A method for automatic identification and calibration of anomalies in a filling system

Abstract

The application discloses a kind of filling system exception automatic identification and calibration method, comprising the following steps: man-machine interaction module is numbered to each filling needle of filling needle group in turn, each bottle body of bottle group is numbered in turn, and numbered signal is sent to control module;Before weighing;Empty bottle group is transported to filling station again, filling needle group moves to above filling station, filling needle of filling needle group and bottle body of bottle group are one-to-one corresponding according to number, control module receives and records the corresponding number signal of filling needle and bottle body;After weighing;Control module calibrates the filling amount of filling pump according to the deviation of before and after weighing, and calculates the calibration coefficient of the filling pump;Comparison identification finds out abnormal filling pump;Abnormal filling pump correction, if it cannot be corrected, then stop corresponding station bottle and filling, and the remaining liquid in abnormal filling pump is used to fill on after-weighing station.This filling system exception automatic identification and calibration method can improve filling precision, can reduce liquid waste, can improve filling efficiency.

Description

Technical Field

[0001] This invention relates to the field of food and pharmaceutical packaging machinery and equipment, and in particular to an automatic identification and calibration method for filling system malfunctions. Background Technology

[0002] When the accuracy of a filling pump in a filling system becomes abnormal, it needs to be calibrated immediately. In the process, how can we ensure that no medicine is wasted? Secondly, how can we quickly identify which pump is causing the problem?

[0003] In conventional solutions, bottles with abnormal filling volumes and already filled bottles often have to be discarded, resulting in significant waste of the medication. Furthermore, identifying which pump is malfunctioning requires a structurally specific matching process. For example, patent application number 202010368574.X, entitled "A Drainage Filling Method," uses eight filling pumps corresponding to eight weighing modules, thus increasing equipment costs.

[0004] There are two traditional methods for detecting and controlling accuracy in filling systems:

[0005] Offline inspection: Bottles filled with medicine are conveyed to an independent channel through a bottle-separating device. The bottles are then manually transferred to a clean room with a weighing system for manual weighing, recording, and printing. This method involves manual inspection, which is labor-intensive, poses a risk of environmental pollution, cannot calibrate filling deviations online, is inconvenient for long-term storage of manually recorded weight values, and lacks traceability.

[0006] Online weighing: Empty bottles are picked up and their weight (tare weight) is obtained at the front end of the filling process. After the tare weight is recorded, the bottles are sent to the filling station for filling. After the liquid is filled, the bottles are picked up and their weight (total weight) is obtained at the back end of the filling process. The PLC calculates the difference between the weight before and after the filling (net weight) by using the tare weight and the total weight, and compares it with the target filling volume to find the error (deviation). The automatic calibration response of this method will only take effect at least in the next cycle, and it cannot achieve precise control of the current filling cycle.

[0007] Traditionally, the emptying of the liquid and the filling of the tail liquid are basically done manually.

[0008] During the evacuation process, liquid is collected in the receiving box and each pump is evacuated one by one. This process inevitably results in a lot of waste of medicine.

[0009] When filling the final liquid, the filling volume will generally be too low when the liquid level reaches a low point. At this point, filling should be stopped, and the remaining liquid can basically no longer be used.

[0010] In summary, in the existing technology, the liquid replenishment is carried out by weighing while filling, which cannot quickly identify the problematic pump or pipeline and cannot solve the problem in a timely manner. Any bottle filled by the problematic pump or pipeline needs to be replenished, which affects the filling efficiency. Summary of the Invention

[0011] The technical problem to be solved by the present invention is to overcome the shortcomings of the prior art and provide an automatic identification and calibration method for filling system abnormalities that can improve filling accuracy, reduce liquid waste, and improve filling efficiency.

[0012] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0013] An automatic identification and calibration method for malfunctions in a filling system includes the following steps:

[0014] S1. Numbering: The human-machine interaction module sequentially numbers each filling needle in the filling needle group and each bottle in the bottle group, and sends the numbering signal to the control module.

[0015] S2, Pre-weighing: Empty bottle groups are transported to the pre-weighing station for pre-weighing. Each weighing sensor at the pre-weighing station sends the weight signal of the empty bottle to the control module.

