A multi-stage defoaming filling machine and a method of using the same

Abstract

The present application relates to the technical field of filling equipment, in particular to a multi-stage defoaming filling machine and a using method thereof. The filling machine comprises a feeding device, a multi-station rotating mechanism, a can conveying mechanism, an output mechanism, a cap conveying mechanism and a capping device. The feeding device performs two-stage vibration defoaming on the material by the first vibration unit and the second vibration unit with low frequency and large amplitude and high frequency and small amplitude respectively. The first material bin is a sealed structure and is connected with a negative pressure source to form a micro-negative pressure environment, thereby realizing efficient removal of bubbles. The material outlet of the hopper is provided with an anti-turbulent flow guide structure to prevent the generation of secondary bubbles. The bubble detection sensor detects the residual bubble rate in real time and feeds back to the controller to realize adaptive adjustment. The liquid level detection sensor is arranged above the multi-station rotating mechanism to realize closed-loop control of the filling liquid level. The present application can effectively remove the bubbles in the material and significantly improve the filling liquid level precision and product quality.

Description

Technical Field

[0001] This invention relates to the field of filling equipment technology, specifically to a multi-stage defoaming filling machine and its usage method. Background Technology

[0002] A filling machine is an automated device that injects materials into containers in a predetermined quantity. It is widely used in the food, beverage, daily chemical, pharmaceutical, and chemical industries. With the increasing demands for filling accuracy and product quality in industrial production, filling machines are developing towards higher speeds, greater precision, and greater intelligence. Controlling material quality and liquid level accuracy during the filling process has become a key focus of the industry.

[0003] Existing filling machines often encounter problems when filling materials containing gas or prone to aerosolization, such as inaccurate filling levels, insufficient product volume, and overflow. Current defoaming methods, typically involving simple vibration or natural settling, are insufficient to effectively remove air bubbles of varying sizes, especially the fine microbubbles embedded in high-viscosity materials. Furthermore, the high-speed injection of material from the hopper into the container during filling can generate secondary air bubbles, further affecting filling accuracy. Moreover, existing filling machines lack real-time detection and dynamic compensation mechanisms for the filling level, making it difficult to consistently guarantee filling accuracy. Summary of the Invention

[0004] In a first aspect, the present invention provides a multi-stage defoaming filling machine, comprising a feeding device, a multi-station rotating mechanism, a can feeding mechanism, an output mechanism, a cap feeding mechanism, and a capping device; the feeding device includes a vibrating feeding mechanism, a first hopper, a first hopper control valve, a vibrating feeding device, a metering hopper, and a hopper; the vibrating feeding mechanism includes a vibrating lower base and a vibrator mounted on the vibrating lower base, the vibrator including a first vibrating unit and a second vibrating unit; the output end of the first vibrating unit transmits vibration to the first hopper through a first vibrating connecting section, and the output end of the second vibrating unit transmits vibration to the first hopper through a second vibrating connecting section. The moving connection section transmits vibration to the vibrating feeding device; the first vibrating unit operates at a frequency of f1 and an amplitude of A1, and the second vibrating unit operates at a frequency of f2 and an amplitude of A2, where f1 < f2 and A1 > A2; the first hopper is a sealed structure, and its top is connected to a negative pressure source through a negative pressure pipeline connector; the first hopper is connected to the inlet end of the vibrating feeding device through the first hopper control valve, the outlet end of the vibrating feeding device is connected to the quantitative hopper, the hopper is located below the quantitative hopper, and the outlet of the hopper corresponds to the filling station of the multi-station rotating mechanism.

[0005] Preferably, the first hopper is equipped with a bubble detection sensor, and the signal output terminal of the bubble detection sensor is connected to a controller; the controller independently adjusts the frequency f1 and amplitude A1 of the first vibrating unit and the frequency f2 and amplitude A2 of the second vibrating unit, as well as the opening degree of the control valve of the first hopper, according to the residual bubble rate signal fed back by the bubble detection sensor.

[0006] Preferably, the bubble detection sensor is any one of a photoelectric bubble sensor, an ultrasonic bubble sensor, or a conductivity bubble sensor; the controller is a PLC or an industrial computer, which has a preset bubble rate threshold. When the detected residual bubble rate exceeds the threshold, the controller automatically increases the frequency f2 of the second vibrating unit and reduces the opening degree of the first silo control valve.

