Method for operating a filling device and filling device

Abstract

Method for operating a filling plant and filling plant. The invention relates to a method for operating a filling plant having at least one first filling point with a filling valve and a flow or level sensor, at least one second filling point with a filling valve and a flow or level sensor and at least one control and evaluation unit for regulating and monitoring the filling process, in which the reference valve characteristic curves of the filling valves are stored, the current valve characteristic curves of the filling valves are determined, the current valve characteristic curves of the filling valves are compared with the respective reference valve characteristic curves, it is checked how many filling points the current valve characteristic curves deviate from the associated reference valve characteristic curves and in the event of a deviation of the valve characteristic curves from the reference valve characteristic curves at one filling point a filling point defect of the respective filling point is identified and signaled and in the event of a deviation of the valve characteristic curves from the reference valve characteristic curves at two filling points a process defect is identified and signaled.

Description

Technical Field

[0001] This invention relates to a method for operating a filling device, wherein the filling device has at least one first filling point, at least one second filling point, and at least one control and evaluation unit for regulating and monitoring the filling process. The first filling point has at least one first filling valve and at least one first flow or level sensor, and the second filling point has at least one second filling valve and at least one second flow or level sensor. The control and evaluation unit stores reference valve characteristic curves for the first and second filling valves. Furthermore, this invention relates to a filling device. Background Technology

[0002] Filling equipment is frequently used in process technology to fill one or more media into containers designed for this purpose. Filling equipment typically has multiple filling points, at which the filling process is performed separately. For this purpose, each filling point has a filling valve for regulating the flow rate and a flow sensor or level sensor for determining the amount of the medium to be filled or being filled.

[0003] It is known in the prior art that the filling process is monitored using external inspection tools, thereby monitoring the operation of the filling equipment and / or individual filling points. For this purpose, for example, cameras are used to monitor the material level in the container after filling and / or determine the weight of the container after filling, thus inferring the degree of filling. Defects in the filling process are inferred when the deviation of the degree of filling from the expected degree of filling exceeds tolerance limits.

[0004] The disadvantages of known processing methods in the prior art are, on the one hand, the need to use external inspection tools, which incurs additional costs and maintenance expenses. On the other hand, while defects in the filling process can be identified, the cause of the defects cannot be easily identified and the source of the defects cannot be located. Summary of the Invention

[0005] The objective of this invention is to describe a method that enables defect monitoring of filling equipment in a simplified manner compared to existing technologies. Furthermore, the objective of this invention is to provide a filling device that can be monitored for defects in a simple manner.

[0006] If the control and evaluation unit stores reference valve characteristic curves for the first filling valve and the second filling valve, then the reference valve characteristic curves may have been determined and stored in the past. Similarly, the reference valve characteristic curves may have been determined and stored immediately before or shortly before the execution of the method steps described below. In particular, one of the reference valve characteristic curves may have been determined and stored in the past, and the other reference valve characteristic curve may have been stored immediately before or shortly before the execution of the method steps. The only relevant aspect is that the reference valve characteristic curves are stored in the control and evaluation unit before the execution of the process steps described below.

[0007] Valve characteristic curves describe flow rates depending on valve opening, particularly the flow rate during valve stroke. In the case of, for example, linear valve characteristic curves, flow rate is directly proportional to valve stroke; in the case of equal percentage valve characteristic curves, each change in valve stroke results in an equal percentage change in flow rate.

[0008] The method according to the invention is characterized first and foremost, namely, by the feature of the characterizing portion of claim 1: in the determining step, during the operation of the filling equipment, the control and evaluation unit determines the current valve characteristic curve of the first filling valve and the current valve characteristic curve of the second filling valve. In this case, the current valve characteristic curve need not be determined over the entire range as the reference valve characteristic curve. More precisely, the current valve characteristic curve must be determined over a persuasive range, wherein a persuasive range should be understood as large enough to identify the range of possible deviations between the current valve characteristic curve and the reference valve characteristic curve. For this purpose, it is particularly sufficient to determine a sufficient number of points on the current valve characteristic curve that enable the identification of deviations. The extent to which the number of points is sufficient is a matter of judgment for those skilled in the art and depends on the corresponding process circumstances. However, it is preferable to determine at least two, more preferably at least three, points on the current valve characteristic curve.

[0009] According to the present invention, in the comparison step, the control and evaluation unit compares the current valve characteristic curve of the first filling valve with a reference valve characteristic curve of the first filling valve and compares the current valve characteristic curve of the second filling valve with a reference valve characteristic curve of the second filling valve. In the comparison step, the control and evaluation unit identifies whether the current valve characteristic curve deviates from the reference valve characteristic curve beyond a predetermined tolerance range. The predetermined tolerance range can, for example, be selected by the user and stored in the control and evaluation unit.

