A bottled water filling control system and method

Abstract

The application provides a bottled water filling control system and method, and belongs to the technical field of filling control, and comprises a PLC main controller as a core control unit; the PLC main controller is installed in a central control room of a production line and is in communication connection with each actuating mechanism and sensor through a bus; a raw water pretreatment unit, a secondary reverse osmosis deionization purification unit, a blending unit and an ozone sterilization unit are sequentially arranged along the water flow direction, and a bottle cleaning and disinfecting unit, a filling unit and an auxiliary system are additionally arranged, and each unit forms a full-process closed-loop control architecture. The bottled water filling control system and method solve the problems of independent control of each process of a traditional production line, poor coordination, incomplete water purification, low filling precision, uncontrollable disinfection parameters and much manual intervention.

Description

Technical Field

[0001] This invention relates to the field of filling control technology, and in particular to a bottled water filling control system and method. Background Technology

[0002] In traditional bottled water production, each process, such as raw water pretreatment, water purification, mineral blending, sterilization, empty bottle cleaning, and quantitative filling, often operates independently, lacking an effective collaborative control mechanism. This production method results in incomplete water purification, poor water quality stability, low filling accuracy, and a tendency for overflows or underfilling. Furthermore, disinfection and purification parameters are difficult to control precisely, leading to wasted disinfectants or inadequate sterilization. In addition, traditional production lines rely heavily on manual intervention, resulting in high energy consumption, difficult troubleshooting, and hindering digital control and end-to-end quality traceability. As market demands for bottled water quality continue to rise, traditional production methods are no longer sufficient to meet the needs of large-scale, high-precision production. Summary of the Invention

[0003] The purpose of this invention is to provide a bottled water filling control system and method that solves the problems of independent control of each process in traditional production lines, poor coordination, incomplete water purification, low filling accuracy, uncontrollable disinfection parameters, and excessive manual intervention.

[0004] To achieve the above objectives, the present invention provides a bottled water filling control system, comprising: The raw water pretreatment unit includes a raw water tank, a booster pump, a multi-media filter, an activated carbon filter, and a security filter connected in sequence. The two-stage reverse osmosis deionization purification unit includes a security filter, a primary high-pressure pump, a primary RO membrane module, an intermediate water tank, a secondary high-pressure pump, a secondary RO membrane module, and a pure water tank. The mixing unit includes a mineral hopper, a metering pump, a mixing tank, and a mixer; The ozone sterilization unit includes an ozone generator, a gas-liquid mixing pump, and an ozone contact tank; The bottle cleaning and disinfection unit includes a bottle washing machine, which has a pre-rinsing area, a disinfectant spraying area, a sterile water rinsing area, and a hot air drying area. The filling unit includes a filling buffer tank, a servo filling valve, a weighing sensor, and a capping machine; The auxiliary system includes a sensor array, an alarm module, a CIP online cleaning module, and a concentrate recovery module; The PLC main controller communicates with the raw water pretreatment unit, the secondary reverse osmosis deionization purification unit, the blending unit, the ozone sterilization unit, the bottle cleaning and disinfection unit, the filling unit, and the auxiliary unit via a bus.

[0005] Preferably, each equipment in the raw water pretreatment unit is equipped with a pressure sensor and a flow sensor at its inlet and outlet to collect pressure and flow data at the equipment inlet and outlet in real time and transmit them to the PLC main controller for monitoring and adjustment.

[0006] Preferably, in the two-stage reverse osmosis deionization purification unit, the intermediate water tank is equipped with a pH adjustment device, and pressure sensors, flow sensors, and conductivity sensors are installed at the inlet and outlet of each stage of the RO membrane module, all of which are connected to the PLC main controller.

[0007] Preferably, the mixing tank is equipped with a stirrer, a temperature sensor, and a concentration sensor. The stirrer adopts a frequency conversion control method, and the temperature sensor, concentration sensor, stirrer, and quantitative feeding pump are all connected to the PLC main controller.

[0008] Preferably, in the ozone sterilization unit, the ozone contact tank is equipped with an ozone concentration sensor and a liquid level sensor, and the ozone generator, gas-liquid mixing pump, and ozone concentration sensor are all connected to the PLC main controller.

[0009] Preferably, in the bottle cleaning and disinfection unit, a photoelectric sensor is installed at the outlet of the bottle washing machine to detect the integrity of empty bottles and the cleaning effect, and unqualified bottles are automatically rejected; the disinfectant spraying device, the sterile water rinsing device, and the hot air drying device are all controlled by a PLC main controller.

[0010] Preferably, in the filling unit, the filling buffer tank is equipped with a level sensor and a pressure sensor, the electromagnetic flow meter is installed on the outlet pipe of the filling buffer tank, the servo filling valve is controlled by a servo motor, the weighing sensor is installed under the bottle holder of the filling machine, and all data are fed back to the PLC main controller for real-time adjustment and control.

[0011] Preferably, in the auxiliary system, the sensor group includes a temperature sensor, a pressure sensor, and a pH sensor, arranged in each unit to monitor the water temperature, pipeline pressure, and water pH value in each unit in real time; the alarm module is installed in the central control room and each production area to monitor production parameters in real time and issue an alarm signal when the parameters are abnormal; the CIP online cleaning module consists of a cleaning fluid storage tank, a cleaning pump, and cleaning pipelines, and can perform online cleaning of each piece of equipment and pipelines; the concentrate recovery module is connected to the concentrate end of the primary and secondary RO membrane modules, with some concentrate flowing back to the raw water tank, and the remaining concentrate being treated to meet standards before being discharged.