[0007] Preferably, a pressure regulating valve is provided between the negative pressure source and the first silo to adjust the negative pressure inside the first silo according to the material viscosity; the gauge pressure inside the first silo is -0.01MPa to -0.05MPa.

[0008] Preferably, the lower end of the hopper is provided with an anti-turbulence guiding structure inside the discharge port. The anti-turbulence guiding structure is connected to the vibrator through a guide rod. The anti-turbulence guiding structure is any one or a combination of a spiral guide vane, an umbrella-shaped guide hood, or a stepped buffer plate.

[0009] Preferably, a vibration damping component is provided between the vibrating base and the frame of the filling machine. The vibration damping component is any one or a combination of vibration damping rubber pads, vibration damping springs, or air springs. The feeding device is installed on the frame as an independent module.

[0010] Preferably, a liquid level detection sensor is provided above the filling station of the multi-station rotary mechanism, and the signal output terminal of the liquid level detection sensor is connected to the controller; the controller adjusts the discharge volume of the quantitative hopper or the opening degree of the first hopper control valve according to the filling liquid level signal fed back by the liquid level detection sensor, forming a closed loop of liquid level accuracy for filling, detection and compensation.

[0011] Preferably, the vibrating feeding device is a downwardly inclined vibrating square tube with turbulence ribs on its inner wall. The turbulence ribs work in synergy with the vibration of the second vibrating unit to subject the material to multi-directional disturbance forces during the conveying process, thereby accelerating the separation of bubbles from the material.

[0012] Preferably, the turbulence ribs are arranged vertically on the bottom inner wall of the vibrating square tube, horizontally on the upper inner wall of the vibrating square tube, or in a staggered arrangement; wherein in the staggered arrangement, some turbulence ribs are vertically arranged at the bottom of the square tube and some turbulence ribs are horizontally suspended on the upper inner wall of the square tube, and the upper and lower turbulence ribs are staggered and alternately arranged along the material conveying direction.

[0013] Preferably, the cross-section of the turbulence rib is rectangular, semi-circular, or trapezoidal; the turbulence rib and the inner wall of the vibrating square tube are integrally welded or integrally cast.

[0014] Preferably, the downward tilt angle of the vibrating square tube is 3° to 8°.

[0015] Preferably, the frequency f1 of the first vibration unit is 20Hz to 35Hz and the amplitude A1 is 2mm to 5mm; the frequency f2 of the second vibration unit is 40Hz to 65Hz and the amplitude A2 is 0.3mm to 1.5mm; the frequency ratio f2 / f1 between the first vibration unit and the second vibration unit is 1.5 to 3.0.

[0016] A second aspect of the present invention provides a method of using a multi-stage defoaming filling machine, the filling machine comprising a feeding device, a multi-station rotating mechanism, a can feeding mechanism, an output mechanism, a cap feeding mechanism, and a capping device; the feeding device comprises a vibrating feeding mechanism, a first hopper, a first hopper control valve, a vibrating feeding device, a metering hopper, and a hopper; the vibrating feeding mechanism comprises a vibrating lower base and a vibrator mounted on the vibrating lower base, the vibrator comprising a first vibrating unit and a second vibrating unit; the output end of the first vibrating unit transmits vibration to the first hopper through a first vibrating connecting section, and the output end of the second vibrating unit transmits vibration to the first hopper through a second vibrating connecting section. The material is fed to the vibrating feeding device; the first vibrating unit operates at a frequency of f1 and an amplitude of A1, and the second vibrating unit operates at a frequency of f2 and an amplitude of A2, where f1 < f2 and A1 > A2; the first hopper is a sealed structure, and its top is connected to a negative pressure source through a negative pressure pipeline connector; the lower end of the hopper has an anti-turbulence guiding structure inside its discharge port; a bubble detection sensor is installed in the first hopper, and the signal output terminal of the bubble detection sensor is connected to a controller; a liquid level detection sensor is installed above the filling station of the multi-station rotating mechanism, and the signal output terminal of the liquid level detection sensor is connected to the controller; the method of use includes the following steps: S1: Start the filling machine. The first vibrating unit generates low-frequency, large-amplitude vibration at frequency f1 and amplitude A1, which is transmitted to the first hopper through the first vibration connecting section. At the same time, the second vibrating unit generates high-frequency, small-amplitude vibration at frequency f2 and amplitude A2, which is transmitted to the vibrating feeding device and the anti-turbulence guiding structure through the second vibration connecting section. S2: The material to be filled enters the first hopper. Under the combined effect of low-frequency large-amplitude vibration and micro-negative pressure environment in the first hopper, large bubbles in the material aggregate, float, break and escape, completing the first stage of defoaming. S3: The material after primary defoaming enters the vibrating feeding device through the first hopper control valve. During the conveying process, it is continuously subjected to high-frequency, small-amplitude vibration. The remaining micro bubbles are broken and escaped by the high-frequency excitation force, thus completing the secondary defoaming. S4: The bubble detection sensor detects the residual bubble rate in the material in real time. When the residual bubble rate exceeds the preset threshold, the controller automatically increases the frequency f2 of the second vibrating unit and reduces the opening degree of the first silo control valve until the residual bubble rate drops below the threshold. S5: The defoamed material is discharged through the hopper and flows down the inner wall of the filling container through the anti-turbulence guiding structure into the filling station of the multi-station rotating mechanism for filling; after filling, the liquid level detection sensor detects the liquid level height in the filling container, and the controller compensates and corrects subsequent filling according to the liquid level deviation signal. S6: The multi-station rotating mechanism sequentially drives each filling station through the filling, can delivery, cap delivery, and cap sealing processes, and finally outputs the finished product through the output mechanism.

