Filling method for syrup

Abstract

The invention provides a filling method for syrup, and relates to the technical field of food processing.The filling method comprises the steps that before filling is started, the filling amount threshold value of a target container is preset; dynamically adjusting the filling speed based on a comparison result of the liquid level height, monitored in real time, in the target container and a preset threshold value; when it is detected that the liquid level is close to a preset threshold value, the filling speed is gradually decreased till stopping, so that it is ensured that the preset filling amount is accurately reached, and overflowing is avoided; in the filling process, a sensor is used for continuously monitoring liquid level changes, and the liquid level changes are fed back to a control system for real-time adjustment. By means of the scheme, the problem how to achieve accurate control over syrup in the filling process so as to avoid overflow and waste can be solved, meanwhile, the wall hanging situation in the filling process can be effectively prevented in the filling process, the production quality and stability can be improved, and the overall operation efficiency of a production line and the qualified rate of final products are remarkably improved.

Description

Technical Field

[0001] The invention relates to the technical field of food processing technology, and in particular to a filling method for syrup. Background Art

[0002] For the filling method used for syrup, it usually involves the process of transferring the syrup from the storage container to the packaging container (such as a bottle or a can). This method needs to ensure that the amount of syrup in each packaging container is accurate, and at the same time, the filling speed must be fast enough to meet the needs of production efficiency. However, in the actual operation process, there is a key problem: how to achieve precise control of the syrup during the filling process to avoid overflow and waste. Since the syrup has a high viscosity, it is easy to produce wall hanging phenomenon during filling, resulting in the syrup remaining on the filling equipment and unable to completely enter the packaging container, which not only affects the filling accuracy, but also may cause waste of raw materials. In order to solve this problem, special filling techniques and equipment are usually required to improve the accuracy and efficiency of the filling process. Summary of the invention

[0003] In view of this, the present invention provides a filling method for syrup, which at least partially solves the problems existing in the prior art.

[0004] A filling method for syrup, comprising:

[0005] Before filling begins, the filling volume threshold of the target container is pre-set;

[0006] Dynamically adjust the filling speed based on the comparison result between the liquid level in the target container monitored in real time and the preset threshold value;

[0007] When the liquid level is detected to be close to the preset threshold, the filling speed is gradually slowed down until it stops to ensure that the preset filling volume is accurately reached to avoid overflow;

[0008] During the filling process, sensors are used to continuously monitor liquid level changes and provide feedback to the control system for real-time adjustments;

[0009] Obtain the current liquid level H in the target container in real time;

[0010] Compare the current liquid level H with the preset threshold value T;

[0011] When H is less than a certain ratio of T, such as 80%, the current filling speed V is maintained;

[0012] When H is greater than or equal to 80% of T but less than T, the filling speed V is reduced by a predetermined ratio, for example, 50%.

[0013] If H is less than T multiplied by 0.8, the filling speed remains unchanged;

[0014] If H is greater than or equal to T multiplied by 0.8 and H is less than T, the filling speed is reduced;

[0015] If H is greater than or equal to T, stop filling;

[0016] Among them, if H is greater than or equal to T multiplied by 0.8 and H is less than T, the filling speed is dynamically adjusted based on the relationship between H and T.

[0017] When H is less than T multiplied by 0.9, the filling speed V remains unchanged;

[0018] When H is greater than or equal to T times 0.9 and H is less than T, the filling speed V is adjusted to V times 5;

[0019] When H is greater than or equal to T, the filling speed V is adjusted to 0;

[0020] If H is greater than or equal to T times 0.9 and H is less than T, then based on the relationship between H and T, the filling speed V is adjusted to V times 0.5.

[0021] Preferably, determining a current filling speed V;

[0022] Calculate the new filling speed V, where V = V multiplied by 0.5;

[0023] If H is greater than or equal to T multiplied by 0.9 and H is less than T, adjust the filling speed to V;

[0024] If H is greater than or equal to T, filling is stopped.

[0025] Preferably, when H is greater than or equal to T, the filling process is stopped immediately;

[0026] If H is less than T, continue filling;

[0027] If H is greater than or equal to T, the filling process is stopped.

[0028] Preferably, the liquid level height H in the target container monitored by the sensor is obtained in real time;

[0029] Compare the liquid level H with a preset threshold value T;

[0030] When H is less than 80% of T, keep the current filling speed unchanged;

[0031] When H is greater than or equal to 80% of T and less than T, reduce the filling speed to 50% of the original speed.

[0032] Preferably, if H is less than T, continue filling;

[0033] If H is equal to or greater than T, the deceleration signal is triggered;

[0034] Based on the difference ΔH between H and T, the deceleration ratio R is calculated, where R = (TH) / T*100%;

[0035] When ΔH is less than or equal to the preset difference threshold D, a deceleration instruction is executed.

[0036] Preferably, a difference ΔH between the current liquid level height H and a preset threshold value T is determined;

[0037] Determine whether ΔH is less than or equal to a preset difference threshold D;

[0038] If ΔH is less than or equal to D, the deceleration ratio R is calculated as R = (TH) / T*100%;

[0039] If ΔH is greater than D, the current filling speed remains unchanged.

[0040] Preferably, a difference ΔH between the current liquid level height H and a preset threshold value T is obtained;

[0041] Set a preset difference threshold D;

[0042] If ΔH≤D, proceed to the next step;

[0043] If ΔH>D, the current filling speed remains unchanged.

[0044] Preferably, when ΔH≤D, the deceleration ratio R=(TH) / T*100% is calculated;

[0045] If R is greater than the minimum deceleration ratio M, the deceleration instruction is executed;

[0046] If R is less than or equal to M, keep the current filling speed unchanged;

[0047] Preferably, the temperature of the syrup is controlled to be constant during the syrup filling, and the syrup is poured into the container through a preheated filling nozzle;

[0048] Based on the balance between the set temperature and the constant temperature range, the heating time and power are adjusted to achieve the best anti-wall effect;

[0049] The steps to control the syrup temperature to remain constant and ensure that the syrup is poured into the container through the preheated filling nozzle include:

[0050] Step 1: Measure the initial temperature T of the syrup before filling 初 ;

[0051] Step 2: Stabilize the temperature T according to the desired target 目标 To T 初 Make adjustments to ensure syrup remains within preset temperature;

[0052] Step 3: During the filling process, monitor and maintain the temperature at the syrup outlet at a stable state until the filling is completed;

[0053] Step 4: Adjust the speed of the delivery pump to maintain a steady flow of syrup.

[0054] The steps to adjust the heating time and power also include:

[0055] Calculate the average filling rate based on the current syrup filling volume Qcurrent and the filling time t;

[0056] If the average filling rate is less than a predetermined threshold value Tthreshold, increasing the operating power P of the electric heater to a higher value to increase the filling rate;

[0057] If the average filling rate is greater than or equal to the predetermined threshold Tthreshold and the temperature deviates from the target temperature T 目标 If it exceeds the preset allowable range, the power fine-tuning ratio DP is calculated based on the filling error E;

[0058] The formula is DP=aE+b, where a and b are proportionality coefficients obtained from experiments.

[0059] The operation of fine-tuning the power according to the filling error E further comprises the following steps:

[0060] When E<0, it means that the filling temperature is lower than the target temperature range, and the working power P should be increased to make up for this gap;

[0061] When E=0, the existing working power is maintained unchanged to ensure that the temperature is within a constant range;

[0062] When E>0, if it continues to exceed the predetermined range, the working power P needs to be reduced;

[0063] The working power micro-increment DP adjusted based on the filling error and the preset coefficient will be applied to the next power control.