[0016] S3, Filling: Empty bottle groups are then transported to the filling station, and the filling needle group is moved above the filling station. The filling needles of the filling needle group correspond one-to-one with the bottles of the bottle group according to their numbers. The control module receives and records the corresponding number signals of the filling needles and the bottles.

[0017] S4. Post-weighing: The bottle group is then transported to the post-weighing station for post-weighing. Each weighing sensor at the post-weighing station sends the weight signal of the bottle to the control module.

[0018] S5. Calibration: The control module calibrates the filling volume of the filling pump of the filling needle according to the deviation value of the weighing before and after, and calculates the calibration coefficient of the filling pump.

[0019] S6. Comparison and Identification: The control module compares the calibration coefficients of the filling pumps of each filling needle, identifies the abnormal filling pumps, and sends the number of the filling needle corresponding to the abnormal filling pump to the human-machine interaction module for alarm reminder.

[0020] S7. Abnormal filling pump handling: Correct the abnormal filling pump. If the abnormal filling pump cannot be corrected, stop the bottle feeding and filling at the corresponding station of the abnormal filling pump. The remaining medicine in the abnormal filling pump will be used for filling at the subsequent weighing station.

[0021] As a further improvement to the above technical solution:

[0022] In step S5, when the calibration coefficient of the filling pump exceeds the set upper limit, the bottle feeding and filling at the corresponding station of the filling pump is stopped, and the control module sends the number of the filling needle corresponding to the filling pump to the human-machine interaction module to issue an alarm reminder.

[0023] When the number of calibrations of the filling pump reaches the set upper limit, the bottle feeding and filling at the corresponding station of the filling pump will be stopped. The control module will send the number of the filling needle corresponding to the filling pump to the human-machine interaction module to issue an alarm reminder.

[0024] Bottles are transported via a conveyor line, with the front weighing station, filling station, and rear weighing station set up sequentially along the conveying direction of the line.

[0025] The conveyor line is equipped with a bottle-blocking mechanism upstream of the weighing station. The opening and closing of the bottle-blocking mechanism is controlled by the control module. The bottle feeding is stopped by opening the bottle-blocking mechanism.

[0026] The number of load cells on the front and rear weighing stations is the same, and this number is half the number of filling needles.

[0027] When the number of abnormal filling pumps reaches a specified number, the pump will be shut down.

[0028] Compared with the prior art, the advantages of the present invention are as follows:

[0029] The automatic identification and calibration method for filling system malfunctions of this invention employs a method where filling stations are numbered one-to-one, accurately corresponding to the filling needles for each bottle. The calibration coefficient of the corresponding filling pump is calculated by measuring the deviation of the filling volume in each bottle. By comparing the calibration coefficients of the filling pumps for each needle, the malfunctioning filling pump is accurately identified and promptly calibrated. This improves filling efficiency and accuracy, preventing substandard filling and resulting in defective products and wasted medication. If the malfunctioning filling pump cannot be calibrated, bottle feeding and filling at the corresponding station are stopped, preventing further bottle feeding and filling at the malfunctioning pump station and avoiding wasted medication due to substandard filling. Furthermore, the remaining medication in the malfunctioning filling pump is used for filling at the subsequent weighing station, minimizing medication waste.

[0030] The automatic identification and calibration method for malfunctions in the filling system of the present invention indicates that when the calibration coefficient of the filling pump exceeds the set upper limit, it proves that the filling pump has a serious problem. There is no need to spend time on calibration and then check the result. The filling pump's corresponding station should be stopped in time to stop the loss and prevent the waste of medicine. Meanwhile, the normal filling pump's corresponding station can continue to fill bottles to avoid downtime and affect filling efficiency.

[0031] The automatic identification and calibration method for malfunctions in the filling system of the present invention indicates that when the calibration coefficient of the filling pump exceeds the set upper limit, it proves that the filling pump has a serious problem. There is no need to spend time on calibration and then check the result. The filling pump's corresponding station should be stopped in time to stop the loss and prevent the waste of medicine. Meanwhile, the normal filling pump's corresponding station can continue to fill bottles to avoid downtime and affect filling efficiency. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of the automatic identification and calibration method for abnormalities in the filling system of the present invention.

