Process and apparatus for dispensing liquid colorants into a paint can, and quality control therefor

• US 5,203,387 A
• Filed: 05/13/1992
• Issued: 04/20/1993
• Est. Priority Date: 11/06/1989
• Status: Expired due to Fees

• Current Assignee: Fluid Management Incorporated
• Original Assignee: Dunn Edwards Corporation & Fluid Management Limited Part
• Inventors: Howlett, Philip, Frederickson, Larry, Edwards, Edward D., Edwards, Kenneth N.
• Primary Examiner(s): CUSICK, ERNEST
• Application Number:
  US07/882,503
• Time in Patent Office: 342 Days
• Field of Search: 141/1, 141/9, 141/83, 141/94, 141/98, 141/102, 141/103, 141/104, 141/129, 141/156, 141/157, 366/605, 365/479, 235/376, 235/462
• US Class Current: 141/103
• CPC Class Codes: B01F 2101/30 Mixing paints or paint ingredients, e.g. pigments, dyes, colours, lacquers or enamel
• CPC Class Codes: B01F 33/84 Mixing plants with mixing receptacles receiving material dispensed from several component receptacles, e.g. paint tins
• CPC Class Codes: B01F 33/848 using data, i.e. barcodes, 3D codes or similar type of tagging information, as instruction or identification codes for controlling the dispensing and mixing operations
• CPC Class Codes: B01F 33/85 Mixing plants with mixing receptacles or mixing tools that can be indexed into different working positions
• CPC Class Codes: B01F 35/2218 Weight of at least one component to be mixed
• CPC Class Codes: B01F 35/71 Feed mechanisms with proportioning B01F35/80
• CPC Class Codes: B01F 35/712 for feeding fluids
• CPC Class Codes: B01F 35/714 for feeding predetermined amounts B01F35/88 takes precedence
• CPC Class Codes: B01F 35/715 Feeding the components in several steps, e.g. successive steps
• CPC Class Codes: B01F 35/7176 using pumps
• CPC Class Codes: B01F 35/7179 using sprayers, nozzles or jets
• CPC Class Codes: B01F 35/881 by weighing, e.g. with automatic discharge
• CPC Class Codes: B65G 2201/0244 Bottles
• CPC Class Codes: B65G 2203/0216 Codes or marks on the article
• CPC Class Codes: Y10S 366/605 Paint mixer

Abstract

An automated paint-batching system for producing paint cans of any size and color. The system includes a plurality of paint-batching cells, with each cell having a machine comprised of either one or two dispensing stations. When two dispensing stations are used, the two dispensing stations are: A first tint-station, where a small volumetric dispensing of the base, water-base or oil base, of the paint is dispensed, in order to wet the bottom of the can, at which first station, thereafter, is dispensed all of the liquid colorants making up the formula of the paint can, at which the remainder of the base of the formula of the paint is dispensed, and a second base-dispensing station. Each of the first and second stations of the paint-batching machine of the invention has operatively associated therewith a weighing platform upon which rests the paint can during the dispensing at the respective station used in quality-control weighing of each dispensing. When only one dispensing station is used, all of the above-steps are performed at the one station. Each paint can has attached to it a bar-code label which represents a relocatable memory-address of the computer which stores the color-formula from that can and other information. The computer operating system controls the guidance of the particular paint can along its conveyance, so that the paint can is designated to one of a plurality of paint-batching cells of the system of the invention, with the bar-code of the paint can being read at a plurality of stations along the entire manufacturing process.

Claims

1. A paint batching apparatus, comprising:

a first tint-dispensing station comprising first storage means for storing the paint ingredients for dispensing into a paint can, first nozzle means for dispensing the paint ingredients directly into the paint can positioned therebelow, first pump means for pumping the paint ingredients from said first storage means to said first nozzle means, and first control means for controlling the operations of said first nozzle means and said first pump means for dispensing desired ones of paint ingredients; and

a second base-dispensing station comprising second storage means for storing the liquid base paint ingredients for dispensing into a paint can, second nozzle means for dispensing the paint ingredients directly into the paint can positioned therebelow, second pump means for pumping the paint ingredients from said second storage means to said second nozzle means, and second control means for controlling the operations of said second nozzle means and said second pump means for dispensing desired ones of paint ingredients;

said first storage means comprising a plurality of first supply-containers for storing therein a respective liquid-colorant paint ingredient, and said first nozzle means comprising a plurality of first dispensing nozzles;

said first pump means comprising a plurality of first conduit means for fluidly connecting each of said first supply-containers to a respective and unique one of said first dispensing nozzles, and a plurality of valves operatively associated with said plurality of first conduit means, one said valve for one said first conduit means, for controlling the flow through said first conduit means;

said first nozzle means further comprising at least one supplemental dispensing nozzle for dispensing liquid base paint ingredient at said first tint-dispensing station.