[0017] In summary, this application has the following beneficial effects: (1) By setting up a first vibration unit and a second vibration unit, the material is subjected to two-stage vibration defoaming with low-frequency large amplitude and high-frequency small amplitude respectively. The low-frequency large amplitude vibration causes large bubbles in the material to aggregate and break, while the high-frequency small amplitude vibration causes tiny bubbles in the material to break and escape. The two stages work together to achieve a highly efficient and comprehensive defoaming effect.

[0018] (2) By creating a micro-negative pressure environment in the first silo, and in conjunction with low-frequency large-amplitude vibration, the large bubbles in the material are accelerated to expand, coalesce and float to the surface and break under negative pressure conditions, which significantly improves the first-level defoaming efficiency.

[0019] (3) The residual bubble rate in the material is detected in real time by the bubble detection sensor, and the vibration parameters and the opening degree of the silo control valve are adaptively adjusted by the controller to realize the closed-loop intelligent control of the defoaming process and ensure that the discharge bubble rate is always within the qualified range.

[0020] (4) By setting an anti-turbulence guiding structure at the hopper outlet, the material flows down along the inner wall of the container, avoiding the material from directly impacting the bottom of the container and generating secondary bubbles. At the same time, the guide rod transmits vibration to accelerate the flow of high-viscosity material and eliminate bubbles.

[0021] (5) The filling liquid level is detected by the liquid level detection sensor. The controller compensates and corrects the subsequent filling according to the liquid level deviation signal, forming a closed loop of liquid level accuracy of filling, detection and compensation, which significantly improves the long-term consistency of filling liquid level.

[0022] (6) By setting up vibration damping components between the base and the frame under vibration, the vibration is only applied to the inside of the feeding device and is not transmitted to other mechanisms, thus ensuring the stable operation of the multi-station rotating mechanism, the cover feeding mechanism and the cover sealing device.

[0023] (7) By setting turbulence ribs on the inner wall of the vibrating feeder, and cooperating with high-frequency vibration, the material is subjected to multi-directional disturbance force during the conveying process, which further accelerates the separation of bubbles from the material and improves the secondary defoaming effect. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a top view of the overall structure of the present invention; Figure 3 This is a cross-sectional view of the first hopper of the present invention; Figure 4 This is a schematic diagram of the installation of the vibration damping component of the present invention; Figure 5 This is a partial enlarged view of the vibration damping assembly of the present invention; Figure 6 This is a schematic diagram of the installation of the anti-turbulence guiding structure of the present invention; Figure 7 This is a schematic diagram of the installation of an anti-turbulence guiding structure according to another specific embodiment of the present invention; Figure 8 This is a cross-sectional view of the vibratory feeding device of the present invention; Figure 9 This is a cross-sectional view of another specific embodiment of the vibratory feeding device of the present invention; Figure 10 This is a cross-sectional view of another specific embodiment of the vibratory feeding device of the present invention; Figure 11 This is a framework diagram of the controller of the present invention.

