All-in-one rotary sauce filling system

Abstract

This application relates to an all-in-one rotary sauce filling system, comprising a rotary flow module for driving a rotary worktable to rotate at a constant speed via a servo motor, sequentially transferring containers from container positioning seats to various functional stations, and achieving precise container loading and unloading through synchronization signals linked with a circular conveyor track; a central control module for performing pre-filling preparation: calling a sauce database based on the identification information of the sauce to be filled, matching the corresponding filling parameter set, and simultaneously receiving container specifications and positioning status information from sensors on the container positioning seats, triggering subsequent processes after confirming container readiness; and an adaptive filling module located at the filling station for driving the filling nozzle to rise and fall to a preset height inside the container, conveying the sauce according to the matched filling parameter set, and spraying pulsed airflow to break up air bubbles in the sauce during filling. This application significantly improves the versatility, filling accuracy, and filling quality of the filling system.

Description

Technical Field

[0001] This application relates to the field of sauce filling, and more particularly to an all-in-one rotary sauce filling system. Background Technology

[0002] In the sauce and food packaging industry, rotary filling machines are widely used due to their high efficiency. Existing technologies mostly employ mechanical cams or simple PLC control to achieve container rotation and filling. These devices are typically mechanically adjusted for sauces of specific viscosities, with fixed filling parameters (such as flow rate and speed) or only allowing for limited manual adjustment. Furthermore, their functional modules are relatively independent, resulting in poor coordination between cleaning, filling, and testing processes, and a lack of data collection and correlation throughout the entire production process.

[0003] However, sauce products are becoming increasingly diversified, with significant differences in their physical properties (such as viscosity and particle size). Existing equipment's rigid, fixed parameter modes struggle to adapt to the varying filling requirements of different sauces. This results in high-viscosity sauces being prone to air bubbles and residue buildup on the filling walls, while low-viscosity sauces may splatter due to excessive flow rates, severely impacting filling accuracy and product consistency. Furthermore, the fragmented functional modules lead to insufficient production line flexibility. Changing products requires lengthy cleaning and debugging processes, and once quality issues arise, it's difficult to quickly trace back to the specific production stage, hindering improvements in production efficiency and quality control.

[0004] In response to the aforementioned technologies, an all-in-one rotary sauce filling system is proposed. Summary of the Invention

[0005] To address the aforementioned technical problems, this application provides an all-in-one rotary sauce filling system.

[0006] In a first aspect, this application provides an all-in-one rotary sauce filling system, which adopts the following technical solution:

[0007] A multi-functional rotary sauce filling system includes a rotary flow module, a central control module, an adaptive filling module, a container pretreatment module, a post-processing quality inspection module, a cleaning and maintenance module, and a data traceability module, all interconnected to collaboratively realize the entire sauce filling process. The core architecture is as follows:

[0008] The rotary transfer module includes a servo motor, a rotary table, a circular conveyor track, and a container positioning seat. It is used to drive the rotary table to rotate at a constant speed through the servo motor, and to transfer the containers on the container positioning seat to each functional station in sequence. It also achieves precise loading and unloading of containers through synchronization signals and linkage with the circular conveyor track.

[0009] The central control module includes a controller and a pre-stored sauce database, used to perform pre-filling preparation: calling the sauce database according to the identification information of the sauce to be filled, matching the corresponding filling parameter set, which includes at least quantitative delivery flow rate, filling nozzle lifting height, airflow disturbance parameters and container clamping force; at the same time, receiving container specifications and positioning status information fed back by sensors on the container positioning seat, and triggering subsequent processes after confirming that the container is ready;

[0010] The adaptive filling module, located at the filling station, includes a filling head lifting mechanism, a quantitative conveying unit, an airflow disturbance unit, and a scraping unit. The filling head lifting mechanism drives the filling nozzle to rise and fall to a preset height inside the container. The quantitative conveying unit conveys the sauce according to a matching set of filling parameters. The airflow disturbance unit is integrated inside the filling nozzle and sprays pulsed airflow to break up air bubbles in the sauce during filling. The scraping unit is located on the outer wall of the filling nozzle and scrapes off any residual sauce on its outer wall when the filling nozzle rises.

[0011] The container pretreatment module is located at the pretreatment station and is used to perform high-pressure cleaning and hot air drying on the containers transferred to the station.

[0012] The post-processing quality inspection module is set at the post-processing station and is used to perform capping and sealing, precise labeling and quality inspection on the filled containers.

[0013] The cleaning and maintenance module is used to initiate a cleaning program for filling-related components when preset trigger conditions are met. The trigger conditions include at least switching sauce types, reaching the cumulative filling volume target, and reaching the continuous operation target.