[0064] The operating power changes during fine-tuning operations include:

[0065] In the next cycle, adjust P according to the calculated micro-increment DP and record the result R;

[0066] Determine whether the result R is within the set effective temperature adjustment range R is valid; if not, continue with the adjustment in step 5;

[0067] Determine whether the current working power P plus the working power P after this adjustment is between the maximum allowable power and the minimum necessary power;

[0068] The final change in operating power is determined by the following formula: P = P + DP, confirming that the adjusted power is suitable for maintaining the stability of the target set value.

[0069] Correction of the filling temperature to take into account external influencing factors includes:

[0070] For the influence of ambient temperature, if the measured external temperature T 环 Beyond the reference interval [TR m in,TR m ax], and dynamically correct it based on the degree of deviation;

[0071] If T 环 >TR m ax, then reduce the operating current I by 5% to the new set current I; if T 环 <TR m in, the working current is increased by 5% accordingly to reduce the impact on the temperature stability during the filling process;

[0072] Test the power change ΔP caused by the corrected current I versus the temperature T 实时 Whether the influence degree makes the target temperature T 目标 Keep within an allowable range T 阈正 , +T 阈正 ];

[0073] If T 实时 Still in [T 目标 –T 阈正 , T 目标 +T 阈正 ], then this power correction is accepted and used for further controlling the process.

[0074] Preferably, based on the balance between the set temperature and the constant temperature range, the heating time and power are adjusted to achieve the optimal anti-wall hanging effect, specifically including:

[0075] Based on the set temperature T s The actual measured constant temperature of the syrup T c The difference between ΔT=|T s T c |The temperature difference factor δT is calculated;

[0076] If the temperature difference factor δT is greater than or equal to the preset temperature difference upper limit ΔT u , then increase the preset power limit P m ax to accelerate the temperature adjustment to the equilibrium state and reduce the power change step size P s tep to adjust the power setting more finely;

[0077] If the temperature difference factor δT is less than the preset temperature difference lower limit ΔT l However, if the above conditions are not met, the power is maintained unchanged to ensure a stable supply of heat;

[0078] If the average temperature T of N consecutive measurements is within a specific temperature range a If vg remains within the preset range, the preset heating time T is gradually reduced. p re to avoid overheating and ensure that the final heating time T_f reaches the value required for optimal wall protection;

[0079] If the temperature difference factor δT is greater than or equal to the preset temperature difference upper limit ΔT u The specific operations include:

[0080] If ΔT>=ΔT u , then calculate the increased new preset power limit P n ew m ax=P m ax+δTP, where δTP represents the amount of additional power added and is adjusted according to the actual environment to obtain the optimal parameters;

[0081] Adjusted power P t =P m ax+n*P s tep, n represents the number of heating cycles and satisfies the condition P m ax≤P n ew m ax;

[0082] If P t >=P n ew m ax, based on the maximum power P in this case t Execute the next step of temperature calibration;

[0083] Otherwise, keep the power P m ax remains unchanged until the condition is met or the next evaluation point is reached.

[0084] If the temperature is close to the set value, judge P t Whether the required temperature balance condition (P t +n*P s tep>=T p *K), where T p is the predicted final heating temperature under the influence of the current power, and K is the correction factor;

[0085] If the temperature is too low (T p *K <T s δT p ), based on the current conditions, gradually adjust the power change step size to a lower step value, such as P s tep*m;

[0086] When P is adjusted sAfter tep, verify again in the subsequent N detection times whether it can enter the optimal temperature balance condition interval [TR m in,TR m ax], if it does not meet the standard, continue to adjust P s tep until the range is met;

[0087] Before the end of this step, update and record the actual step value P of the last adjustment. s tep is used for the next reference adjustment process.

[0088] The final actual heating time T for each adjustment f =∑(n*T p er)–m*δT t

[0089] Statistics are performed, m represents the relationship between the reduction factor and the temperature difference, and T p er is an estimated time period, and the optimal heating time is calculated based on the average;

[0090] Based on the average final heating time of the most recent M tests Judge T s T c Whether the change range of T is stable s T c ≤|ΔT l |;

[0091] According to the above conditions, if it is stable and the preset time is not less than T s T l , the strategy to reduce the next preset heating time to the optimal value: N is the total number of attempts and should be greater than or equal to the predefined lower limit of the number of safe attempts N m in;

[0092] Finally, if the preset heating time T pre If the temperature has been reduced to the minimum allowable value and still cannot be kept constant, restore the original preset heating time and re-enter the temperature monitoring mode.

[0093] Calculate the average value T_avg and standard deviation σ, and compare and analyze whether the average temperature of the current period falls within [TR m in,TR m ax] to confirm whether to continue to reduce T pre : If TR m in≤T a vg

[0094] +σ≤TR m ax, then the next stage of power regulation is carried out;

[0095] On the contrary, if the current temperature does not fluctuate within the expected range, reset and increase the power limit P t Until the condition is met or the loop starts again

[0096] After executing the deceleration command, the liquid level continues to be monitored until it reaches the preset threshold T.

[0097] The present invention provides a filling method for syrup, comprising: presetting a filling amount threshold of a target container before filling; dynamically adjusting the filling speed based on the comparison result of the liquid level height in the target container monitored in real time and the preset threshold; gradually slowing down the filling speed until stopping when it is detected that the liquid level is close to the preset threshold, so as to ensure that the preset filling amount is accurately reached to avoid overflow; using a sensor to continuously monitor the liquid level change during the filling process, and feeding it back to the control system for real-time adjustment. Through the solution of the present invention, it is possible to solve how to achieve accurate control of syrup during the filling process to avoid overflow and waste. BRIEF DESCRIPTION OF THE DRAWINGS

[0098] In order to more clearly illustrate the technical solutions of the exemplary embodiments of the present invention, the drawings required for use in the embodiments will be briefly introduced below. It should be understood that the following drawings only show certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without paying creative work.

[0099] Figure 1 is a flow chart of a filling method for syrup;

[0100] Figure 2 It is a flowchart for dynamically adjusting the filling speed based on the comparison result between the liquid level height in the target container monitored in real time and the preset threshold value;

[0101] Figure 3 It is a flow chart for comparing the current liquid level height H with the preset threshold value T;

[0102] Figure 4 It is a flow chart for dynamically adjusting the filling speed based on the relationship between H and T;

[0103] Figure 5 It is a flow chart of the filling speed V adjusted to V multiplied by 0.5;

[0104] Figure 6 It is a flowchart that stops filling if H is greater than or equal to T;

[0105] Figure 7 It is a flowchart for dynamically adjusting the filling speed based on the comparison result between the liquid level height in the target container monitored in real time and the preset threshold value;

[0106] Figure 8 It is a flow chart for comparing the liquid level height H with a preset threshold value T;

[0107] Fig. 9 It is a flow chart for calculating the deceleration ratio R based on the difference ΔH between H and T;

[0108] Fig.10 is a flow chart for determining whether ΔH is less than or equal to a preset difference threshold D;

[0109] Fig.11 It is a flowchart in which if ΔH≤D, the next step is executed. DETAILED DESCRIPTION

[0110] The present invention is described in detail below with reference to the accompanying drawings.

[0111] The following describes the embodiments of the present disclosure through specific examples, and those skilled in the art can easily understand other advantages and effects of the present disclosure from the contents disclosed in this specification. Obviously, the described embodiments are only a part of the embodiments of the present disclosure, rather than all of the embodiments. The present disclosure can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed in various ways based on different viewpoints and applications without departing from the spirit of the present disclosure. It should be noted that the following embodiments and features in the embodiments can be combined with each other without conflict. Based on the embodiments in the present disclosure, all other embodiments obtained by ordinary technicians in the field without making creative work are within the scope of protection of the present disclosure.