[0025] The diagram includes: 1. Feeding device; 2. Multi-station rotating mechanism; 3. Can feeding mechanism; 4. Output mechanism; 5. Cover feeding mechanism; 6. Covering device; 10. Vibrating feeding mechanism; 11. First hopper; 12. First hopper control valve; 13. Vibrating feeding device; 14. Quantitative hopper; 15. Hopper; 100. Vibrating lower base; 101. Vibrator; 101. First vibrating unit; 101b. Second vibrating unit; 102a. Second vibrating connecting section; 102b. Vibration damping component; 103. Negative pressure pipeline connector; 16. Feed connector; 17. Bubble detection sensor; 19. Controller; 20. Turbulence rib; 131. Anti-turbulence guiding structure; 21. Liquid level detection sensor; 22. Vibration guide rod; 23. Detailed Implementation

[0026] The following description is intended to disclose the invention and enable those skilled in the art to implement it. The preferred embodiments described below are merely examples, and other obvious variations will occur to those skilled in the art.

[0027] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this application as detailed in the appended claims.

[0028] The terminology used in this application is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. The singular forms "a," "the," and "the" as used in this application and the appended claims are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the term "and / or" as used herein refers to and includes any and all possible combinations of one or more of the associated listed items.

[0029] To better understand the above technical solution, the following will provide a detailed explanation of the above technical solution in conjunction with specific implementation methods.

[0030] In some embodiments of this application, such as Figure 1 , 2As shown in Figures 3 and 4, a multi-stage defoaming filling machine includes a feeding device 1, a multi-station rotating mechanism 2, a can feeding mechanism 3, an output mechanism 4, a cap feeding mechanism 5, and a capping device 6. The feeding device 1 includes a vibrating feeding mechanism 10, a first hopper 11, a first hopper control valve 12, a vibrating feeding device 13, a quantitative hopper 14, and a hopper 15. The vibrating feeding mechanism 10 includes a vibrating lower base 100 and a vibrator 101 mounted on the vibrating lower base 100. The vibrator 101 includes a first vibrating unit 101a and a second vibrating unit 101b. The output end of the first vibrating unit 101a transmits vibration to the first hopper 11 through a first vibrating connecting section 102a. The output end of the second vibrating unit 101b transmits vibration to the first hopper 11. The vibration is transmitted to the vibrating feeding device 13 through the second vibration connection section 102b at the outlet end; the operating frequency of the first vibrating unit 101a is f1 and the amplitude is A1, and the operating frequency of the second vibrating unit 101b is f2 and the amplitude is A2, where f1 < f2 and A1 > A2; the first hopper 11 is a sealed structure, and its top is connected to a negative pressure source through a negative pressure pipeline connector 16; the first hopper 11 is connected to the feed end of the vibrating feeding device 13 through the first hopper control valve 12, the discharge end of the vibrating feeding device 13 is connected to the quantitative hopper 14, the hopper 15 is located below the quantitative hopper 14, and the discharge port of the hopper 15 corresponds to the filling station of the multi-station rotating mechanism 2.

[0031] In the specific implementation process, the material enters the first silo 11 sequentially through the feed connector 17. The first vibrating unit 101a drives the first silo 11 with low-frequency, large-amplitude vibration, causing the material in the first silo 11 to undergo large-amplitude turbulence under the action of low-frequency, large-amplitude vibration. Large bubbles in the material collide with each other and coalesce into larger bubbles during the violent turbulence, accelerating to the surface and bursting out. At the same time, the first silo 11 is a sealed structure and is connected to an external negative pressure source through a negative pressure pipeline connector 16, forming a micro-negative pressure environment inside the first silo 11. This causes the bubbles in the material to expand rapidly under negative pressure conditions, further promoting the coalescence and buoyancy of the bubbles. The second vibrating unit 101b drives the vibrating feeding device 13 with high-frequency, small-amplitude vibration, causing the material in the vibrating feeding device 13 to undergo fine excitation under the action of high-frequency micro-amplitude vibration. The residual microbubbles in the material burst and escape under the repeated action of the high-frequency excitation force. Through the dual-frequency synergy of low-frequency, large-amplitude and high-frequency, small-amplitude vibrations, comprehensive and efficient removal from large bubbles to microbubbles is achieved. After the first defoaming is completed in the first hopper 11, the material enters the vibrating feeding device 13 through the first hopper control valve 12 to complete the second defoaming, and is finally discharged into the filling station of the multi-station rotating mechanism 2 by the hopper 15. The multi-station rotating mechanism 2 drives each filling station through filling, can feeding, cap feeding, and cap sealing processes in sequence, and finally outputs the finished product through the output mechanism 4.

