Apparatus and method for filling a container with a material

Abstract

The present application relates to the technical field of food and medicine packaging method and equipment, and particularly relates to a device and method for material filling into a container. The present application provides a device for material filling into a container, which comprises a liquid source assembly, a buffer tank, a distribution unit, a calibration assembly, a gas source assembly and a control assembly. The present application realizes accurate filling through a multiple feedback control mechanism. The pressure sensor and the liquid level sensor in the buffer tank provide real-time data, and the control assembly adjusts the liquid inlet and the gas pressure stabilization accordingly, so as to ensure the pressure stability during the filling process. Meanwhile, through the feedback of the net weight of the material by the calibration assembly, the control assembly can dynamically adjust the opening duration of the filling assembly and the proportional-integral-derivative parameters, so as to continuously optimize the filling accuracy. Compared with the traditional method, the closed-loop control system greatly improves the filling accuracy, simplifies the control process, and avoids the complicated multi-branch pressure control.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of food and medicine packaging methods and equipment, in particular to a device and method for filling containers with materials. BACKGROUND

[0002] In the process of food and medicine packaging, the existing technology is to directly input the solution into the branch through the buffer tank, and then use the pressure detection device on each branch to detect the pressure of each branch to feedback to the controller to control the filling amount and filling precision. This method has the following problems:

[0003] Firstly, it is necessary to accurately control the pressure of each branch, which makes the control feedback process complicated. Each branch needs a separate pressure detection device and control mechanism, which increases the complexity and cost of the system.

[0004] Secondly, since the pressure of each branch needs to be controlled separately, it is easy to cause the pressure imbalance between the branches, thereby affecting the consistency and precision of the filling.

[0005] In addition, the instability of pressure control may also cause liquid overflow or insufficient filling during the filling process, increasing the waste rate and material waste in the production process. SUMMARY

[0006] The purpose of the present application is to provide a device and method for filling containers with materials to improve filling precision, simplify pressure control feedback process, and improve the stability of pressure control.

[0007] The present application provides a device for filling containers with materials, comprising a liquid source assembly, a buffer tank, a distribution unit, a verification assembly, an air source assembly, and a control assembly;

[0008] The buffer tank comprises a tank body, an interface connected with the air source assembly arranged on the tank body, and a first sensor and a second sensor connected with the tank body. The tank body is provided with an inlet and an outlet. The inlet is connected with the liquid source assembly, the outlet is connected with the distribution unit, and the outlet is connected with the control assembly. The first sensor is used to detect the pressure in the tank body and feedback to the control assembly. The second sensor is used to detect the height of the material in the tank body and feedback to the control assembly;

[0009] The distribution unit is one-to-one corresponding to a plurality of filling needles. The filling needles are used to fill the materials in the distribution unit into designated containers;

[0010] The verification assembly is used to obtain the net weight of the materials in each container and feedback the net weight of the materials to the control assembly;

[0011] The control component is configured to control the liquid source component to adjust the height of the material in the tank and control the gas source component to adjust the pressure in the tank according to the feedback of the first sensor and the second sensor, and dynamically adjust the filling time of the filling needle by the monitoring of the verification component.

[0012] Further, a pinch valve assembly is provided, the dispensing unit comprises a dispensing main pipe, a hose and an adapter assembly, the dispensing main pipe is connected with the outlet of the tank, the adapter assembly is configured to connect the material in the dispensing main pipe with the filling needle through the hose, and the pinch valve assembly is configured to pinch or release the hose to enable or stop the filling of the filling needle.

[0013] Further, the adapter assembly comprises a dispensing pipe, a first adapter and a second adapter, the first adapter and the second adapter each have a first end and a second end, one end of the dispensing pipe is connected with the dispensing main pipe, and the other end is connected with the first end of the first adapter, one end of the hose is connected with the second end of the first adapter, and the other end is connected with the first end of the second adapter, the second end of the second adapter is connected with the filling needle, and the first adapter and the second adapter fix the hose on the pinch valve assembly.

[0014] Further, the inlet diameter at the first end of the first adapter is greater than the outlet diameter at the second end, the inlet diameter at the first end of the second adapter is greater than the outlet diameter at the second end, and the outlet diameter at the second end of the first adapter is equal to the inlet diameter at the first end of the second adapter.

[0015] Further, the inlet diameter at the first end of the first adapter is a first set multiple of the outlet diameter at the second end, the first set multiple is greater than or equal to 1.2 and less than 2, or greater than 2 and less than or equal to 2.2, and the inlet diameter at the first end of the second adapter is a first set multiple of the outlet diameter at the second end, the first set multiple is greater than or equal to 1.2 and less than 2, or greater than 2 and less than or equal to 2.2.

[0016] Further, the pinch valve assembly comprises at least one pressing plate and at least one pinch valve assembly, the pinch valve assembly corresponds to the filling needle one by one, the pinch valve assembly comprises a driving mechanism and a driving rod, the hose passes through the gap between the pressing plate and the driving rod, and the driving mechanism is configured to drive the driving rod to approach or move away from the pressing plate to pinch or release the hose.