[0112] It should be noted that various aspects of the embodiments within the scope of the appended claims are described below. It should be apparent that the aspects described herein may be embodied in a wide variety of forms, and any specific structure and / or function described herein is merely illustrative. Based on the present disclosure, it should be understood by those skilled in the art that an aspect described herein may be implemented independently of any other aspect, and two or more of these aspects may be combined in various ways. For example, any number of aspects described herein may be used to implement the device and / or practice the method. In addition, other structures and / or functionalities other than one or more of the aspects described herein may be used to implement this device and / or practice this method.

[0113] It should also be noted that the illustrations provided in the following embodiments are only schematic illustrations of the basic concept of the present disclosure. The drawings only show components related to the present disclosure rather than being drawn according to the number, shape and size of components in actual implementation. In actual implementation, the type, quantity and proportion of each component may be changed arbitrarily, and the component layout may also be more complicated.

[0114] Additionally, in the following description, specific details are provided to facilitate a thorough understanding of the examples. However, it will be understood by those skilled in the art that the aspects described may be practiced without these specific details.

[0115] Next, refer to Figure 1 Description of this filling method for syrup:

[0116] S101: Ensure precise control of the filling process by presetting the fill volume threshold of the target container. Before filling begins, the operator or the automated system determines the ideal fill volume based on product specifications, container size, and customer requirements. For example, if syrup needs to be filled into a 500 ml bottle, the preset fill volume threshold may be set between 495 ml and 505 ml to allow for a certain margin of error. This setting can be done through a human-computer interface or automatically through a pre-programmed automated system. To ensure accuracy, the system also needs to take into account the effects of factors such as the density and temperature of the syrup on the volume. For example, when filling high-density syrup, the fill volume threshold may need to be adjusted to compensate for the actual volume reduction caused by the increase in density.

[0117] S102: Dynamically adjust the filling speed based on the comparison result of the liquid level height in the target container monitored in real time with the preset threshold. During the filling process, the sensor installed near the filling head continuously monitors the liquid level changes inside the container. These sensors can be optical sensors, ultrasonic sensors or other types of liquid level detection devices. For example, when an ultrasonic sensor is used, it emits ultrasonic pulses and receives signals reflected from the liquid surface to calculate the height of the liquid level. The control system compares the information fed back by the sensor with the preset filling volume threshold, and then adjusts the filling speed according to the difference. For example, when the liquid level is lower than 80% of the preset threshold, the system may maintain a faster filling speed; when the liquid level approaches 90% of the preset threshold, the system will gradually reduce the filling speed to ensure that the preset filling volume can be accurately reached in the end.

[0118] S103: When it is detected that the liquid level is close to the preset threshold, the filling speed is gradually slowed down until it stops, so as to ensure that the preset filling volume is accurately reached to avoid overflow. As the liquid level gradually approaches the preset threshold, the control system will further slow down the filling speed until the filling is completely stopped when the liquid level reaches the preset filling volume threshold. For example, assuming that the preset filling volume threshold is 500 ml, when the liquid level reaches 490 ml, the system may reduce the filling speed to half; when the liquid level reaches 495 ml, the system slows down the filling speed again until the liquid level reaches 500 ml and stops completely. This gradual slowing method helps to avoid liquid level fluctuations caused by sudden stops in filling, thereby reducing the risk of overflow.

[0119] S104: During the filling process, sensors are used to continuously monitor changes in the liquid level and provide feedback to the control system for real-time adjustments. To ensure the accuracy of the entire filling process, sensors continuously monitor changes in the liquid level and transmit data to the control system in real time. For example, if the liquid level is found to be rising faster than expected during the filling process, the control system will immediately adjust the filling speed to accommodate this change. This real-time monitoring and adjustment mechanism is particularly important for handling syrups of different viscosities, because different types of syrups flow at different speeds and require flexible adjustment of filling parameters. For example, for syrups with higher viscosities, the system may start to slow down in advance to prevent overfilling due to slow syrup flow.

[0120] Through the above steps, the problem of "how to achieve precise control of syrup during the filling process to avoid overflow and waste" can be solved. By pre-setting the filling volume threshold, real-time monitoring of liquid level changes and dynamically adjusting the filling speed, it can not only ensure that each container accurately reaches the preset filling volume, but also effectively avoid product waste and cost increase caused by overfilling. In addition, this precise control can also help improve production efficiency and product quality, reduce the failure rate on the production line, and thus bring higher economic benefits to the company.

[0121] Next, refer to Figure 2 Describe the specific steps of dynamically adjusting the filling speed in a filling method for syrup:

[0122] S201: Continuously obtain the current liquid level height H in the target container through a real-time monitoring device. This process usually involves using sensors or other measuring tools to accurately measure the actual height of the liquid inside the container, and transmit these data to the control system for subsequent processing.

[0123] S202: Compare the current liquid level H with the preset threshold T. This comparison operation can be completed in the processor of the control system, and the programming logic is used to determine whether the current liquid level is close to the preset upper limit, that is, whether it has reached the standard that requires adjustment of the filling speed.

[0124] S203: When it is detected that the current liquid level height H is less than 80% of the preset threshold value T, the system maintains the current filling speed V. This means that when the liquid level is low, in order to ensure the filling efficiency, the system will not adjust the filling speed.

[0125] S204: When it is detected that the current liquid level height H is greater than or equal to 80% of the preset threshold value T, but still less than T, the system will automatically reduce the current filling speed V by a predetermined ratio, such as 50%. This adjustment helps prevent overflow problems caused by over-fast filling and ensures the accuracy and stability of the filling process.

[0126] Through the above steps, the filling process of the syrup can be effectively controlled to ensure the filling accuracy and improve the production efficiency.

[0127] Next, refer to Figure 3 Describe the specific steps of comparing the current liquid level H with a preset threshold value T in a filling method for syrup:

[0128] S301: The current liquid level H in the container is detected by a sensor and compared with a preset threshold value T. This process can be achieved by a liquid level sensor installed on the filling equipment, which can monitor the height of the liquid in the container in real time and transmit the data to the control system. The control system determines whether the current liquid level H meets specific conditions based on the received data.

[0129] S302: If the current liquid level H is less than the preset threshold value T multiplied by 0.8, i.e. 80% of T, the control system maintains the existing filling speed unchanged. This means that when the liquid level is low, in order to ensure filling efficiency, the system will not adjust the filling speed.

[0130] S303: If the current liquid level H is greater than or equal to the preset threshold T multiplied by 0.8 and less than T, the control system will reduce the filling speed. Specifically, when the liquid level is close to but does not reach the preset threshold, the control system will dynamically adjust the filling speed according to the difference between H and T to ensure that the liquid level rises steadily and avoid overflow or other problems caused by too fast filling.

[0131] S304: When the current liquid level H is greater than or equal to the preset threshold value T, the control system will immediately stop the filling process. This step ensures that the liquid level in the container does not exceed the predetermined maximum value, thereby avoiding possible overflow.

[0132] Through the above steps, the filling process of the syrup can be effectively controlled, ensuring the filling accuracy while also improving the production efficiency.

[0133] Next, refer to Figure 4 Describe the specific steps of dynamically adjusting the filling speed in a filling method for syrup:

[0134] S401: Determine the relationship between the liquid level height H and the target liquid level T: First, it is necessary to monitor the liquid level height H in the container in real time and compare it with the preset target liquid level T. This process can be completed by a sensor installed on the filling equipment, which can accurately measure the current liquid level height H and transmit the data to the control system.

