Determining functionality of closed-loop control valve of device for filling containers

Abstract

The invention relates in particular to a device (10) for filling a container (12) with a filling material. The apparatus (10) comprises a closed-loop control valve (36, 44, 52) for the filling material and a diagnostic device (56). The diagnostic device (56) is configured to monitor a control value of a control variable of the closed-loop control valve (36, 44, 52) during closed-loop control and to determine a functional state of the closed-loop control valve (36, 44, 52) from the monitored control value. Advantageously, the apparatus (10) may allow the functionality of the closed loop control valve (36, 44, 52) to be monitored and detected during operation and thus wear to be monitored and detected.

Description

Technical Field

[0001] The invention relates to a device for filling containers with a filling material, wherein the device has a closed-loop control valve. The invention also relates to a method for determining the functionality of a closed-loop control valve of a device for filling containers with a filling material. Background Art

[0002] A device for filling containers, such as a rotary filler, may use a closed-loop control valve in various locations. For example, a closed-loop control valve may be arranged at a filling material inlet leading to a filling material reservoir of the filler in order to adjust the filling level in the filling material reservoir to a constant value. A closed-loop control valve may also be integrated in a filling station of the filler to adjust the flow of the filling material when filling the container.

[0003] A closed-loop control valve will wear out during its service life. For example, the sealing surface between the valve seat and the valve member may wear out over time, the sealing elastomer insert may wear out over time, or the actuator of the closed-loop control valve may wear out over time. If the wear increases, the closed-loop control valve may suddenly fail (leak).

[0004] Traditionally, closed-loop control valves can be serviced, overhauled or replaced at certain intervals (e.g. after 6000 hours of operating time or once a year). A disadvantage of this technique can be that no reliable statements can be made about the durability or wear of the closed-loop control valve during operation. For example, the selected maintenance intervals can be too long or too short. Since large variations can occur due to external influences (chemical, temperature, manufacturing precision, material fluctuations, etc.), only rough information about the service life can be given.

[0005] The object of the present invention is to provide an improved monitoring of the function of a closed-loop control valve of an apparatus for filling containers. Summary of the invention

[0006] This object is achieved by the features according to the invention. Advantageous developments are specified in the invention.

[0007] One aspect of the present disclosure relates to a device for filling a container with a filling material. The device has (at least) one closed-loop control valve for the filling material (e.g., configured and arranged to adjust the flow of the filling material or to adjust the filling level or pressure in the filling material reservoir of the device). The device has a diagnostic device, which is configured to monitor the control value of a control variable of (e.g., a corresponding) closed-loop control valve during the closed-loop control (e.g., of the flow or filling level or pressure), preferably the control value of the valve lift (e.g., specified in a dimensionless manner, as a percentage, or specified in a unit of length, etc.) or the control value of the valve opening (e.g., specified in a dimensionless manner, as a percentage, or specified in a unit of length or an area, etc.). The diagnostic device is further configured to determine the functional (e.g., normal and / or damaged) state of the (e.g., corresponding) closed-loop control valve based on the monitored control value, preferably a wear state.

[0008] Advantageously, the device can allow monitoring and determining the functionality of the closed-loop control valve and thus the wear during the operation of the device and during the closed-loop control performed using the closed-loop control valve. When monitoring the control value, for example, abnormalities and the like can be detected, from which the functional state of the closed-loop control valve can be derived. This makes it possible to observe individually when each closed-loop control valve needs to be replaced or maintained. This determination can also be made in advance, so that it is possible to respond not only after the closed-loop control valve has failed, but also when there is a risk of a closed-loop control valve failing. Therefore, maintenance and the like can be planned preventively. Therefore, unnecessary premature replacement can also be avoided. Even during production, monitoring and the like can be performed automatically without removal and disassembly. In addition, this allows each closed-loop control valve in the device to be monitored individually, which is a significant improvement compared to traditional random disassembly and testing. For example, even if the push rod on the closed-loop control valve becomes loose, it can be detected immediately and responded to.

[0009] For example, the diagnostic device may be further configured to receive the control value from a signal output of the closed-loop control valve or a closed-loop control controller / closed-loop control device associated with the closed-loop control valve.

[0010] The closed-loop control variable (process variable, manipulated variable) for the closed-loop control may preferably be the detected flow through the closed-loop control valve or the detected fill level in a filling material reservoir of the device or the detected pressure in a filling material reservoir of the device.

[0011] The reference variable (desired variable, setpoint variable) for the closed-loop control may preferably be a desired flow through the closed-loop control valve or a desired fill level in a filling material reservoir of the device or a desired pressure in a filling material reservoir of the device.

[0012] In an exemplary embodiment, the diagnostic device is further configured to determine the functional state of the closed-loop control valve also based on an allowed control value range (e.g. specified using a user interface of the device), wherein preferably, if the monitored control value is outside the allowed control value range, the functional state of the closed-loop control valve is determined to be a functionally impaired state, and / or if the monitored control value is within the allowed control value range, the functional state of the closed-loop control valve is determined to be a functionally normal state. This allows anomalies in the operation of the closed-loop control valve to be easily detected, for example, whether the control value fluctuates beyond a normal situation or fluctuates in a range different from a normal situation.

[0013] Preferably, the impaired functionality status may indicate that the closed-loop control valve is still functional, but is expected to fail (eg, due to wear).

[0014] Preferably, the impaired functionality state may indicate an expected failure of the closed-loop control valve.

[0015] In another exemplary embodiment, the permissible control value range is within a range of ≥50%, ≥55% or ≥60% and / or ≤75%, ≤70% or ≤65% of the maximum value of the control variable. Therefore, the closed-loop control valve is advantageously designed so that during normal operation and in the absence of abnormalities, there is sufficient power reserve for fast response closed-loop control.

[0016] In one embodiment, the allowed control value range is specified according to at least one of the following:

[0017] - the output of the equipment (e.g., output of containers per unit time);

[0018] - the form and / or fill volume of the container;

[0019] - the filling level in the filling material reservoir of the device;

[0020] - the pressure in the filling material reservoir of the device;

[0021] - a pre-pressure of the filling material upstream of a filling material reservoir of the apparatus; and

[0022] - The temperature of the filling material.

[0023] Advantageously, different permissible control value ranges may thus be specified for different operating parameters and operating conditions, for example a first permissible control value range for a first output of the device and a second, lower permissible control value range for a second, smaller power of the device.