[0017] The application also provides a pressure filling method, which is applied to the device for filling the material into the container in any of the above technical solutions, and comprises the following steps:

[0018] controlling the height of the material in the tank within a set height range and the pressure in the tank within a set pressure range by a proportional-integral-derivative control algorithm;

[0019] controlling the filling duration of the filling needle according to the target filling amount;

[0020] correcting the filling duration and the proportional-integral-derivative parameters of the filling needle according to the net weight of the material.

[0021] Further, the pressure in the tank is controlled within a set range by introducing inert gas into the tank through a gas source assembly.

[0022] Further, when the height decreases, the liquid flow is adjusted synchronously by a flow proportional valve and the gas flow is adjusted synchronously by a pressure proportional valve.

[0023] Further, a hose is used to supply the material to the filling needle, and the filling material is stopped by clamping the hose, which includes a first stage and a second stage, in the first stage, the hose is clamped to a set retention rate at a first speed to stop the liquid from flowing out of the hose, in the second stage, the hose is continuously clamped to complete closure at a second speed to suck back the residual material in the filling needle, the second speed is greater than the first speed, and the first retention rate ranges from 90% to 98%.

[0024] Compared with the prior art, the present application has at least the following beneficial effects:

[0025] The present application realizes accurate filling through a multiple feedback control mechanism, the pressure sensor and the height sensor in the buffer tank provide real-time data, and the control assembly adjusts the liquid inlet and the gas pressure stabilization accordingly to ensure the stability of the pressure during the filling process. At the same time, through the feedback of the net weight of the material by the verification assembly, the control assembly can dynamically adjust the filling duration and the proportional-integral-derivative parameters of the filling needle, and continuously optimize the filling accuracy. Compared with the traditional method, this closed-loop control system greatly improves the filling accuracy, simplifies the control process, and avoids the complicated multi-branch pressure control. BRIEF DESCRIPTION OF DRAWINGS

[0026] Figure 1 a structural schematic diagram of one embodiment of the device for filling a container with material according to the present application;

[0027] Figure 2 a structural schematic diagram of the buffer tank of the device for filling a container with material according to the present application in Figure 1

[0028] Figure 3 a structural schematic diagram of the pinch valve assembly and the filling assembly of the device for filling a container with material according to the present application in Figure 1 ​​

[0029] Figure 4 Fig. 2 is a structural schematic view of the filling assembly in Fig. 1 from another perspective; Figure 3

[0030] Figure 5 Fig. 3 is a structural schematic view of the filling assembly in Fig. 1 from another perspective; Figure 3

[0031] Figure 6 Fig. 4 is a sectional view of the first adapter in Fig. 3 along A-A direction. Figure 5

[0032] Reference signs:

[0033] 10, frame body;

[0034] 20, liquid source assembly;

[0035] 30, buffer tank; 31, tank body; 311, inlet; 312, outlet; 32, interface; 33, second sensor; 34, third sensor; 35, fourth sensor; 36, first sensor; 37, conversion joint;

[0036] 40, distribution main pipeline;

[0037] 50, pinch tube assembly; 81, pressing plate; 82, driving mechanism; 83, driving rod; 84, fixed base plate; 85, semi-cylindrical plate;

[0038] 60, calibration assembly;

[0039] 71, filling needle; 72, first adapter; 73, second adapter;

[0040] 80, touch screen. DETAILED DESCRIPTION

[0041] The device and method for filling a container with a material according to the present application will be described below with reference to the accompanying drawings, in which the preferred embodiments of the present application are shown, it should be understood that those skilled in the art can modify the present application described herein while still achieving the advantageous effects of the present application. Therefore, the following description should be understood as a broad knowledge for those skilled in the art, and not as a limitation of the present application.

[0042] ​​​The serial numbers of components used herein, such as "first", "second", etc., are only used to distinguish the described objects, and do not have any sequential or technical meaning. The "connection" and "coupling" in the present application, unless otherwise specified, include direct and indirect connections (couplings). In the description of the present application, it should be understood that the orientations or positional relationships indicated by the terms "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc. are based on the orientations or positional relationships shown in the drawings, and are only for the purpose of facilitating the description of the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application.

[0043] In the present application, unless otherwise explicitly specified and limited, the "on" or "under" of a first feature to a second feature can be that the first and second features are in direct contact, or the first and second features are in indirect contact through an intermediate medium. Moreover, the "over", "above" and "on" of the first feature to the second feature can be that the first feature is directly above or obliquely above the second feature, or only indicates that the horizontal height of the first feature is higher than that of the second feature. The "under", "below" and "under" of the first feature to the second feature can be that the first feature is directly below or obliquely below the second feature, or only indicates that the horizontal height of the first feature is less than that of the second feature.

[0044] The present application will be described in more detail by way of example with reference to the accompanying drawings in the following paragraphs. The advantages and features of the present application will be more apparent from the following description and claims. It should be noted that the drawings are very simplified and all use non-precise proportions, only for the purpose of facilitating, clarifying and assisting the description of the embodiments of the present application.

[0045] The present application will be described in more detail by way of example with reference to the accompanying drawings in the following paragraphs. The advantages and features of the present application will be more apparent from the following description and claims. It should be noted that the drawings are very simplified and all use non-precise proportions, only for the purpose of facilitating, clarifying and assisting the description of the embodiments of the present application. Figures 1 to 6 A device for filling a container with a material and a filling method are introduced.