2. The paint batching apparatus according to claim 1, wherein said second pump means comprises second conduit means for fluidly connecting said second storage means to said second nozzle means for the pumping thereof from said second storage means to said second second nozzle means, and valve means for controlling the flow through said second conduit means.

3. The paint batching apparatus according to claim 2, wherein said second pump means further comprises interconnecting conduit means fluidly connecting said second storage means of said second base-dispensing station to said at least one supplemental dispensing nozzle of said first tint-dispensing station, whereby liquid base stored at said second station may be dispensed at said first station before the dispensing of any liquid colorant thereat, in order to prewet the bottom of the paint can to prevent adhesion of liquid colorants to the bottom of the paint can, to ensure thorough mixing of the paint.

4. The paint batching apparatus according to claim 3, wherein said first pump means further comprises supplemental valve means for controlling the flow through said interconnecting conduit means for controlling the supply of liquid base to said first tint-dispensing station.

5. The paint batching apparatus according to claim 4, wherein said second storage means comprises a plurality of second supply-containers for storing liquid base, at least one said second supply-container being operatively coupled to said second conduit means for supplying liquid base at said second base-dispensing station, and at least one said second supply-container being operatively coupled to said interconnecting conduit means for supplying liquid base to said first tint-dispensing station for prewetting a paint can.

6. The paint batching apparatus according to claim 5, wherein each of said plurality of second supply-containers is operatively coupled to said second conduit means and to said interconnecting conduit means for selectively providing liquid base to said first and second stations;

said second control means of said second station controlling the operation of said supplemental valve means of said interconnecting conduit means.

7. The paint batching apparatus according to claim 4, further comprising conveyer means for conveying a paint can from said first tint-dispensing station to said second base-dispensing station, and conveyer-control means controlling the operation of said conveyer means for periodic operation of transporting of cans.

8. The paint batching apparatus according to claim 7, wherein said conveyor means comprises a first transport-section associated with said first tint-dispensing station, and a second transport-section associated with said second base-dispensing station upon which a paint can is supported and moved, each said second being mounted below a respective said nozzle means of the respective said station;

said conveyer means also comprising a first pair of adjustable, laterally-opposite guide-rails operatively associated with said first transport-section and positioned one along each edge-surface of said first transport-section, and a second pair of adjustable, laterally-opposite guide-rails operatively associated with said second transport-section and positioned one along each edge-surface of said second transport-section, each said guide-rail of each of said first and second pair of guide-rails being adjustably positionable toward and way from the other of the same said pair, whereby paint cans of different sizes may be accomodated, said guide-rails guiding the paint cans along said first and second transport-sections;

said conveyer means also comprising means for moving each said guide-rail toward and away from the other said guide-rail of the same said pair.

9. The paint batching apparatus according to claim 1, further comprising a first paint-can bar-code reading station located forwardly, upstream of said first tint-dispensing station;

and a second paint-can bar-code reading station located rearwardly, downstream of said first reading station between said first and second dispensing stations;

whereby informational bar-code on the paint can may be read in order to determine color-formula for that paint can, size of can, and other information.

10. The paint batching apparatus according to claim 9, wherein each of said bar-code reading stations comprises means for rotating the paint can, and optical scanner means for scanning the bar-code on the can for the actual reading thereof.

11. The paint batching apparatus according to claim 1, wherein said first tint-dispensing station comprises a first microprocessor-control, and said second base-dispensing station comprises a second microprocessor-control;

each said microprocessor-control controlling the amounts of liquid paint ingredients dispensed at the respective said station.