[0024] In another embodiment, the diagnostic device is further configured to monitor the control value of the closed-loop control valve during closed-loop control, such that the control value is monitored in a specified time window and / or in a steady state (of the control value). Preferably, the diagnostic device may be further configured to determine the functional state of the closed-loop control valve based on the monitored control value, such that the functional state of the closed-loop control valve is determined based on (e.g., only based on) the control value monitored in the specified time window and / or in the steady state. This may advantageously result in anomaly detection in the following situations: when the anomaly may be particularly significant, i.e., preferably when the control value is stable.

[0025] In one embodiment variant, the specified time window can:

[0026] - starts after a start-up phase (e.g., container filling) of the device; and / or

[0027] - starts no earlier than 1 minute, no earlier than 2 minutes or no earlier than 3 minutes after activation of the apparatus (e.g., filling of a container); and / or

[0028] - ends before a stop phase (e.g. container filling) of the apparatus; and / or

[0029] - ends no later than 3 minutes, no later than 2 minutes or no later than 1 minute before cessation of the equipment (e.g., container filling); and / or

[0030] - ends before the output of the device changes and / or starts after the output of the device changes.

[0031] In another embodiment variant, the diagnostic device is further configured to monitor the control value of the closed-loop control valve during closed-loop control, such that the control value is monitored under substantially constant operating conditions of the device. Preferably, the diagnostic device can be further configured to determine the functional state of the closed-loop control valve based on the monitored control value, such that the functional state is determined based on (e.g., only based on) the monitored control value under substantially constant operating conditions. This can advantageously lead to anomaly detection in the following situations: when the anomaly may be particularly significant, i.e. when all other main parameters of the device remain substantially the same.

[0032] In an exemplary embodiment, the diagnostic device is further configured to determine that substantially constant operating conditions exist when at least one of the following applies:

[0033] -The output of the device is within the specified output range;

[0034] - the container locking device of the device is open;

[0035] - the fill level in the filling material receptacle of the device is within the specified fill level range;

[0036] - the pressure in the filling material reservoir of the device is within the specified pressure range;

[0037] - the valve of the broken glass removal system of the device is closed;

[0038] - the pre-pressure of the filling material when supplied to the filling material receptacle of the apparatus is within a specified pre-pressure range; and / or

[0039] -The temperature of the filling material is within the specified temperature range.

[0040] In an exemplary embodiment, the apparatus comprises a flow detection device arranged to detect a filling material flow through the closed-loop control valve. Preferably, the diagnostic device may be further configured to determine the functional state of the closed-loop control valve also based on the filling material flow detected by the flow detection device, preferably by comparing the detected filling material flow with a theoretical filling material flow through the closed-loop control valve, the theoretical filling material flow being determined based on the monitored control value. When the actual (detected) flow differs significantly from the theoretical flow, which may be due to premature wear of the closed-loop control valve, this situation may be easily detected.

[0041] Preferably, the diagnostic device may be further configured to determine the functional state as follows:

[0042] - a functional impairment state is determined when the deviation between the measured filling material flow and the theoretical filling material flow is greater than a limit value; and / or

[0043] A functionally normal state is determined when the deviation between the measured filling material flow and the theoretical filling material flow is less than or equal to a limit value.

[0044] In another exemplary embodiment, the apparatus further comprises a (e.g., visual, auditory and / or tactile) output device for outputting information to a user. Preferably, the diagnostic device may be further configured to operate the output device to output information about the determined functional state. This advantageously allows issuing instructions and warnings about the functionality of the closed-loop control valve and / or requesting replacement of the closed-loop control valve at the next opportunity.

[0045] Another aspect of the present disclosure relates to a method for determining the functionality of a closed-loop control valve of an apparatus (preferably an apparatus for filling a container with a filling material as disclosed herein). The method includes using the closed-loop control valve for closed-loop control (e.g., closed-loop control of the flow rate of the filling material or the fill level in the filling material reservoir of the apparatus or the pressure in the filling material reservoir of the apparatus). The method includes using a diagnostic device to monitor the control value of a control variable of the closed-loop control valve, preferably the control value of the valve lift or the control value of the valve opening during the closed-loop control. The method includes using the diagnostic device to determine the functional state of the closed-loop control valve based on the monitored control value. Optionally, the method may also include outputting the determined functional state to a user using an output device. Advantageously, the method can achieve the same advantages as those already described herein with reference to the apparatus. The same applies to the preferred exemplary embodiment of the method below.

[0046] In an exemplary embodiment, determining the functional state of the closed-loop control valve is also dependent on an allowed control value range (e.g., specified using a user interface of the device). Preferably, if the monitored control value is outside the allowed control value range, the functional state of the closed-loop control valve may be determined to be a functionally impaired state. Alternatively or in addition, if the monitored control value is within the allowed control value range, the functional state of the closed-loop control valve may be determined to be a functionally normal state.

[0047] Preferably, the allowable range of control variables can be determined empirically and / or by simulation, preferably for different outputs of the device, different filling levels of the filling material reservoir of the device, different pressures of the filling material reservoir of the device, different pre-pressures of the filling material when being supplied to the filling material reservoir of the device and / or different temperatures of the filling material (for example, before or during commissioning of the device).

[0048] In another exemplary embodiment, the control value is monitored in a specified time window, in a steady state (of the control value) and / or under substantially constant operating conditions of the device. Preferably, the functional state of the closed-loop control valve can be determined based on (e.g., based only on) the control value monitored in the specified time window, in the steady state and / or under the substantially constant operating conditions.

[0049] In another exemplary embodiment, the method further comprises detecting a filling material flow through the closed-loop control valve using a flow detection device. Preferably, the functional state of the closed-loop control valve can also be determined based on the detected filling material flow, preferably by comparing the detected filling material flow with a theoretical filling material flow through the closed-loop control valve, wherein the theoretical filling material flow is determined based on the monitored control value.

[0050] Preferably, when the deviation between the measured filling material flow and the theoretical filling material flow is greater than a limit value, a functionally impaired state can be determined. Alternatively or in addition, when the deviation between the measured filling material flow and the theoretical filling material flow is less than a limit value, a functionally normal state can be determined.