[0046] In one embodiment, as shown in Figure 1 、 Figure 2 、 Figure 3 and Figure 4 , the device for filling a container with a material includes a frame body 10, a liquid source assembly 20, a buffer tank 30, a dispensing unit, a verification assembly 60, a gas source assembly and a control assembly arranged on the frame body 10.

[0047] As shown in Figure 2As shown, the buffer tank 30 comprises a tank body 31, an interface 32 arranged on the tank body 31, and a first sensor 36 and a second sensor 33 connected with the tank body, the tank body 31 is provided with an inlet 311 and an outlet 312, the inlet 311 is connected with the liquid source assembly 20, the outlet 312 is connected with the dispensing unit and is electrically connected with the control assembly, the first sensor 36 is a pressure sensor for detecting the pressure in the tank body 31 and feeding back to the control assembly, specifically detecting the liquid pressure at the bottom of the tank body 31, and the second sensor 33 is a liquid level sensor for detecting the height of the material in the tank body 31 and feeding back to the control assembly.

[0048] The dispensing unit is provided with a plurality of filling needles 71 one-to-one corresponding to the dispensing unit, and the filling needles 71 are used to fill the material in the dispensing unit into the specified container. Specifically, the outlet 312 of the tank body 31 is connected with a conversion joint 37, the first sensor 36 is connected with the conversion joint 37, and the inlet end of the dispensing unit is also connected with the conversion joint 37.

[0049] The verification assembly 60 is used to obtain the net weight of the material in each container and feed back the net weight of the material to the control assembly.

[0050] The control assembly is used to control the liquid source assembly 20 to adjust the height of the material in the tank body 31 and control the gas source assembly to adjust the pressure in the tank body 31 according to the feedback of the first sensor 36 and the second sensor 33, and the control assembly dynamically adjusts the filling time of the filling needle 71 through the monitoring of the verification assembly 60.

[0051] Among them, the liquid source assembly 20 refers to a pipeline system for delivering material to the buffer tank 30, which can be realized by using stainless steel pipe or food-grade hose.

[0052] The buffer tank 30 refers to a container for temporarily storing and stabilizing the material, which can be realized by using a sealed tank body made of stainless steel.

[0053] The dispensing unit refers to a pipeline system for dispensing material from the buffer tank 30 to each filling needle 71, which can be realized by using a stainless steel pipeline with multiple branch outlets and a branch assembly.

[0054] The verification assembly 60 refers to a device for measuring the net weight of the material, which can be realized by using a high-precision electronic scale or a weighing sensor.

[0055] The gas source assembly is used to introduce gas into the buffer tank 30 to stabilize the pressure in the buffer tank 30, which can be realized by using a stainless steel pipe or a food-grade hose.

[0056] The control assembly includes a touch screen 80 and a central processing unit connected to the touch screen 80 for coordinating and controlling the entire filling process, which can be implemented by a programmable logic controller (PLC) or an industrial computer.

[0057] The present application realizes accurate filling through a multiple feedback control mechanism. The pressure sensor and the liquid level sensor in the buffer tank 30 provide real-time data, and the control assembly adjusts the liquid inlet and gas pressure stabilization accordingly to ensure the pressure stability during the filling process. At the same time, through the feedback of the material net weight of the verification assembly 60, the control assembly can dynamically adjust the filling time of the filling needle 71 to continuously optimize the filling accuracy. Compared with the traditional method, this closed-loop control system greatly improves the filling accuracy, simplifies the control process, and avoids the complicated multi-branch pressure control.

[0058] In some embodiments, a third sensor 34 is further arranged in the tank body 31, which is a pressure sensor for detecting the gas pressure in the tank body 31 in real time, so as to facilitate the operator to monitor the pressure in the tank body 31 in real time. A fourth sensor 35 is further arranged at the bottom of the tank body 31, which is a temperature sensor for monitoring the temperature of the material in the tank body 31 in real time.

[0059] In some embodiments, the device for filling the material into the container further includes a pipe clamping assembly, and the distribution unit further includes a distribution main pipeline 40, a hose (not shown in the drawings), and an adapter assembly. The distribution main pipeline 40 is connected to the outlet 312 of the tank body 31, the adapter assembly is used to introduce the material in the distribution main pipeline 40 into the filling needle 71 through the hose, and the pipe clamping assembly 50 is used to clamp or release the hose to enable or stop the filling of the filling needle 71. The pipe clamping assembly 50 can be implemented by an electric or pneumatic clamping device.

[0060] The hose, as a flexible connecting component, can be selected from hoses made of different materials and having different diameters to adapt to materials with different viscosities and flow rates. The length of the hose can be adjusted according to actual needs to meet the requirements of different filling positions. The flexible nature of the hose not only facilitates the filling operation but also provides convenience for the control of the pipe clamping assembly 50.

[0061] The filling needle 71 is connected to the end of the hose, and its design can be optimized according to the characteristics of the filling material and the shape of the container. For example, for high-viscosity materials, a filling needle 71 with a larger inner diameter can be designed; for materials prone to foaming, a special anti-foam filling needle 71 can be designed. The length and angle of the filling needle 71 can also be adjusted according to the size and depth of the opening of the container to ensure that the material accurately enters the container.