[0014] The data traceability module is used to collect the operating parameters and quality data of each module in real time, establish a full-process data association for a single can product, and realize traceable management.

[0015] Preferably, the sauce database uses sauce viscosity as a key index parameter; the viscosity is divided into at least two ranges and matched with a differentiated filling parameter set: when the sauce viscosity is in the first range of 100-5000 mPa·s, a first parameter set is matched, with a quantitative delivery flow rate of 150-500 mL / min and an airflow disturbance frequency of 10-30 Hz; when the sauce viscosity is in the second range of 5000-10000 mPa·s, a second parameter set is matched, with a quantitative delivery flow rate of 50-150 mL / min and an airflow disturbance frequency of 30-50 Hz.

[0016] Preferably, the adaptive filling module further includes a heat-insulating storage unit, which includes a jacketed storage tank and a temperature controller; the central control module is further configured to: when a high-viscosity sauce corresponding to the second parameter set is identified, activate the heat-insulating storage unit to stabilize the sauce temperature within a preset viscosity optimization range.

[0017] Preferably, the scraping unit is an elastic scraper ring made of food-grade silicone material, with its inner diameter having an interference fit of 0.1-0.3mm with the outer diameter of the filling nozzle; the scraper ring is kept stationary by the lifting and lowering movement of the fixing member relative to the filling nozzle, thereby achieving scraping when the filling nozzle rises.

[0018] Preferably, the quality inspection of the post-processing quality inspection module employs dual verification, specifically including:

[0019] The net content of the product is detected by a pre-set weight sensor. When the error exceeds the preset net content threshold, the product is directly marked as unqualified.

[0020] For products with qualified net content, a pre-set visual inspection device is triggered to perform visual analysis of the labeling position and bottle cap sealing.

[0021] The product is only allowed to move to the unloading station if both checks pass.

[0022] Preferably, the cleaning procedure of the cleaning and maintenance module specifically includes:

[0023] In the first stage, a cleaning solution compatible with the previous batch of sauce is sprayed to rinse the adaptive filling module. The rinsing pressure is 1-1.5 MPa and the duration is 30 seconds.

[0024] In the second stage, the system switches to sterile water rinsing at a pressure of 0.8-1 MPa for 30 seconds to rinse the adaptive filling module. The rinsing waste liquid is then filtered and collected.

[0025] Preferably, the rotary transfer module further includes a photoelectric encoder; the photoelectric encoder is used to detect the angular position of the rotary worktable and send a synchronization pulse signal to the annular conveying track when the preset angle is reached, so as to achieve precise positioning and synchronization of the container during the transfer process.

[0026] Preferably, the sauce database of the central control module has a built-in parameter self-learning unit; the parameter self-learning unit is configured to: dynamically optimize the parameter matching logic based on the parameters corresponding to the best filling effect of sauces of different viscosities in historical production data; when the viscosity and solid content parameters of a new sauce are input, the system automatically generates and outputs a recommended parameter set based on the optimized logic.

[0027] Preferably, the data traceability module establishes end-to-end data association for a single can product, specifically including the following steps:

[0028] Collect the actual filling time and flow rate curves for each container at the filling station;

[0029] The actual filling time and flow rate curve is associated with and stored with the container's unique identifier and its final quality inspection result.

[0030] When a batch of quality defects is discovered, the abnormal parameters in the filling process are traced back based on the associated data.

[0031] Preferably, the data traceability module is further configured with an early warning unit; the early warning unit is configured to: perform trend analysis on the real-time collected filling parameters, and if it is detected that the key parameters continuously deviate from their set values ​​but have not yet exceeded the qualified range, send a maintenance early warning signal to the operator.

[0032] In summary, this application includes at least one of the following beneficial technical effects:

[0033] 1. This application constructs an intelligent sauce filling solution by integrating a central control module with adaptive parameters, an adaptive filling module with bubble breaking and self-cleaning functions, and various functional modules that coordinate the entire process. This system not only automatically matches and executes optimal filling parameters based on the viscosity and other characteristics of the sauce, significantly improving its adaptability to sauces with different physical properties and filling accuracy, but also achieves flexible production processes, rapid cleaning switching, and traceability of quality issues through efficient collaboration and data closure among modules. This comprehensively solves the core defects of traditional equipment, such as rigid parameters, fragmented modules, and difficulties in quality control traceability, significantly improving the universality, filling accuracy, and filling quality of the filling system.