[0010] In the verification step, the control and evaluation unit, according to the present invention, further verifies: at how many fill points the current valve characteristic curve deviates from the relevant reference valve characteristic curve.

[0011] According to a further provision of the present invention, the control and evaluation unit identifies and signals a process defect when the valve characteristic curve deviates from the reference valve characteristic curve at two filling points during the signal notification step, and identifies and signals a filling point defect when the valve characteristic curve deviates from the reference valve characteristic curve at one filling point. Signal notification can be implemented, for example, by outputting acoustic or optical signals; however, signal notification can also be implemented, for example, by outputting or storing a corresponding message, such as storing the corresponding message in the internal memory of the control and evaluation unit.

[0012] The method according to the invention enables the identification of defects and the differentiation of defect sources in filling equipment in a simple manner. Therefore, according to the invention, it is possible to identify whether a defect is a process defect or a filling point defect without significant overhead.

[0013] The basic idea behind the proposed protection method is to inspect the current valve characteristic curve for all filling points when multiple filling points are used in the filling equipment. If a deviation outside the tolerance range of the reference valve characteristic curve is found in only one current valve characteristic curve of multiple filling points, the defect at that filling point can be inferred with a high probability. However, if all current valve characteristic curves of multiple filling points show similar deviations to their respective reference valve characteristic curves, then there is a defect unrelated to each filling point. It is entirely impossible, in any case, that all filling points simultaneously possess similar defects.

[0014] In a particularly preferred design, the control and evaluation unit has at least a first subunit and a second subunit. The first subunit implements the adjustment and monitoring of a first filling point, and the second subunit implements the adjustment and monitoring of a second filling point. The first and second subunits are further interconnected via a communication channel. The subunits can exchange data and information via the communication channel. The communication channel can be wired or wireless. In a particularly preferred variant of this design of the control and evaluation unit, the method according to the invention is characterized in that the first and second subunits exchange and verify information about the state of the filling valve during a verification step. Particularly preferably, the deviation of the current valve characteristic curve from the corresponding reference valve characteristic curve is verified. Specifically, the presence of a deviation is verified.

[0015] In one variant, the first subunit requests information from the second subunit, and the second subunit transmits the requested information to the first subunit. The first subunit then performs a verification of the information. Preferably, the first subunit then further performs a signal notification step.

[0016] In another variant, the first subunit requests information from the second subunit, and the second subunit further requests information from the first subunit. The two subunits independently perform information verification. More preferably, the two subunits exchange their respective verification results with another subunit. In one variant, one of the two subunits performs a signal notification step. In an alternative variant, both subunits perform a signal notification step. In the design where both subunits perform the verification step, redundancy in the verification is achieved.

[0017] Particularly advantageous is an embodiment of the method according to the invention in which the degree and / or direction of deviation between the current valve characteristic curve of the filling valve and a reference valve characteristic curve of the filling valve is checked in the verification step. More preferably, if the degree and / or direction of deviation is the same for both filling valves within a pre-given tolerance range, a process defect is identified and output in the signal notification step.

[0018] By employing this method of processing according to the invention, the probability that two valve defects occurring independently at two filling valves can be defectively evaluated as process defects can be reduced.

[0019] This implementation is based on the understanding that process defects within tolerance ranges have the same effect on each fill point and generate substantially identical defects. The substantially identical defects become apparent through substantially similar deviations between the current valve characteristic curve and the reference valve characteristic curve at each fill point. If the deviation of the current valve characteristic curve at one fill point differs in degree and / or direction from the deviations of the current valve characteristic curve and the reference valve characteristic curve at other fill points, it is likely that there are two independent fill point defects, but no process defect.

[0020] The method according to the invention has been previously described as enabling the identification of process defects. The severity of the defects may vary. For example, minor defects may be involved, which can be corrected using defined measures so that the operation of the filling equipment is not jeopardized and can continue. In the case of severe defects, however, shutting down the filling equipment may be necessary.

[0021] A preferred variation of the method according to the invention is characterized in that the valve is recalibrated when the deviation of the valve characteristic curve exceeds a pre-defined first tolerance range. The recalibration is preferably performed by the control and evaluation unit.

[0022] In one variant, the tolerance range is specified by the user. Preferably, the tolerance range is stored in the control and evaluation unit.