[0062] In one embodiment, as shown in FIG. 6, the device for filling the material into the container further includes a weighing assembly 70 arranged on the tank body 31. The weighing assembly 70 is used to weigh the material in the tank body 31 and provide the weight data to the control assembly. Figure 3 and Figure 4As shown, the adapter assembly includes a distribution pipe, a first adapter 72 and a second adapter 73, both of which have a first end and a second end. One end of the distribution pipe is connected to the distribution manifold 40, and the other end is connected to the first end of the first adapter 72. One end of the hose is connected to the second end of the first adapter 72, and the other end is connected to the first end of the second adapter 73. The second end of the second adapter 73 is connected to the filling needle 71. The first adapter 72 and the second adapter 73 can also support and constrain the hose, thereby fixing the hose on the pinch unit.

[0063] Specifically, the distribution pipe can be made of different materials, preferably a hard pipe such as stainless steel, hard plastic or hard composite material, so as not to be easily deformed. The first adapter 72 and the second adapter 73 can be designed to be detachable for easy cleaning and maintenance. The internal structure of these adapters can be further optimized, such as setting up streamlined channels to reduce the resistance and dead angle of the material in the flow process. The first adapter 72 and the second adapter 73 are supported by the adapter bracket on the frame 10.

[0064] The connection between the various components of the adapter assembly can also be designed flexibly. For example, the connection between the distribution pipe and the first adapter 72 can be achieved by screw connection, buckle connection or quick connector, etc. The connection between the hose and the adapter can use a special hose connector to ensure the sealing and stability of the connection. The choice of these connection methods needs to take into account the actual application scenario, such as the characteristics of the filling medium, the requirements of the operating environment, etc.

[0065] During the filling process, the material first enters the distribution pipe from the distribution manifold 40, and then enters the hose through the first adapter 72. The flexible design of the hose allows it to be deformed when clamped to control the filling or stop filling of the filling needle 71. In addition, the flexible design of the hose also allows the filling needle 71 to have a certain degree of freedom of movement, which is convenient for aligning containers of different heights or positions. The material continues to enter the filling needle 71 through the second adapter 73 and is finally accurately filled into the designated container.

[0066] In some embodiments, in order to improve the smoothness of liquid flow, the inlet diameter at the first end of the first adapter 72 is greater than the outlet diameter at the second end, the inlet diameter at the first end of the second adapter 73 is greater than the outlet diameter at the second end, and the outlet diameter at the second end of the first adapter 72 is equal to the inlet diameter at the first end of the second adapter 73.

[0067] As Figure 5 and Figure 6As shown, the inlet diameter of the first adapter 72 and the second adapter 73 is larger than the outlet diameter, which can reduce the resistance when the liquid enters, and at the same time form a certain pressure at the outlet, which is conducive to the flow of the liquid. The outlet diameter of the first adapter 72 is equal to the inlet diameter of the second adapter 73, which ensures that the connection between the two adapters will not produce additional flow resistance due to the sudden change in diameter, so that the liquid flows smoothly, avoiding the flow resistance caused by the change in diameter.

[0068] Preferably, the inlet diameter at the first end of the first adapter 72 is a first set multiple of the outlet diameter at the second end, the first set multiple being greater than or equal to 1.2 and less than 2 or greater than 2 and less than or equal to 2.2. The inlet diameter at the first end of the second adapter 73 is a first set multiple of the outlet diameter at the second end, the first set multiple being greater than or equal to 1.2 and less than 2 or greater than 2 and less than or equal to 2.2.

[0069] The ratio of the inlet and outlet diameters of the first adapter 72 and the second adapter 73 can be adjusted according to actual needs. For example, when the filling material is a low-viscosity liquid, a smaller first set multiple and a second set multiple can be selected, such as 1.2-1.5; when the filling material is a high-viscosity liquid, a larger first set multiple and a second set multiple can be selected, such as greater than 2 and less than or equal to 2.2. This flexible design can adapt to the filling needs of different types of materials, further improving the filling accuracy.

[0070] As a preferred embodiment, the first adapter 72 can be made of stainless steel, with an inlet diameter of 15 mm at the first end and an outlet diameter of 10 mm at the second end. The second adapter 73 is also made of stainless steel, with an inlet diameter of 10 mm at the first end, equal to the outlet diameter of the first adapter 72, and an outlet diameter of 7 mm at the second end. This design not only ensures smooth flow of the liquid in the adapter assembly, but also improves the durability and hygiene of the entire device.

[0071] In some embodiments, in order to clamp or release the hose, the hose clamping assembly 50 includes a pressing plate 81 and a plurality of hose clamping units corresponding to the plurality of filling needles 71, the hose clamping unit including a driving mechanism 82 and a driving rod 83, the hose passing through the gap between the pressing plate 81 and the driving rod 83, the driving mechanism 82 being used to drive the driving rod 83 to approach or away from the pressing plate 81 to clamp or release the hose.

[0072] The clamp pipe assembly 50 of the present application can achieve independent control of each filling needle 71, improving the accuracy and flexibility of the filling process. By controlling the driving mechanism 82, the position of the driving rod 83 can be accurately adjusted to achieve precise clamping or release of the hose. This mechanism design is simple and reliable, easy to operate and maintain, and can quickly respond to control instructions, which helps to improve filling efficiency and accuracy.