[0051] In another exemplary embodiment, the device has a preferably annular filling material reservoir, and the closed-loop control valve is arranged upstream (along the movement direction of the filling material) of the filling material reservoir for closed-loop control of the filling level or pressure in the filling material reservoir. Alternatively, the closed-loop control valve can be, for example, a filling valve for closed-loop control of the flow of the filling material, with which the filling material can be delivered to a container to fill the container. Alternatively, the closed-loop control valve can be connected to a filling valve for closed-loop control of the flow of the filling material, with which the filling material can be delivered to a container to fill the container.

[0052] In another exemplary embodiment, the device has at least one filling station for filling containers, and the closed-loop control valve is included in or connected to the at least one filling station. Alternatively or in addition, the device has a rotary filler, which includes the closed-loop control valve.

[0053] Another aspect of the present disclosure relates to a container processing facility for manufacturing, cleaning, coating, inspecting, filling, closing, labeling, printing and / or packaging containers for liquid media (preferably, beverages or liquid foods). The container processing facility may include an apparatus as disclosed herein.

[0054] For example, the container may be configured as a bottle, a can, a cartridge, a carton, a vial, or the like.

[0055] Preferably, the term "diagnostic device" may refer to an electronic system (e.g., embodied as a drive circuit or having a microprocessor and a memory) that can perform a processing task according to the configuration. Optionally, the diagnostic device may be part of a closed-loop control device that can perform a closed-loop control task. The closed-loop control device may include electronic, mechanical, pneumatic and / or hydraulic control elements. The closed-loop control device may be part of a closed-loop control and control device that can also perform a control task.

[0056] The preferred embodiments and features of the present invention described above can be combined with each other as desired. BRIEF DESCRIPTION OF THE DRAWINGS

[0057] Further details and advantages of the present invention are described below with reference to the accompanying drawings. In the accompanying drawings:

[0058] Figure 1 An apparatus for filling a container according to an exemplary embodiment of the present disclosure is shown;

[0059] Figure 2 An exemplary filling station is shown;

[0060] Figure 3 Another exemplary filling station is shown;

[0061] Figure 4 A time control value / control variable diagram of a closed-loop control valve of an exemplary apparatus is shown; and

[0062] Figure 5 A time flow diagram of a closed loop control valve of an exemplary apparatus is shown.

[0063] The embodiments shown in the drawings correspond at least partially, so that similar or identical components have the same reference numerals, and reference is also made to the description of other embodiments or drawings for their explanation in order to avoid repetitions. DETAILED DESCRIPTION

[0064] Figure 1 An apparatus 10 is shown for filling a container 12. For clarity, Figure 1 Only some of the containers 12 are shown. Figure 2 An exemplary filling station 38 of the apparatus 10 is shown. Figure 3 An exemplary alternative embodiment of a filling station 38 ′ is shown.

[0065] The device 10 is configured to fill the container 12 with a filling material which is preferably liquid or pasty. The filling material may be carbonized.

[0066] The device 10 comprises at least closed-loop control valves 36, 44, 52 and a diagnostic device 56. Optionally, the device 10 can have, for example, a container conveyor 14, a (further) container conveyor 20, a container locking device 24, a cullet removal system 26, a filler 28, at least one filling station 38 and / or a user interface 54.

[0067] The container conveyor 14 can be arranged upstream (in the moving direction of the containers) of the filler 28 or at least one filling station 38. For example, the container conveyor 14 can have an infeed star wheel 16 and / or a conveyor section 18.

[0068] The infeed starwheel 16 makes it possible to transfer the containers 12 , preferably individually or in a single transport, to a filler 28 or to at least one filling station 38 .

[0069] The conveyor section 18 may preferably be a monorail section and / or be configured for a single transfer of the containers 12. The conveyor section 18 may be arranged, for example, upstream (in the direction of movement of the containers) of the feed star wheel 16. The containers may be transferred (preferably individually or in a single transfer) to the feed star wheel 16 at one end of the conveyor section 18. The conveyor section 18 may, for example, be a conveyor section of a linear conveyor.

[0070] The container conveyor 20 can be arranged downstream (in the direction of movement of the containers) of the filler 28 or at least one filling station 38. For example, the container conveyor 20 can have an outfeed star wheel 22. The outfeed star wheel 22 can take over the filled containers 12 from at least one filling station 38 (preferably individually or in a single transport).

[0071] Preferably, the container 12 can be closed after filling. For example, the container conveyor 20 can convey the filled container 12 to a closing device, such as a closing turntable.

[0072] The container locking device 24 can be arranged upstream (in the moving direction of the containers) of the filler 28 or at least one filling station 38. For example, the container locking device 24 can be arranged on the container conveyor 14, preferably on the conveyor part 18 of the container conveyor.

[0073] The container locking device 24 can lock (or block) and release the transport of the container 12. For example, the container locking device 24 can extend or swing out a locking element to block the transport of the container 12. The blocking element can, for example, extend above the container conveyor 14. The container 12 can be stacked on the blocking element, for example, standing upright on the container conveyor 14. Preferably, the locking element can be retracted or pivoted to release the transport of the container 12.

[0074] The container locking device 24 can also be integrated in the feed star wheel 16 , for example.

[0075] The cullet removal system 26 can remove cullet from a broken container in the filler 28 or at least one filling station 38. The cullet removal system 26 is preferably arranged in the area of ​​the outlet of the filler 28 and / or adjacent to the discharge star wheel 22. The cullet removal system 26 can be fluid-operated and / or fluid-distributed. Preferably, the cullet removal system 26 can include a valve for blocking, releasing and / or adjusting the flow of fluid. Preferably, the cullet removal system 26 can (e.g., controlled by a valve) deliver a fluid (e.g., sterile air or sterile water) to a container receiving space of at least one filling station 38. Preferably, the cullet removal system 26 can be configured as a cullet injection system for ejecting cullet from a container receiving space of at least one filling station 38.

[0076] The filler 28 may preferably be configured as a rotary filler or a filler carousel. For example, several filling stations 38 may be arranged to be distributed around the circumference of the filler 28.

[0077] The filler 28 can be configured, for example, as a linear filler having several filling stations 38 arranged in parallel and / or one behind the other (not shown in the figures). The device 10 or the filler 28 can also have only one filling station 38 .

[0078] Preferably, the apparatus 10 or the filler 28 may have a filling material source 30 , a (filling material) piping system 32 and / or a filling material reservoir 34 .