[0023] In a variant, the tolerance range is selected, for example, based on the average variance of the filling volume occurring in the filling equipment. Preferably, the time variation of the valve characteristic curve and / or the total filling volume are used to evaluate the valve characteristic curve. In this case, the total filling volume is derived from the integral of the valve characteristic curve. In a preferred embodiment of the method according to the invention, the control and evaluation unit is adapted to the valve characteristic curve to calibrate the valve. This takes into account the aforementioned deviations. The valve is calibrated according to the new valve characteristic curve so that it is not necessary to adapt to the adjustment of the filling equipment. From now on, these valves respond to the same control commands with different opening degrees. This design scheme of the method according to the invention can compensate for small process defects and thus maintain the accuracy of the filling process.

[0024] A particularly preferred embodiment of the method according to the invention is characterized by identifying and signaling a serious process defect and / or halting the operation of the filling equipment when the valve characteristic curve deviates from a reference valve characteristic curve by more than a predetermined second tolerance range. The second tolerance range is preferably stored in the control and evaluation unit. More preferably, the second tolerance range is defined by the user. The second tolerance range can, for example, be specified according to the same standard as the first tolerance range. If the deviation exceeds the second tolerance range, the defect is serious, making reliable operation of the filling equipment, especially reliable filling, no longer possible. The filling process can no longer be reliably performed. If a serious process defect is identified and signaled, but the filling equipment is not automatically halted, the user can decide whether they want to halt the filling equipment.

[0025] Another teaching of the invention relates to further improvements in the detectability and accuracy of defects in the filling process. According to the invention, reference valve speeds for a first filling valve and / or a second filling valve are stored in the control and evaluation unit. An embodiment of the method according to the invention is characterized in that, in an additional step, the valve speeds of the first filling valve and / or the second filling valve are determined. This determination step can be performed as a separate determination step or in conjunction with a determination step for determining the characteristic curves of the reference valves. According to the invention, the determined valve speed or multiple determined valve speeds are compared with the reference valve speed of a corresponding filling valve or multiple reference valve speeds of multiple corresponding filling valves, and if the valve speed deviates from one or more reference valve speeds, the corresponding filling valve or the multiple corresponding filling valves are recalibrated. The valve speed is currently derived from the time required for a change in valve opening by one step or a predetermined number of steps. With this variation, defects associated with valve speed can be corrected without having to stop the filling equipment.

[0026] If a deviation in the valve characteristic curve is detected only at a single filling point, then according to the invention, a filling point defect is identified and signaled. According to the invention, a variant of the method is further characterized in that, upon identification of a filling point defect, the control and evaluation unit manipulates the filling valve at the defective filling point using a pre-given number and type of control commands and detects the filling valve's response to the control commands. If the filling valve's response deviates from the expected response, a first type of valve defect is identified. This first type of valve defect is preferably understood to be a defect that directly affects the servo motor of the filling valve. More preferably, in this variant, the filling point is decommissioned. Additionally or alternatively, a requirement for valve replacement is output.

[0027] If the filling valve responds to a pre-given control command in the expected manner and method, i.e., the filling valve's response does not deviate from the expected response, then an alternative to the method according to the invention is characterized by identifying a second type of valve defect or sensor defect. The second type of valve defect currently refers to a defect at the valve that has no effect on the valve's servo motor. It is impossible to distinguish whether the cause of the defect can be found in the valve or in the sensor (flow sensor or level sensor); that is, only one of these two components can be identified. More preferably, in this variant, it is specified that the filling point be decommissioned. Additionally or alternatively, a requirement for replacing the valve and sensor is output.

[0028] In an alternative variation of the method according to the invention, when a filler point defect is identified, the defective filler point is inspected using an external inspection tool. Any inspection tool known from the prior art can be used as the external inspection tool, and it can also be used in a manner and method known from the prior art. The use of the additional external inspection tool enables a more precise investigation of the cause of the defect in the presence of a filler point defect, since the filler point defect may be caused by a sensor defect or a valve defect.

[0029] Particularly preferably, to check the filling point or to find the cause of a defect, the filling degree of the container is determined by means of an external inspection tool after the container has been filled. Based on the filling degree and the direction of deviation of the valve characteristic curve from the reference valve characteristic curve, either a valve defect or a sensor defect is inferred. For example, if the valve characteristic curve deviates downward from the reference valve characteristic curve and the container is not full, or if the valve characteristic curve deviates upward from the reference valve characteristic curve and the container is overfilled, it indicates that the valve is discharging too little or too much medium and the flow or level sensor is measuring correctly. Therefore, a valve defect exists. Conversely, if the valve characteristic curve deviates downward from the reference valve characteristic curve and the container is overfilled, or if the valve characteristic curve deviates upward from the reference valve characteristic curve and the container is not full, it indicates that the valve is working correctly; however, the flow or level sensor is measuring too little or too much.