[0073] Specifically, in the clamp pipe assembly 50 of the present application, the pressing plate 81 can be made of rigid materials such as stainless steel or high-strength engineering plastics to provide a stable support surface. The surface of the pressing plate 81 can be polished to reduce friction with the hose and prolong the service life of the hose. In the present embodiment, the lower surface of the pressing plate 81 forms an arc surface. The driving rod 83 can be designed in a cylindrical or prismatic shape, and the surface in contact with the hose can be rounded to avoid damaging the hose. In the present embodiment, the pressing plate 81 includes a fixed base plate 84 and a semi-cylindrical plate 85 located at the bottom of the fixed base plate 84. The fixed base plate 84 is fixed to the frame 10, and the outer peripheral surface of the semi-cylindrical plate 85 forms the arc surface.

[0074] The driving mechanism 82 can be implemented in various forms, for example, as shown, a crank and connecting rod mechanism driven by a motor can be used, and the precise displacement of the driving rod 83 can be achieved by controlling the forward and reverse rotation of the motor. For another example, a lead screw mechanism driven by a motor can be used, and the precise displacement of the driving rod 83 can be achieved by controlling the forward and reverse rotation of the motor. Another way is to use a gas cylinder or a hydraulic cylinder as a driving source, and to adjust the position of the driving rod 83 by controlling the gas pressure or hydraulic pressure. These driving mechanisms 82 can be selected according to the actual application scenario and the accuracy requirement.

[0075] The clamp pipe assembly 50 of the present application is designed to cooperate well with the filling needle 71. When the material flow needs to be controlled, the driving mechanism 82 drives the driving rod 83 to approach the pressing plate 81, and the hose is clamped to prevent the material from flowing. When filling is needed, the driving mechanism 82 drives the driving rod 83 away from the pressing plate 81, and the hose is released to allow the material to flow. This design allows each filling needle 71 to be controlled independently, greatly improving the flexibility and accuracy of the filling system.

[0076] Further, the clamp pipe assembly 50 of the present application can be integrated with a control system to achieve automatic control. The control system can accurately control the action time and displacement of each driving mechanism 82 according to the filling requirements. For example, the PID control algorithm (i.e. proportional-integral-derivative control algorithm) can be used to achieve precise control of the position of the driving rod 83, thereby achieving precise adjustment of the clamping force of the hose. This precise control not only ensures the accuracy of the filling amount, but also prolongs the service life of the hose.

[0077] In one specific embodiment, the pressing plate 81 can be designed as a stainless steel plate with a length of 500 mm, a width of 100 mm, and a thickness of 20 mm. Ten clamping units can be evenly distributed below the pressing plate 81, with a spacing of 50 mm between each unit. The drive mechanism 82 of each clamping unit adopts a crank and connecting rod structure driven by a stepper motor, and the stepping accuracy of the stepper motor is 0.1 mm / step. The drive rod 83 is a stainless steel cylinder with a diameter of 10 mm, and the surface in contact with the hose can be polished to a round shape. The hose is a food-grade silicone tube with an inner diameter of 6 mm and an outer diameter of 8 mm. The maximum stroke of the drive rod 83 is 20 mm, which can be accurately controlled to a position accuracy of 0.1 mm by the control system.

[0078] This design can achieve precise clamping control of the hose. For example, when the hose needs to be completely closed, the drive rod 83 can be moved to a position 2 mm away from the pressing plate, at which point the hose is completely flattened and prevents material flow. When precise flow control is required, the opening of the hose can be adjusted by adjusting the position of the drive rod 83, thereby achieving precise control of the flow.

[0079] Compared with the prior art, the clamping assembly 50 of the present application has significant advantages. Traditional clamping devices usually use a unified clamping mechanism, which is difficult to achieve independent and precise control of each filling needle 71. The design of the present application provides each filling needle 71 with an independent clamping unit, achieving precise control of each hose. This design not only improves the filling accuracy, but also increases the flexibility of the system, allowing quick adjustment of filling parameters according to different product requirements.

[0080] In addition, the design of the present application adjusts the opening of the hose by precisely controlling the position of the drive rod 83, which can achieve more precise flow regulation compared to traditional on-off control. This fine control is of great significance in certain special applications, such as the filling of precision chemicals or pharmaceuticals.

[0081] The working process of the material filling device of the present application is as follows:

[0082] First, the liquid source assembly 20 delivers the material to the buffer tank 30. The tank body 31 of the buffer tank 30 is made of stainless steel material, which has good sealing performance and corrosion resistance. The tank body 31 is provided with an inlet 311 and an outlet 312, which are connected with the liquid source assembly 20 and the distribution main line 40, respectively. The first sensor 36 is installed at the bottom of the tank body 31 for detecting the liquid pressure at the bottom of the tank body 31; the second sensor 33 extends into the tank body 31 for detecting the height of the material in the tank body 31. Both sensors are electrically connected with the control assembly, and real-time detection data is fed back to the control assembly.

[0083] The control component adjusts the height of the material in the tank 31 by adjusting the flow proportional valve on the liquid source component 20 and adjusts the pressure in the tank 31 by adjusting the pressure proportional valve on the gas source component according to the feedback data of the first sensor 36 and the second sensor 33. This double adjustment mechanism can ensure that the material in the buffer tank 30 is in a stable pressure and height state, laying the foundation for accurate filling.