[0034] 2. This application uses sauce viscosity as the core index to divide the range and matches it with a differentiated set of filling parameters. Through a refined design that adapts high flow rate and low frequency airflow to the low and medium viscosity range, and low flow rate and high frequency airflow to the high viscosity range, it accurately meets the filling needs of sauces with different rheological properties. It fundamentally solves the industry pain points of existing equipment with single fixed parameters, such as high viscosity sauces having many bubbles and serious residues, and low viscosity sauces being prone to splashing. It eliminates the need for repeated manual parameter adjustments, significantly shortens product changeover time, and ensures the filling accuracy and product consistency of various sauces. It significantly improves the system's adaptability to diverse sauces and production efficiency.

[0035] 3. By setting up parameter self-learning units, the system is upgraded from a static parameter executor to a dynamic process optimizer. Its core advantage lies in its ability to automatically discover and solidify the optimal filling logic by continuously analyzing the correlation between process parameters and quality results in historical production data. This allows the parameter matching strategy to continuously improve itself with accumulated production experience. It not only transforms the fuzzy debugging process, which relies on experienced technicians, into a precise and transferable data algorithm, but also, when faced with new sauces, it can quickly deduce high-success-rate initial parameters based on learned patterns. This significantly shortens the debugging cycle for new product introductions, reduces trial-and-error costs, and fundamentally realizes the intelligentization and knowledge-based management of the filling process. Attached Figure Description

[0036] Figure 1 This is a system block diagram of an all-in-one rotary sauce filling system according to an embodiment of this application;

[0037] Figure 2 This is a cross-sectional schematic diagram of the filling nozzle in an embodiment of this application;

[0038] Figure 3 This is a flowchart of the cleaning procedure in an embodiment of this application;

[0039] Figure 4 This is a flowchart illustrating the method for establishing full-process data association for a single-can product in this application embodiment.

[0040] Explanation of reference numerals in the attached diagram: 1. Rotary conveyor module; 11. Servo motor; 12. Rotary worktable; 13. Circular conveyor track; 14. Container positioning seat; 15. Photoelectric encoder; 2. Central control module; 21. Parameter self-learning unit; 3. Adaptive filling module; 31. Filling head lifting mechanism; 32. Quantitative conveying unit; 33. Airflow disturbance unit; 34. Scraping unit; 35. Insulated storage unit; 36. Filling nozzle; 361. Insulated chamber; 362. Circulating temperature control unit; 4. Container pretreatment module; 5. Post-treatment quality inspection module; 51. Photoelectric material shortage detection sensor; 6. Cleaning and maintenance module; 61. Cleaning liquid concentration sensor; 7. Data traceability module; 71. Early warning unit. Detailed Implementation

[0041] The following is in conjunction with the appendix Figures 1-4 This application will be described in further detail.

[0042] This application discloses an all-in-one rotary sauce filling system. (Refer to...) Figure 1 A multi-functional rotary sauce filling system includes a rotary flow module 1, a central control module 2, an adaptive filling module 3, a container pretreatment module 4, a post-processing quality inspection module 5, a cleaning and maintenance module 6, and a data traceability module 7, all interconnected to collaboratively realize the entire sauce filling process. Its core architecture is as follows:

[0043] The rotary transfer module 1 includes a servo motor 11, a rotary worktable 12, an annular conveying track 13, and a container positioning seat 14. It is used to drive the rotary worktable 12 to rotate at a constant speed through the servo motor 11, and to transfer the containers on the container positioning seat 14 to each functional station in sequence. It also achieves precise loading and unloading of containers through synchronization signals and linkage with the annular conveying track 13.

[0044] The central control module 2 includes a controller and a pre-stored sauce database, and is used to perform pre-filling preparation: it calls the sauce database according to the identification information of the sauce to be filled, matches the corresponding filling parameter set, which includes at least the quantitative delivery flow rate, the lifting height of the filling nozzle 36, the airflow disturbance parameters, and the container clamping force; at the same time, it receives the container specifications and positioning status information fed back by the sensor on the container positioning seat 14, and triggers the subsequent process after confirming that the container is ready.

[0045] The adaptive filling module 3, located at the filling station, includes a filling head lifting mechanism 31, a quantitative conveying unit 32, an airflow disturbance unit 33, and a scraping unit 34. The filling head lifting mechanism 31 drives the filling nozzle 36 to rise and fall to a preset height inside the container. The quantitative conveying unit 32 conveys the sauce according to a set of matching filling parameters. The airflow disturbance unit 33 uses a pneumatic jet defoamer integrated inside the filling nozzle 36. During filling, it sprays pulsed airflow to break up air bubbles in the sauce. The pneumatic jet defoamer is a mature standard component in the filling equipment field, and its specific structure is existing technology and will not be described in detail here. The scraping unit 34 is located on the outer wall of the filling nozzle 36 and scrapes off any residual sauce on its outer wall when the filling nozzle 36 rises.

