Foam-in-bag apparatus with power-failure protection
View Patent ↗Exemplary embodiments of the present disclosure can provide a foam-in-bag device. The device can include a dispenser unit configured for dispensing a fluid foam-precursor into a web of film material for making foam-in-bag packaging material, a fluid supply conduit connected to the dispenser unit for delivering the foam-precursor to the dispenser unit, a valve connected to the dispenser outlet and that is actuatable between: an open condition allowing flow of the foam-precursor so as to permit the dispensing of the foam precursor, and a closed condition preventing flow of the-foam precursor so as to prevent the dispensing of the foam precursor. The device can further include a power-loss protection mechanism configured to direct auxiliary power to actuate the valve to the closed condition upon a loss of incoming power.
1. A foam-in-bag device powered by an incoming power supply, comprising:
a dispenser unit configured for dispensing a foam-precursor into a web of film material for making foam-in-bag packaging material;
a fluid supply conduit connected to the dispenser unit for delivering the foam-precursor to the dispenser unit;
a valve that is normally powered by incoming power from the incoming power supply and is connected to the dispenser outlet and actuatable between:
an open condition allowing flow of the foam-precursor so as to permit the dispensing of the foam precursor, and
a closed condition preventing flow of the-foam precursor so as to prevent the dispensing of the foam precursor; and
a power-loss protection mechanism configured to direct remaining power from the incoming power supply to actuate the valve to the closed condition upon detecting a loss of the incoming power and terminate foam-in-bag production of the foam-in-bag device.
2. The device of claim 1 , wherein the power-loss protection mechanism is connected for detecting the loss of incoming power and directing the remaining power to the valve when the loss of incoming power is detected.
3. The device of claim 1 , wherein the remaining power is supplied by the incoming power supply.
4. The device of claim 3 , wherein the remaining power includes residual power from the first power supply after the loss of incoming power.
5. The device of claim 4 , wherein the incoming power supply includes at least one capacitor and the residual power includes power stored on the capacitor.
6. The device of claim 1 , wherein the power-loss protection mechanism is configured to direct the remaining power to actuate the valve to the closed condition for less than about 10 seconds.
7. The device of claim 1 , wherein the power-loss protection mechanism includes:
a power-loss detection arrangement configured to detect the loss of incoming power and generate a power failure signal; and
a power-loss processing arrangement configured to process the power failure signal.
8. The device of claim 7 , wherein the power-loss processing arrangement includes
a field programmable gate array; and
an optical isolator for processing the power failure signal.
9. The device of claim 1 , further comprising a valve actuation arrangement operably associated with the valve for actuating the valve between the open and closed conditions, the valve actuation arrangement including a sensor configured to detect a position of the valve for controlling the actuation for closing the valve when the loss of incoming power is detected.
10. The device of claim 9 , wherein the actuation arrangement comprises a motor.
11. The device of claim 1 , wherein the foam precursor includes first and second foam precursors selected for reacting together to produce a foam that expands and solidifies for the foam-in-bag protective packaging, and wherein the dispenser unit comprises a mixing module configured for mixing and dispensing the foam precursors.
12. The device of claim 11 , wherein the valve in the closed condition prevents the flow of the first and second foam precursors from the dispenser unit.
13. The device of claim 1 , wherein the valve comprises a valving rod.
14. The foam-in-bag device of claim 1 , further comprising:
a valve actuation assembly comprising:
a motor normally powered by the incoming power supply and operably connected to the valve, wherein the motor moves the valve between the open condition and the closed condition; and
a valve sensor that detects a position of the valve.
15. The foam-in-bag device of claim 14 , wherein the power-loss protection mechanism further comprises:
a processor in electrical communication with the valve actuation assembly; and
a monitoring module in communication with the processor and the incoming power supply; wherein
the monitoring module monitors the incoming power supply and transmits a power fail signal to the processor upon detecting the loss of incoming power;
the processor receives the position of the valve from the valve sensor; and
if the valve is in the open condition, the processor provides remaining power from the incoming power supply to the motor to actuate the valve to the closed condition.
16. The foam-in-bag device of claim 15 , wherein the power-loss protection mechanism further comprises a filter in electrical communication with the monitoring module and the processor, wherein the filter receives the power fail signal from the monitoring module and filters the power fail signal prior to transmitting the power fail signal to the processor.
17. The foam-in-bag device of claim 16 , wherein the filter comprises:
an optical isolator filter that provides initial filtering for the power fail signal; and
a digital filter that introduces a time delay into the power fail signal.
18. A method for preventing dispensing of a foam precursor in a foam-in-bag device, comprising:
detecting a loss of incoming power from a main power supply; and
directing auxiliary power to actuate a valve to a closed condition when the loss of incoming power is detected to prevent the dispensing of the foam precursor and terminate foam-in-bag production of the foam-in-bag device.
19. The method of claim 18 , wherein the auxiliary power includes residual power from the main power supply after the loss of incoming power.
20. The method of claim 19 , wherein the residual power is stored on a capacitor.
21. The method of claim 18 , wherein the auxiliary power is supplied from an auxiliary power supply to actuate the valve to the closed condition.
22. The method of claim 18 , further comprising:
generating a power failure signal when the loss of incoming power is detected; and
processing the power failure signal to effectuate direction of the auxiliary power to actuate the valve.
23. The method of claim 22 , wherein the processing is at least partially performed by a field programmable gate array.
24. The method of claim 22 , further comprising detecting a position of the valve prior to directing the auxiliary power to actuate the valve.
25. The foam-in-bag device of claim 1 including a main power supply circuit in electrical communication with the incoming power supply, wherein the main power supply circuit stores the remaining power from the incoming power supply to actuate the valve.
26. The method of claim 18 , wherein the closed condition of the valve is a position between a fully open position and a fully closed position.