[0084] The distribution unit distributes the material from the buffer tank 30 to a plurality of filling needles 71. The pinch valve assembly 50 controls the filling or stops the filling of the filling needles 71 by clamping or releasing the hose. This design can achieve fast and accurate filling control, with higher response speed and better sealing than traditional valve control.

[0085] The verification component 60 is installed below each filling position for real-time measurement of the net weight of the material in the container. The verification component 60 feeds back these data to the control component in real time.

[0086] The control component dynamically adjusts the filling time of each filling needle 71 according to the net weight of the material fed back by the verification component 60. For example, if it is detected that the filling amount of a certain filling needle 71 is slightly insufficient, the control component will slightly prolong the opening time of the component; on the contrary, if the filling amount is slightly more, the filling needle 71 will be closed in advance. This dynamic adjustment mechanism can effectively compensate for filling errors caused by pressure fluctuations or other factors, thereby achieving high-precision filling.

[0087] The application also provides a pressure filling method applied to the device for filling a container with material as described in any of the above technical solutions, comprising:

[0088] controlling the height of the material in the tank 31 within a set height range and the pressure at the bottom of the tank 31 within a set pressure range by a proportional-integral-derivative control algorithm;

[0089] controlling the filling time of the filling needle 71 according to the target filling amount;

[0090] dynamically correcting the filling time and proportional-integral-derivative parameters of the filling needle 71 according to the net weight of the material.

[0091] The pressure filling method proposed in the present application effectively solves the problems of low filling accuracy and unstable pressure control by precisely controlling the material height and pressure in the tank 31, combining the preliminary control and dynamic correction of the filling time of the filling needle 71 and the proportional-integral-derivative parameters. The proportional-integral-derivative control algorithm can quickly respond and accurately adjust the height and pressure, ensuring the stability of the filling process. According to the target filling amount, the initial filling amount control is provided by controlling the opening time, and according to the actual material net weight, the opening time and proportional-integral-derivative parameters are dynamically corrected to further improve the filling accuracy. This method avoids the complexity of precisely controlling the pressure of each branch in traditional technology, simplifies the control process, and improves the filling accuracy and stability.

[0092] Specifically, the pressure filling method proposed in the present application includes three main steps:

[0093] Firstly, the height and pressure of the material in the tank 31 are controlled within the set range by the proportional-integral-derivative control algorithm. This step can be realized in various ways. For example, height sensors and pressure sensors can be used to monitor the height and pressure in the tank 31 in real time, and then the height and pressure can be adjusted by controlling the liquid source assembly 20 and the gas source assembly. The proportional-integral-derivative control algorithm can quickly and accurately adjust the liquid inflow rate and gas pressure according to the deviation of the current height and pressure from the set value, thereby achieving stable control.

[0094] Secondly, the filling time of the filling needle 71 is controlled according to the target filling amount. This step can be realized by pre-setting the corresponding relationship between the filling amount and the opening time. For example, a lookup table can be established to select the corresponding initial opening time according to different target filling amounts. In addition, the opening time can also be calculated through a mathematical model, considering factors such as tank 31 pressure and fluid viscosity.

[0095] Finally, the filling time of the filling needle 71 and the proportional-integral-derivative parameters are dynamically corrected according to the material net weight. This step can be realized by real-time weighing feedback. For example, after each filling is completed, the difference between the actual material net weight and the target filling amount is compared, and then the opening time and proportional-integral-derivative parameters of the next filling are adjusted according to this difference. By dynamically correcting the proportional-integral-derivative parameters, the control accuracy of the height and pressure in the tank 31 can be improved to further improve the filling accuracy.

[0096] There is a close correlation and interaction between the three steps. The proportional-integral-derivative control algorithm ensures stable height and pressure in the tank 31, providing the basis for accurate filling. The control of the opening time according to the target filling amount provides preliminary control of the filling amount, and the dynamic correction of the opening time and proportional-integral-derivative parameters according to the actual material net weight further improves the filling accuracy. This multiple control and feedback mechanism forms a closed-loop system that can continuously optimize the filling process and improve the filling accuracy.

[0097] In some embodiments, in order to control the pressure in the tank 31, inert gas is introduced into the tank 31 through the gas source assembly to control the pressure in the tank 31 to float within a set range.

[0098] This method can achieve accurate control of the pressure in the tank 31, thereby solving the technical problem of controlling the pressure in the tank 31. By stably controlling the pressure in the tank 31 to float within a set range, the pressure stability during filling can be ensured, thereby improving the filling accuracy and filling quality. In addition, the use of inert gas can also prevent the material from contacting air, avoiding oxidation or other adverse reactions, and ensuring the quality of the material.

[0099] Specifically, the gas source assembly can introduce inert gas into the tank 31 in various ways. For example, the gas source assembly can use a pressure proportional valve to control the pressure of the inert gas introduced, which can achieve accurate adjustment of the pressure in the tank 31.

[0100] Further, the selection of inert gas can be determined according to the characteristics of the material. Commonly used inert gases include nitrogen, argon, or carbon dioxide, etc. These gases will not react with most materials and can effectively prevent the material from deteriorating or oxidizing.