12. A paint batching apparatus, comprising:

a first tint-dispensing station comprising first storage means for storing the paint ingredients for dispensing into a paint can, first nozzle means for dispensing the paint ingredients directly into the paint can positioned therebelow, first pump means for pumping the paint ingredients from said first storage means to said first nozzle means, and first control means for controlling the operations of said first nozzle means and said first pump means for dispensing desired ones of paint ingredients;

a second base-dispensing station comprising second storage means for storing the liquid base paint ingredients for dispensing into a paint can, second nozzle means for dispensing the paint ingredients directly into the paint can positioned therebelow, second pump means for pumping the paint ingredients from said second storage means to said second nozzle means, and second control means for controlling the operations of said second nozzle means and said second pump means for dispensing desired ones of paint ingredients;

conveyer means for conveying a paint can from said first tint-dispensing station to said second base-dispensing station, and conveyer-control means controlling the operation of said conveyer means for periodic operation of transporting of cans;

said conveyor means comprising a first transport-section associated with said first tint-dispensing station, and a second transport-section associated with said second base-dispensing station upon which a paint can is supported and moved, each said section being mounted below a respective said nozzle means of the respective said station;

said conveyer means also comprising a first pair of adjustable, laterally-opposite guide-rails operatively associated with said first transport-section and positioned one along each edge-surface of said first transport-section, and a second pair of adjustable, laterally-opposite guide-rails operatively associated with said second transport-section and positioned one along each edge-surface of said second transport-section, each said guide-rail of each of said first and second pair of guide-rails being adjustably positionable toward and way from the other of the same said pair, whereby paint cans of different sizes may be accomodated, said guide-rails guiding the paint cans along said first and second transport-sections;

said conveyer means also comprising means for moving each said guide-rail toward and away from the other said guide-rail of the same said pair.

13. The paint batching apparatus according to claim 12, wherein said first pair of guide-rails is positioned along the forward, upstream portion of said first transport-section, and said second pair of guide-rails is positioned along the forward, upstream portion of said second transport-section;

said conveyer means further comprising a first supplemental pair of adjustable, laterally-opposite guide-rails operatively associated with said first transport-section and positioned one along each edge-surface of said second transport-section along the rearward, downstream portion thereof, and a second supplemental pair of adjustable, laterally-opposite guide-rails operatively associated with said second transport-section and positioned one along each edge-surface of said second transport-section along the rearward, downstream portion thereof, each said guide-rail of each of said first and second supplemental pairs of guide-rails being adjustably positionable toward and way from the other of the same said supplemental pair;

said means for moving each said guide-rail toward and away from the other said guide-rail of the same said pair also moving each said guide-rail of said first and second supplemental pairs of guide-rails toward and away from each other said guide-rail of same said supplemental pair.

14. The paint batching apparatus according to claim 13, wherein the rearward, downstream end of said first pair of guide-rails and the forward, upstream end of said first supplemental pair of guide-rails are spaced apart in the longitudinal, downstream direction to define a first paint-can tint-filling location under said first nozzle means where the can receives the liquid colorants at said first tint-dispensing station;

and the rearward, downstream end of said second pair of guide-rails and the forward, upstream end of said second supplemental pair of guide-rails are spaced apart in the longitudinal, downstream direction to define a second paint-can base-filling location under said second nozzle means where the can receives the liquid base at said second base-dispensing station;

said means for moving the guide-rails of said conveyer means independently moving a respective said first pair of guide-rails, said second pair of guide-rails, said first supplemental pair of guide-rails, and said second supplemental pair of guide-rails.

15. The paint batching apparatus according to claim 14, wherein said means for moving of said conveyor means comprises a first plurality of piston-cylinder assemblies for moving said first pair of guide-rails toward and away from each other, a second plurality of piston-cylinder assemblies for moving said second pair of guide-rails toward and away from each other, a third plurality of piston-cylinder assemblies for moving said first supplemental pair of guide-rails toward and away from each other, and a fourth plurality of piston-cylinder assemblies for moving said second pair of supplemental guide-rails toward and away from each other, whereby said independent movement is achieved.

16. The paint batching apparatus according to claim 14, wherein said conveyer means further comprises a first reject-branch having an inlet juxtapositioned adjacent said first filling station onto which rejected cans of poor quality are sent, and a second reject-branch having an inlet juxtapositioned adjacent said second filling station onto which rejected cans of poor quality are sent;

said first tint-dispensing station comprising first means for diverting a rejected paint can to said inlet of said first reject-branch, and said second base-dispensing station comprising second means for diverting a rejected paint can to said inlet of said second reject-branch.

17. The paint batching apparatus according to claim 16, wherein each of said first and second means for diverting comprises a push-plate, and means for reciprocating said push-plate toward and away from the respective said inlet;

said push-plate being mounted at a respective said filling station and movable into a retracted state laterally inwardly of the respective said filling station to allow proper clearance for a paint can being transported.