[0030] Particularly preferably, defective filling points are discontinued. More preferably, a requirement is output for replacing valves or for replacing flow or level sensors.

[0031] In addition to the method for operating filling equipment, the present invention also relates to a filling device. The filling device has at least one first filling point, at least one second filling point, and at least one control and evaluation unit for regulating and monitoring the filling process, wherein the first filling point has at least one first filling valve and at least one first flow sensor or a first level sensor, and wherein the second filling point has at least one second filling valve and at least one second flow sensor or a second level sensor, and wherein the control and evaluation unit stores reference valve characteristic curves for the first filling valve and the second filling valve.

[0032] The objective of this invention, in the case of a filling equipment, is solved by means of a control and evaluation unit designed such that, in a determination step, the control and evaluation unit determines, within the operating state of the filling equipment, the current valve characteristic curves of the first filling valve and the second filling valve. In the comparison step, the control and evaluation unit compares the current valve characteristic curve of the first filling valve with its reference valve characteristic curve and the current valve characteristic curve of the second filling valve with its reference valve characteristic curve. The control and evaluation unit checks during the verification step whether the deviation of the current valve characteristic curve from the relevant reference valve characteristic curve occurs at one fill point or two fill points, and The control and evaluation unit identifies and signals a process defect when the valve characteristic curve deviates from the reference valve characteristic curve at two fill points during the signal notification step. Furthermore, when the valve characteristic curve deviates from the reference valve characteristic curve at a filling point, the filling point defect is identified and signaled to the corresponding filling point.

[0033] A particularly preferred design of the filling apparatus according to the invention is characterized in that the control and evaluation unit has at least a first subunit and a second subunit, wherein the first subunit implements control of the first filling point and the second subunit implements control of the second filling point, wherein the first subunit and the second subunit are connected via a communication channel and constitute for mutual data and communication exchange, and in particular the first subunit and the second subunit are designed such that the first subunit and the second subunit exchange and verify data regarding the status of the filling valve in a verification step.

[0034] The control and evaluation unit, or a subunit of the control and evaluation unit, can be implemented in a variant using a control and evaluation unit based on a flow sensor or a level sensor.

[0035] Another preferred design of the filling apparatus according to the invention is characterized in that the control and evaluation unit is designed such that it can perform one or more of the method steps previously described in conjunction with the method according to the invention.

[0036] All the advantageous designs and benefits described in conjunction with the method according to the invention are similarly applicable to the filling equipment according to the invention, and vice versa. Attached Figure Description

[0037] Specifically, there are now numerous possibilities for designing and improving the method and filling apparatus according to the invention. For this purpose, reference is made to the claims, which are dependent on the independent patent claims, and to the description of preferred embodiments in conjunction with the accompanying drawings. In the drawings: Figure 1 A first block diagram of a method for operating filling equipment is shown. Figure 2 A second block diagram showing a method for operating filling equipment is presented. Figure 3 A first flowchart of a method for operating filling equipment is shown. Figure 4 A second flowchart illustrating a method for operating filling equipment is shown. Figure 5 A schematic diagram of the first filling equipment is shown, and Figure 6 A schematic diagram of the second filling equipment is shown. Detailed Implementation

[0038] Figure 1 Showing the method for running as in Figure 5A block diagram schematically illustrating a method 100 for filling equipment 1. (See diagram from...) Figure 5 As can be seen, the filling equipment 1 has a first filling point 2 and a second filling point 3. Furthermore, the filling equipment 1 has a control and evaluation unit 4 for regulating and monitoring the filling process. The first filling point 2 has a first filling valve 5 and a first flow sensor 6. The second filling point 3 has a second filling valve 7 and a second flow sensor 8. Currently, flow sensors 6 and 8 are designed as flow sensors; however, the use of level sensors is also possible. The control and evaluation unit 4 stores reference valve characteristic curves for the first filling valve 5 and the second filling valve 7. Furthermore, the control and evaluation unit 4 is designed to perform... Figure 1 The method described in [the document / document].