[0033] Figure 2 This is a schematic diagram of the first half of the filling needle replenishment in the automatic identification and calibration method for abnormalities in the filling system of the present invention.

[0034] Figure 3 This is a schematic diagram of the second half of the filling needle replenishment in the automatic identification and calibration method for abnormalities in the filling system of the present invention.

[0035] The labels in the diagram represent:

[0036] 1. Filling needle; 2. Bottle body; 3. Front weighing station; 4. Weighing sensor; 5. Filling station; 6. Rear weighing station; 7. Filling pump. Detailed Implementation

[0037] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0038] Figures 1 to 3 An embodiment of the automatic identification and calibration method for malfunctions in the filling system of the present invention is shown. The automatic identification and calibration method for malfunctions in the filling system includes the following steps:

[0039] S1. Numbering: The human-machine interaction module sequentially numbers each filling needle 1 in the filling needle group and each bottle 2 in the bottle group, and sends the numbering signal to the control module.

[0040] S2, Pre-weighing: Empty bottle groups are transported to the pre-weighing station 3 for pre-weighing. Each weighing sensor 4 on the pre-weighing station 3 sends the weight signal of the empty bottle to the control module.

[0041] S3, Filling: Empty bottle groups are then transported to filling station 5. Filling needle group is moved above filling station 5. Filling needle 1 of filling needle group corresponds to bottle body 2 of bottle group according to number. Control module receives and records the corresponding number signal of filling needle 1 and bottle body 2.

[0042] S4. Post-weighing: The bottle group is then transported to the post-weighing station 6 for post-weighing. Each weighing sensor 4 on the post-weighing station 6 sends the weight signal of the bottle 2 to the control module.

[0043] S5. Calibration: The control module calibrates the filling volume of the filling pump 7 of the filling needle 1 based on the deviation value of the weighing before and after, and calculates the calibration coefficient of the filling pump 7.

[0044] S6. Comparison and Identification: The control module compares the calibration coefficients of the filling pumps 7 of each filling needle 1, identifies the abnormal filling pump 7, and sends the number of the filling needle 1 corresponding to the abnormal filling pump 7 to the human-machine interaction module for alarm reminder.

[0045] S7, Abnormal filling pump 7 handling: Correct the abnormal filling pump 7. If the abnormal filling pump 7 cannot be corrected, stop the bottle feeding and filling at the station corresponding to the abnormal filling pump 7. The remaining medicine in the abnormal filling pump 7 is used for filling at the subsequent weighing station 6.

[0046] The automatic identification and calibration method for anomalies in this filling system involves filling each bottle 2 at the filling station 5 according to its number, accurately corresponding to the filling needle 1. The calibration coefficient of the corresponding filling pump 7 is calculated by measuring the deviation of the filling volume of each bottle 2. By comparing the calibration coefficients of the filling pumps 7 for each filling needle 1, the abnormal filling pump 7 is accurately identified and promptly corrected, improving filling efficiency and accuracy, and preventing substandard filling. When the filling volume is too high, the medicine overflows from the bottle 2, contaminating the workbench and the bottle 2. When the filling volume is too low, the filling needle 1 moves to the total weight weighing sensor, and the corresponding filling pump 7 replenishes the liquid to reach the target value. When the number of bottles 2 with substandard filling volume is small, the substandard products are directly rejected, resulting in waste of bottles 2 and medicine, and also affecting product production efficiency. If the abnormal filling pump 7 cannot be calibrated, the bottle feeding and filling at the corresponding station of the abnormal filling pump 7 will be stopped, thereby preventing the corresponding station of the abnormal filling pump 7 from continuing to feed and fill bottles, preventing substandard filling from causing waste of medicine and pollution of the operating environment; and the remaining medicine in the abnormal filling pump 7 will be used for filling at the subsequent weighing station 6, minimizing the waste of medicine.

[0047] In this embodiment, in step S5, when the calibration coefficient of filling pump 7 exceeds the set upper limit, the bottle feeding and filling at the corresponding station of filling pump 7 is stopped. The control module sends the number of the filling needle 1 corresponding to filling pump 7 to the human-machine interaction module to issue an alarm reminder. When the calibration coefficient of filling pump 7 exceeds the set upper limit, it proves that there is a serious problem with filling pump 7. There is no need to spend time on calibration and then consider the result. The bottle feeding and filling at the corresponding station of filling pump 7 should be stopped in time to stop the loss and prevent waste of medicine. Meanwhile, the corresponding station of normal filling pump 7 continues to feed bottles and fill, avoiding downtime and affecting filling efficiency.