18. The paint batching apparatus according to claim 14, further comprising a first bar-code reading station located forwardly, upstream of said first transport-section;

and a second paint-can bar-code bar-code reading station located rearwardly, downstream of said first reading station between the rearward, downstream end of said first supplemental pair of guide-rails and the forward, upstream end of said second pair of guide-rails;

the rearward, downstream end of said first transport-section being spaced from the forward, upstream end of said second transport-section;

said second reading station being located thereat, whereby informational bar-code on the paint can may be read in order to determine color-formula for that paint can, size of can, and other information.

19. The paint batching apparatus according to claim 18, wherein each of said bar-code reading stations comprises means for rotating the paint can, and stationary optical scanner means for scanning the bar-code on the can for the actual reading thereof.

20. A paint batching apparatus, comprising:

a first tint-dispensing station comprising first storage means for storing the paint ingredients for dispensing into a paint can, first nozzle means for dispensing the paint ingredients directly into the paint can positioned therebelow, first pump means for pumping the paint ingredients from said first storage means to said first nozzle means, and first control means for controlling the operations of said first nozzle means and said first pump means for dispensing desired ones of paint ingredients; and

a second base-dispensing station comprising second storage means for storing the liquid base ingredients for dispensing into a paint can, second nozzle means for dispensing the paint ingredients directly into the paint can positioned therebelow, second pump means for pumping the paint ingredients from said second storage means to said second nozzle means, and second control means for controlling the operations of said second nozzle means and said second pump means for dispensing desired ones of paint ingredients;

a first paint-can bar-code reading station located forwardly, upstream of said first tint-dispensing station; and

a second paint-can bar-code reading station located rearwardly, downstream of said first reading station between said first and second dispensing stations;

whereby informational bar-code on the paint can may be read in order to determine color-formula for that paint can, size of can, and other information;

each of said bar-code reading stations comprising means for rotating the paint can, and optical scanner means for scanning the bar-code on the can for the actual reading thereof.

21. The paint batching apparatus according to claim 20, wherein said means for rotating the can at at least said second bar-code reading station comprises a driven roller stationarily mounted laterally inwardly of inner edge surfaces of said first and second transport-sections, a bifurcated idle-roller means movable toward and away from said driven roller to cause positive driven engagement of said driven roller with a paint can, means for reciprocating said bifurcated idle-roller means toward and away from said driven roller such that in the retracted state thereof, said bifurcated idle-roller means is laterally outwardly of the outer edge surfaces of said first and second transport-sections, whereby upon actuation of said means for reciprocating to move said bifurcated idle-roller means toward said driven roller, a paint can positioned at said second reading section is moved inwardly into engagement with said driven roller.

22. The paint batching apparatus according to claim 21, wherein said conveyer means further comprises tertiary conveyer means at at least said second bar-code reading station along the longitudinal direction thereof and bridging the rearward, downstream end of said first transport-section with the forward, upstream end of said second transport-section;

and means for independently moving said tertiary conveyer means in order transport a paint can onto said forward, upstream end of said second transport-section after the optical scanning of the bar-code thereof at said second bar-code reading station.

23. The paint batching apparatus according to claim 20, further comprising conveyer means for conveying a paint can from said first bar-code reading station to said first tint-dispensing station, from said first tint-dispensing station to said second bar-code reading station, and from said second bar-code reading station to second base-dispensing station;

and conveyer-control means controlling the periodic operation of said conveyer means for periodic operation of transporting of cans.

24. The paint batching apparatus according to claim 23, further comprising a plurality of photodetecting means for sensing the presence of a paint can at said first bar-code reading station, at said first tint-dispensing station, at said second bar-code reading station, and at said second base-dispensing station;

said conveyor-control means being operatively coupled with said plurality of photodetecting means for determining when said conveyer means is to be deactivated in order to position a can at a respective said station for processing thereat.

25. The paint batching apparatus according to claim 20, wherein said means for rotating the can at at least said second bar-code reading station comprises a driven roller, a bifurcated idle-roller means movable toward and away from said driven roller to cause positive driven engagement of said driven roller with a paint can, and means for reciprocating said bifurcated idle-roller means toward and away from said driven roller, whereby upon actuation of said means for reciprocating to move said bifurcated idle-roller means toward said driven roller, a paint can positioned at said second reading section is moved inwardly into engagement with said driven roller.