[0012] A method for controlling the filling of bottled water includes the following steps: Raw water is stored in a raw water tank and then pressurized by a booster pump before entering a multi-media filter, activated carbon filter, and security filter in sequence to remove large particulate impurities, organic matter, odors, and residual chlorine. The pretreated raw water is pressurized by a first-stage high-pressure pump and enters the first-stage RO membrane module for preliminary desalination. The permeate enters the intermediate water tank, and the concentrate is partially recycled. The intermediate water tank maintains the water quality through a pH adjustment device. The second-stage high-pressure pump pressurizes the water and sends it to the second-stage RO membrane module for deep desalination to obtain high-purity pure water. According to the preset formula, the PLC controller controls the quantitative feeding device and quantitative feeding pump of the mineral hopper to accurately add minerals to the mixing tank, and the agitator uses frequency conversion control to ensure that the minerals and pure water are fully mixed. The PLC controller calculates the ozone dosage based on the filling flow rate, controls the ozone generator to produce high-purity ozone, and mixes it thoroughly with the prepared water through a gas-liquid mixing pump. The mixed water then enters the ozone contact tank for sterilization. Empty bottles enter the bottle washing machine via conveyor belt and pass through the pre-rinsing, disinfectant spraying, sterile water rinsing and hot air drying zone in sequence. Photoelectric sensors on the bottle body detect the integrity of the empty bottle and the cleaning effect, and unqualified bottles are automatically rejected. Qualified empty bottles are sent to the filling machine. The weighing sensor detects the weight of the empty bottle. The PLC controller calculates the target filling weight according to the preset nominal volume and controls the servo filling valve to open for filling. The electromagnetic flow meter and the weighing sensor monitor the filling flow and weight in real time to complete accurate filling. When the production line reaches the preset cleaning cycle or when contamination occurs, the PLC automatically starts the CIP online cleaning program. The cleaning fluid circulates to clean each piece of equipment and pipeline in a preset sequence, and the conductivity sensor and pH sensor monitor the cleaning endpoint.

[0013] Therefore, the present invention employs the above-described bottled water filling control system and method, and the technical effects are as follows: 1. Achieve standardized management and control throughout the entire process: A closed-loop control architecture is built with the PLC main controller as the core. The units such as raw water pretreatment, secondary reverse osmosis purification, mineral blending, ozone sterilization, bottle cleaning and disinfection, and quantitative filling are linked through bus communication. The operating parameters of each device and sensor are communicated in real time and uniformly adjusted by the main controller, so as to achieve seamless connection of processes from raw water to finished bottled water.

[0014] 2. Enhanced Production Automation: The system achieves fully automated operation throughout the entire process, from raw water replenishment, equipment start-up and shutdown, parameter adjustment, to automatic rejection of unqualified empty bottles, precise filling control, and CIP online cleaning. All of these are automatically completed by the PLC main controller based on sensor data, significantly reducing manual intervention. At the same time, the filling machine and capping machine are linked, and each unit flows seamlessly through the conveyor belt, achieving continuous production and effectively improving the overall operating efficiency of the production line, adapting to the needs of large-scale production. Attached Figure Description

[0015] Figure 1This is a process flow diagram of a bottled water filling control system according to the present invention; Figure 2 This is a flowchart of a bottled water filling control method according to the present invention. Detailed Implementation

[0016] The technical solution of the present invention will be further described below with reference to the accompanying drawings and embodiments.

[0017] Unless otherwise defined, the technical or scientific terms used in this invention shall have the ordinary meaning as understood by one of ordinary skill in the art to which this invention pertains.

[0018] Example 1 like Figure 1 As shown, this invention provides a bottled water filling control system, including a raw water pretreatment unit, a two-stage reverse osmosis deionization purification unit, a blending unit, an ozone sterilization unit, a bottle cleaning and disinfection unit, a filling unit, and an auxiliary system. This system uses a PLC main controller as the core control unit, installed in the central control room of the production line. It establishes communication connections with various actuators and sensors via a bus to achieve full-process data acquisition, command issuance, and closed-loop regulation. The system sequentially constructs multiple functional units along the water flow direction, forming a full-process closed-loop control architecture.

[0019] The PLC main controller is installed on the control panel in the central control room. It is a high-performance programmable logic controller with built-in control algorithms and recipe management modules. It is responsible for receiving real-time data collected by various sensors and issuing action commands to various actuators according to preset parameters and control logic to achieve full-process automated control. At the same time, it is connected to a touch screen host computer for parameter setting, real-time monitoring, data query and fault alarm. It supports historical data storage and traceability, providing data support for production optimization.

[0020] The raw water pretreatment unit is located at the very beginning of the production line, at the raw water inlet. It includes a raw water tank, whose outlet is connected to the inlet of a booster pump via a pipe. The booster pump's outlet is then connected to the inlet of a multi-media filter. The multi-media filter's outlet connects to the inlet of an activated carbon filter, which in turn connects to the inlet of a security filter. The security filter's outlet connects to a secondary reverse osmosis deionization purification unit, thus forming a complete raw water pretreatment production line.