[0135] S402: Adjust the filling speed V according to the relationship between H and T: When the control system receives the data of the liquid level height H, it will decide whether to adjust the filling speed V and how to adjust it according to the relationship between H and T. Specifically, if H is less than T multiplied by 0.9, it is considered that the liquid level is low, and the filling speed V remains unchanged; if H is greater than or equal to T multiplied by 0.9 and less than T, it is considered that the liquid level is close to the target value, and the filling speed V is halved, that is, V is multiplied by 0.5; if H is greater than or equal to T, it is considered that the target liquid level has been reached or exceeded, and filling is stopped at this time, that is, V is adjusted to 0.

[0136] S403: Implement the adjusted filling speed V: Once the control system calculates the new filling speed V, it sends instructions to the actuator to adjust the actual filling speed. For example, the filling speed can be changed by controlling the valve opening or the speed of the pump. This ensures that the filling speed can be accurately controlled at different liquid level stages, thereby improving filling accuracy and efficiency.

[0137] Next, refer to Figure 5 Describe the specific steps of dynamically adjusting the filling speed in a filling method for syrup:

[0138] S501: Determine the current filling speed - When implementing the present invention, it is first necessary to obtain the current filling speed V through a sensor or other measuring device. This step ensures that the system can monitor the actual flow rate during the filling process in real time, thereby providing an accurate data basis for subsequent adjustments.

[0139] S502: Calculate new filling speed – Then, according to a pre-set algorithm, calculate a new filling speed. Specifically, the new filling speed V is obtained by multiplying the current filling speed V by 0.5. This calculation process can be implemented by an embedded controller or dedicated control software, ensuring that the filling speed can be accurately adjusted to the required value.

[0140] S503: Determine and adjust filling speed – The system then checks whether the current filling height H meets certain conditions. If H is greater than or equal to 90% of the target filling height T but less than T, the new filling speed V calculated above will be applied to the filling process, that is, the filling machine will continue filling at the new speed. This judgment and adjustment process can be automatically completed by the control system, ensuring filling accuracy while also improving production efficiency.

[0141] S504: Stop filling – Finally, when it is detected that the filling height H reaches or exceeds the target filling height T, the control system will immediately stop the filling process. This operation is also automatically performed by the control system, ensuring that the amount of syrup in each container meets the preset standard, avoiding product waste caused by overfilling or quality problems caused by insufficient filling.

[0142] Next, refer to Figure 6 Describe the specific steps of "a filling method for syrup, if H is greater than or equal to T, then stopping the filling includes":

[0143] S601: Monitor the liquid level in the container through sensors

[0144] During the filling process, the liquid level H of the syrup in the container is monitored in real time by a liquid level sensor installed above the container. When the sensor detects that the liquid level H reaches the preset target liquid level T, it immediately sends a signal to the control system.

[0145] S602: The control system receives the signal and determines whether the target liquid level is reached

[0146] After receiving the signal from the sensor, the control system compares the currently detected liquid level H with the preset target liquid level T. If H is greater than or equal to T, the control system will immediately start to stop the filling process; if H is less than T, the control system allows the filling process to continue.

[0147] S603: Stop the filling process immediately

[0148] When the control system determines that H is greater than or equal to T, it will immediately send a command to the filling equipment to close the filling valve, thereby stopping the filling of syrup. At the same time, the control system can also record the relevant data of this filling for subsequent analysis and quality control.

[0149] Next, refer to Figure 7 Describe the specific steps of dynamically adjusting the filling speed in a filling method for syrup:

[0150] S701: Real-time acquisition of the liquid level height H in the target container monitored by the sensor

[0151] In the process of implementing the present invention, it is first necessary to install a liquid level sensor above the target container, which can continuously monitor the liquid level changes inside the container and transmit the monitored liquid level height H to the control system in real time. For example, an ultrasonic sensor or a capacitive liquid level sensor can be used to achieve this function, and these sensors can accurately measure the height of the liquid in the container.

[0152] S702: Compare the liquid level H with the preset threshold T

[0153] After the control system receives the liquid level height H transmitted by the sensor, it will compare it with the pre-set threshold value T. Here, the threshold value T can be determined according to the actual production requirements and the capacity of the container. For example, if the maximum capacity of the container is 1 liter, then the threshold value T can be set to 0.9 liters. The control system automatically completes this comparison process through software algorithms.

[0154] S703: Dynamically adjust the filling speed according to the comparison result

[0155] When the control system completes the comparison of the liquid level height H and the preset threshold value T, it will decide whether to adjust the filling speed according to the comparison result. Specifically, when H is less than 80% of T, that is, H < 0.8T, it is considered that the liquid level in the container is still at a relatively low level, and at this time, there is no need to change the filling speed; while when H is greater than or equal to 80% of T and less than T, that is, 0.8T ≤ H < T, it is considered that the liquid level in the container is close to the preset threshold value. To prevent overflow, the filling speed needs to be reduced to 50% of the original speed. This adjustment can be achieved by controlling the rotation speed of the filling pump. For example, an inverter is used to adjust the rotation speed of the motor, so as to achieve the purpose of controlling the filling speed.

[0156] Next, refer to Figure 8 Describe the specific steps for controlling the liquid level height in a filling method for syrup:

[0157] S801: Monitor the liquid level height H in the container through the sensor and compare it with the preset threshold value T. If the detected liquid level height H is less than the preset threshold value T, the system determines that the container has not reached the predetermined liquid level, so the filling operation continues at the current speed until the liquid level approaches the set value.

[0158] S802: When the liquid level height H is equal to or exceeds the preset threshold value T, the control system will trigger a deceleration signal, instructing the filling equipment to start slowing down the filling speed. At the same time, calculate the deceleration ratio R according to the difference ΔH between the liquid level height H and the preset threshold value T. The calculation formula is R = (T - H) / T * 100%, where R represents the deceleration percentage relative to the current speed.

[0159] S803: As the liquid level height H gradually approaches the preset threshold value T, when the difference ΔH between the two is less than or equal to the preset difference threshold value D, that is, the liquid level is close to the final set value, the control system will execute the deceleration instruction according to the previously calculated deceleration ratio R, so as to accurately control the final liquid level height and ensure the filling quantity is accurate.

[0160] Through the above steps, the liquid level height in the syrup filling process can be effectively controlled, ensuring the filling accuracy and product quality.

[0161] Next, refer to Fig. 9Describe the specific steps of calculating the speed reduction ratio R based on the difference ΔH between H and T in a filling method for syrup:

[0162] S901: Determine the difference ΔH between the current liquid level H and the preset threshold T: During the filling process, the liquid level H in the container is monitored in real time and compared with the preset threshold T to calculate the difference ΔH between the two. This process can be completed by the sensor installed on the filling equipment, which can accurately measure the actual height of the liquid in the container and transmit the data to the control system for processing.

[0163] S902: Determine whether ΔH is less than or equal to the preset difference threshold D: The control system further determines whether the calculated ΔH value is less than or equal to the preset difference threshold D. If ΔH is less than or equal to D, it indicates that the liquid level in the container is close to the preset threshold T, and the filling speed needs to be adjusted to ensure that the target liquid level is accurately reached; conversely, if ΔH is greater than D, it indicates that the liquid level in the container is still far from the preset threshold, and filling can continue at the current speed.

[0164] S903: If ΔH is less than or equal to D, calculate the deceleration ratio R = TH / T*100%: When the control system detects that ΔH is less than or equal to the preset difference threshold D, it will calculate the deceleration ratio R according to the formula R = TH / T*100%. Here R represents the deceleration ratio, T is the preset liquid level threshold, and H is the current liquid level height. The calculated R value will be used to adjust the filling speed of the filling machine to ensure that the final liquid level accurately reaches the preset threshold T.