[0048] In this embodiment, when the number of calibrations of filling pump 7 reaches the set upper limit, the bottle feeding and filling at the corresponding station of filling pump 7 is stopped. The control module sends the number of the filling needle 1 corresponding to filling pump 7 to the human-machine interaction module to issue an alarm reminder. When the number of calibrations of filling pump 7 reaches the set upper limit, it proves that there is a serious problem with filling pump 7. There is no need to spend time on calibration and recalibration. Bottle feeding and filling at the corresponding station of filling pump 7 should be stopped in time to stop losses, prevent waste of medicine and bottle 2 and pollution of the operating environment. Meanwhile, the corresponding station of normal filling pump 7 continues to feed and fill bottles to avoid downtime and affect filling efficiency.

[0049] In this embodiment, the bottle assembly is transported via a conveyor line. The front weighing station 3, filling station 5, and rear weighing station 6 are sequentially arranged along the conveyor line's transport direction. A bottle-stopping mechanism is installed upstream of the front weighing station 3. The opening and closing of the bottle-stopping mechanism is controlled by a control module; opening the mechanism stops the bottle feeding. The number of weighing sensors 4 on the front weighing station 3 and the rear weighing station 6 is the same, and this number is half the number of filling needles 1.

[0050] In this embodiment, when the number of abnormal filling pumps 7 reaches a specified number, the pump is stopped.

[0051] The automatic identification and calibration method for abnormalities in this filling system utilizes a filling system comprising a conveyor line, a front weighing station 3, a filling station 5, a rear weighing station 6, a drug supply device (reservoir), multiple filling needles 1 connected to the drug supply device, and silicone tubing connecting the filling needles 1 and the drug supply device. Each silicone tubing is equipped with a filling pump 7. The front weighing station 3, filling station 5, and rear weighing station 6 are arranged sequentially along the conveying direction of the conveyor line. A bottle-stopping mechanism is located upstream of the front weighing station 3. The opening and closing of the bottle-stopping mechanism is controlled by a control module; opening the bottle-stopping mechanism stops bottle feeding. The number of weighing sensors 4 on the front weighing station 3 and the rear weighing station 6 is the same, and this number is half the number of filling needles 1. Each filling needle 1 is mounted on a movable filling needle holder.

[0052] The characteristics of each component are as follows:

[0053] Medicine supply device: It is set at an angle and has a liquid inlet valve at the front end, which can slowly introduce liquid and automatically vent air.

[0054] Filling pump 7: Eight filling pumps 7, matched with 8 sets of filling needles (J1 / J2 / J3 / J4 / J5 / J6 / J7 / J8), each filling pump 7 is driven by a separate servo motor and the filling volume is adjusted individually.

[0055] Weighing stations: The front weighing station 3 is equipped with four tare weight weighing sensors (T1 / T2 / T3 / T4), and the rear weighing station 6 is equipped with four gross weight weighing sensors (G1 / G2 / G3 / G4). Each of them has a high-speed data transmission interface, provides real-time feedback of weight values, and all have the function of weighing while filling.

[0056] Filling method of the filling system:

[0057] (1) Emptying stage

[0058] The purpose of purging is to remove all air from the silicone tube, ensuring that there are no air bubbles inside the tube during filling, thereby guaranteeing a stable filling volume; the specific process is as follows:

[0059] a) Start the evacuation program with one click on the control panel.

[0060] b) Pulsating intermittent liquid inlet achieves bubble-free filling of the drug supply device.

[0061] c) The filling needle holder moves automatically, aligning the J1 / J2 / J3 / J4 filling needles with the total weight weighing sensor G1 / G2 / G3 / G4.

[0062] d) After the bottle is placed onto the total weight weighing sensor, each filling needle is inserted into the bottle mouth, and the filling and weighing mode is started to continue filling until the filling amount is qualified.