[0046] The container pretreatment module 4 is located at the pretreatment station and is used to perform high-pressure cleaning and hot air drying on the containers transferred to the station.

[0047] The post-processing quality inspection module 5 is set at the post-processing station and is used to perform capping and sealing, precise labeling and quality inspection on the filled containers.

[0048] The cleaning and maintenance module 6 is used to start a cleaning program for filling-related components when preset triggering conditions are met. The triggering conditions include at least switching sauce types, reaching the cumulative filling volume target, and reaching the continuous operation target.

[0049] The data traceability module 7 is used to collect the operating parameters and quality data of each module in real time, establish a full-process data association for a single can of product, and realize traceable management. This application constructs an intelligent sauce filling solution by integrating a central control module 2 with adaptive parameters, an adaptive filling module 3 with bubble breaking and self-cleaning functions, and various functional modules that coordinate the entire process. This system can not only automatically match and execute the optimal filling parameters according to the viscosity and other characteristics of the sauce, significantly improving the adaptability and filling accuracy of sauces with different physical properties, but also realizes the flexibility of the production process, the speed of cleaning switching, and the traceability of quality problems through the efficient coordination and data closed loop of each module. Thus, it comprehensively solves the core defects of traditional equipment parameters being rigid, modules being fragmented, and quality control traceability being difficult, and significantly improves the universality, filling accuracy, and filling quality of the filling system.

[0050] Reference Figure 1The rotary flow module 1 also includes a photoelectric encoder 15. The photoelectric encoder 15 detects the angular position of the rotary table 12 and sends a synchronization pulse signal to the annular conveyor track 13 when a preset angle is reached, thereby achieving precise positioning and synchronization of the containers during the flow process. The design of the photoelectric encoder 15 and the synchronization pulse signal constitutes the closed-loop feedback control core of the rotary flow module 1. Its advantage lies in that, through real-time, high-resolution angle feedback and precise pulse triggering, it fundamentally eliminates the cumulative positioning error caused by inertia or mechanical clearance between the rotary table 12 and the conveyor track, ensuring that each container achieves sub-millimeter repeatability accuracy during flow between workstations. This not only provides a reliable spatial reference for subsequent precision operations such as adaptive filling but also significantly reduces the risk of collisions and jamming caused by positioning deviations during high-speed flow, thereby improving the stability and reliability of the entire line operation.

[0051] The aforementioned sauce database uses sauce viscosity as a key index parameter. Viscosity is divided into at least two ranges and matched with differentiated filling parameter sets: when the sauce viscosity is in the first range of 100-5000 mPa·s, a first parameter set is used, with a quantitative delivery flow rate of 150-500 mL / min and an airflow disturbance frequency of 10-30 Hz; when the sauce viscosity is in the second range of 5000-10000 mPa·s (higher than the first range), a second parameter set is used, with a quantitative delivery flow rate of 50-150 mL / min (lower than the first flow rate) and an airflow disturbance frequency of 30-50 Hz (higher than the first parameter set). More ranges can be divided according to actual operating conditions. Through this refined parameter matching based on viscosity, the system can adapt to the rheological characteristics of different sauces, fundamentally solving the problem that a single parameter cannot simultaneously address the filling quality of various sauces. This solution uses sauce viscosity as the core index to divide the range and matches it with a differentiated set of filling parameters. Through a refined design that adapts high flow rate and low frequency airflow to the low and medium viscosity range, and low flow rate and high frequency airflow to the high viscosity range, it accurately meets the filling needs of sauces with different rheological properties. It fundamentally solves the industry pain points of existing equipment with single fixed parameters, such as high viscosity sauces having many bubbles and serious residues, and low viscosity sauces being prone to splashing. It eliminates the need for repeated manual parameter adjustments, significantly shortens product changeover time, and ensures the filling accuracy and product consistency of various sauces. It significantly improves the system's adaptability to diverse sauces and production efficiency.

[0052] Furthermore, refer to Figure 1The central control module 2 has a built-in parameter self-learning unit 21 in its sauce database. This unit is configured to continuously collect and analyze historical production data, including at least the actual filling parameters of sauces with different viscosities, as well as the corresponding product qualification rate and filling residue. By analyzing the parameter combinations corresponding to the optimal filling effect in the data, the unit can autonomously adjust and optimize the parameter matching logic in the sauce database, making the matching logic continuously approach the optimal level. When the viscosity and solids content parameters of a new sauce are input, the system automatically generates and outputs a recommended parameter set based on the optimized logic, supporting manual fine-tuning. By setting the parameter self-learning unit 21, the system is upgraded from a static parameter executor to a dynamic process optimizer. Its core advantage lies in the ability to automatically discover and solidify the optimal filling logic by continuously analyzing the correlation between process parameters and quality results in historical production data, allowing the parameter matching strategy to continuously improve itself with production accumulation. It not only transforms the fuzzy debugging process that relies on the experience of master craftsmen into a precise and inheritable data algorithm, but also enables the rapid deduction of high-success-rate initial parameters based on learned patterns when facing new sauces. This significantly shortens the debugging cycle for new product introductions, reduces trial-and-error costs, and fundamentally realizes the intelligentization and knowledge-based processing of the filling process.