[0165] S904: If ΔH is greater than D, keep the current filling speed unchanged: When the control system detects that ΔH is greater than the preset difference threshold D, it means that the liquid level in the container is still some distance away from the preset threshold T, so there is no need to adjust the filling speed. Filling can continue at the current speed until the liquid level height approaches the preset threshold T and then the speed is adjusted.

[0166] Next, refer to Fig.10 Describe the specific steps of determining whether ΔH is less than or equal to a preset difference threshold D in a filling method for syrup:

[0167] S1001: Obtain the difference ΔH between the current liquid level height H and the preset threshold value T: During the filling process, the liquid level height H in the container is monitored in real time by a sensor, and compared with the preset liquid level threshold value T, and the difference ΔH between the two is calculated. This process can be achieved by a liquid level sensor installed on the filling equipment, and the sensor converts the detected liquid level information into an electrical signal and transmits it to the control system for processing.

[0168] S1002: Set preset difference threshold D: According to the filling accuracy requirements and actual production conditions, a difference threshold D is preset. The setting of this threshold D needs to comprehensively consider factors such as product characteristics, filling speed and production line stability. Usually, this threshold is determined by engineers based on experience or through experiments and input into the parameter setting of the control system.

[0169] S1003: Determine whether ΔH is less than or equal to the preset difference threshold D: After receiving the liquid level information from the sensor, the control system automatically calculates the difference ΔH between the current liquid level height H and the preset threshold T, and compares it with the preset difference threshold D. If the calculated ΔH is less than or equal to the preset difference threshold D, it is considered that the liquid level is close to the target height, and the system will trigger the next step; if ΔH is greater than the preset difference threshold D, it is considered that the liquid level is significantly different from the target height, and the system will keep the current filling speed unchanged and continue filling until the liquid level is close to the target height.

[0170] Through the above steps, it can be ensured that the liquid level height is accurately controlled during the filling process, thereby improving the filling accuracy and product quality.

[0171] Next, refer to Fig.11 Describe the specific steps of performing the next step when ΔH≤D in a filling method for syrup:

[0172] S1101: The liquid level height change ΔH in the container is monitored by the sensor and compared with the preset liquid level height difference threshold D. When the monitored liquid level height change ΔH is less than or equal to the preset liquid level height difference threshold D, the system enters the next step, i.e., calculating the deceleration ratio R. The calculation formula of the deceleration ratio R is R=TH / T*100%, where TH represents the target liquid level height and T represents the current liquid level height.

[0173] S1102: The calculated deceleration ratio R is compared with the preset minimum deceleration ratio M. If the calculated deceleration ratio R is greater than the preset minimum deceleration ratio M, a deceleration instruction is sent to the control system; if the deceleration ratio R is less than or equal to the minimum deceleration ratio M, the current filling speed is maintained unchanged and no deceleration instruction is sent.

[0174] S1103: After executing the deceleration instruction, the control system adjusts the speed of the filling equipment to slow down the filling process. At the same time, the sensor continues to monitor the liquid level in the container in real time until the liquid level reaches the preset target liquid level T. Once the liquid level reaches the target liquid level T, the filling process stops and a filling operation is completed.

[0175] For example, in actual applications, assume that the current liquid level T is 10 cm, the target liquid level TH is 20 cm, the preset liquid level height difference threshold D is 5 cm, and the preset minimum deceleration ratio M is 10%. When the liquid level change ΔH reaches 5 cm, that is, when the liquid level increases to 15 cm, the deceleration ratio R is calculated. At this time, the deceleration ratio R = 20-15 / 10*100% = 50%. Since 50% is greater than the preset minimum deceleration ratio of 10%, the control system will execute the deceleration instruction and reduce the filling speed. During the deceleration process, the sensor continues to monitor the liquid level until the liquid level reaches 20 cm and the filling process ends.

[0176] In order to prevent the syrup from sticking to the wall during the filling process, by preheating the filling nozzle to a set temperature range, a good thermal conductivity environment can be formed before filling begins, preventing the syrup from solidifying or losing fluidity due to excessive temperature differences. This preheating can not only reduce the temperature difference between the syrup and the surface of the equipment, thereby avoiding the phenomenon of sticking to the wall caused by excessive temperature differences, but also improve production efficiency and ensure that the filling nozzle is always in good working condition. For example, assuming that the ideal preheating temperature is 45-55 degrees Celsius, the technician will stabilize the filling nozzle within this temperature range by setting the preheating module of the equipment, ensuring that even if the filling time is extended, the filling nozzle can still effectively resist sticking to the wall.

[0177] By monitoring the temperature of the syrup and controlling the syrup temperature to remain within a stable set range during the entire filling process, a series of problems caused by temperature fluctuations can be avoided, especially the phenomenon that the syrup becomes viscous due to the decrease in temperature, resulting in a decrease in flow properties and then sticking to the wall. For this purpose, it is necessary to adopt advanced temperature control systems, such as infrared sensors combined with PID temperature control systems, to strictly manage the temperature of each batch of products on the entire process line. For example, assuming that the optimal syrup temperature during filling is set within a range of 65 degrees Celsius plus or minus 2 degrees, the staff must observe the temperature monitoring display at any time to ensure that the syrup temperature is within this set range; once it deviates from the set range, take immediate measures to fine-tune it to maintain stability. Such measures ensure that the syrup remains in an ideal state to deal with the problem of sticking to the wall, both in the initial state and in subsequent batch continuous processing.

[0178] By balancing the set temperature with the actual temperature and adjusting the heating time and power in a timely manner, we can effectively transfer the syrup while keeping it in the best physical state, and prevent the syrup from adhering to the filling equipment due to condensation. To ensure the implementation of this, we can set up an automated control system to automatically detect and adjust the power of the temperature control heating component accordingly according to the preset program. For example, if the system detects insufficient heat due to changes in the production cycle, it can promptly increase the temperature near the filling nozzle, thereby effectively maintaining its heating capacity to meet the optimal conditions required to prevent wall hanging. This can be achieved through software settings to achieve automatic compensation and power increase strategies to achieve this balanced control.

[0179] For the method of the present invention, the first step is to measure and determine the initial temperature T of the syrup in the container before filling by using an appropriate thermometer or other temperature measuring device before the filling process begins. 初 This measurement process is intended to ensure that the temperature of the syrup can be adjusted to the desired T by subsequent heating or cooling devices. 目标 For example, using a jacketed reactor with a precise temperature control system, it is possible to heat and maintain the desired initial temperature of the syrup directly inside while stirring.

[0180] After clarifying T 初 After the value is set, the necessary adjustment needs to be made to this reading so that the syrup can be heated to the set target temperature range, i.e., T 目标 This regulation can be achieved by using a thermostatic device. For example, a stainless steel insulated barrel with a built-in temperature controller is used, and the PID proportional-integral-differential temperature control system is used to monitor the syrup temperature in real time and dynamically adjust the heating degree to ensure that the temperature reaches and stabilizes at the predetermined target value, while further transmitting and preheating through preheated pipes to reduce temperature loss.

[0181] Next, we need to continuously monitor the syrup temperature at the filling point or nozzle outlet during actual filling to maintain it within its target range T 目标 To this end, a temperature sensor can be placed near the outlet and connected to the automatic temperature control system to monitor the outlet temperature changes during the entire filling period, and automatically or manually adjust the heating amount to keep the temperature at a stable state until all cans are completed; this can ensure that there are always suitable temperature conditions during filling to reduce viscosity, thereby reducing the probability of syrup adhering to the container wall. For example, by using an intelligent temperature control device with feedback, combined with an external temperature monitor, the heating element is immediately activated when a temperature change is detected to make rapid adjustments to ensure temperature consistency.