[0039] exist Figure 1 In the method 100 shown, the current valve characteristic curve of the first filling valve 5 and the current valve characteristic curve of the second filling valve 7 are determined in the determination step 101. In the comparison step 102, the current valve characteristic curves of the two filling valves 5 and 7 are then compared with the corresponding reference valve characteristic curves. To compare the current valve characteristic curves with the reference valve characteristic curves, multiple points of the characteristic curves are preferably checked. In the checking step 103, the control and evaluation unit checks how many filling points 2 and 3 show a deviation of the current valve characteristic curve from the relevant reference valve characteristic curve. Furthermore, in the illustrated embodiment, not only the degree of deviation of the valve characteristic curve from the reference valve characteristic curve but also the direction of the deviation is determined. In the subsequent signal notification step 104, if the valve characteristic curve deviates from the reference valve characteristic curve at only one filling point 2 or 3, a filling point defect at the corresponding filling point 2 or 3 is identified and signaled; and if both valve characteristic curves deviate from the reference valve characteristic curve, a process defect is identified and signaled.

[0040] Figure 2 Another block diagram shows a method 100' for operating filling equipment 1. The method 100' shown here is suitable for operating as in Figure 6 The filling equipment 1 shown is illustrated.

[0041] Figure 6 Another schematic diagram of the filling equipment 1 is shown. Figure 6 The filling equipment 1 shown is in Figure 5The filling device 1 shown differs in that the control and evaluation unit 4 has a first subunit 4' and a second subunit 4''. These two subunits 4' and 4'' are interconnected via a communication channel 9. Data exchange between these two subunits 4' and 4'' is performed via this communication channel 9. The first subunit 4' is designed to monitor and adjust the first filling point 2. The second subunit 4'' is designed to adjust and monitor the second filling point 3. Furthermore, these two subunits 4' and 4'' are designed to achieve... Figure 2 Method 100 as described in the document.

[0042] exist Figure 2 The method 100' shown is the same as in Figure 1 The difference in the method shown is that, in verification step 103', the first subunit 4' and the second subunit 4'' respectively verify whether the current valve characteristic curve deviates from the reference valve characteristic curve, and then exchange information about the state of filling valves 2 and 3 and verify the information. Here, in particular, information about the deviation of the current valve characteristic curve of one of the filling valves 2 and 3 from the corresponding reference valve characteristic curve is exchanged. The reference valve characteristic curve of the first filling valve 5 is stored in the first subunit 4', and the reference valve characteristic curve of the second filling valve 7 is stored in subunit 4''. In the illustrated embodiment, the first subunit 4' requests the information from the second subunit 4'' and then determines whether there is a filling point defect or a process defect. If the degree of deviation of the valve characteristic curves of the two filling valves 2 and 3 from the reference valve characteristic curve is the same within a predetermined tolerance range and / or if the direction of deviation of the valve characteristic curves of the two filling valves 2 and 3 from the reference valve characteristic curve is the same within a predetermined tolerance range, then a process defect is currently identified.

[0043] Figure 3 Showing the method for running as in Figure 5 The flowchart of method 100 for filling equipment 1 shown is as follows. First, in determination step 101, the current valve characteristic curves of filling valves 5 and 7 are determined. Then, the equipment is in normal operation 106. In comparison step 102, the control and evaluation unit compares the current valve characteristic curves of filling valves 5 and 7 with reference valve characteristic curves stored in the control and evaluation unit. In the subsequent verification step 103, the control and evaluation unit 4 verifies: at how many filling points among filling points 2 and 3 has the current valve characteristic curve been found to deviate from the corresponding reference valve characteristic curve.

[0044] In parallel with this, in additional step 105, the control and evaluation unit determines the valve speeds of filling valves 5 and 7 and compares these valve speeds with reference valve speeds stored in the control and evaluation unit 4. If a deviation is found between at least one valve speed and the corresponding reference valve speed, the corresponding filling valve is recalibrated. Immediately afterwards, the filling equipment 1 returns to normal operation 106.

[0045] If it is found in verification step 103 that there is no deviation of the current valve characteristic curve from the A reference valve characteristic curve (n=0) at either filling point 2 or 3, then filling equipment 1 will switch to normal operation 106.

[0046] If it is determined that the current valve characteristic curve deviates from the reference valve characteristic curve A (n=2) at two filling points 2 and 3, a process defect is identified and signaled in step 104''. Next, in the illustrated embodiment, the degree and direction of the deviation A are determined. If the deviation A of the current valve characteristic curve exceeds the first tolerance range TB1, filling valves 5 and 7 are recalibrated in step 107 by adapting the valve characteristic curve. Then, filling equipment 1 transitions to normal operation 106. If the deviation A of the current valve characteristic curve exceeds the second tolerance range TB2, a serious process defect is identified and signaled in step 108, and / or operation of filling equipment 1 is stopped.