[0053] The scraping unit 34 is specifically a passive scraping mechanism, which includes an elastic scraper ring made of food-grade silicone and a mounting bracket for fixing the scraper ring. Preferably, the elastic scraper ring has a Shore hardness of 50-60 degrees to ensure sufficient elastic deformation capacity and wear resistance. The inner diameter of the scraper ring and the outer diameter of the filling nozzle 36 are designed to have an interference fit of 0.1-0.3 mm, and it is fixed to the frame of the filling station by the mounting bracket, thereby keeping it fixed in space.

[0054] Based on the above structure, when filling is complete and the filling nozzle 36 rises under the drive of the lifting mechanism, the stationary scraper ring can automatically scrape off the residual sauce adhering to the nozzle wall by means of its interference fit with the outer wall of the filling nozzle 36. This scraping process is entirely driven by the lifting movement of the filling nozzle 36 itself, without the need for an additional power source or control unit. Through this design, firstly, the dripping of sauce during the lifting stage of the filling nozzle 36 is fundamentally eliminated, ensuring high accuracy of the filling net content and a clean working environment. Secondly, cross-contamination caused by residues in the filling nozzle 36 from different batches and types of sauces is completely avoided, making it particularly suitable for flexible production of multiple varieties and small batches. Finally, its passive working characteristic means that the mechanism does not require complex drive devices and control programs, resulting in an extremely simple structure, low manufacturing cost, high reliability, and maintenance-free operation, perfectly meeting the high-paced, continuous operation requirements of rotary filling equipment.

[0055] Reference Figure 1The adaptive filling module 3 further includes a heat-insulating storage unit 35, which includes a jacketed storage tank and a temperature controller. The central control module 2 is further configured to activate the heat-insulating storage unit 35 when a high-viscosity sauce corresponding to the second parameter set is detected, thereby stabilizing the sauce temperature within a preset viscosity optimization range. Addressing the industry pain points of high-viscosity sauces being prone to solidification and having poor flowability, the central control module 2 can automatically link with the heat-insulating storage unit 35 to stabilize the high-viscosity sauce within the optimal viscosity range through precise temperature control. This ensures uniform flowability of the sauce and lays a solid foundation for subsequent refined parameter matching, reducing air bubbles and residues during high-viscosity sauce filling from the source. No additional manual temperature control adjustments are required, further enhancing the system's automation level and significantly improving the stability and consistency of high-viscosity sauce filling quality.

[0056] Further optimization, refer to Figure 2 The filling nozzle 36 of the adaptive filling module 3 has a double-layer hollow structure. The inner tube is used to transport the sauce, and the interlayer between the outer and inner tubes forms an insulation cavity 361. The system is equipped with a circulating temperature control unit 362. When filling sauces with a viscosity ≥5000mPa・s, circulating insulated water at 30-50℃ is introduced into the insulation cavity 361. Through heat conduction, the sauce is prevented from solidifying on the inner wall of the filling nozzle 36, reducing the residue to below 0.1g. The synergistic design of the double-layer hollow structure of the filling nozzle 36 and the circulating temperature control unit 362 has the outstanding advantage of precisely extending the core intervention of temperature control from the material storage stage to the final discharge point. By establishing an independent dynamic insulation environment within the wall of the filling nozzle 36, the system can accurately compensate for the heat loss and sudden increase in viscosity of high-viscosity sauces in the last centimeter of the filling path. This not only effectively prevents the sauce from cooling, solidifying, and adhering to the inner wall of the filling nozzle 36, keeping the residual amount after each filling at an extremely low level (e.g., below 0.1g), but more importantly, it ensures that the sauce maintains the desired, uniform flowability throughout the entire transport process from the storage tank to the container. This allows viscosity-based adaptive filling parameters (such as low speed, pulsed airflow, etc.) to remain effective throughout the entire filling process, ultimately achieving high precision and high cleanliness in the filling of ultra-high viscosity sauces.