[0021] The raw water tank, as the starting device of the raw water pretreatment unit, primarily stores raw water. Its volume is designed specifically for production scale and is equipped with a level sensor. This sensor monitors the liquid level in the raw water tank in real time, providing level information for the operation of subsequent equipment. A booster pump is installed on the outlet pipe of the raw water tank. Its function is to increase the pressure of the raw water flowing out of the tank, thereby ensuring the stable operation of subsequent filtration stages and preventing poor filtration or failure to filter properly due to insufficient raw water pressure. A multi-media filter is located immediately after the booster pump. It is filled with filter media such as quartz sand and anthracite. When raw water flows into the multi-media filter, these filter media effectively remove suspended solids, silt, colloids, and other large particulate impurities, providing initial purification of the raw water. An activated carbon filter is arranged adjacent to the multi-media filter. Raw water flows directly into the activated carbon filter after exiting the multi-media filter. The activated carbon filter utilizes the adsorption properties of activated carbon to adsorb organic matter, odors, residual chlorine, and some heavy metal ions in the raw water, further improving the water quality. The security filter is installed at the outlet of the activated carbon filter, with a filtration accuracy of 5μm. As a pre-filter for the subsequent reverse osmosis system, the security filter removes residual micro-impurities in the raw water, preventing these impurities from entering the reverse osmosis system and causing RO membrane blockage, thereby ensuring the normal operation of the reverse osmosis system.

[0022] All equipment in the raw water pretreatment unit is equipped with pressure and flow sensors at its inlet and outlet. These sensors can collect pressure and flow data at the equipment inlet and outlet in real time and transmit these data signals to the PLC main controller. Based on the received signals, the PLC main controller monitors and adjusts the raw water pretreatment process in real time to ensure that the pretreatment process is always in a stable and efficient state, providing qualified pretreated water for subsequent water treatment stages.

[0023] The secondary reverse osmosis deionization purification unit includes a security filter. The outlet of the security filter is connected to the inlet of the primary high-pressure pump via a pipe. The outlet of the primary high-pressure pump is connected to the inlet of the primary RO membrane module. The product water end of the primary RO membrane module is connected to the inlet of the intermediate water tank, and its concentrate end is connected to a concentrate recovery pipe. Part of the concentrate can be returned to the raw water tank, thereby improving water resource utilization. The outlet of the intermediate water tank is connected to the inlet of the secondary high-pressure pump, and the outlet of the secondary high-pressure pump is connected to the inlet of the secondary RO membrane module. The product water end of the secondary RO membrane module is connected to the inlet of the pure water tank. Its concentrate is combined with the concentrate from the primary RO membrane module and discharged or recycled as needed.

[0024] The primary high-pressure pump is installed above the outlet pipe of the security filter. Its core function is to provide the high-pressure environment required for the operation of the primary RO membrane module, ensuring that the primary RO membrane module can perform its purification function normally. The primary RO membrane module, as the core purification component of this purification unit, adopts a spiral wound reverse osmosis membrane structure. When raw water enters the primary RO membrane module under the pressure provided by the primary high-pressure pump, it achieves preliminary desalination treatment, effectively removing dissolved solids and purifying the water initially. The intermediate water tank stores the water produced by the primary RO membrane module. This tank is equipped with a level sensor to monitor the water level in real time, and also has a pH adjustment device to regulate the pH value of the water in the tank, thereby stabilizing the influent water quality of the secondary RO membrane module and ensuring subsequent deep purification. The secondary high-pressure pump is installed at the outlet of the intermediate water tank. Its function is to provide high-pressure power to the secondary RO membrane module, and the pressure it provides is higher than that of the primary high-pressure pump, to meet the pressure requirements of the secondary RO membrane module for deep purification. The secondary RO membrane module uses a high-precision reverse osmosis membrane, which further achieves deep desalination and deionization treatment on the basis of the preliminary purification of the primary RO membrane module, significantly improving the purity of the water and enabling the produced water to reach a higher purity standard. The pure water tank is used to store the pure water produced by the secondary RO membrane module. This tank is equipped with a conductivity sensor and a level sensor. The conductivity sensor can monitor the conductivity of the produced water in real time, thus reflecting the water quality; the level sensor can monitor the liquid level in the tank in real time, providing information on the quantity of produced water.

[0025] The pH adjustment device in the intermediate water tank, and the pressure sensors, flow sensors, and conductivity sensors installed at the inlet and outlet of each stage of the RO membrane module, are all connected to the PLC main controller. Based on the signals fed back from these sensors, the PLC main controller monitors and precisely adjusts various parameters in the purification process in real time, realizing closed-loop control of purification parameters. This ensures the stable and efficient operation of the entire two-stage reverse osmosis deionization purification unit, producing high-quality pure water that meets the requirements.

[0026] The blending unit is located behind and closely adjacent to the pure water tank. The blending unit includes a mineral hopper, a metering pump, a blending tank, and a stirrer. The outlet of the pure water tank is connected to the inlet of the blending tank via a pipe, allowing pure water from the tank to flow smoothly into the blending tank. The discharge port of the mineral hopper is connected to the inlet of the metering pump, and the outlet of the metering pump is connected to the top inlet of the blending tank, forming a transport path for the mineral raw materials. The outlet of the blending tank is connected to the ozone sterilization unit, providing the blended water for subsequent sterilization treatment.