[0079] For example, the filling material source 30 may be configured as a filling material reservoir. The filling material may be stored in the filling material reservoir. The filling material reservoir may be refillable. Preferably, the filling material source 30 may be arranged at a higher level than the filling material reservoir 34.

[0080] The piping system 32 can connect the filling material source 30 and the filling material reservoir 34 to each other. The piping system 32 can, for example, have a main line, which can be connected to the filling material source 30 at its upstream end. The filling material distributor of the piping system 32 can be arranged at the downstream end of the main line. Several distribution lines can branch from the filling material distributor. The distribution lines can, for example, be connected to the filling material reservoir 34 at different circumferential positions.

[0081] The filling material reservoir 34 is preferably annular or configured as an annular reservoir.The filling material reservoir 34 may be connected to a filling station 38 via several filling material lines.

[0082] The closed-loop control valve 36 may be arranged upstream (in the moving direction of the filling material) of the filling material reservoir 34 and configured to perform closed-loop control of the filling level or pressure in the filling material reservoir 34. In detail, the closed-loop control valve 36 may adjust the flow rate of the filling material from the filling material source 30 to the filling material reservoir 34, for example during closed-loop control.

[0083] The closed-loop control valve 36 may, for example, be arranged at the outlet of the filling material source 30 or in the pipe system 32. The closed-loop control valve 36 may preferably be arranged in a main line of the pipe system 32 or in a filling material dispenser.

[0084] For example, the closed-loop control valve 36 may be able to be adjusted continuously or discretely between a closed position with a 0% flow cross section and a maximum open position with a 100% flow cross section.

[0085] The closed-loop control valve 36 may be operated, for example, electrically, electromagnetically, pneumatically, hydraulically, or mechanically.

[0086] Preferably, the closed-loop control valve 36 may have a movable, preferably displaceable valve member for opening and closing the closed-loop control valve 36. The valve member may preferably have a conical, particularly preferably frustoconical, portion that can be lifted from the valve seat of the closed-loop control valve 36 to open the closed-loop control valve 36.

[0087] The valve lift or valve opening of the closed-loop control valve 36 is preferably a control variable of the closed-loop control valve 36. The control variable is an output variable (position) of an actuator (=closed-loop control valve 36) used in the closed-loop control device, with the help of which a targeted intervention is carried out in the control process. The actual valve lift or the actual valve opening of the closed-loop control valve 36 is preferably a control value of the closed-loop control valve 36 or an instantaneous value of this control variable. The valve lift or the valve opening can be expressed, for example, in a standardized dimensionless manner, in %, or in length units or area units (e.g. mm or mm 2 ) to specify.

[0088] The detected (measured) filling level of the filling material or the pressure in the filling material reservoir 34 can be a closed-loop control variable (process variable, manipulated variable) of the closed-loop control valve 36. The closed-loop control variable is a variable that is to be kept constant or intentionally changed using a closed-loop control. The detected actual filling level of the filling material or the actual pressure in the filling material reservoir 34 can be the actual value / process value of the closed-loop control variable. The (actual) filling level can be detected, for example, by a filling level sensor of the filling material reservoir 34. The (actual) pressure can be detected, for example, by a pressure sensor of the filling material reservoir 34.

[0089] The desired filling level or the desired pressure in the filling material reservoir 34 can be a reference variable (desired variable, set point variable) for the closed-loop control valve 36. The reference variable is the variable into which the closed-loop control variable will be introduced. The reference variable can vary over time. The reference variable can be specified, for example, by a user using the user interface 54 or a technical system of the device 10. The control deviation can be calculated as the difference between the reference variable and the closed-loop control variable or the actual value / process value. The control value can then be formed accordingly and the system to be controlled can be influenced via the closed-loop control valve 36 (=actuator).

[0090] The at least one filling station 38 can fill the container 12 with a preferably liquid or pasty filling material. The container 12 can also be emptied, prestressed and / or flushed in the at least one filling station 38. Thus, the at least one filling station 38 can each have an emptying channel, a biasing channel and / or a flushing channel.

[0091] Figure 2 and Figure 3 An exemplary embodiment of a filling station 38 or 38 ′ is shown in each case.

[0092] The filling station 38 may have a receiving space 40 , a container support 42 , a closed-loop control valve 44 , a filling material channel 46 and / or a flow detection device 48 .

[0093] One container 12 may be received or positioned at a time to be filled in the receiving space 40 .

[0094] The container 12 can be supported in the receiving space 40 using a container support 42 of the filling station 38. The container support 42 can, for example, have a base plate for supporting the respective container 12 at the bottom. Alternatively or in addition, the container support 42 can support the container 12, for example on its shell or neck.

[0095] The closed-loop control valve 44 may be configured as a filling valve. Preferably, the closed-loop control valve 44 may be configured as a so-called proportional flow closed-loop control valve.

[0096] The closed-loop control valve 44 can release the filling material into the container 12, which is positioned in the receiving space 40 of the filling station 38. For example, the closed-loop control valve 44 can be adjusted continuously or discretely between a closed position with a 0% flow cross section and a maximum open position with a 100% flow cross section.

[0097] The closed-loop control valve 44 may be operated, for example, electrically, electromagnetically, pneumatically, hydraulically, or mechanically.

[0098] Preferably, the closed-loop control valve 44 may have a movable, preferably displaceable valve member for opening and closing the closed-loop control valve 44. The valve member may preferably have a conical, particularly preferably frustoconical, portion that can be lifted from the valve seat of the closed-loop control valve 44 to open the closed-loop control valve 44.

[0099] The outlet of the closed-loop control valve 44 and the container mouth of the container 12 in the receiving space 40 can be pressed against each other for filling. To this end, the filling station 38 can have a preferably vertical adjustment device (not shown separately in the figure). The adjustment device can move the container support 42 (together with the supported container 12) towards and away from the outlet of the closed-loop control valve 44. Alternatively or in addition, the adjustment device can move the closed-loop control valve 44 towards and away from the container support 42 (or the supported container 12). The adjustment device can be operated in an electrical, electromagnetic, pneumatic, hydraulic or mechanical manner.

[0100] The closed-loop control valve 44 can receive fill material via a fill material passage 46. The fill material passage 46 can connect the closed-loop control valve 44 to the fill material reservoir 34 (see FIG. Figure 1 ).