[0057] The quality inspection of the post-processing quality inspection module 5 mentioned above adopts dual verification, specifically including:

[0058] The net content of the product is detected by a pre-set weight sensor. When the error exceeds the preset net content threshold, the product is directly marked as unqualified. In this embodiment, when the error is > ±0.2%, the product is directly marked as unqualified.

[0059] For products with qualified net content, a pre-set visual inspection device is triggered to perform visual analysis of the labeling position and bottle cap sealing. Specifically, the visual inspection device collects container images and analyzes the labeling offset (allowed ≤ ±0.5mm) and the bottle cap fitting gap (allowed ≤ 0.1mm).

[0060] Only when both checks pass can a product be allowed to proceed to the unloading station. This dual-check mechanism, with its clearly defined division of labor and sequential execution, not only significantly improves the defect detection rate and the consistency of product quality, but also optimizes the allocation efficiency of testing resources by proceeding from easy to difficult steps, achieving the best balance between quality control accuracy and production line operating efficiency.

[0061] Reference Figure 3 The cleaning procedure of the aforementioned cleaning and maintenance module 6 specifically includes:

[0062] A1. Residue Removal: In the first stage, a cleaning solution compatible with the previous batch of sauce (alkaline cleaning solution is suitable for oily sauces, and neutral cleaning solution is suitable for water-based sauces) is sprayed to rinse the adaptive filling module 3. The rinsing pressure is 1-1.5 MPa and the duration is 30 seconds.

[0063] A2. Sterile Water Rinsing: In the second stage, the system switches to sterile water rinsing at a pressure of 0.8-1 MPa for 30 seconds to rinse the adaptive filling module 3. The rinsing wastewater is filtered and collected centrally. This two-step combination of adaptable cleaning solution dissolution and sterile water final rinsing achieves a balance between cleaning effectiveness and resource efficiency. The first stage uses a suitable cleaning agent to efficiently decompose and remove specific sauce residues (such as oils and proteins) under optimized pressure and time parameters, ensuring no residue dead spots. The second stage thoroughly removes cleaning agent residues with sterile water to prevent contamination of subsequent batches. The entire process is parameterized and automated, ensuring not only the cleanliness and product safety of the filling system when switching between different sauces, but also reducing water consumption and sewage costs through wastewater filtration and recycling, significantly improving production continuity and environmental protection.

[0064] The above-mentioned cleaning and maintenance module 6 is equipped with a cleaning liquid concentration sensor 61 for real-time detection of the pH value of the cleaning liquid. When the pH of the alkaline cleaning liquid is ≤ 10 or the pH of the neutral cleaning liquid deviates from 7 ± 0.5, the concentrated cleaning liquid supply valve is automatically opened, and the supply volume is adjusted according to the concentration deviation ratio. The air pressure holding test for the tightness detection of the offline cleaning unit adopts the standard of maintaining an air pressure of 0.3 MPa for 30 seconds, and if the pressure drop is ≤ 0.01 MPa, it is considered qualified. Through the combination of closed-loop control of the cleaning liquid concentration and quantitative detection of the offline tightness, its core advantage lies in upgrading the cleaning and maintenance process from relying on manual experience judgment to data-driven precise operation. The real-time feedback of the concentration sensor and the automatic supply mechanism ensure that the activity of the cleaning liquid is always maintained within the effective range, eliminating the risk of incomplete cleaning or chemical residues caused by concentration attenuation. At the same time, the standardized air pressure holding test replaces subjective visual inspection with objective and quantitative data, providing an indisputable qualified basis for the sealing reliability of key components. The two work together to jointly build a verifiable and reproducible cleaning and maintenance quality standard, significantly improving the stability of the long-term operation of the equipment and the guarantee level of product safety.

[0065] Refer to Figure 4 , the data traceability module 7 establishes the full-process data association of a single tank of product, which specifically includes the following steps:

[0066] B1. Collect the production process fingerprint: Collect the actual filling time and flow rate curve of each container at the filling station;

[0067] B2. Associate data with the container: Associate and store the actual filling time and flow rate curve with the unique identifier of the container and its final quality inspection result;

[0068] B3. Reverse traceability: When batch quality defects are found, reverse trace to the abnormal parameters during the filling process based on the associated data. By binding a unique production process fingerprint (filling time and flow rate curve) to each container and precisely associating it with the final quality result, the system for the first time establishes a clear causal chain from microscopic process fluctuations to macroscopic quality defects. When batch problems occur, it can instantly lock the abnormal process parameter period, achieving minute-level precise traceability from discovering unqualified products to locating the root cause production line and specific parameter abnormalities. This not only greatly accelerates the analysis and solution of quality problems, but also provides unprecedented data insight capabilities for process optimization and preventive maintenance through the continuously accumulated process big data.