[0032] By adopting the above technical solution, dual-frequency vibration is used to defoam. Low-frequency large-amplitude vibration is used to break up large bubbles, while high-frequency small-amplitude vibration is used to break up tiny bubbles. The two-stage vibration is used to precisely eliminate bubbles of different sizes. Combined with the micro-negative pressure environment of the first silo, comprehensive and efficient removal of bubbles from large to tiny bubbles is achieved, so that the material entering the filling container is free of bubbles, thereby ensuring the accuracy of the filling liquid level.

[0033] In some preferred embodiments of this application, such as Figure 1 , 2 Combination Figure 6 and Figure 11 As shown, the first hopper 11 is equipped with a bubble detection sensor 19, and the signal output terminal of the bubble detection sensor 19 is connected to the controller 20. The controller 20 independently adjusts the frequency f1 and amplitude A1 of the first vibrating unit 101a and the frequency f2 and amplitude A2 of the second vibrating unit 101b, as well as the opening degree of the first hopper control valve 12, according to the residual bubble rate signal fed back by the bubble detection sensor 19.

[0034] In the specific implementation process, the bubble detection sensor 19 is installed inside the first hopper 11 or on the pipeline between the first hopper 11 and the vibrating feeding device 13 to detect the residual bubble content in the material after primary defoaming in real time. After receiving the signal from the bubble detection sensor 19, the controller 20 compares the detected residual bubble rate with a preset bubble rate threshold. When the residual bubble rate exceeds the threshold, the controller 20 automatically increases the frequency f2 of the second vibrating unit 101b to enhance the high-frequency excitation force and promote the rupture of microbubbles; at the same time, it reduces the opening degree of the first hopper control valve 12, reduces the material flow rate, and prolongs the residence time of the material in the vibrating feeding device 13, so that the material receives more thorough secondary defoaming treatment. When the residual bubble rate is below the threshold, the controller 20 can appropriately reduce the frequency f2 of the second vibrating unit 101b and increase the opening degree of the first hopper control valve 12 to improve production efficiency. Through the above closed-loop control strategy, adaptive intelligent adjustment of the defoaming process is achieved.

[0035] By adopting the above technical solution, the residual bubble rate is detected in real time by a bubble detection sensor and fed back to the controller, so as to realize the adaptive adjustment of the defoaming parameters, ensuring that the output bubble rate is always within the qualified range, while taking into account production efficiency.

[0036] In some preferred embodiments of this application, the bubble detection sensor 19 is any one of a photoelectric bubble sensor, an ultrasonic bubble sensor, or a conductivity bubble sensor. Specifically, a photoelectric bubble sensor detects bubbles by utilizing the principle of light scattering and refraction by bubbles when light propagates in a liquid, and is suitable for transparent or translucent liquids; an ultrasonic bubble sensor detects bubbles by utilizing the principle of reflection and attenuation of ultrasound waves when they encounter bubbles while propagating in a liquid, and is suitable for opaque liquids; a conductivity bubble sensor detects bubbles by utilizing the principle that the presence of bubbles changes the conductivity of the liquid, and is suitable for conductive liquids. The controller 20 is a PLC or industrial computer, which has a preset bubble rate threshold. When the detected residual bubble rate exceeds the threshold, the controller 20 automatically increases the frequency f2 of the second vibrating unit 101b and decreases the opening degree of the first hopper control valve 12.

[0037] In practical implementation, the bubble rate threshold can be set according to the process requirements of different materials, generally set to 0.5% to 1.0%. Different types of bubble detection sensors can be selected for different material types and viscosities to achieve the best detection results. When the controller 20 uses a PLC, it has the advantages of strong anti-interference ability and fast response speed, making it suitable for harsh industrial environments; when using an industrial computer, it has the advantages of strong computing power and a user-friendly human-machine interface, making it suitable for occasions requiring complex control strategies.

[0038] The above technical solution provides a variety of bubble detection sensors to suit different material conditions. The controller uses industrial-grade control equipment to ensure the reliability and stability of the system.

[0039] In some preferred embodiments of this application, the first silo 11 is a sealed structure, and its top is connected to a negative pressure source via a negative pressure pipeline connector 16, so that a micro-negative pressure environment with a gauge pressure of -0.01MPa to -0.05MPa is formed inside the first silo 11. A pressure regulating valve is provided between the negative pressure source and the first silo 11 to adjust the negative pressure inside the first silo 11 according to the viscosity of the material.