[0182] The last task is to monitor the speed of the syrup delivery pump during operation and fine-tune the speed value as needed to ensure that the fluid is smooth and continuous during filling, to maintain a stable filling pressure and flow rate, and to avoid splashing of liquid due to too fast or too slow. This may involve the use of a screw pump or gear pump with a variable speed function, and connect it to a speed controller, through which the pump speed can be adjusted to control the flow rate and maintain filling stability. For example, when the system detects that the syrup fluidity is reduced, such as when the ambient temperature changes and the viscosity increases, which affects the smooth passage of the fluid, the rotation frequency of the delivery pump can be adjusted to slow it down to an appropriate level to maintain good flow performance.

[0183] In order to accurately control the filling process and avoid wall hanging, it is necessary to first evaluate the filling performance of the syrup in unit time. This is done by collecting the time t required for the filling machine to fill a certain amount of syrup Q, and calculating the average speed of syrup filling based on this data, which is called the average filling rate.

[0184] - If it is found that the average filling rate is lower than the preset target value, i.e., the predetermined threshold value T, it means that the existing heating rate is insufficient to support the ideal filling speed. To this end, the present invention sets the power of the electric heater to a higher level P, thereby quickly increasing the heat supply, accelerating the fluidity of the syrup and thus improving the filling efficiency.

[0185] When the average filling rate has reached the target level, that is, greater than or equal to the T threshold, if there is still a difference between the actual temperature and the expected temperature T 目标 The inventors propose to analyze the filling error E and use a simple and effective linear function, namely DP = aE + b, where DP refers to the power adjustment ratio and a and b represent empirical parameters obtained through a large amount of experimental data statistics to finely control the change range of the working power. This adjustment scheme can optimize the temperature matching while ensuring that the filling rate remains unchanged as much as possible and further avoid unnecessary quality problems or wall hanging.

[0186] Example Implementation Instructions

[0187] If in an implementation case, it is found that the current syrup filling rate is an assumed value of 200 mL / s during the filling process, and a filling needs to be completed within 1 second, at this time, Q current = 200 mL, t = 1s, and assuming that the pre-set standard average filling rate is 250 mL / s, the calculated 200 < 250. This means that the power P of the heater must be increased to a higher level such as 1200 W to increase the temperature and promote the flow rate to increase until the standard is met.

[0188] When the actual temperature detection value and the preset value, such as the set target temperature of 65°C, vary beyond the allowable limit, such as when it actually reaches 75°C, the power reduction ratio DP can be calculated according to the formula DP=a75-65+b and then adjusted down to 985W to stabilize the system while avoiding affecting the taste of the final product.

[0189] The filling error is determined to evaluate the deviation between the actual filling temperature and the expected value, and to use this as the basis for fine-tuning. Specifically, by comparing the actual measured temperature T f ill and the preset target temperature value T t arget to obtain the filling error E. The calculation formula is as follows: E = T t arget-T f This step helps to provide real-time feedback on the temperature status and ensure that the appropriate heating power level is maintained during the syrup tank filling process to maintain optimal syrup fluidity and reduce the possibility of wall sticking.

[0190] After obtaining the specific value of the filling error E, it is necessary to further dynamically update the strategy of fine-tuning the heating power based on the positive and negative values ​​of the error to compensate for the deviation. When the calculated E value is less than zero, that is, E<0, it means that the actual filling temperature T f ill is lower than the lower limit of the ideal syrup filling temperature range T t arget, the output power P of the heater should be increased to make the actual filling temperature close to the target temperature; if the E value is exactly equal to zero, that is, E=0, it means that the heating power during filling is within the appropriate range and should be kept unchanged as much as possible, and the temperature should continue to be monitored to maintain the consistency of the filling environment temperature; on the contrary, if it is calculated that E>0, it means that T f ill has exceeded the pre-defined target temperature range. At this time, if E is greater than a certain error limit, the power should be reduced to avoid wall hanging problems caused by excessive temperature difference and avoid unnecessary energy consumption.

[0191] After updating the operating parameters of the working heater according to the E value and its changing trend, the system will further calculate the specific power increment DP to reflect the power adjustment requirements. DP can be obtained by accumulating the product of E and its preset proportionality coefficient, which is expressed as follows: DP = β·E. Where β is the optimal coefficient factor pre-adjusted according to conditions such as syrup type and filling rate. The new actual working power value P' after final adjustment will be assigned as the difference P+DP of the original efficiency plus DP.

[0192] Through this method based on feedback and incremental correction, real-time power adjustment is achieved in continuous or batch production operations, which effectively improves the automation and process controllability of the entire syrup production process, while significantly enhancing the working efficiency of the packaging line and the quality performance of the syrup canned products.

[0193] Determine the amount of adjustment that needs to be made, i.e., the micro-increment DP, based on the result of the previous cycle. Then, at the beginning of the next cycle, make specific changes to the current working power P according to the adjustment amount, and perform a filling process; at the same time, monitor the actual change in the solution temperature caused by this micro-adjustment, and record the result R. Determine whether the observed change range R falls within the preset effective temperature adjustment range, i.e., R 有效 ; If not, repeat this step until the observed data is within the valid range.

[0194] After determining the effective adjustment amount and the adjustment range is correct, it is necessary to recheck the new heating working power P+DP to be adopted. Specifically, before adjusting the new power, the modified working parameter should be checked to ensure that it is between the maximum optional power and the minimum required heating power of the entire power adjustment array.

[0195] Only when the proposed change does not cause the system to exceed the operating safety boundary, that is, between the highest and lowest thresholds, can the actual power update be performed according to the determined change value: that is, the equipment is operated with the updated value P+DP as the new operating power. In this way, the heating efficiency and the stability of the syrup tank can be ensured while maintaining the heating set point.

[0196] For example, if it is found in a monitoring cycle that the heating power is too high and the target setting temperature rises beyond the range, the algorithm will calculate a negative fine-tuning value DP to reduce the heat output in the next round. Assuming that the original working power is P = 50 watts, the adjustment suggestion obtained by the algorithm is DP = -2 watts. At this time, P = 48 watts should be tried. After the filling process is implemented and the syrup temperature in the tank is found to be stable within the expected range during the monitoring process, the new power value will be applied to the subsequent production process. If the system still cannot meet the target conditions after this attempt, the entire adjustment process is repeated until the appropriate power setting is obtained.

[0197] By the ambient temperature T 环 The measurement is used to determine whether it deviates from the preset operating temperature range [TR m in,TR m This monitoring can be done by placing temperature sensors at the work site. The temperature sensors can be integrated into the signal feedback network of the control system. Once the temperature data is transmitted to the central controller, T can be evaluated immediately. 环Deviations from a reference interval to determine the basis for initiating a corrective action plan.

[0198] According to the temperature deviation, adjust the current I to adjust the power of the heating element to achieve the purpose of stabilizing the working temperature. 环 Greater than TR m ax, the system needs to be cooled, and the current is reduced by 5%. Conversely, if T 环 Too low means below TR m in, the current I is increased by the same 5%. In this step, a set of automatic control circuits and drive devices connected to the control system, such as heating belts and temperature regulators, need to be designed, and combined with the instructions of the PLC programmable logic controller or other embedded systems to perform adjustment actions, so that the system can respond to environmental changes and quickly give feedback to ensure the accuracy of the target temperature.