[0047] If it is determined that the current valve characteristic curve deviates from the reference valve characteristic curve A (n=1) at one of the two fill points 2 and 3, then in the signal notification step 104', the fill point defect of the corresponding fill point 2 or 3 is identified and signaled. To further identify the cause of the defect, in step 109, the fill valves 5 and 7 of the defective fill points 2 and 3 are manipulated using pre-given control commands of a predetermined quantity and type, and the response of fill valves 2 and 3 to the control commands is monitored. Check: Does the response of fill valves 2 and 3 to the control commands correspond to the expected response?

[0048] If the response of filling valves 5 and 7 deviates from the expected response, a first type of valve defect is identified in step 110. The first type of valve defect should be understood as a valve defect affecting the servo motor of filling valves 5 and 7. The relevant filling points 2 and 3 are taken out of service, and a request is issued to replace the defective filling valves 5 and 7. After the filling valves 5 and 7 are replaced, the valve speed and valve characteristic curves (101) of the replaced filling valves 5 and 7 can be re-recorded, and the filling equipment 1 can be switched to normal operation 106.

[0049] If the response of filling valves 5 and 7 does not deviate from the expected response, then either a valve defect that does not affect the servo motor of filling valves 5 and 7 (this type of valve defect is called a second-type valve defect) or a sensor defect must exist. It is impossible to distinguish between these two types of defects. Therefore, in step 111, a defect of the "second-type valve defect or sensor defect" type is identified. The filling points 2 and 3 involved are then taken out of service. Furthermore, filling valves 5 and 7, as well as flow or level sensors 6 and 8, are to be replaced. After replacing filling valves 5 and 7 and flow or level sensors 6 and 8, the valve speed and valve characteristic curves of the replaced filling valves 5 and 7 can be re-recorded (101), and the filling equipment can be switched to normal operation (106).

[0050] Figure 4 Another flowchart of a method 100 for operating filling equipment 1 is shown. In the method 100 shown here, [the process is similar to...] Figure 3 Compared to the method shown, the use of external inspection tools allows for a more precise identification of the cause of the defect when a filling point defect (104') is identified. In this case, the external inspection tool could be, for example, a camera used to determine the degree of filling of the container, or, for example, a scale used to determine the weight of the container after filling, thereby inferring the degree of filling. Any external inspection tool known from any prior art can currently be used.

[0051] In step 112, the container is first filled by performing the filling process as usual. Then, the filling level of the container is determined using an external inspection tool. Furthermore, the deviation of the valve characteristic curves of the filling valves 5 and 7 at the defective filling points 2 and 3 from the reference valve characteristic curve is determined. Based on the filling level of the filled container and the direction of the deviation of the valve characteristic curve from the reference valve characteristic curve, a valve defect or sensor defect can be inferred. Therefore, it is checked whether the conditions for a valve defect exist. These conditions are predefined by the user and can be stored in the control and evaluation unit 4. Currently, the following conditions must be met to identify a valve defect: the valve characteristic curve deviates downward and the container is not full; or the valve characteristic curve deviates upward and the container is overfilled. If one of these conditions is identified, the valve defect is identified and output in step 113. Additionally, a requirement for replacing the filling valves 5 and 7 is output. After replacing the filling valves 5 and 7, the valve speed and valve characteristic curve (101) of the replaced filling valves 5 and 7 can be re-recorded, and the filling equipment can be switched to normal operation 106.

[0052] If the condition for a valve defect is not met, a further step 114 checks whether the condition for a sensor defect is met. These conditions can also be user-defined and stored in the control and evaluation unit. In the current embodiment, the conditions for a sensor defect are: the valve characteristic curve deviates downward and the container is overfilled; or the valve characteristic curve deviates upward and the container is not full. If one of these conditions is identified, a sensor defect is identified and output. Additionally, a requirement for replacing flow or level sensors 6, 8 is output. After replacing flow or level sensors 6, 8, the valve speed and valve characteristic curves (101) of filling valves 5, 7 can be re-recorded, and the filling equipment can be switched to normal operation 106.

