from the valve opening assembly towards a bag filling apparatus, wherein the removing and moving steps occur simultaneously.

15. A system for obtaining, opening, placing and filling a valve bag, the system comprising:

a bag supply assembly configured to supply a plurality of groups of valve bags;

a valve opening assembly configured to open a valve end of each of the valve bags;

a bag separator assembly configured to raise and lower along a first slot in a housing and to rotate towards and away from the housing in order to individually obtain each of the valve bags in the groups of valve bags while avoiding contact with the valve opening assembly, the bag separator assembly individually lifting each of the valve bags to the valve opening assembly;

a grabbing assembly configured to engage the valve end of each of the valve bags; and

a placement assembly configured to move the valve end from a location that is proximate to the valve opening assembly and to place the valve end in a location that is proximate to a bag filling assembly.

16. The system according to claim 15, wherein the bag separator assembly is configured to obtain a valve bag from the bag supply assembly by rotating towards the housing, lowering towards the bag supply assembly, rotating away from the housing, engaging the valve bag, and lifting the valve bag to the valve opening assembly.

17. The system according to claim 15, wherein the valve opening assembly is configured to move in two diametrically opposed directions along a second slot in the housing, the valve opening assembly moving in a first direction along the second slot to be inserted into the valve end and moving in a second direction along the second slot to be removed from the valve end.

18. The system according to claim 17, wherein the valve opening assembly moves in the second direction to avoid contact with the bag separator assembly when the bag separator assembly lifts a valve bag.

19. The system according to claim 15, wherein the placement assembly moves the valve end of a valve bag away from the valve opening assembly as the valve opening assembly is removed from the valve end.

20. The system according to claim 15, wherein the grabbing assembly disengages the valve end of a valve bag once the placement assembly has placed the valve end in the location that is proximate to the bag filling assembly.