[0063] e) Continue filling the bottle, using the same filling and weighing mode to empty the filling needle tubing of J1 / J2 / J3 / J4, until all air bubbles in the tubing are completely emptied.

[0064] f) After needles J1 / J2 / J3 / J4 have been emptied 3 times (the number of times can be set), the filling needle holder will move automatically and align needles J5 / J6 / J7 / J8 with the total weight weighing sensor G1 / G2 / G3 / G4.

[0065] g) After the conveyor line delivers the bottle to the total weight weighing sensor, the filling needle is inserted into the bottle mouth, and the filling and weighing mode is started to continue filling until the filling amount is qualified.

[0066] h) Continue filling the bottle, using the same filling and weighing mode to empty the tubing of filling needles J5 / J6 / J7 / J8, until all air bubbles are completely emptied from the tubing.

[0067] i) After all needles J1 / J2 / J3 / J4 / J5 / J6 / J7 / J8 have been emptied, the filling needle rack will automatically move to its original position and wait to enter normal production mode.

[0068] (2) Normal filling stage

[0069] During normal filling, eight filling pumps 7 fill bottles according to the set filling volume. When a filled bottle passes the weighing station 6, the system determines whether the weight of the liquid in each bottle is within acceptable limits. If the filling volume is too low, the filling needle holder will move to the total weight weighing sensor, and the corresponding filling pump 7 will replenish the liquid to reach the target value, thus ensuring that no defective products with low filling volumes occur during the entire production process. The specific process is as follows:

[0070] a) Normal filling starts, and the automatic liquid replenishment function is activated.

[0071] b) When the total weight weighing sensor determines that the bottle filling volume at the current station is too low, it triggers the liquid replenishment function. After the filling pump 7 completes the normal filling of the current group, it moves the filling needle frame to reach above the total weight weighing sensor to achieve one-to-one liquid replenishment.

[0072] c) During normal filling, replenishing the liquid can bring all bottles with low filling volume after one filling to the qualified level, reducing the generation of waste products in production.

[0073] (3) Tail liquid filling stage

[0074] The purpose of tail liquid filling is to complete the final stage of filling with the medicine, avoiding waste. Weighing sensor 4 determines whether the weight of the medicine in each bottle is within the acceptable range. If the filling volume is too low, liquid is added to bring the volume to the target level, completing the filling process without manual intervention. The specific procedure is as follows:

[0075] a) When the tail liquid filling sensor of the drug supply device detects that tail liquid filling is required, the tail liquid filling mode is activated.

[0076] b) In the tail liquid filling mode, the total weight weighing sensor will determine whether the bottle filling volume at the current station is qualified. If it is not qualified, the liquid replenishment process will be automatically activated to perform one-to-one liquid replenishment until the filling volume is qualified.

[0077] c) If, during continuous replenishment, the corresponding filling needle still fails to meet the required filling volume after more than 30 seconds of replenishment (the time is set according to the dosage), it indicates that the medication in that filling line has been completely filled, and the system will automatically disable that filling needle. The entire tail liquid filling process will end when each filling needle has been filled and replenished.

[0078] Online fluid replenishment in case of filling abnormalities:

[0079] During normal filling, eight filling pumps 7 fill bottles according to the set filling volume. When a filled bottle passes the weighing station 6, the system determines whether the weight of the liquid in each bottle is within acceptable limits. If the filling volume is too low, the filling needle holder will move to the total weight weighing sensor, and the corresponding filling pump 7 will replenish the liquid to reach the target value, thus ensuring that no defective products with low filling volumes occur during the entire production process. The specific process is as follows:

[0080] (1) Normal filling start-up;

[0081] (2) When the total weight weighing sensor determines that the bottle filling volume at the current station is too low, it triggers the liquid replenishment function. The filling pump 7 first completes the normal filling of the current group and then moves the filling needle holder (e.g. Figure 2 or Figure 3 Once the bottles reach the total weight weighing sensor, a one-to-one liquid replenishment is achieved. This correspondence is ensured by the control module. The first set of bottles corresponds to the total weight weighing sensors G1 / G2 / G3 / G4 and the filling needles J1 / J2 / J3 / J4. The second set of bottles corresponds to the total weight weighing sensors G1 / G2 / G3 / G4 and the filling needles J5 / J6 / J7 / J8.