[0027] The mineral hopper, used in the mixing unit to store mineral raw materials such as magnesium sulfate and potassium chloride, is equipped with a metering device that precisely controls the amount of mineral raw materials fed, providing a fundamental guarantee for subsequent accurate mixing. A metering pump is installed below the mineral hopper, with its inlet connected to the hopper's outlet and its outlet connected to the top inlet of the mixing tank. The main function of the metering pump is to establish a precise delivery channel between the mineral hopper and the mixing tank, delivering the mineral raw materials from the hopper to the mixing tank in a preset, precise quantity. The mixing tank is the core equipment of the mixing unit, capable of uniformly mixing minerals and pure water. It is equipped with a stirrer, a temperature sensor, and a concentration sensor. The stirrer, installed at the top of the mixing tank, uses frequency conversion control, allowing for flexible adjustment of the stirring speed according to actual needs to ensure thorough and uniform mixing of minerals and pure water. The temperature sensor monitors the temperature of the mixture in the mixing tank in real time, while the concentration sensor monitors the concentration of minerals in the mixture in real time. The agitator is installed on top of the mixing tank and, through frequency conversion control technology, can precisely adjust its stirring speed according to different mixing requirements. During the mixing process, an appropriate speed ensures sufficient contact between the minerals and pure water, achieving uniform mixing and avoiding localized excessively high or low concentrations. In terms of connections, the outlet of the pure water tank is connected to the inlet of the mixing tank via a pipe, allowing pure water from the tank to flow smoothly into the mixing tank. The discharge port of the mineral hopper is connected to the inlet of the metering pump, and the outlet of the metering pump is connected to the top inlet of the mixing tank, forming a conveying path for the mineral raw materials. The outlet of the mixing tank is connected to the ozone sterilization unit, providing the prepared water for subsequent sterilization treatment.

[0028] The temperature sensor, concentration sensor, stirrer, and metering pump inside the mixing tank are all connected to the PLC main controller. Based on real-time data from the temperature and concentration sensors, the PLC main controller precisely controls the stirring speed of the stirrer and the feeding amount of the metering pump, thereby achieving accurate formulation and effective control of mixing uniformity, ensuring that the mixed water meets the predetermined quality standards.

[0029] The ozone sterilization unit is located after the mixing unit and before the filling unit. It includes an ozone generator, a gas-liquid mixing pump, and an ozone contact tank. The outlet of the mixing tank is connected to the inlet of the gas-liquid mixing pump via a pipe, allowing the mixed water to flow smoothly into the pump. The ozone outlet of the ozone generator is connected to the inlet of the gas-liquid mixing pump via a pipe, delivering the generated ozone to the pump. The outlet of the gas-liquid mixing pump is connected to the inlet of the ozone contact tank via a pipe, allowing the mixed ozone and water solution to enter the ozone contact tank. The outlet of the ozone contact tank is connected to the filling buffer tank via a pipe, providing sterilized water for subsequent filling processes.

[0030] An ozone generator, installed within the sterilization zone, is a high-frequency discharge type. This generator produces high-purity ozone through high-frequency discharge, providing a sufficient ozone source for the subsequent sterilization process. A gas-liquid mixing pump is installed between the ozone generator and the ozone contact tank. Its function is to thoroughly mix the ozone generated by the generator with the prepared water flowing from the mixing tank. Through a reasonable pump structure and operation, the utilization rate of ozone in the water is improved, ensuring that the ozone can effectively contact harmful substances such as microorganisms in the water. The ozone contact tank is used to hold the ozone-water mixture after being mixed by the gas-liquid mixing pump. This contact tank ensures sufficient sterilization contact time between the ozone and water, allowing the ozone to fully exert its sterilization effect. Simultaneously, the ozone contact tank is equipped with an ozone concentration sensor and a liquid level sensor. The ozone concentration sensor monitors the ozone concentration in the tank in real time, and the liquid level sensor monitors the liquid level in the tank in real time, providing data support for the control of the sterilization process. The ozone concentration sensor is installed at the inlet and outlet of the ozone contact tank. Its function is to monitor the ozone concentration at the inlet and outlet of the contact tank in real time. By comparing the ozone concentration at the inlet and outlet, the consumption of ozone during the sterilization process can be understood, providing a basis for adjusting the ozone dosage.

[0031] The ozone generator, gas-liquid mixing pump, and ozone concentration sensor are all connected to the PLC main controller. Based on the data fed back from the ozone concentration sensor, the PLC main controller precisely controls the ozone production of the ozone generator and the operating parameters of the gas-liquid mixing pump, thereby achieving precise regulation of ozone dosage and contact time, ensuring a good sterilization effect throughout the entire sterilization process, and protecting water quality safety.

[0032] The bottle washing and disinfection unit is located to the left of the filling unit and is connected to the filling unit via a conveyor belt. Empty bottles are fed into the inlet of the bottle washing machine via the feeding conveyor belt. After a series of washing, disinfection, and drying processes, the bottles are connected from the outlet of the bottle washing machine to the inlet of the filling machine via a sterile conveyor belt, realizing a smooth flow of empty bottles from washing and disinfection to filling.

[0033] The bottle washer employs a tunnel-type structure, with empty bottles sequentially passing through various functional areas along a conveyor belt. These areas are arranged sequentially along the conveyor belt as a pre-rinsing zone, a disinfectant spray zone, a sterile water rinsing zone, and a hot air drying zone. The pre-rinsing zone performs a preliminary rinse to remove larger impurities; the disinfectant spray zone provides deep disinfection; the sterile water rinsing zone removes any residual disinfectant; and the hot air drying zone thoroughly dries the inner walls of the bottles. A disinfectant spray device is installed in the disinfectant spray zone of the bottle washer. This device sprays chlorine dioxide or peracetic acid disinfectant, ensuring even coverage of the bottle's inner wall for effective disinfection and killing any microorganisms that may be present. A sterile water rinsing device is installed behind the disinfectant spray zone. After the empty bottles are sprayed with disinfectant, a sterile water rinsing device sprays sterile water to thoroughly rinse away any residual disinfectant, preventing it from adversely affecting the quality of the filling water. A hot air drying device is installed at the end of the bottle washing machine. This device uses high-temperature hot air to dry the empty bottles after sterile water rinsing, quickly removing moisture from the inner walls of the bottles and preventing residual moisture from affecting the quality of the filling water. This ensures the empty bottles are dry and clean, ready for the subsequent filling process. A photoelectric sensor is installed at the outlet of the bottle washing machine. Its function is to detect the cleaned and disinfected empty bottles, determining whether they are clean enough and whether there is any damage. If a non-compliant bottle is detected, the system will automatically reject it, ensuring that all empty bottles entering the filling process meet quality requirements.