[0101] The technical solution of the present application not only solves the problem of controlling the pressure in the tank 31, but also has a synergistic effect with the entire device for filling the container with material. Through stable pressure control, the filling accuracy can be improved and the filling error can be reduced. At the same time, the use of inert gas can also prolong the shelf life of the material and improve the product quality.

[0102] As a preferred embodiment, the gas source assembly can include a gas source and a pressure proportional valve. The gas source provides inert gas, and the pressure proportional valve is used to adjust the gas pressure. The control assembly can dynamically adjust the opening degree of the pressure proportional valve according to the pressure in the bottom of the tank 31 detected by the first sensor 36, thereby achieving real-time and accurate control of the pressure in the tank 31.

[0103] For example, when the pressure inside the tank 31 is detected to be lower than a set value, the control assembly can increase the opening of the pressure proportional valve to increase the amount of inert gas introduced; when the pressure is higher than the set value, the opening of the pressure proportional valve can be decreased or temporarily closed. This closed-loop control method can keep the pressure inside the tank 31 within the desired range, ensuring the stability and accuracy of the filling process.

[0104] In one embodiment, the liquid supplement flow is adjusted synchronously by the flow proportional valve, and the gas supplement pressure is adjusted synchronously by the pressure proportional valve when the height decreases.

[0105] Specifically, the second sensor 33 is used to detect the height of the material inside the tank 31 and feed back to the control assembly. When the second sensor 33 detects a decrease in height, the control assembly will control the pressure proportional valve and the flow proportional valve according to the feedback information.

[0106] The liquid supplement flow is adjusted by controlling the liquid source assembly 20. When the height decreases, the flow proportional valve will increase the opening of the liquid source assembly 20, thereby increasing the liquid supplement flow to maintain the height inside the tank 31. At the same time, the gas supplement pressure is adjusted by controlling the gas source assembly. When the height decreases, the pressure proportional valve will adjust the opening of the gas source assembly accordingly to adjust the pressure inside the tank 31.

[0107] This synchronous adjustment method can better maintain the balance of the height and pressure inside the tank 31. For example, when the height decreases by 2 cm, the proportional valve may increase the opening of the liquid source assembly 20 by 10%, while increasing the opening of the gas source assembly by 5%. This precise adjustment can ensure that while the liquid is being supplemented, the pressure inside the tank 31 is also adjusted accordingly, thereby avoiding fluctuations in pressure due to changes in height.

[0108] Further, by combining the proportional-integral-derivative control algorithm with the synchronous adjustment of the pressure proportional valve and the flow proportional valve, the height change can be responded to more quickly and accurately. The proportional-integral-derivative control algorithm can calculate the optimal adjustment parameters according to the real-time changes in height and pressure, while the pressure proportional valve and the flow proportional valve can accurately execute these adjustment instructions. This combination not only solves the problem of synchronous adjustment when the height decreases, but also improves the stability and accuracy of the entire filling process.

[0109] In one embodiment, to improve the filling accuracy and prevent residual material droplets in the filling needle 71, a hose is used to supply material to the filling needle 71, and the filling material is stopped by clamping the hose, which includes a first stage and a second stage. In the first stage, the hose is clamped at a first speed to a set retention rate to stop the hose from flowing, and in the second stage, the hose is continuously clamped to complete closure at a second speed to suck back the residual material in the filling needle 71. The second speed is greater than the first speed, and the first retention rate ranges from 90% to 98%.

[0110] The present application solves the problem of controlling filling accuracy and reducing residual material in the hose clamping process by designing a two-stage clamping process. In the first stage, the hose is clamped at a slower speed to a retention rate of 90%-98% to ensure accurate control of the filling amount. In the second stage, the hose is completely clamped at a faster speed to achieve the suction back of the residual material in the filling needle 71. This method not only improves the filling accuracy, but also reduces material waste, and at the same time improves the efficiency of the whole process through speed control.

[0111] For example, a stepper motor or a servo motor can be used to control the movement speed of the clamping mechanism. In the first stage, the motor runs at a lower speed to slowly clamp the hose. When the set retention rate is reached, the control system immediately switches to the second stage, the motor speed is increased, and the complete closure of the hose is quickly completed.

[0112] The two-stage clamping process of the present application is closely matched with the entire filling system. In the first stage, the system accurately controls the clamping speed and time to ensure that the filling amount reaches the preset value. The fast clamping in the second stage not only effectively sucks back the residual material, but also prevents material dripping, further improving the filling accuracy.

[0113] Obviously, those skilled in the art can make various modifications and variations to the present application without departing from the spirit and scope of the present application. Thus, if these modifications and variations of the present application fall within the scope of the claims of the present application and their equivalent technologies, the present application also intends to include these modifications and variations.