[0053] Figure Labels 1. Filling equipment 2 First fill point 3 Second fill point 4. Control and Evaluation Unit 4' First sub-unit of the control and evaluation unit The second sub-unit of the 4'' control and evaluation unit 5 First filling valve 6 First flow rate or level sensor 7 Second filling valve 8 Second flow or level sensor 9 communication channels n is the number of fill points with deviation. A deviation TB1 First Tolerance Range TB2 Second Tolerance Range 100 methods 101 Determine the steps 102 Comparison Steps 103 Verification Steps 104. Notification steps using signals 105 Additional Steps 106 Normal operation 107 Recalibrate the filling valve 108. Identify and signal serious filling point defects and / or stop the filling equipment. 109 Steps for controlling the filling valve and monitoring the reaction 110 identified a first-type valve defect and requested replacement. 111 Identify a second type of valve or sensor defect and request replacement. 112 Fill the container and use external inspection tools to determine the degree of filling. 113 Identify and signal the valve defect, requesting replacement. 114 Identified and signaled a sensor defect, requesting replacement.

Claims

1. A method (100) for operating a filling device (1), wherein the filling device (1) has at least one first filling point (2), at least one second filling point (3), and at least one control and evaluation unit (4) for regulating and monitoring the filling process, wherein the first filling point (2) has at least one first filling valve (5) and at least one first flow or level sensor (6), and wherein the second filling point (3) has at least one second filling valve (7) and at least one second flow or level sensor (8), and wherein a reference valve characteristic curve of the first filling valve (5) and a reference valve characteristic curve of the second filling valve (7) are stored in the control and evaluation unit (4). Its features , In the operating state of the filling equipment (1), in the determination step (101), the control and evaluation unit (4) determines the current valve characteristic curve of the first filling valve (5) and the current valve characteristic curve of the second filling valve (7). In the comparison step (102), the control and evaluation unit (4) compares the current valve characteristic curve of the first filling valve (5) with the reference valve characteristic curve of the first filling valve (5), and compares the current valve characteristic curve of the second filling valve (7) with the reference valve characteristic curve of the second filling valve (7). In the verification step (103), the control and evaluation unit (4) verifies: at how many fill points in the fill points (2, 3) the current valve characteristic curve deviates from the relevant reference valve characteristic curve, and In the signal notification step (104), the control and evaluation unit (4) identifies and signals (104') a fill point defect when the valve characteristic curve deviates from the reference valve characteristic curve at a fill point (2, 3). Furthermore, when the valve characteristic curve deviates from the reference valve characteristic curve at the two filling points (2, 3), the process defect is identified and signaled (104'').

2. The method (100) according to claim 1, characterized in that, The control and evaluation unit (4) has at least a first subunit (4') and a second subunit (4''), wherein the first subunit (4') implements the adjustment and monitoring of the first filling point (2), and the second subunit (4'') implements the adjustment and monitoring of the second filling point (3), wherein the first subunit (4') and the second subunit (4'') are interconnected via a communication channel (9), wherein in the verification step (103), the first subunit (4') and the second subunit (4'') exchange and verify information about the status of the filling valves (5, 7).

3. The method (100) according to claim 1, characterized in that, The control and evaluation unit (4) has at least a first subunit (4') and a second subunit (4''), wherein the first subunit (4') implements the adjustment and monitoring of the first filling point (2), and the second subunit (4'') implements the adjustment and monitoring of the second filling point (3), wherein the first subunit (4') and the second subunit (4'') are interconnected via a communication channel (9), wherein in the verification step (103), the first subunit (4') and the second subunit (4'') exchange and verify information about the deviation between the current valve characteristic curve and the corresponding reference valve characteristic curve.

4. The method (100) according to claim 1, characterized in that, In the verification step (103), the degree and / or direction of the deviation (A) between the valve characteristic curve of the filling valve (5, 7) at the filling point (2, 3) and the reference valve characteristic curve are verified. In the signal notification step (104), if the degree of deviation (A) between the valve characteristic curves of the two filling valves (5, 7) and the reference valve characteristic curve is the same within a pre-given tolerance range and / or the direction of the deviation (A) between the valve characteristic curves of the two filling valves (5, 7) and the reference valve characteristic curve is the same, then a process defect is identified and signaled.

5. The method (100) according to any one of claims 1 to 4, characterized in that, If the valve characteristic curve deviates from (A) the reference valve characteristic curve beyond the pre-given first tolerance range (TB1), the filling valve (5, 7) is recalibrated (107).

6. The method (100) according to any one of claims 1 to 4, characterized in that, If the valve characteristic curve deviates from (A) the reference valve characteristic curve by more than a predetermined first tolerance range (TB1), the filling valve (5, 7) is recalibrated (107) by adapting the valve characteristic curve of the corresponding filling valve (5, 7).

7. The method (100) according to any one of claims 1 to 4, characterized in that, If the valve characteristic curve deviates from (A) the reference valve characteristic curve by more than a predetermined second tolerance range (TB2), a serious process defect is identified and signaled and / or the operation of the filling equipment (1) is stopped (108).