[0034] The disinfectant spraying device, sterile water rinsing device, and hot air drying device are all controlled by a PLC main controller. The photoelectric sensors on the bottles transmit the detected signals to the PLC main controller in real time. Based on these signals, the PLC main controller automatically rejects unqualified bottles and adjusts the cleaning parameters in real time according to actual conditions, ensuring a stable, efficient, and reliable bottle cleaning and disinfection process, and guaranteeing the quality of empty bottle cleaning and disinfection.

[0035] The filling unit is located in the middle of the production line, between the bottle washing machine and the capping machine. It includes a filling buffer tank. The outlet of the ozone contact tank is connected to the inlet of the filling buffer tank via a pipe, allowing sterilized water to flow smoothly into the buffer tank for storage and pressure stabilization. The outlet of the filling buffer tank is connected to each servo filling valve via a pipe, providing them with water for filling. The servo filling valves are installed below the filling head of the filling machine and operate synchronously with the conveyor belt, ensuring accurate filling of bottles during transport. Weighing sensors are installed on the bottle holder below the filling head, collecting real-time weight data of the filled bottles and feeding this data back to the PLC main controller. The PLC main controller processes and analyzes the received data, adjusting and controlling the filling process in real time. The filling machine's outlet is connected to the capping machine via a conveyor belt. The capping machine's operation is linked to the filling machine and uniformly controlled by the PLC, enabling continuous filling and capping operations and improving the automation and production efficiency of the entire production line.

[0036] A filling buffer tank is used to store water that has undergone ozone sterilization. This buffer tank has the function of stabilizing filling pressure to ensure the stability and consistency of the filling process. Simultaneously, the filling buffer tank is equipped with a level sensor and a pressure sensor. The level sensor monitors the water level in the tank in real time, while the pressure sensor monitors the pressure in the tank in real time, providing crucial data support for subsequent filling operations. An electromagnetic flow meter is installed on the outlet pipe of the filling buffer tank. Its function is to monitor the flow rate of water flowing out of the filling buffer tank in real time. Through precise flow monitoring, accurate flow data can be provided for subsequent filling volume control, ensuring the accuracy of the filling volume. A servo filling valve is installed at the filling head of the filling machine. This servo filling valve is controlled by a servo motor, which can perform precise flow control operations according to preset instructions, thereby accurately controlling the water volume for each filling and ensuring that the filling volume in each bottle meets the standard requirements. A weighing sensor is installed under the bottle holder of the filling machine. After the bottles are filled, the weighing sensor detects the weight of the bottles in real time and feeds the weight data back to the control system. By comparing the actual weight with the standard weight, filling accuracy can be verified, and potential filling errors can be detected and corrected in a timely manner. The capping machine is located adjacent to the outlet of the filling machine. Its function is to cap and seal the filled bottles to prevent water leakage or external contamination. The capping machine and the filling machine operate in conjunction, ensuring a seamless connection between the filling and capping processes and improving production efficiency.

[0037] The CIP (Clean-In-Place) online cleaning module consists of a cleaning fluid storage tank, a cleaning pump, and cleaning pipelines. The cleaning fluid storage tank stores various cleaning fluids, providing ample cleaning medium for the cleaning process. The cleaning pump draws the cleaning fluid from the storage tank and applies pressure to ensure smooth flow through the pipelines. The cleaning pipelines have multiple branches, connecting to key equipment such as the pretreatment unit, secondary RO membrane module, mixing tank, ozone contact tank, filling buffer tank, and filling valves. This connection method allows the CIP online cleaning module to perform online cleaning of various equipment and pipelines without disassembling the equipment, effectively reducing the risk of contamination that may be introduced during disassembly, while improving cleaning efficiency and ensuring the cleanliness and hygiene of production equipment.

[0038] In addition to the sensors already mentioned in the aforementioned units, the sensor group also includes temperature sensors, pressure sensors, and pH sensors. Temperature sensors are arranged in each unit to monitor the water temperature in real time, ensuring it remains within the suitable production range and preventing abnormal temperatures from affecting product quality or equipment performance. Pressure sensors are installed on each pipeline to monitor the pressure in real time, promptly detecting abnormal pressure and preventing accidents such as pipeline rupture or equipment damage due to excessively high or low pressure. pH sensors are mainly used to monitor the pH value of the water in the intermediate water tank and mixing tank, ensuring the acidity or alkalinity of the water meets production requirements, thereby ensuring product quality stability. All these sensors are connected to the PLC main controller, enabling real-time acquisition of parameters throughout the entire process and providing data support for precise control of the production process.