[0040] In practical implementation, the negative pressure of the micro-negative pressure environment is adaptively adjusted according to the material viscosity. When the material viscosity is high (≥500 mPa·s), bubbles in the material are difficult to float naturally. In this case, the negative pressure is adjusted to -0.03 MPa to -0.05 MPa. The larger negative pressure difference accelerates the expansion of bubbles, reduces the solubility of gas inside the bubbles, and promotes bubble aggregation and floating. When the material viscosity is low (<500 mPa·s), bubbles in the material float more easily. In this case, the negative pressure is adjusted to -0.01 MPa to -0.03 MPa. A moderate negative pressure can meet the defoaming requirements while avoiding excessively low negative pressure that would cause a large amount of volatile components in the material to escape. The air pressure regulating valve can be an electric proportional regulating valve, and the controller 20 automatically adjusts the valve opening according to the material viscosity parameters.

[0041] By adopting the above technical solution, an adjustable micro-negative pressure environment is formed in the first silo, and the negative pressure is adaptively adjusted according to the material viscosity, so that materials of different viscosities can obtain the best defoaming effect.

[0042] In some preferred embodiments of this application, such as Figure 6 , 7 As shown, the lower discharge port of the hopper 15 is provided with an anti-turbulence guiding structure 21, which is connected to the vibrator 101 via a guide rod 23. The anti-turbulence guiding structure 21 is any one or a combination of a spiral guide vane, an umbrella-shaped guide shroud, or a stepped buffer plate.

[0043] In the specific implementation process, the anti-turbulence guiding structure 21 is set on the inner wall of the discharge port at the lower end of the hopper 15. Its function is to guide the material to flow down along the inner wall of the filling container, avoiding the material from falling at high speed from the hopper 15 and directly impacting the bottom of the container, thus preventing the generation of secondary bubbles. The spiral guide vane causes the material to rotate and fall along the spiral path during the discharge process, reducing the falling speed of the material and making it flow along the wall; the umbrella-shaped guide cover causes the material to spread outward along the umbrella-shaped surface and fall along the wall during discharge; the stepped buffer plate reduces the flow velocity and potential energy of the material step by step through multiple steps. The anti-turbulence guiding structure 21 is connected to the vibrator 101 through the vibration guide rod 23. Under the vibration generated by the vibrator 101, the vibration guide rod 23 transmits the vibration to the anti-turbulence guiding structure 21, so that the anti-turbulence guiding structure 21 vibrates while guiding the flow. For high-viscosity liquid materials, vibration can accelerate the flow of the material along the guiding structure, prevent high-viscosity materials from adhering to the surface of the guiding structure, and at the same time, vibration also helps to further eliminate residual bubbles in the material.

[0044] By adopting the above technical solution, the anti-turbulence guiding structure guides the material to flow down the inner wall of the container, effectively preventing the material from impacting the bottom of the container and generating secondary bubbles. At the same time, the vibration rod transmits vibration to accelerate the outflow of high-viscosity materials and further eliminates bubbles, ensuring filling quality.

[0045] In some preferred embodiments of this application, a vibration damping component 103 is provided between the vibration base 100 and the frame of the filling machine. The vibration damping component 103 is any one or a combination of vibration damping rubber pads, vibration damping springs, or air springs. The feeding device 1 is installed on the frame as an independent module.

[0046] In the specific implementation process, the vibration damping component 103 is set between the vibrating base 100 and the frame to isolate the vibration generated by the first vibration unit 101a and the second vibration unit 101b from being transmitted to the frame and other mechanisms. The vibration damping rubber pad is suitable for isolating high-frequency, small-amplitude vibrations and has a good mid-to-high frequency vibration damping effect; the vibration damping spring is suitable for isolating low-frequency, large-amplitude vibrations and has a good low-frequency vibration damping effect and a large load-bearing capacity; the air spring has adjustable stiffness and can adjust the vibration damping frequency according to the vibration conditions, making it suitable for complex vibration conditions. The feeding device 1 is installed on the frame as an independent module and is isolated from the frame by the vibration damping component 103, so that the vibration only acts on the first hopper 11 and the vibrating feeding device 13 inside the feeding device 1, and is not transmitted to the multi-station rotating mechanism 2, the can feeding mechanism 3, the lid feeding mechanism 5, and the sealing device 6, ensuring the stable operation and accuracy of these mechanisms.