8. The method (100) according to any one of claims 1 to 4, wherein a reference valve speed for the first filling valve (5) and / or for the second filling valve (7) is stored in the control and evaluation unit (4), characterized in that, The control and evaluation unit (4) determines the valve speed of the first filling valve (5) and / or the second filling valve (7) in an additional step (105) and checks it against the reference valve speed of the corresponding filling valve (5, 7), and performs recalibration of the corresponding filling valve (5, 7) if the valve speed deviates from the reference valve speed.

9. The method (100) according to any one of claims 1 to 4, characterized in that, Upon identification of a filling point defect, the control and evaluation unit (4) manipulates the filling valves (5, 7) of the defective filling point (2, 3) using pre-given control commands of a certain quantity and type, and monitors (109) the response of the filling valves (5, 7) to the control commands. When the response of the filling valves (5, 7) deviates from the expected response, a first type of valve defect (110) is identified. Alternatively, if the response of the filling valve (5, 7) does not deviate from the expected response, a second type of valve defect or sensor defect (111) may be identified.

10. The method (100) according to claim 9, characterized in that, Upon identification of a first-type valve defect (110), the filling points (2, 3) shall be decommissioned and / or a request shall be issued for replacement of the filling valve (5, 7). Alternatively, in the event of identifying a second type of valve defect or sensor defect (111), the filling point (2, 3) may be deactivated and / or a requirement may be output for replacing the filling valve (5, 7) and the flow or level sensor (6, 8).

11. The method (100) according to any one of claims 1 to 4, characterized in that, In cases where fill point defects are identified, the defective fill points are inspected using external inspection tools (2, 3).

12. The method (100) according to claim 11, characterized in that, To inspect the filling point, after the container is filled, the filling degree of the filled container is determined by an external inspection tool, and valve defects or sensor defects are inferred based on the filling degree and the direction of the deviation between the valve characteristic curve and the reference valve characteristic curve (112, 113, 114).

13. The method (100) according to claim 12, characterized in that, The defective filling point (2, 3) is to be deactivated and / or the requirement to replace the filling valve (5, 7) or the flow or level sensor (6, 8) is to be output.

14. A filling apparatus (1), wherein the filling apparatus (1) has at least one first filling point (2), at least one second filling point (3), and at least one control and evaluation unit (4) for regulating and monitoring the filling process, wherein the first filling point (2) has at least one first filling valve (5) and at least one first flow or level sensor (6), and wherein the second filling point (3) has at least one second filling valve (7) and at least one second flow or level sensor (8), and wherein the control and evaluation unit (4) stores a reference valve characteristic curve of the first filling valve (5) and a reference valve characteristic curve of the second filling valve (7). Its features , The control and evaluation unit (4) is designed such that, in the determination step (101), the control and evaluation unit determines the current valve characteristic curve of the first filling valve (5) and the current valve characteristic curve of the second filling valve (7). In the comparison step (102), the control and evaluation unit compares the current valve characteristic curve of the first filling valve (5) with the reference valve characteristic curve of the first filling valve (5) and compares the current valve characteristic curve of the second filling valve (7) with the reference valve characteristic curve of the second filling valve (7). The control and evaluation unit checks in verification step (103) the number of fill points (2, 3) at which the current valve characteristic curve deviates from the relevant reference valve characteristic curve, and In the signal notification step (104), the control and evaluation unit identifies and signals a fill point defect at the corresponding fill point (2, 3) when the valve characteristic curve deviates from the reference valve characteristic curve at a fill point (2, 3). Furthermore, when the valve characteristic curve deviates from the reference valve characteristic curve at the two fill points (2, 3), the process defect is identified and signaled.

15. The filling equipment (1) according to claim 14, characterized in that, The control and evaluation unit (4) has at least a first subunit (4') and a second subunit (4''), wherein the first subunit (4') implements control of the first filling point (2) and the second subunit (4'') implements control of the second filling point (3), wherein the first subunit (4') and the second subunit (4'') are connected via a communication channel (9) and constitute data and communication exchange between them.

16. The filling equipment (1) according to claim 15, characterized in that, The first subunit (4') and the second subunit (4'') are designed such that the first subunit and the second subunit exchange and verify data regarding the status of the filling valve (5, 7) in the verification step (103).

17. The filling equipment (1) according to any one of claims 14 to 16, characterized in that, The control and evaluation unit (4) is further configured to perform the method according to any one of claims 4 to 13.

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