[0039] Alarm modules are installed in the central control room and various production areas. These modules monitor production parameters in real time. When a parameter exceeds a preset threshold, such as excessive conductivity of the produced water or insufficient ozone concentration, the alarm module automatically issues an audible and visual alarm to alert staff. Simultaneously, the alarm module displays the specific location and cause of the fault on the touchscreen computer, allowing staff to quickly pinpoint the problem and take appropriate measures to resolve it promptly, ensuring normal production operations.

[0040] The concentrate recovery module is connected to the concentrate end of the primary and secondary RO membrane modules. Its working principle is to return a portion of the concentrate to the raw water tank, effectively improving water resource utilization and reducing waste. The remaining concentrate is treated to ensure it meets national emission standards before being discharged, thus reducing environmental pollution and achieving environmentally friendly and sustainable production processes.

[0041] like Figure 2As shown, this control method uses a PLC main controller as its core and automates each step of the process, including pretreatment, purification, blending, sterilization, bottle washing, filling, online cleaning, and protection. The steps include: Raw water is first injected into the raw water tank, where a level sensor monitors the water level and automatically replenishes or stops the inflow. Subsequently, the raw water is pressurized by a booster pump and then sequentially enters a multi-media filter, an activated carbon filter, and a security filter to remove large particles, organic matter, odors, and residual chlorine. Each filter inlet and outlet is equipped with a pressure sensor; when the pressure difference is too large, the PLC controller initiates a backwashing procedure to ensure filtration effectiveness. Finally, a turbidity sensor ensures that the effluent turbidity meets standards, preventing substandard water from entering subsequent units.

[0042] The expression for filter backwash intensity is: ; in, Backwash intensity (L / (m)) 2 (·s)), excessive backwashing intensity can damage the filter media, while insufficient intensity will not thoroughly clean the filter media; The backwash flow rate (L / s) is controlled by the frequency regulation of the backwash pump. Filter area (m²) 2 The backwash flow rate is determined based on the filter specifications. This formula is used to calculate the backwash flow rate, and the PLC controls the backwash pump frequency to ensure effective backwashing and extend the filter media's lifespan.

[0043] The expression for the turbidity threshold of pretreated effluent is: ; This threshold is the feed water requirement for subsequent reverse osmosis purification. When the turbidity exceeds the standard, the system will be shut down to prevent the RO membrane from being damaged by impurities and to ensure the stable operation of the purification unit.

[0044] Pretreated raw water is pressurized by a primary high-pressure pump and enters the primary RO membrane module for initial desalination. The permeate enters an intermediate water tank, while the concentrate is partially recycled. The intermediate water tank maintains the water quality within the optimal desalination pH range through a pH adjustment device. Subsequently, a secondary high-pressure pump pressurizes the water and sends it to the secondary RO membrane module for deep desalination, yielding high-purity water. The PLC controller, based on conductivity and flow sensor data, adjusts the concentrate valve opening to achieve closed-loop control of the recovery rate, ensuring that both desalination and recovery rates meet standards.

[0045] The formula for calculating the desalination rate is: ; in, The conductivity of the RO membrane feed water is expressed in μS / cm. The conductivity of the RO membrane permeate (μS / cm) is specified. The desalination rate of the first-stage RO membrane is controlled at ≥95%, the desalination rate of the second-stage RO membrane is controlled at ≥99%, and the overall desalination rate is ≥99.75%.

[0046] The formula for calculating the system recovery rate is: ; in, This represents the total permeate flow rate of the RO system (L / h). The total concentrate flow rate of the RO system is (L / h). The system recovery rate is controlled within the range of 75% to 85%. The recovery rate is adjusted by changing the concentrate flow rate by adjusting the opening of the concentrate valve.

[0047] The pH of the feed water for the secondary RO system is set to 8.2~8.6. This range is the optimal desalination pH value for the secondary RO membrane, which can effectively improve the membrane's retention efficiency of dissolved solids, reduce scaling on the membrane surface, reduce membrane wear, and ensure the long-term stable operation of the secondary RO membrane.

[0048] According to the preset formula, the PLC controller controls the quantitative feeding device and quantitative pump of the mineral hopper to accurately add minerals to the mixing tank. At the same time, the pure water tank fills the mixing tank with water according to the preset volume, and the water level sensor monitors the water level. The stirrer uses frequency conversion control to ensure that the minerals and pure water are fully mixed, and the concentration sensor monitors and adjusts the mixing uniformity in real time until the target concentration is achieved.

[0049] The formula for calculating the amount of minerals added is: ; in, Add mass (g) to minerals. The target mineral concentration (ppm) is determined based on the finished water formulation. The mixing volume (L) is determined based on the mixing tank specifications and production batch size.

[0050] The expression for determining the uniformity of mixing is: ; in, To determine the maximum deviation rate of mineral concentration at multiple points within the tank.

[0051] The PLC controller calculates the ozone dosage based on the filling flow rate, controls the ozone generator to produce high-purity ozone, and thoroughly mixes it with the prepared water via a gas-liquid mixing pump. The mixed water enters the ozone contact tank, ensuring sufficient contact time to kill microorganisms. An ozone concentration sensor monitors the concentration in real time, and the PLC achieves closed-loop control of the CT value by adjusting the ozone generator output, ensuring sterilization effectiveness and preventing ozone residue from exceeding the standard.

[0052] The formula for calculating the output of an ozone generator is: ; in, Ozone generator output (g / h) The water flow rate (L / h) entering the ozone sterilization unit. The ozone dosage (mg / L) is determined based on the microbial indicators of the finished water, and is usually 0.5~1.0 mg / L.