[0047] By adopting the above technical solution, the vibration of the feeding device is isolated from other mechanisms through the vibration damping component, so as to avoid the vibration from interfering with the positioning accuracy of the multi-station rotating mechanism and the sealing quality of the sealing device. At the same time, the feeding device is an independent module, which is convenient for maintenance and replacement.

[0048] In some preferred embodiments of this application, a liquid level detection sensor 22 is provided above the filling station of the multi-station rotary mechanism 2, and the signal output terminal of the liquid level detection sensor 22 is connected to the controller 20. The controller 20 adjusts the discharge rate of the quantitative hopper 14 or the opening degree of the first hopper control valve 12 based on the filling liquid level signal fed back by the liquid level detection sensor 22, compensating for and correcting subsequent filling, thus forming a closed loop of liquid level accuracy for filling, detection, and compensation.

[0049] In the specific implementation process, the liquid level detection sensor 22 is installed directly above the filling station of the multi-station rotating mechanism 2 to detect the liquid level height in the filling container in real time after filling. The liquid level detection sensor 22 can be a laser displacement sensor, an ultrasonic liquid level sensor, or a capacitive liquid level sensor, etc. The controller 20 compares the detected actual liquid level height with the target liquid level height and calculates the liquid level deviation. When the liquid level deviation direction of three consecutive filling containers is consistent and the deviation value exceeds ±0.5mm, the controller 20 starts the compensation correction program, adjusting the filling volume of the subsequent filling process by adjusting the discharge volume of the metering hopper 14 or the opening degree of the first hopper control valve 12. For example, when the liquid level of three consecutive containers is detected to be low, the controller 20 increases the discharge volume of the metering hopper 14 or increases the opening degree of the first hopper control valve 12 to increase the filling volume of the subsequent containers; conversely, it decreases the filling volume. This closed-loop control strategy of "filling-detection-compensation" eliminates systematic filling deviations caused by changes in material properties and fluctuations in environmental factors, ensuring long-term consistency and accuracy of filling liquid level.

[0050] By adopting the above technical solution, the filling liquid level is detected in real time by a liquid level detection sensor, and the controller compensates and corrects according to the liquid level deviation, forming a closed-loop control of liquid level accuracy, which significantly improves the long-term consistency and accuracy of the filling liquid level.

[0051] In some preferred embodiments of this application, such as Figure 8 , 9 As shown in Figure 10, the vibrating feeding device 13 is a downwardly inclined vibrating square tube with turbulence ribs 131 on its inner wall. The turbulence ribs 131 work in synergy with the vibration of the second vibrating unit 101b to subject the material to multi-directional disturbance forces during the conveying process, thereby accelerating the separation of bubbles from the material.

[0052] In the specific implementation process, the vibrating square tube is inclined downwards, and the material slides down the inner wall of the inclined square tube under the combined action of gravity and vibration. The multi-dimensional composite vibration output by the second vibrating unit 101b is transmitted to the vibrating square tube and the turbulence rib 131. The turbulence rib 131 vibrates synchronously with the square tube at high frequency, further applying patting and shearing disturbance to the material in contact, thereby enhancing the defoaming effect.

[0053] like Figure 8 As shown, in the first embodiment, the turbulence ribs 131 are arranged vertically along the inner wall of the bottom of the vibrating square tube. When the material is conveyed downward along the inclined square tube, the longitudinal turbulence ribs 131 continuously obstruct and agitate the flowing material. The material is subjected to combined vertical and horizontal vibration disturbances, and the air bubbles trapped inside the material are released and float upward, achieving gas-liquid separation. This arrangement is suitable for removing air bubbles from materials of general viscosity.

[0054] like Figure 9As shown, in the second embodiment, the turbulence ribs 131 are arranged horizontally on the upper inner wall of the vibrating square tube. The horizontal turbulence ribs 131 are suspended above the material flow. When the material is vibrated and splashes upwards, it impacts the horizontal turbulence ribs 131, breaking and releasing the tiny bubbles inside the material. The bubbles then converge and overflow upwards. This arrangement is suitable for materials with high viscosity and a large number of tiny bubbles.