[0069] In addition, refer to Figure 1The aforementioned data traceability module 7 is also equipped with an early warning unit 71. The early warning unit 71 is configured to perform trend analysis on the real-time collected filling parameters. If a key parameter is detected to continuously deviate from its set value but has not yet exceeded the acceptable range, a maintenance early warning signal is sent to the operator. Specifically, by comparing the deviation trends of real-time filling parameters with the standard parameter set, when a key parameter (such as quantitative delivery flow rate or airflow disturbance pressure) is within the warning range of ±5% of the standard value (not reaching the non-compliance threshold) for five consecutive times, a maintenance early warning signal is immediately sent to the central control module 2, triggering a touchscreen pop-up and audible / visual alarm, prompting the operator to check equipment components. Through real-time trend analysis of key filling parameters, the system can keenly identify potential signs of equipment performance degradation (such as slight wear of the metering pump or minor blockage of the airflow valve) and issue an early warning before these lead to actual quality defects. This allows maintenance personnel to perform precise preventative maintenance without interrupting production, effectively avoiding unplanned downtime and the generation of batches of non-conforming products, significantly improving the overall equipment efficiency (OEE) and the level of intelligent quality control of the production line.

[0070] The capping station of the post-processing quality inspection module 5 is equipped with a photoelectric material shortage detection sensor 51. This sensor is linked to the central control module 2: when three consecutive container positioning seats 14 are found to be without caps, the central control module 2 immediately suspends the capping station and uploads the material shortage information to the cloud platform, triggering a local audible and visual alarm (flashing red light + buzzer). Operation resumes only after manual cap replenishment and resetting. By setting a continuous cap shortage judgment logic (e.g., three consecutive stations), the system can accurately identify genuine upstream material supply interruptions, rather than accidental sensor false alarms. This allows for timely suspension of the station before a large number of capless semi-finished products are produced, simultaneously triggering local and remote alarms. This not only effectively prevents secondary contamination of containers and material waste after filling but also minimizes production interruption time and the urgency of manual intervention through automated process interruption and information reporting, significantly improving the continuous operation efficiency and intelligent management level of the production line.

[0071] The hot air drying equipment of the container pretreatment module 4 described above is equipped with a honeycomb-type flow equalization plate (2mm aperture) at the air outlet, ensuring that the fluctuation of the blown sterile hot air velocity is ≤0.2m / s. This equipment is linked with the vacuum suction component via a time-delay relay. Within 0.5 seconds after the vacuum suction component stops working, the hot air drying unit automatically starts, preventing water droplets from remaining on the inner wall of the container. Through the optimization of physical structure and the precise coordination of control timing, the high efficiency and high consistency of container drying are ensured. The flow equalization plate organizes the disordered airflow into a uniform and stable laminar flow, ensuring that the hot air impact and drying effect are consistent throughout the inner wall of the container, avoiding local under-drying or over-drying. The millisecond-level time delay linkage with the vacuum suction eliminates the time gap in the process connection, ensuring that drying begins before residual water droplets flow back or evaporate, thereby eliminating the formation of visible water stains at the source and providing a clean, dry, and uniform container environment for subsequent high-precision filling.

[0072] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit the scope of protection of the invention. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on these embodiments, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art can still combine, add, delete, or otherwise adjust the features of the various embodiments of the present invention according to the circumstances without conflict or creative effort, thereby obtaining different technical solutions that do not fundamentally depart from the concept of the present invention. These technical solutions also fall within the scope of protection of the present invention.