[0053] The formula for calculating the sterilization CT value is: ; in, This refers to the ozone concentration (mg / L) inside the ozone contact tank. The contact time (in minutes) is the time the water remains in the contact tank. The residual ozone concentration in the water is 0.3~0.5 mg / L. The CT value is the core indicator for ozone sterilization. It replaces the traditional extensive ozone addition control. Through closed-loop adjustment of the CT value, it ensures thorough sterilization (100% microbial compliance rate) while avoiding excessive ozone residue, thus guaranteeing drinking safety.

[0054] Empty bottles enter the bottle washing machine via conveyor belt, passing through pre-rinsing, disinfectant spraying, sterile water rinsing, and hot air drying zones in sequence. Photoelectric sensors on the bottles detect their integrity and cleaning effectiveness; defective bottles are automatically rejected. A PLC controller precisely controls the rinsing time, disinfectant concentration, and drying temperature in each zone to ensure the empty bottles are sterile and free of residual moisture.

[0055] The disinfectant concentration should be controlled between 150 and 250 ppm. This effectively kills microorganisms on the inner wall of the empty bottle without causing disinfectant residue due to excessive concentration, and also avoids corroding the empty bottle. The rinsing water flow rate must be greater than twice the actual production flow rate of the production line to ensure sufficient rinsing water flow to thoroughly rinse away any residual disinfectant in the bottle, preventing disinfectant residue from contaminating the finished water.

[0056] Qualified empty bottles are sent to the filling machine, where a weighing sensor detects their weight. The PLC controller calculates the target filling weight based on the preset nominal volume and controls the servo filling valve to open for filling. An electromagnetic flowmeter monitors the filling flow rate in real time and integrates to calculate the volume, while the weighing sensor monitors the weight after filling. When both volume and weight meet the target, the servo filling valve closes, completing precise filling. If there are no bottles or the bottles are tilted, a photoelectric sensor detects this and prevents misfilling.

[0057] Flow data is collected in real time by an electromagnetic flowmeter, and the PLC performs integral calculations on the flow to obtain the actual filling volume. ; in, This represents the actual filling volume (L). This represents the real-time filling flow rate (L / s). The filling time is in seconds.

[0058] The PLC calculates the actual filling weight by subtracting the empty weight from the full-load weight detected by the weighing sensor. This weight is then compared with the target weight calculated using the gravimetric calibration formula to achieve closed-loop weight calibration. If the deviation exceeds the range, the filling parameters are automatically adjusted to ensure that the filling accuracy is better than ±0.5%.

[0059] The expression for the weight method verification is: ; in, This refers to the weight (kg) of the water after bottling. The density of water (kg / L) at room temperature; Nominal volume (L).

[0060] When the production line reaches the preset cleaning cycle or contamination occurs, the PLC automatically starts the CIP online cleaning program. The cleaning solution circulates to clean each piece of equipment and pipeline in a preset sequence, and conductivity and pH sensors monitor the cleaning endpoint. A full-process interlock protection mechanism automatically alarms and shuts down the system in case of abnormal parameters or equipment failure, preventing the fault from escalating. All fault information and processing records are stored for traceability and analysis.

[0061] The expression for determining the end point of the cleaning process is: , ; Ensure that cleaning fluid residue in equipment and pipelines is completely removed to prevent cleaning fluid from contaminating the finished product water in subsequent production, and also to prevent residual cleaning fluid from corroding the equipment.

[0062] The overall operation of the above control system is referred to as: After impurities are removed by the pretreatment unit, the raw water enters the secondary reverse osmosis deionization purification unit for deep purification to obtain high-purity pure water. The pure water enters the blending unit, where minerals are added quantitatively according to the preset formula. After being stirred evenly, it forms the finished water. The finished water enters the ozone sterilization unit, where it is fully sterilized by ozone and then stored in the filling buffer tank. At the same time, the empty bottles are cleaned, disinfected, and dried by the bottle washing machine, and then sent to the filling machine by the conveyor belt. The servo filling valve accurately fills the bottles, and after passing the weighing sensor verification, the bottles are sent to the capping machine to complete the capping. The operating parameters of all units are collected, analyzed, and controlled by the PLC main controller, and human-machine interaction is realized through the touch screen host computer.

[0063] Therefore, this invention employs the aforementioned bottled water filling control system and method, integrating multiple functional units such as raw water pretreatment, two-stage reverse osmosis deionization purification, mineral blending, ozone sterilization, empty bottle cleaning and disinfection, and quantitative filling, to achieve fully automated closed-loop control from raw material input to finished product output. The system utilizes a high-performance PLC main controller to uniformly collect, analyze, and control the operating parameters of each unit, ensuring the stability, continuity, and efficiency of the production process. Simultaneously, it achieves human-machine interaction through a touchscreen host computer, improving the convenience and intelligence level of production management.

[0064] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the technical solutions of the present invention, and these modifications or equivalent substitutions cannot cause the modified technical solutions to deviate from the spirit and scope of the technical solutions of the present invention.