[0101] The flow detection device 48 can be configured to detect the flow of fill material to the closed-loop control valve 44. For example, the flow detection device 48 can detect the flow through the fill material passage 46. For example, the flow detection device 48 can measure the flow (e.g., in terms of amount and / or volume). The flow detection device 48 can output a measurement signal indicating the detected flow, for example, to the diagnostic device 56.

[0102] The flow detection device 48 may include any suitable flow measurement principle for detecting the flow. Particularly preferably, the flow detection device 48 may be a magnetic induction flow detection device or an ultrasonic flow detection device.

[0103] Figure 3 Shown with Figure 2 Compared to the modified filling station 38'.

[0104] The filling station 38' may have a filling valve 50 instead of the closed-loop control valve 44. The filling valve 50 may, for example, be configured to selectively release or block the filling material passage 46. The filling valve 50 may release the filling material into the container 12, which is positioned in the receiving space 40 of the filling station 38'. The filling valve 50 may, for example, be operated electrically, electromagnetically, pneumatically, hydraulically or mechanically.

[0105] The filling valve 50 may have a movable, preferably displaceable valve member for opening and closing the filling valve 50. The valve member may preferably have a conical, particularly preferably frustoconical, portion which can be lifted from the valve seat of the filling valve 50 to open the filling valve 50. The outlet of the filling valve 50 and the container mouth of the container 12 in the receiving space 40 may be pressed against each other for filling, as already described for the closed-loop control valve 44.

[0106] The filling station 38' may include a closed-loop control valve 52. The closed-loop control valve 52 may, for example, be arranged in the filling material channel 46. The closed-loop control valve 52 may be arranged upstream (in the moving direction of the filling material) of the filling valve 50. The closed-loop control valve 52 may be arranged upstream (in the moving direction of the filling material) or downstream (in the moving direction of the filling material) of the flow detection device 48.

[0107] Furthermore, the closed-loop control valve 52 may be configured as already described with respect to the closed-loop control valve 44 .

[0108] The valve lift or valve opening of the closed-loop control valve 44, 52 is preferably a controlled variable of the closed-loop control valve 44, 52. The controlled variable is an output variable (position) of the actuator (=closed-loop control valve 44, 52) used in the closed-loop control device, with the help of which a targeted intervention is carried out in the control process. The actual valve lift or actual valve opening of the closed-loop control valve 44, 52 is preferably a control value of the closed-loop control valve 44, 52 or an instantaneous value of the controlled variable. The valve lift or valve opening can be expressed, for example, in a standardized dimensionless manner, in %, or in length units or area units (for example, mm or mm 2 ) to specify.

[0109] The detected (measured) flow rate of the filling material passing through the filling material passage 46 (or the closed-loop control valve 44, 52) can be a closed-loop control variable (adjusted variable, process variable) of the closed-loop control valve 44, 52. The closed-loop control variable is a variable that will be kept constant or intentionally changed using closed-loop control. The recorded actual flow rate of the filling material passing through the filling material passage 46 can be the actual value / process value of the closed-loop control variable. The (actual) flow rate can be detected, for example, by the flow detection device 48.

[0110] The desired flow through the closed-loop control valve 44, 52 or the filling material channel 46 can be a reference variable (desired variable, set point variable) of the closed-loop control valve 44, 52. The reference variable is the variable into which the closed-loop control variable will be introduced. The reference variable can vary over time. The reference variable can be specified, for example, by a user using the user interface 54 or a technical system of the device 10. The control deviation can be calculated as the difference between the reference variable and the closed-loop control variable or the actual value / process value. The control value can then be formed accordingly and the system to be controlled can be influenced via the closed-loop control valve 44, 52 (=actuator).

[0111] exist Figure 2 In the embodiment, the filling station 38 includes a closed loop control valve 44 and in Figure 3 In the embodiment, the filling station 38' comprises a closed-loop control valve 52. The filling station 38 or the filler 28 of the device 10 may also not have a closed-loop control valve at all. The device 10 or the filler 28 may, for example, only comprise a closed-loop control valve 36 (see Figure 1 ).

[0112] At least one closed-loop control valve 36, 44, 52 may be connected to a closed-loop control device (not shown) of the device 10. The closed-loop control device may receive signals from and / or output signals to at least one closed-loop control valve 36, 44, 52. The actual closed-loop control may be implemented electronically and / or by a program in the closed-loop control device. The closed-loop control device may also be at least partially included in at least one closed-loop control valve 36, 44, 52.

[0113] The closed-loop control of the at least one closed-loop control valve 36 , 44 , 52 may, for example, be a closed-loop control with a proportional behavior (P element), an integral behavior (I element) and / or a derivative behavior (D element).

[0114] The user interface 54 may include an output device and / or an input device.

[0115] The output device may be, for example, an acoustic, visual and / or tactile output device. Information may be output to a user via the output device. The output device may, for example, have a (eg, touch-sensitive) display, a loudspeaker and / or at least one signal light.

[0116] For example, the output device can be used to output information to a user about the functional state of at least one closed-loop control valve 36, 44, 52 determined by the diagnostic device. For example, a warning or alarm can be issued when an impaired functional state is detected.

[0117] The input device can be, for example, an acoustic, visual and / or tactile input device. Information (preferably input commands) can be input by a user via the input device. The input device can, for example, have a touch-sensitive display, a keyboard, at least one button or switch, etc., a camera and / or a microphone. The input information can, for example, be stored in a data memory of the diagnostic device 56.

[0118] The diagnostic device 56 is configured to monitor the functionality of at least one closed-loop control valve 36 , 44 , 52 .

[0119] The diagnostic device 56 can be connected to any component described herein for sending and / or receiving signals. Specifically, the diagnostic device 56 can be connected to at least one closed-loop control valve 36, 44, 52 and / or its closed-loop control device for sending and / or receiving signals.

[0120] The diagnostic device 56 monitors the corresponding control value of the control variable of at least one closed-loop control valve 36, 44, 52 during the closed-loop control. The diagnostic device 56 can monitor the corresponding control value of at least one closed-loop control valve 36, 44, 52 while performing the closed-loop control. In other words, the closed-loop control is performed using at least one closed-loop control valve 36, 44, 52, and in addition, the diagnostic device 56 monitors the corresponding control value of at least one closed-loop control valve 36, 44, 52.