[0199] Test the actual power consumption change DeltaP after the current correction, and the impact of this change on the temperature stability during filling. Monitor the filling temperature T at the adjusted power 实时 and ensure that it remains within the predefined target range [T 阈正 , +T 阈正 ] to ensure that product quality is not affected; usually, additional sensors are installed to monitor the temperature and display it visually on the control screen for easy observation by operators, which also supports the design and implementation of automatic feedback control loops. Assuming that the initial temperature fluctuation is large but the system can recover after adjustment, the stable state under this new setting can be accepted as the control baseline to continue the subsequent process operation, and the automatic correction mechanism can be used to maintain the constant temperature filling effect to reduce the risk of residual liquid on the side of the container.

[0200] By monitoring the optimal temperature T s The syrup temperature T measured after continuous stabilization c , calculate the absolute difference between them, that is, the temperature difference factor δ|T s -T c The key here is to identify and determine the temperature deviation under the combined effect of current environmental conditions and raw material characteristics, so as to be able to timely and accurately adjust the power and heating time parameters to compensate for this deviation, and ultimately maintain the syrup temperature at the level required for the best anti-wall effect;

[0201] If the δT value is determined to be higher than the set upper temperature difference limit ΔT u When the power upper limit setting value P is increased m ax, so that the syrup can quickly approach the ideal temperature in a short time. In addition, it is necessary to appropriately reduce the power increment P of the heating equipment. step, while ensuring rapid response, can also achieve more detailed regulation of the thermal work adjustment process;

[0202] If δT falls between the upper temperature difference limit ΔT u With lower limit ΔT l The interval between the two and did not reach the point of increasing P m If the boundary condition of ax is set, the existing heating power setting of the heating system should be maintained. This decision can ensure that in the absence of large external or internal disturbances, the entire heating process is in a state of continuous and uniform heat input, which can keep the temperature curve flat and stable, thus helping the fluidity of the syrup to meet the requirements of preventing wall adhesion;

[0203] When the device measures the syrup constant temperature T for N consecutive times, a When vg is kept within a relatively ideal preset temperature range, gradually reduce the preset heating time T p re, preventing additional problems caused by overheating of the syrup. This method helps to further reduce unnecessary heat loss while effectively controlling the degree of heating, maximizing the effect of preventing wall hanging without affecting the production rate, and ensuring that the final actual heating time T_f reaches the optimization target.

[0204] The temperature difference factor δT mentioned here is defined by checking the difference between the actual temperature of the heating system and the ideal set point temperature during the filling process, and compared with the preset temperature difference upper limit ΔT u The comparison starts the operation process of this step. When the monitored temperature difference value δT exceeds the preset maximum allowable deviation value ΔT u When the temperature difference is high, the subsequent calculation logic is triggered to enhance the heating system to quickly correct the temperature difference.

[0205] Calculate the upper limit P of the new preset power n ew m ax is the current power P m The improvement is based on ax, and the degree of improvement is increased by increasing the original preset power limit P m The sum of ax and the additional power added δTP gives P n ew m ax=P m ax+δTP. The specific value of δTP here can be determined according to the actual environmental conditions and parameters that need to be further optimized. The purpose of this additional power increase is to ensure that the actual heat shortage caused by excessive temperature deviation can be more effectively compensated, thereby ensuring the efficiency of the heating system and its heating consistency for the syrup.

[0206] After the new power limit is obtained by the above calculation, the effective heating power P during the heating cycle will be dynamically adjusted. t The adjustment is made in equal steps, and the change in heating power each time is P s tep, and make P t Gradually increase to the newly calculated maximum preset power P n ew m ax range, while ensuring that it remains within the updated upper limit P n ew m Within the range of ax, the constraint P is followed m ax≤P t ≤P n ew m ax.

[0207] The actual heating power P is continuously monitored during each individual heating cycle t If the detection result shows that the actual power has reached or exceeded the updated maximum allowable power value P n ew m ax, the heating step is continued at this maximum power state while the next temperature correction procedure is immediately performed to prevent overheating. This correction usually involves some cooling mechanism to prevent the temperature from rising too quickly.

[0208] On the other hand, if the updated maximum permissible power P is not reached within a complete heating cycle n ew m When the state is ax, the actual power value P t The maximum power state P will continue to be set to maintain the original preset m ax, and repeatedly evaluate whether the adjustment conditions are met or enter the next cycle to re-evaluate the temperature and power status.

[0209] As an example, assume that the maximum limit value of the heating power under the ideal working conditions set by the current system is P m ax = 3kW, the temperature difference δT measured during the test exceeds the allowable threshold value set to ΔT u =3℃, an additional heating energy of δTP = 0.5kW is required. So we calculate P n ew m ax=P m ax+δTP=3kW+0.5kW=3.5kW. According to the system setting, the maximum power step value P that can be added in each round s tep is 0.1kW and the calculation is run every five minutes in a heating cycle. Therefore, one cycle contains six heating periods. The system will first gradually increase the power to a maximum of P in the first five-minute heating phase.m ax is initially 3kW plus three P s tep is equivalent to the sum of an additional 0.3kW, which is the final P t =3kW+0.3kW=3.3kW, the maximum power limit has not been reached yet, and the next cycle will be executed. During the second five-minute heating period, if the monitoring shows that the power demand is still not fully met, the heating power will be increased again by P s tep*6 0.1kW×6 means the maximum power can be increased to 3.9kW, which obviously exceeds P n ew m ax=3.5kW limit, so the next heating operation will be performed according to the maximum allowable power of 3.5kW, and further cooling measures will be taken to maintain the optimal temperature range of the tank and syrup. In this example, each link is evaluated and controlled in sequence to ensure the stability and accuracy of the system.

[0210] Specifically, when the measured temperature gradually approaches the preset target temperature T s And determine the current actual heating power P t Weighted change n*P s Is tep sufficient to allow the syrup to enter a stable state when it reaches or is very close to the target preset temperature? Here, T_p is the predicted steady-state temperature under a given power, and is multiplied by the correction factor K to reflect the effective heating temperature level that needs to be achieved under different operating conditions. The correction factor here can be flexibly adjusted according to the specific equipment or process requirements.

[0211] Next, determine the target steady-state temperature T obtained by the above calculation p and the actual set temperature T s Is there a low temperature difference? If the actual predicted temperature T p *K is much lower than the set target temperature T s An acceptable temperature difference δTT p , the system will reduce the original power step change P based on the current situation s tep*m, where coefficient m is a coefficient less than 1 and greater than 0, which is used to ensure that the temperature can move closer to the target more delicately rather than directly crossing it; this ensures that the temperature can get as close to the target as possible during the adjustment process and reduce over-adjustment.

[0212] The system continues to run a set number of measurement cycles N according to the adjusted step change value, and re-tests the actual working conditions in the tank during this period; the purpose is to determine whether the new step can keep the temperature within the optimal range, that is, T m in and T mThe equilibrium temperature between ax, if deviation is still found, the above adjustment will be repeated continuously until the range is met to avoid the situation where the syrup sticks to the inside of the container due to excessive power adjustment.

[0213] After completing this stage of the control strategy, the most recently executed step parameter changes should be retained as the benchmark for the next round of possible control, so as to more effectively and accurately adapt to possible changes in the future and keep the equipment running in an ideal temperature control state.

[0214] The actual heating time is determined by the final

[0215] T f =sumn·T per -m·δT t

[0216] Statistical processing is performed here. per is the length of a single expected heating period, while the variable m is a coefficient that represents the relationship between the reduction factor and the temperature difference caused by the heat loss generated by the actual state of the system; deltaT t It is a quantitative assessment of the temperature fluctuations within the estimated time. The purpose of this statistical process is to calculate the best average value of the final heating time with the help of data obtained from multiple tests.