Claims

1. A bottled water filling control system, characterized in that, include: The raw water pretreatment unit includes a raw water tank, a booster pump, a multi-media filter, an activated carbon filter, and a security filter connected in sequence. The two-stage reverse osmosis deionization purification unit includes a security filter, a primary high-pressure pump, a primary RO membrane module, an intermediate water tank, a secondary high-pressure pump, a secondary RO membrane module, and a pure water tank. The mixing unit includes a mineral hopper, a metering pump, a mixing tank, and a mixer; The ozone sterilization unit includes an ozone generator, a gas-liquid mixing pump, and an ozone contact tank; The bottle cleaning and disinfection unit includes a bottle washing machine, which has a pre-rinsing area, a disinfectant spraying area, a sterile water rinsing area, and a hot air drying area. The filling unit includes a filling buffer tank, a servo filling valve, a weighing sensor, and a capping machine; The auxiliary system includes a sensor array, an alarm module, a CIP online cleaning module, and a concentrate recovery module; The PLC main controller communicates with the raw water pretreatment unit, the secondary reverse osmosis deionization purification unit, the blending unit, the ozone sterilization unit, the bottle cleaning and disinfection unit, the filling unit, and the auxiliary unit via a bus.

2. The bottled water filling control system according to claim 1, characterized in that, Pressure sensors and flow sensors are installed at the inlet and outlet of each piece of equipment in the raw water pretreatment unit to collect pressure and flow data at the inlet and outlet of the equipment in real time and transmit them to the PLC main controller for monitoring and adjustment.

3. The bottled water filling control system according to claim 1, characterized in that, In the two-stage reverse osmosis deionization purification unit, the intermediate water tank is equipped with a pH adjustment device, and pressure sensors, flow sensors, and conductivity sensors are installed at the inlet and outlet of each stage of the RO membrane module, all of which are connected to the PLC main controller.

4. The bottled water filling control system according to claim 1, characterized in that, The mixing tank is equipped with a stirrer, a temperature sensor, and a concentration sensor. The stirrer is controlled by a frequency converter. The temperature sensor, concentration sensor, stirrer, and quantitative feed pump are all connected to the PLC main controller.

5. A bottled water filling control system according to claim 1, characterized in that, In the ozone sterilization unit, the ozone contact tank is equipped with an ozone concentration sensor and a liquid level sensor. The ozone generator, gas-liquid mixing pump, and ozone concentration sensor are all connected to the PLC main controller.

6. A bottled water filling control system according to claim 1, characterized in that, In the bottle cleaning and disinfection unit, a photoelectric sensor is installed at the outlet of the bottle washing machine to detect the integrity of empty bottles and the cleaning effect. Unqualified bottles are automatically rejected. The disinfectant spraying device, sterile water rinsing device, and hot air drying device are all controlled by a PLC main controller.

7. A bottled water filling control system according to claim 1, characterized in that, In the filling unit, the filling buffer tank is equipped with a level sensor and a pressure sensor. An electromagnetic flow meter is installed on the outlet pipe of the filling buffer tank. The servo filling valve is controlled by a servo motor. A weighing sensor is installed under the bottle holder of the filling machine. All data are fed back to the PLC main controller for real-time adjustment and control.

8. A bottled water filling control system according to claim 1, characterized in that, The auxiliary system includes a sensor group consisting of temperature, pressure, and pH sensors, arranged in each unit to monitor water temperature, pipeline pressure, and water pH in real time. An alarm module is installed in the central control room and various production areas to monitor production parameters in real time and issue alarm signals when parameters are abnormal. The CIP online cleaning module consists of a cleaning solution storage tank, a cleaning pump, and cleaning pipelines, enabling online cleaning of various equipment and pipelines. The concentrate recovery module is connected to the concentrate end of the primary and secondary RO membrane modules, with some concentrate returning to the raw water tank, and the remaining concentrate being treated to meet standards before being discharged.

9. A bottled water filling control method, wherein any one of the bottled water filling control systems described in claims 1-8 is applied to filling, characterized in that, Includes the following steps: Raw water is stored in a raw water tank and then pressurized by a booster pump before entering a multi-media filter, activated carbon filter, and security filter in sequence to remove large particulate impurities, organic matter, odors, and residual chlorine. The pretreated raw water is pressurized by a first-stage high-pressure pump and enters the first-stage RO membrane module for preliminary desalination. The permeate enters the intermediate water tank, and the concentrate is partially recycled. The intermediate water tank maintains water quality through a pH adjustment device, and the secondary high-pressure pump pressurizes the water and sends it into the secondary RO membrane module for deep desalination to obtain high-purity pure water. According to the preset formula, the PLC controller controls the quantitative feeding device and quantitative feeding pump of the mineral hopper to accurately add minerals to the mixing tank, and the agitator uses frequency conversion control to ensure that the minerals and pure water are fully mixed. The PLC controller calculates the ozone dosage based on the filling flow rate, controls the ozone generator to produce high-purity ozone, and mixes it thoroughly with the prepared water through a gas-liquid mixing pump. The mixed water then enters the ozone contact tank for sterilization. Empty bottles enter the bottle washing machine via conveyor belt and pass through the pre-rinsing, disinfectant spraying, sterile water rinsing and hot air drying zone in sequence. Photoelectric sensors on the bottle body detect the integrity of the empty bottle and the cleaning effect, and unqualified bottles are automatically rejected. Qualified empty bottles are sent to the filling machine. The weighing sensor detects the weight of the empty bottle. The PLC controller calculates the target filling weight according to the preset nominal volume and controls the servo filling valve to open for filling. The electromagnetic flow meter and the weighing sensor monitor the filling flow and weight in real time to complete accurate filling. When the production line reaches the preset cleaning cycle or when contamination occurs, the PLC automatically starts the CIP online cleaning program. The cleaning fluid circulates to clean each piece of equipment and pipeline in a preset sequence, and the conductivity sensor and pH sensor monitor the cleaning endpoint.

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