[0121] In detail, the diagnostic device 56 may monitor the control value during a period of time when the closed-loop control is performed using the corresponding closed-loop control valve 36 , 44 , 52 .

[0122] The diagnostic device 56 determines, based on the monitoring, the functional state of the corresponding closed-loop control valve 36, 44, 52. For example, the diagnostic device 56 can determine a functionally normal state or a functionally impaired state.

[0123] Different variants of monitoring and determining functional states that can be combined with one another will be described below. Figure 4 An exemplary normal operation of the closed-loop control valve 36 is described.

[0124] Figure 4 An example of a control value or a controlled variable u(t) (=valve lift or valve opening) of a closed-loop control valve 36 over time t in a functionally normal state of the closed-loop control valve 36 is shown.

[0125] The startup of the device 10 can be carried out at time t0. At this time point, for example, the filling of the container 12 and / or the filling material reservoir 34 can be started. Therefore, the closed-loop control valve 36 can be opened to allow the (re) filling of the filling material reservoir 34. From time t0 to time t1, a transient response of the control value of the closed-loop control valve 36 can occur. Between time t1 and t2, the control value can be in a steady state. The control value can be substantially constant or only slightly fluctuates. Here, the device 10 can show a substantially constant operating condition. At time t2, the output of the device 10 or the filler 28 can be reduced, for example, from 60,000 containers per hour to 40,000 containers per hour. From time t2 to time t3, a transient response of the control value of the closed-loop control valve 36 can occur again. Between time t3 and time t4, the control value can be in a steady state again. The control value can be substantially constant or only slightly fluctuates. Here, the device 10 can show a substantially constant operating condition again. Stopping of the apparatus 10 may be initiated at time t4. Between time t4 and time t5, less and less filling material needs to be supplied to the filling material reservoir 34. The closed loop control valve 36 may be closed until time t5. The control value may be reduced to zero until time t5.

[0126] Preferably, the control value of the closed-loop control valve 36 may be monitored in a specified time window, and the functional state of the closed-loop control valve 36 may be determined based on the control value monitored in the specified time window.

[0127] Reference Figure 4 , the specified time window can be between t1 and t2 and / or between t3 and t4. Generally speaking, the specified time window can be determined by one or more conditions. The specified time window can, for example, start after the (for example, container filling) startup phase of equipment 10. The specified time window can, for example, start no earlier than 1 minute, no earlier than 2 minutes or no earlier than 3 minutes after the (for example, container filling) startup of equipment 10. The specified time window can, for example, end before the (for example, container filling) stop phase of equipment 10. The specified time window can, for example, end no more than 3 minutes, no more than 2 minutes or no more than 1 minute before the (container filling) stop of equipment 10. The specified time window can, for example, end before the output of equipment 10 changes and / or start after the output of equipment 10 changes.

[0128] Preferably, the control value of the closed-loop control valve 36 can be monitored in a steady state of the control value, and the functional state of the closed-loop control valve 36 can be determined based on the control value monitored in the steady state.

[0129] Reference Figure 4, the control value may be stable between t1 and t2 and / or between t3 and t4. Generally speaking, a steady state may exist if the control value fluctuates around an average value over time. For example, in the steady state, the control value may fluctuate around the average value within a range of ±5%, preferably ±3%. In the steady state, the course of the control value may not be affected by trends or the like. In the steady state, the control value may, for example, fluctuate by no more than 7%, no more than 6%, or no more than 5%.

[0130] Preferably, the control value of the closed-loop control valve 36 may be monitored such that it is monitored under constant operating conditions of the apparatus 10. The functional state of the closed-loop control valve 36 may be determined from the control value monitored under constant operating conditions.

[0131] Reference Figure 4 , there may be substantially constant operating conditions of the device 10 between t1 and t2 and / or between t3 and t4. Generally speaking, when one or more conditions are met, the diagnostic device 56 can determine that constant operating conditions exist. For example, the output of the device 10 can be substantially constant and within a specified output range. For example, the container locking device 24 can be open. For example, the fill level in the filling material reservoir 34 can be substantially constant and within a specified fill level range. For example, the pressure in the filling material reservoir 34 can be substantially constant and within a specified pressure range. For example, the valve of the broken glass removal system 26 can be closed. For example, when the filling material is supplied to the filling material reservoir 34, the pre-pressure of the filling material can be substantially constant and within a specified pre-pressure range. For example, the temperature of the filling material can be substantially constant and within a specified temperature range.

[0132] Preferably, the functional state of the closed-loop control valve 36 can also be determined based on the permissible control value range. If the monitored control value is, for example, within the permissible control value range, a functionally normal state of the closed-loop control valve 36 can be determined, that is, the closed-loop control valve 36 functions normally. If, for example, the monitored control value is outside the permissible control value range, a functionally impaired state of the closed-loop control valve 36 can be determined, for example, the closed-loop control valve 36 does not function, does not function completely, functions abnormally, or is expected to fail due to wear.

[0133] Reference Figure 4 , the first allowed control value range may be, for example, between u2 and u3. For example, the first allowed control value range may be specified for a steady state between t1 and t2, a constant operating condition between t1 and t2, and / or a specified time window between t1 and t2.

[0134] Reference Figure 4, the second allowed control value range may be, for example, between u1 and u2. For example, the second allowed control value range may be specified for a steady state between t3 and t4, a constant operating condition between t3 and t4, and / or a specified time window between t3 and t4.

[0135] Generally speaking, the allowable control value range may be, for example, within a range of ≥50%, ≥55%, or ≥60% and / or ≤75%, ≤70%, or ≤65% of the maximum value of the control variable. The allowable control value range may be specified based on at least one parameter. For example, the allowable control value range may be specified based on the following: the output of the device 10 (e.g., see Figure 4 - a first permissible control value range of 60,000 containers per hour; a second permissible control value range of 40,000 containers per hour), the form and / or the filling volume of the container 12, the filling level of the filling material reservoir 34, the pressure in the filling material reservoir 34, the pre-pressure of the filling material upstream of the filling material reservoir 34 and / or the temperature of the filling material. This means that, if necessary, different permissible control value ranges can be specified for different parameters.