Claims

1. A multi-in-one rotary sauce filling system, characterized in that, The core architecture is as follows: The rotating flow module includes a servo motor, a rotating workbench, an annular conveying track and a container positioning seat, is used for rotating the rotating workbench at a constant speed through the servo motor, and sequentially flows the containers on the container positioning seat to each function station, and realizes accurate feeding and discharging of the containers through synchronous signals and linkage of the annular conveying track. The central control module includes a controller and a pre-stored sauce database, is used for performing preparation before filling, calling the sauce database according to identification information of the sauce to be filled, matching a corresponding filling parameter set, and the filling parameter set at least contains quantitative conveying flow, filling nozzle lifting height, airflow disturbance parameters and container clamping force; simultaneously receiving container specifications and positioning state information fed back by sensors on the container positioning seat, confirming that the container is ready, and triggering the subsequent process; The adaptive filling module is arranged at a filling station, and includes a filling head lifting mechanism, a quantitative conveying unit, an airflow disturbance unit and a scraping unit; the filling head lifting mechanism drives the filling nozzle to lift to a preset height in the container; the quantitative conveying unit conveys the sauce according to the matched filling parameter set; the airflow disturbance unit is integrated in the filling nozzle, and pulse airflow is sprayed out to break the sauce bubbles during filling; the scraping unit is arranged on the outer wall of the filling nozzle, and scrapes off the residual sauce on the outer wall of the filling nozzle when the filling nozzle rises; The container pretreatment module is arranged at a pretreatment station, and is used for performing high-pressure cleaning and hot air drying on the containers flowed to the station; The post-processing quality inspection module is arranged at a post-processing station, and is used for performing cap sealing, accurate labeling and quality detection on the containers after filling; The cleaning and maintenance module is used for starting a cleaning program for filling related components when a preset triggering condition is met, and the triggering condition at least includes switching of sauce types, cumulative filling amount reaching a standard and continuous running time reaching a standard; The data tracing module is used for collecting running parameters and quality data of each module in real time, establishing full-process data association of single-tank products, and realizing traceable management; The sauce database takes sauce viscosity as a key index parameter; The viscosity is divided into at least two intervals and matched with differentiated filling parameter sets: when the sauce viscosity is in a first interval of 100-5000 mPa・s, a first parameter set is matched, the quantitative conveying flow is 150-500 mL / min, and the airflow disturbance frequency is 10-30 Hz; when the sauce viscosity is in a second interval of 5000-10000 mPa・s, a second parameter set is matched, the quantitative conveying flow is 50-150 mL / min, and the airflow disturbance frequency is 30-50 Hz; The data tracing module establishes full-process data association of single-tank products, and specifically includes the following steps: Collecting actual filling time and flow rate curve of each container at the filling station; Storing the actual filling time and flow rate curve in association with the unique identifier of the container and the final quality detection result; When a batch quality defect is found, the associated data is used to trace back to abnormal parameters in the filling process.

2. A multi-in-one rotary sauce filling system as claimed in claim 1, wherein, The adaptive filling module further comprises a heat preservation storage unit, which comprises a jacketed storage tank and a temperature controller; the central control module is further configured to: when a high-viscosity sauce corresponding to the second parameter set is identified, the heat preservation storage unit is started to stabilize the sauce temperature within a preset viscosity optimization interval.

3. A multi-purpose rotary sauce filling system as defined in claim 1, wherein: The scraping unit is an elastic scraping ring made of food-grade silicone, with an inner diameter that is 0.1-0.3mm larger than the outer diameter of the filling nozzle; the scraping ring remains stationary through the lifting movement of the fixing part relative to the filling nozzle, thereby achieving scraping when the filling nozzle is lifted.

4. A multi-purpose rotary sauce filling system as defined in claim 1, wherein, The quality detection of the post-processing quality inspection module adopts double verification, which specifically includes: The pre-set weight sensor detects the net content of the product, and when the error exceeds the pre-set net content threshold, it is directly marked as unqualified; For products with qualified net content, the pre-set visual detection device is triggered to perform visual analysis of the label position and bottle cap tightness; Only when both double verifications pass, the product is allowed to flow to the unloading station.

5. A multi-purpose rotary sauce filling system as defined in claim 1, wherein, The cleaning program of the cleaning and maintenance module specifically includes: In the first stage, the self-adaptive filling module is flushed with a cleaning liquid suitable for the previous batch of sauce, with a flushing pressure of 1-1.5MPa and a duration of 30 seconds; In the second stage, the flushing is switched to sterile water, with a pressure of 0.8-1MPa and a duration of 30 seconds, and the flushing waste liquid is filtered and then recycled.

6. A multi-purpose rotary sauce filling system as defined in claim 1, wherein, The rotary transfer module further comprises a photoelectric encoder; the photoelectric encoder is used to detect the rotation angle position of the rotary workbench and send a synchronization pulse signal to the ring-shaped conveying track when a preset angle is reached, to achieve accurate positioning and synchronization of the containers during the transfer process.

7. A multi-purpose rotary sauce filling system as claimed in claim 1, wherein: The sauce database of the central control module has a parameter self-learning unit; the parameter self-learning unit is configured to: dynamically optimize the parameter matching logic according to the parameters corresponding to the best filling effect of different viscosity sauces in the historical production data; when the viscosity and solid content parameters of a new sauce are input, the system automatically generates and outputs a recommended parameter set based on the optimized logic.

8. A multi-purpose rotary sauce filling system as defined in claim 1, wherein: The data tracing module is further configured with a warning unit; the warning unit is configured to: perform trend analysis on the real-time collected filling parameters, and if it is detected that a key parameter continuously deviates from its set value but has not yet exceeded the qualified range, a maintenance warning signal is sent to the operator.

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