Claims

1. A method for filling containers with a material, applied to a device for filling containers with a material, the device comprising a liquid source assembly, a buffer tank, a dispensing unit, a verification assembly, a gas source assembly and a control assembly; the buffer tank comprising a tank body, an interface provided on the tank body and connected to the gas source assembly, and a first sensor and a second sensor connected to the tank body, the tank body being provided with an inlet and an outlet, the inlet being connected to the liquid source assembly, the outlet being connected to the dispensing unit and being in electrical signal connection with the control assembly, the first sensor being used to detect the pressure in the tank body and feed back to the control assembly, and the second sensor being used to detect the height of the material in the tank body and feed back to the control assembly; the dispensing unit being provided with a plurality of filling needles in one-to-one correspondence, the filling needles being used to fill the material in the dispensing unit into designated containers; the verification assembly being used to obtain the net weight of the material in each of the containers and feed back the net weight of the material to the control assembly; The control component is configured to control the liquid source component to adjust the height of the material in the tank body and the gas source component to adjust the pressure in the tank body according to the feedback of the first sensor and the second sensor, and dynamically adjust the filling time of the filling needle by monitoring of the verification component, characterized in that, the method comprising: controlling the height of the material in the tank body within a set height range and the pressure in the tank body within a set pressure range by a proportional-integral-derivative control algorithm; controlling the filling duration of the filling needles according to a target filling amount; dynamically correcting the filling duration of the filling needles and the proportional-integral-derivative parameters according to the net weight of the material; supplying the filling needles with the material by a hose and stopping the filling of the material by clamping the hose, the process of clamping the hose including a first stage and a second stage, in the first stage, the hose is clamped to a set retention rate at a first speed to stop the hose from discharging liquid, in the second stage, the hose is continuously clamped to complete closure at a second speed to suck back the residual material in the filling needles, the second speed being greater than the first speed, and the first retention rate being in a range of 90%-98%.

2. The method of filling a container with a material according to claim 1, wherein, introducing inert gas into the tank body by the gas source assembly to control the pressure in the tank body to float within a set range.

3. The method of filling a container with a material of claim 1, wherein, when the height decreases, synchronously adjusting the flow rate of the liquid supplemented by a flow rate proportional valve on the liquid source assembly and synchronously adjusting the flow rate of the gas supplemented by a pressure proportional valve on the gas source assembly.

4. An apparatus for filling a container with a material, characterized by a device for filling containers with a material, comprising a liquid source assembly, a buffer tank, a dispensing unit, a verification assembly, a gas source assembly and a control assembly; the buffer tank comprising a tank body, an interface provided on the tank body and connected to the gas source assembly, and a first sensor and a second sensor connected to the tank body, the tank body being provided with an inlet and an outlet, the inlet being connected to the liquid source assembly, the outlet being connected to the dispensing unit and being in electrical signal connection with the control assembly, the first sensor being used to detect the pressure in the tank body and feed back to the control assembly, and the second sensor being used to detect the height of the material in the tank body and feed back to the control assembly; the dispensing unit being provided with a plurality of filling needles in one-to-one correspondence, the filling needles being used to fill the material in the dispensing unit into designated containers; the verification assembly being used to obtain the net weight of the material in each of the containers and feed back the net weight of the material to the control assembly; The control component is configured to control the liquid source component to adjust the height of the material in the tank and the gas source component to adjust the pressure in the tank according to feedback from the first sensor and the second sensor, and dynamically adjust the filling time of the filling needle by monitoring of the verification component.

5. A device for filling a container with a material according to claim 4, characterized in that The dispensing unit further comprises a pinch component, a distribution main pipe, a hose and an adapter component, the distribution main pipe is connected to the outlet of the tank, the adapter component is configured to connect the material in the distribution main pipe to the filling needle through the hose, and the pinch component is configured to pinch or release the hose to enable or stop the filling needle from filling.

6. A device for filling a container with a material according to claim 5, characterized in that The pinch component comprises at least one pressing plate and at least one pinch unit, the pinch unit corresponds to the filling needle one-to-one, the pinch unit comprises a driving mechanism and a driving rod, the hose passes through the gap between the pressing plate and the driving rod, and the driving mechanism is configured to drive the driving rod to approach or move away from the pressing plate to pinch or release the hose.

7. The apparatus for filling a container with a material of claim 5, wherein, The adapter component comprises a distribution pipe, a first adapter head and a second adapter head, the first adapter head and the second adapter head each have a first end and a second end, one end of the distribution pipe is connected to the distribution main pipe, the other end is connected to the first end of the first adapter head, one end of the hose is connected to the second end of the first adapter head, the other end is connected to the first end of the second adapter head, and the second end of the second adapter head is connected to the filling needle, the first adapter head and the second adapter head fix the hose on the pinch unit.

8. A device for filling a container with a material according to claim 7, characterized in that The inlet diameter at the first end of the first adapter head is greater than the outlet diameter at the second end of the first adapter head, the inlet diameter at the first end of the second adapter head is greater than the outlet diameter at the second end of the second adapter head, and the outlet diameter at the second end of the first adapter head is equal to the inlet diameter at the first end of the second adapter head.

9. The apparatus for filling a container with a material of claim 7, wherein, The inlet diameter at the first end of the first adapter head is a first set multiple of the outlet diameter at the second end of the first adapter head, the first set multiple is greater than or equal to 1.2 and less than 2, or greater than 2 and less than or equal to 2.2, and the inlet diameter at the first end of the second adapter head is a second set multiple of the outlet diameter at the second end of the second adapter head, the second set multiple is greater than or equal to 1.2 and less than 2, or greater than 2 and less than or equal to 2.2.

Images