[0136] The above description of monitoring the control value of the closed-loop control valve 36 and determining its functional state can also be applied to the closed-loop control valve 44 or 52. However, preferably, the monitoring of the control value of the closed-loop control valve 44, 52 and the determination of the functional state of the closed-loop control valve 44, 52 can be as will be described below with reference to Figure 5 Proceed as described by way of example.

[0137] Figure 5 An example of a detected flow rate (solid curve A) through the closed-loop control valves 44 , 52 over time t for a filling process of the container 12 is shown.

[0138] At time t6, filling of the container 12 may begin. Between time t6 and time t7, the control value of the closed-loop control valve 44, 52 and thus the measured flow rate may be stable. From time t7 to time t8, the control value of the closed-loop control valve 44, 52 and thus the detected flow rate may be substantially constant or stable. A filling stop may be initiated from time t8. The closed-loop control valve 44, 52 begins to close. The detected flow rate may decrease. Filling of the container 12 may be completed at time t9. The control value of the closed-loop control valve 44, 52 and the detected flow rate may be zero.

[0139] Figure 5Also shown is a theoretical flow rate (curve B) through the closed-loop control valves 44, 52 over time t for the filling process of the container 12. In detail, the theoretical flow rate can be determined (e.g., calculated) from the monitored control values ​​of the closed-loop control valves 44, 52. For example, the corresponding flow cross-sectional area can be determined from the monitored control values, and the theoretical flow rate can be determined therefrom. The determination can be performed or supported, for example, mathematically, empirically and / or by simulation.

[0140] By comparing the measured filling material flow with the theoretical filling material flow, the diagnostic device 56 can now determine the functional state of the closed-loop control valve 44, 52. This comparison can preferably be carried out for a constant flow phase, a specified time window and / or a steady state of the control value / flow (see also the description of the invention). Figure 4 If the deviation x between the measured flow rate (curve A) and the theoretical flow rate (curve B) in the monitored time period is, for example, greater than a specified limit value, a functionally impaired state of the closed-loop control valve 44, 52 can be determined. If the deviation x between the measured flow rate (curve A) and the theoretical flow rate (curve B) in the monitored time period is less than a specified limit value, a functionally normal state of the closed-loop control valve 44, 52 can be determined.

[0141] The above description of monitoring the control values ​​of the closed-loop control valves 44, 52 and determining their functional status can also be applied to the closed-loop control valve 36. These processes can also be combined.

[0142] The present invention is not limited to the preferred exemplary embodiments described above. On the contrary, there may be a variety of variants and modifications, which also utilize the inventive concept and therefore fall within the scope of protection. All ranges specified herein are understood to be disclosed in such a way that all values ​​falling within the corresponding range are disclosed individually, for example also disclosed as the corresponding preferred narrower outer limit values ​​of the corresponding range.

[0143] Reference numerals list

[0144] 10 Equipment for filling containers

[0145] 12 Container

[0146] 14 Container conveyor

[0147] 16 Feed star wheel

[0148] 18 Conveyor device part

[0149] 20 Container conveyor

[0150] 22 Discharging star wheel

[0151] 24 Container locking device

[0152] 26 Broken Glass Removal System

[0153] 28 Filler

[0154] 30 Filling material source

[0155] 32 Pipeline system

[0156] 34 Filling material receptacles

[0157] 36 Closed loop control valve

[0158] 38 Filling Stations

[0159] 40 Receiving Space

[0160] 42 Container support

[0161] 44 Closed loop control valve

[0162] 46 Filling material channel

[0163] 48 Flow detection device

[0164] 50 Filling valve

[0165] 52 Closed loop control valve

[0166] 54 User Interface

[0167] 56 Diagnostic Devices

Claims

1. A device (10) for filling a container (12) with a filling material, wherein the device (10) comprises: a closed-loop control valve (36, 44, 52), the closed-loop control valve being used for the filling material; and A diagnostic device (56), the diagnostic device being configured to: - monitoring the control variation of the closed-loop control valve (36, 44, 52) during closed-loop control Control value of quantity; and - determining the functional state of the closed-loop control valve (36, 44, 52) based on the monitored control value.

2. The device (10) according to claim 1, wherein: The diagnostic device is configured to: - monitoring a control value of a valve lift or a control value of a valve opening of the closed-loop control valve (36, 44, 52) during closed-loop control; and - determining the wear state of the closed-loop control valve (36, 44, 52) based on the monitored control value.

3. The device (10) according to claim 1, wherein: The diagnostic device (56) is further configured to determine the functional state of the closed-loop control valve (36, 44, 52) also based on an allowed control value range.

4. The device (10) according to claim 3, wherein If the monitored control value is outside the permissible control value range, the functional state of the closed-loop control valve (36, 44, 52) is determined to be a functionally impaired state, and / or if the monitored control value is within the permissible control value range, the functional state of the closed-loop control valve is determined to be a functionally normal state.

5. The device (10) according to claim 3, wherein: The permissible control value range is within a range of ≥50%, ≥55% or ≥60% and / or ≤75%, ≤70% or ≤65% of the maximum value of the control variable; and / or The allowed control value range is specified according to at least one of the following: - an output of the device (10); - the form and / or filling volume of the container (12); - the filling level in the filling material reservoir (34) of the device (10); - the pressure in the filling material reservoir (34) of the device (10); - a pre-pressure of the filling material upstream of a filling material reservoir (34) of the device (10); and - The temperature of the filling material.

6. The device (10) according to claim 1, wherein: The diagnostic device (56) is further configured to: - monitoring the control value of the closed-loop control valve (36, 44, 52) during closed-loop control, such that the control value is monitored within a specified time window and / or in a steady state; as well as - determining the functional state of the closed-loop control valve (36, 44, 52) based on the monitored control value, such that the functional state of the closed-loop control valve (36, 44, 52) is determined based on the control value monitored in the specified time window and / or in the steady state.

7. The apparatus (10) of claim 6, wherein the specified time window: Beginning after a start-up phase of the device (10); and / or starts no earlier than 1 minute, no earlier than 2 minutes or no earlier than 3 minutes after the device (10) has been activated; and / or ends before the stopping phase of the device (10); and / or ends no more than 3 minutes, no more than 2 minutes or no more than 1 minute before stopping of the apparatus (10) (e.g., container filling); and / or Ends before the output of the device (10) changes and / or begins after the output of the device (10) changes.