[0082] (3) During normal filling, replenishing the liquid can replenish all bottles with low filling volume after one filling to meet the standard, reducing the generation of waste products in production.

[0083] When filling accuracy is compromised, liquid can be replenished online without wasting any medicine; the faulty pump can be quickly located; and once the faulty pump is located, it can be calibrated without affecting production.

[0084] While the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the invention. Any person skilled in the art can make many possible variations and modifications to the technical solutions of the present invention, or modify them into equivalent embodiments, without departing from the scope of the present invention. Therefore, any simple modifications, equivalent changes, and modifications made to the above embodiments based on the technical essence of the present invention, without departing from the scope of the present invention, should fall within the protection scope of the present invention.

Claims

1. An automatic identification and calibration method for malfunctions in a filling system, characterized in that: Includes the following steps: S1. Numbering: The human-machine interaction module numbers each filling needle (1) of the filling needle group in sequence, and each bottle (2) of the bottle group in sequence, and sends the numbering signal to the control module. S2, Pre-weighing: Empty bottle groups are transported to the pre-weighing station (3) for pre-weighing. Each weighing sensor (4) on the pre-weighing station (3) sends the weight signal of the empty bottle to the control module. S3, Filling: The empty bottle group is then transported to the filling station (5), the filling needle group is moved above the filling station (5), the filling needle (1) of the filling needle group and the bottle body (2) of the bottle group correspond one-to-one according to the number, and the control module receives and records the corresponding number signal of the filling needle (1) and the bottle body (2). S4, Post-weighing: The bottle group is then transported to the post-weighing station (6) for post-weighing. Each weighing sensor (4) on the post-weighing station (6) sends the weight signal of the bottle (2) to the control module. S5. Calibration: The control module calibrates the filling volume of the filling pump (7) of the filling needle (1) according to the deviation value of the weighing before and after, and calculates the calibration coefficient of the filling pump (7). S6. Comparison and identification: The control module compares the calibration coefficients of the filling pumps (7) of each filling needle (1), finds the abnormal filling pumps (7), and sends the number of the filling needle (1) corresponding to the abnormal filling pump (7) to the human-machine interaction module for alarm reminder; S7. Abnormal filling pump (7) handling: Correct the abnormal filling pump (7). If the abnormal filling pump (7) cannot be corrected, stop the bottle feeding and filling at the station corresponding to the abnormal filling pump (7). The remaining liquid in the abnormal filling pump (7) is used for filling at the subsequent weighing station (6).

2. The automatic identification and calibration method for filling system anomalies according to claim 1, characterized in that: In step S5, when the calibration coefficient of the filling pump (7) exceeds the set upper limit, the bottle feeding and filling of the station corresponding to the filling pump (7) is stopped, and the control module sends the number of the filling needle (1) corresponding to the filling pump (7) to the human-machine interaction module to provide an alarm reminder.

3. The automatic identification and calibration method for filling system anomalies according to claim 1, characterized in that: When the number of calibrations of the filling pump (7) reaches the set upper limit, the bottle feeding and filling of the station corresponding to the filling pump (7) is stopped, and the control module sends the number of the filling needle (1) corresponding to the filling pump (7) to the human-machine interaction module to provide an alarm reminder.

4. The automatic identification and calibration method for filling system malfunctions according to claim 2 or 3, characterized in that: Bottle groups are transported via a conveyor line. The front weighing station (3), the filling station (5), and the rear weighing station (6) are set up sequentially along the conveying direction of the conveyor line.

5. The automatic identification and calibration method for filling system malfunctions according to claim 4, characterized in that: The conveyor line is equipped with a bottle-blocking mechanism upstream of the weighing station (3). The opening and closing of the bottle-blocking mechanism is controlled by the control module. The bottle feeding is stopped by opening the bottle-blocking mechanism.

6. The automatic identification and calibration method for filling system anomalies according to claim 4, characterized in that: The number of weighing sensors (4) on the front weighing station (3) and the rear weighing station (6) is the same, and this number is half the number of filling needles (1).

7. The automatic identification and calibration method for filling system anomalies according to claim 1, characterized in that: When the number of abnormal filling pumps (7) reaches a specified number, the pump will be shut down.

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