Apparatus and method for sensing a container positioned about a filling spout

Abstract

An apparatus for filling at least one container includes a filling spout in flow communication with a source of filling material. The filling spout is configured to enable the opening of the at least one container to fit about the filling spout. Two sensor assemblies are positioned about the filling spout. The two sensor assemblies are configured to detect whether a container is positioned about the filling spout. A controller operatively coupled to each sensor assembly of the two sensor assemblies is configured to initiate a filling process.

1 . An apparatus for filling at least one container, the at least one container defining an opening, the apparatus comprising:
 a filling spout in flow communication with a source of filling material, the filling spout configured to enable the opening of the at least one container to fit about the filling spout;   at least two sensor assemblies positioned about the filling spout, the at least two sensor assemblies configured to detect whether a container is positioned about the filling spout; and   a controller operatively coupled to each sensor assembly of the at least two sensor assemblies and configured to initiate a filling process.   
     
     
         2 . An apparatus in accordance with  claim 1  wherein each sensor assembly of the at least two sensor assemblies is positioned with respect to the filling spout, each sensor assembly comprising at least one of a laser sensing component, an ultrasonic sensing component and a photoeye sensing component. 
     
     
         3 . An apparatus in accordance with  claim 1  wherein each sensor assembly of the at least two sensor assemblies comprises a sensing component configured to emit a light beam directed at a first reference point proximate to the filling spout. 
     
     
         4 . An apparatus in accordance with  claim 3  wherein each sensor assembly is configured to measure a first distance between a sensing component position and the first reference point and a second distance between the sensing component position and a second reference point, the first reference point and the second reference point at least partially defining a sensing range. 
     
     
         5 . An apparatus in accordance with  claim 4  wherein the first reference point corresponds to a first point on the filling spout outer surface and the second reference point corresponds to an opposing second point on the filling spout outer surface. 
     
     
         6 . An apparatus in accordance with  claim 5  wherein the first distance is defined between the sensing component position and the first reference point on a first plane tangential to the first point, and the second distance is defined between the sensing component position and the second reference point on a second plane tangential to the second point. 
     
     
         7 . An apparatus in accordance with  claim 6  wherein, upon at least one sensor assembly of the at least two sensor assemblies detecting one of a third distance greater than the second distance and a fourth distance less than the first distance, the at least one sensor assembly prevents transmission of a confirmation signal from the at least one sensor assembly to the controller indicating that the container is properly positioned about the filling spout. 
     
     
         8 . An apparatus in accordance with  claim 6  wherein, upon each sensor assembly detecting a container position point within the sensing range, each sensor assembly transmits a confirmation signal to the controller indicating that the container is properly positioned about the filling spout. 
     
     
         9 . A detection system for determining whether a container is positioned about a filling spout of an apparatus for filling at least one container, the filling spout in flow communication with a source of filling material, the filling spout configured to enable an opening defined by the container to fit about the filling spout, the detection system comprising:
 at least two sensor assemblies positioned with respect to the filling spout, each sensor assembly of the at least two sensor assemblies including a sensing component, the sensing component calibrated to measure a first distance between a sensing component position and a first reference point and a second distance less than the first distance between the sensing component position and a second reference point such that a sensing range is at least partially defined between the first reference point and the second reference point; and   a controller operatively coupled to each sensor assembly and configured to initiate a filling process.   
     
     
         10 . A detection system in accordance with  claim 9  wherein each sensing component comprises a laser sensing component configured to emit a light beam directed at the first reference point, the laser sensing component electrically coupled to the controller. 
     
     
         11 . A detection system in accordance with  claim 9  wherein, upon each sensing component detecting a third distance within the sensing range, each sensing component configured to transmit a confirmation signal to the controller indicating that a container is properly positioned about the filling spout. 
     
     
         12 . A detection system in accordance with  claim 9  wherein, upon at least one sensing component detecting one of a third distance greater than the first distance and a fourth distance less than the second distance, the at least one sensing component configured to transmit a container positioning error signal to the controller indicating that a container is not properly positioned about the filling spout. 
     
     
         13 . A method for filling a container, the container defining an opening, an apparatus being positioned along a processing path, the method comprising:
 positioning at least two sensor assemblies with respect to a filling spout of the apparatus, each sensor assembly of the at least two sensor assemblies comprising at least one of a laser sensing component, an ultrasonic sensing component and a photoeye sensing component, the filling spout in flow communication with a source of filling material, the filling spout configured to enable the opening of the container to fit about the filling spout;   calibrating the at least two sensor assemblies to define a sensing area;   placing the container on a support configured for receiving, in succession, a plurality of containers, the support configured to maintain each successive container of the plurality of containers in an orientation with the opening extending toward the apparatus;   confirming that the container is positioned about the filling spout; and   filling the container with filling material.   
     
     
         14 . A method in accordance with  claim 13  wherein calibrating the two sensor assemblies to define a sensing range further comprises:
 sensing a first distance corresponding to a container positioned on said filling spout; and   sensing a second distance less than the first distance and corresponding to a container positioned on said filling spout, the first distance and the second distance at least partially defining the sensing range.   
     
     
         15 . A method in accordance with  claim 14  wherein, upon at least one sensor assemblies of the at least two sensor assemblies detecting one of a third distance greater than the first distance and a fourth distance less than the second distance, the at least one sensor assembly transmitting a container positioning error signal to a controller in operational control communication with the filling spout indicating that a container is not properly positioned about the filling spout. 
     
     
         16 . A method in accordance with  claim 14  wherein, upon each sensor assembly of the at least two sensor assemblies detecting a third distance within the sensing range, each sensor assembly transmitting a confirmation signal to a controller in operational control communication with the filling spout indicating that a container is properly positioned about the filling spout. 
     
     
         17 . A method in accordance with  claim 14  further comprising preventing flow of filling material through the filling spout until each sensor assembly of the at least two sensor assemblies detects a third distance within the sensing range. 
     
     
         18 . A method for determining whether a container is positioned about a filling spout of an apparatus for filling the container, the filling spout in flow communication with a source of filling material and configured to enable an opening defined by the container to fit about the filling spout, the method comprising:
 providing at least two sensor assemblies positioned with respect to the filling spout, each sensing assembly of the two sensor assemblies including a sensing component; and   calibrating the sensing component to measure a first distance corresponding to a first container position on the filling spout and a second distance greater than the first distance and corresponding to a second container position on the filling spout, the first distance and the second distance at least partially defining a sensing range.   
     
     
         19 . A method in accordance with  claim 18  wherein, upon each sensing component detecting a third distance within the sensing range, each sensing component transmits a signal to a controller in operational control communication with the filling spout indicting that a container is positioned about the filling spout. 
     
     
         20 . A method in accordance with  claim 18  wherein, upon at least one sensing component detecting one of a third distance greater than the second distance and a fourth distance less than the first distance, the at least one sensing component transmitting a container positioning error signal to a controller in operational control communication with the filling spout indicating that a container is not properly positioned about the filling spout.