8. The apparatus (10) of claim 1, wherein: The diagnostic device (56) is further configured to: - monitoring the control value of the closed-loop control valve (36, 44, 52) during closed-loop control, such that the control value is monitored under substantially constant operating conditions of the device (10); as well as - determining the functional state of the closed-loop control valve (36, 44, 52) as a function of the monitored control value, such that the functional state is determined as a function of the monitored control value under the substantially constant operating conditions.

9. The apparatus (10) of claim 8, wherein the diagnostic device (56) is further configured to determine that the substantially constant operating condition exists when at least one of the following applies: The output of the device (10) is within a specified output range; The container locking device (24) of the device (10) is open; a fill level in a filling material reservoir (34) of the device (10) being within a specified fill level range; The pressure in the filling material reservoir (34) of the apparatus (10) is within a specified pressure range; The valve of the cullet removal system (26) of the apparatus (10) is closed; The pre-pressure of the filling material when it is supplied to the filling material reservoir (34) of the apparatus (10) is within a specified pre-pressure range; and / or The temperature of the filling material is within a specified temperature range.

10. The device (10) according to claim 1, further comprising: a flow detection device (48) arranged to detect a flow of filler material through the closed-loop control valve (36, 44, 52), in: The diagnostic device (56) is further configured to determine the functional state of the closed-loop control valve (36, 44, 52) also based on the filling material flow detected by the flow detection device (48), the theoretical filling material flow being determined based on the monitored control value.

11. The device (10) according to claim 10, wherein: The diagnostic device (56) is further configured to determine the functional state of the closed-loop control valve (36, 44, 52) by also comparing the detected filling material flow rate with a theoretical filling material flow rate through the closed-loop control valve (36, 44, 52), the theoretical filling material flow rate being determined based on the monitored control value.

12. The device (10) according to claim 1, further comprising: An output device, the output device is used to output information to a user; The diagnostic device (56) is further configured to operate the output device to output information about the determined functional status.

13. The apparatus (10) of claim 1, wherein: The device (10) has a filling material reservoir (34), and the closed-loop control valve (36) is arranged upstream of the filling material reservoir (34) for closed-loop control of the filling level or pressure in the filling material reservoir (34); or The closed-loop control valve (44) is a filling valve for performing closed-loop control on the flow rate of the filling material, and the filling material can be delivered to the container (12) by means of the filling valve to fill the container (12); or The closed-loop control valve (52) is connected to a filling valve (50) for closed-loop control of a flow rate of the filling material, with which the filling material can be delivered to a container (12) to fill the container (12).

14. The device (10) according to claim 13, wherein: The device (10) has an annular filling material reservoir (34).

15. The apparatus (10) of claim 1, wherein: The device (10) has at least one filling station (38) for filling the container (12), and the closed-loop control valve (36, 44, 52) is included in the at least one filling station (38) or is connected to the at least one filling station (38); or The apparatus (10) includes a rotary filler (28) including the closed-loop control valve (36, 44, 52).

16. A method for determining the functionality of a closed-loop control valve (36, 44, 52) of an apparatus (10) for filling a container (12) with a filling material according to any one of claims 1 to 15, wherein the method comprises: Using the closed-loop control valve (36, 44, 52) to perform closed-loop control; using a diagnostic device (56) to monitor a control value of a control variable of the closed-loop control valve (36, 44, 52) during the closed-loop control; as well as using the diagnostic device (56) to determine the functional state of the closed-loop control valve (36, 44, 52) based on the monitored control value; and optionally The determined functionality status is output to a user using an output device.

17. The method according to claim 16, wherein the method comprises: Using the closed-loop control valve (36, 44, 52) to perform closed-loop control; During the closed-loop control, a diagnostic device (56) is used to monitor a control value of a valve lift or a control value of a valve opening of the closed-loop control valve (36, 44, 52); and using the diagnostic device (56) to determine the functional state of the closed-loop control valve (36, 44, 52) based on the monitored control value; and optionally The determined functionality status is output to a user using an output device.

18. The method of claim 16, wherein: Determining the functional state of the closed-loop control valve (36, 44, 52) also depends on a permissible control value range.

19. The method of claim 18, wherein: If the monitored control value is outside the permissible control value range, the functional state of the closed-loop control valve (36, 44, 52) is determined to be a functionally impaired state, and / or if the monitored control value is within the permissible control value range, the functional state of the closed-loop control valve is determined to be a functionally normal state.

20. The method of claim 16, wherein: monitoring the control value during a specified time window, at a steady state of the control value and / or under substantially constant operating conditions of the device (10); and The functional state of the closed-loop control valve (36, 44, 52) is determined based on the control value monitored in the specified time window, in the steady state and / or under the substantially constant operating conditions.

21. The method according to claim 16, further comprising: using a flow detection device (48) to detect the flow of filling material passing through the closed-loop control valve (36, 44, 52), The functional state of the closed-loop control valve (36, 44, 52) is also determined based on the detected filling material flow, and the theoretical filling material flow is determined based on the monitored control value.

22. The method according to claim 21, further comprising: using a flow detection device (48) to detect the flow of filling material passing through the closed-loop control valve (36, 44, 52), The functional state of the closed-loop control valve (36, 44, 52) is also determined by comparing the detected filling material flow with a theoretical filling material flow through the closed-loop control valve (36, 44, 52), the theoretical filling material flow being determined based on the monitored control value.

23. The method of claim 16, wherein: The device (10) has a filling material reservoir (34), and the closed-loop control valve (36) is arranged upstream of the filling material reservoir (34) for closed-loop control of the filling level or pressure in the filling material reservoir (34); or The closed-loop control valve (44) is a filling valve for performing closed-loop control on the flow rate of the filling material, and the filling material can be delivered to the container (12) by means of the filling valve to fill the container (12); or The closed-loop control valve (52) is connected to a filling valve (50) for closed-loop control of a flow rate of the filling material, with which the filling material can be delivered to a container (12) to fill the container (12).

24. The method according to claim 23, wherein: The device (10) has an annular filling material reservoir (34).

25. The method of claim 16, wherein: The device (10) has at least one filling station (38) for filling the container (12), and the closed-loop control valve (36, 44, 52) is included in the at least one filling station (38) or is connected to the at least one filling station (38); or The apparatus (10) includes a rotary filler (28) including the closed-loop control valve (36, 44, 52).

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