[0217] The average heating time for the final determination within the recent M consecutive cycles Implement dynamic comparison and evaluate the target temperature zone set value T according to its change trend s and target temperature control threshold T c Whether the stability under the influence of the environment can meet the temperature difference threshold condition, that is, to ensure that the change range between the two remains within a reasonable range ∥ΔT l Only when the variation of these two temperature benchmarks is maintained within this standard, the next step is considered.

[0218] On this basis, when confirming that the aforementioned temperature zone settings and temperature control threshold conditions are operating under ideal and stable conditions, it is also necessary to verify T s ,T c The setting is not lower than the minimum operating temperature limit of the system. Then, the formula is used:

[0219] Further reduce the subsequent preset heating time until the best optimization setting, where the variable N represents the number of experimental rounds that have been tried overall, and requires that the measured number of times should meet or exceed the minimum cycle count N required by a series of preset safety protection measures min, in order to avoid the risk of excessive deviation of results due to insufficient data representation caused by too few experiments. In this way, an optimal solution can be found by continuously adjusting the experimental parameters, and gradually approaching the most effective initial setting of the heating time configuration value.

[0220] These steps explain in detail how to adjust and optimize the preset heating time settings based on the current system operating status to effectively achieve the goal of fine-tuning and real-time dynamic optimization of heating control during the syrup filling process.

[0221] The actual temperature in the syrup container is sampled at each set time period, and the average temperature reading T within the period is calculated based on the collected temperature data. a vg and the standard deviation σ of the temperature distribution, and evaluate the heating efficiency during this period based on these data; if the standard deviation of the average temperature in the current cycle plus one times falls within the predetermined target temperature range [T m in,T m ax], it is considered that the current heating power is appropriate and stable, that is, the current heating process can control the syrup temperature within the ideal range without overheating or insufficient temperature;

[0222] If the calculated average temperature plus double the standard deviation is not within the predetermined target temperature range [T m in,T m ax] range, indicating that the current temperature regulation is unstable, then further increase the power limit P t Used to increase the heater output power; this increase operation is repeated until the average temperature plus the standard deviation falls into the target range again, or a certain maximum allowed heating number is reached. This ensures that the system can automatically adjust to adapt to temperature changes, so that the syrup always maintains appropriate viscosity and fluidity during the filling process.

[0223] In summary, the above method can not only effectively prevent wall hanging during filling, but also improve production quality and stability. This method is not only simple and easy to operate, but also can significantly improve the overall operation efficiency of the production line and the qualified rate of the final product on the basis of achieving the goal of preventing wall hanging.

[0224] In actual operation, when this device is used, the target container needs to be located first, and the filling volume threshold of the container is pre-set through the control system. This threshold is determined according to the required amount of syrup. Then, the filling process starts, and the filling head starts to inject syrup into the target container. During this process, the sensor installed near the filling head will continuously monitor the liquid level in the target container and feed back these data to the control system in real time. The control system compares the received liquid level information with the pre-set filling volume threshold, and then decides whether to adjust the filling speed. When the liquid level is detected to be close to the preset threshold, the control system will issue an instruction to gradually slow down the filling speed until it stops completely, so as to ensure that the filling volume of syrup reaches the preset value accurately without overflowing. In the whole process, the sensor, control system and filling mechanism are closely coordinated to ensure the filling accuracy while improving the production efficiency and product quality. This intelligent control method can not only effectively reduce the errors caused by human factors, but also adapt to containers of different capacity specifications, with high flexibility and practicality.

[0225] The above is a preferred embodiment of the present application. It should be pointed out that, for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principles of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present application.

Claims

1. A filling method for syrup, characterized in that: include: Before filling begins, the filling volume threshold of the target container is pre-set; Dynamically adjust the filling speed based on the comparison result between the liquid level in the target container monitored in real time and the preset threshold value; When the liquid level is detected to be close to the preset threshold, the filling speed is gradually slowed down until it stops to ensure that the preset filling volume is accurately reached to avoid overflow; During the filling process, sensors are used to continuously monitor liquid level changes and provide feedback to the control system for real-time adjustments; The method of dynamically adjusting the filling speed based on the comparison result between the liquid level height in the target container monitored in real time and the preset threshold value includes: Obtain the current liquid level H in the target container in real time; Compare the current liquid level H with the preset threshold T; When H is less than a certain proportion of T, maintain the current filling speed V; When H is greater than or equal to 80% of T but less than T, the filling speed V is reduced according to a predetermined ratio; If H is less than T multiplied by 0.8, the filling speed remains unchanged; If H is greater than or equal to T multiplied by 0.8 and H is less than T, the filling speed is reduced; If H is greater than or equal to T, stop filling; Among them, if H is greater than or equal to T multiplied by 0.8 and H is less than T, the filling speed is dynamically adjusted based on the relationship between H and T. When H is less than T multiplied by 0.9, the filling speed V remains unchanged; When H is greater than or equal to T times 0.9 and H is less than T, the filling speed V is adjusted to V times 0.5; When H is greater than or equal to T, the filling speed V is adjusted to 0; If H is greater than or equal to T times 0.9 and H is less than T, then based on the relationship between H and T, the filling speed V is adjusted to V times 0.

5.

2. A filling method for syrup according to claim 1, characterized in that: The filling speed V is adjusted to V multiplied by 0.5 including: Determine the current filling speed V; Calculate the new filling speed V, where V = V multiplied by 0.5; If H is greater than or equal to T multiplied by 0.9 and H is less than T, adjust the filling speed to V; If H is greater than or equal to T, filling is stopped.

3. A filling method for syrup according to claim 1, characterized in that: If H is greater than or equal to T, then stop filling including: When H is greater than or equal to T, the filling process is stopped immediately; If H is less than T, continue filling; If H is greater than or equal to T, the filling process is stopped.

4. A filling method for syrup according to claim 1, characterized in that: The method of dynamically adjusting the filling speed based on the comparison result between the liquid level height in the target container monitored in real time and the preset threshold value includes: Real-time acquisition of the liquid level height H in the target container monitored by the sensor; Compare the liquid level H with a preset threshold value T; When H is less than 80% of T, keep the current filling speed unchanged; When H is greater than or equal to 80% of T and less than T, reduce the filling speed to 50% of the original speed.

5. A filling method for syrup according to claim 1, characterized in that: The step of comparing the liquid level height H with a preset threshold value T comprises: If H is less than T, continue filling; If H is equal to or greater than T, the deceleration signal is triggered; Based on the difference ΔH between H and T, the deceleration ratio R is calculated, where R = (TH) / T*100%; When ΔH is less than or equal to the preset difference threshold D, a deceleration instruction is executed.

6. A filling method for syrup according to claim 1, characterized in that: The calculation of the deceleration ratio R based on the difference ΔH between H and T includes: Determine the difference ΔH between the current liquid level height H and the preset threshold value T; Determine whether ΔH is less than or equal to a preset difference threshold D; If ΔH is less than or equal to D, the deceleration ratio R is calculated as R = (TH) / T*100%; If ΔH is greater than D, the current filling speed remains unchanged.

7. A filling method for syrup according to claim 6, characterized in that: The step of determining whether ΔH is less than or equal to a preset difference threshold D includes: Obtain the difference ΔH between the current liquid level height H and the preset threshold T; Set a preset difference threshold D; If ΔH≤D, proceed to the next step; If ΔH>D, the current filling speed remains unchanged.

8. A filling method for syrup according to claim 1, characterized in that: If ΔH≤D, the next step includes: When ΔH≤D, calculate the deceleration ratio R=(TH) / T*100%; If R is greater than the minimum deceleration ratio M, the deceleration instruction is executed; If R is less than or equal to M, keep the current filling speed unchanged; After executing the deceleration command, the liquid level continues to be monitored until it reaches the preset threshold T.

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