[0055] like Figure 10 As shown, in the third embodiment, the turbulence ribs 131 are arranged in a staggered pattern. Some turbulence ribs 131 are vertically positioned at the bottom of the square tube, while others are horizontally suspended on the upper inner wall of the square tube. The upper and lower turbulence ribs are staggered and alternately arranged along the material conveying direction. When the material is conveyed downwards, it is both lifted and churned by the bottom longitudinal turbulence ribs and impacts the upper horizontal turbulence ribs, creating a turbulent and rolling state. The material is continuously torn and thinned, significantly improving the bubble precipitation efficiency. This arrangement is suitable for viscous materials containing a large number of fine microbubbles.

[0056] By adopting the above technical solution, by setting up turbulence ribs with various arrangements on the inner wall of the vibrating feeder, and combining them with high-frequency vibration to apply multi-directional disturbance to the material, the material is continuously tumbled, torn, and thinned during the conveying process, which greatly improves the efficiency of bubble precipitation and achieves enhanced secondary defoaming treatment.

[0057] In some preferred embodiments of this application, the cross-section of the baffle 131 can also be rectangular, semi-circular, or trapezoidal. Rectangular cross-section baffles have a stronger effect on blocking and agitating materials, making them suitable for materials with high viscosity; semi-circular cross-section baffles have a smooth surface, making them less prone to material adhesion, making them suitable for materials that are easily solidified or crystallized; trapezoidal cross-section baffles combine blocking and anti-adhesion properties, making them suitable for various material conditions. The baffle 131 is integrally welded or cast with the inner wall of the vibrating square tube to ensure vibration transmission efficiency and prevent the baffle from detaching under vibration conditions.

[0058] In specific implementation, the height of the baffle 131 (i.e., the height protruding from the inner wall of the square tube) can be adjusted according to the material characteristics and defoaming requirements, generally from 5mm to 20mm. The spacing of the baffle 131 can also be adjusted according to the material characteristics, generally from 10mm to 50mm. As a supplementary embodiment, the baffle 131 can also be set as a sawtooth structure, with the sawtooth facing the material feeding side along the material's forward direction. When the material flows through the sawtooth baffle 131, it is continuously cut and disturbed, breaking the bubble encapsulation layer inside the material and causing the bubbles to converge, float, and be discharged.

[0059] By adopting the above technical solution, various cross-sectional shapes and supplementary sawtooth structures of the baffle ribs are provided to adapt to different material properties. At the same time, the structural reliability of the baffle ribs under vibration conditions is ensured by integral welding or integral casting.

[0060] In some preferred embodiments of this application, the downward tilt angle of the vibrating square tube is preferably 3° to 8°. If the tilt angle is too small, the material flow is slow, affecting production efficiency; if the tilt angle is too large, the material flow rate is too fast, and the material flows out of the vibrating feeder before it can complete defoaming, affecting the defoaming effect. More preferably, the tilt angle is 5° to 6°, which ensures sufficient defoaming of the material while also considering production efficiency.

[0061] In practice, the tilt angle of the vibrating square tube can be adjusted according to the viscosity and flowability of the material. For high-viscosity materials, the tilt angle can be increased to accelerate material flow; for low-viscosity materials, the tilt angle can be decreased to prolong the residence time of the material in the vibrating feeding device.

[0062] By adopting the above technical solution and optimizing the tilt angle of the vibrating square tube, production efficiency can be ensured while guaranteeing sufficient degassing of the material.

[0063] In some preferred embodiments of this application, the frequency f1 of the first vibration unit 101a is 20Hz to 35Hz and the amplitude A1 is 2mm to 5mm; the frequency f2 of the second vibration unit 101b is 40Hz to 65Hz and the amplitude A2 is 0.3mm to 1.5mm; the frequency ratio f2 / f1 between the first vibration unit 101a and the second vibration unit 101b is 1.5 to 3.0.

[0064] In the specific implementation process, the first vibrating unit 101a drives the first hopper 11 with low-frequency, large-amplitude vibration. The frequency f1 is preferably 25Hz to 30Hz, and the amplitude A1 is preferably 3mm to 4mm. This parameter range causes the material in the first hopper 11 to churn moderately. Large bubbles collide, coalesce, and rise to the surface and burst during the churn, while preventing material splashing or overflow due to excessive amplitude. The second vibrating unit 101b drives the vibrating feeding device 13 with high-frequency, small-amplitude vibration. The frequency f2 is preferably 45Hz to 55Hz, and the amplitude A2 is preferably 0.5mm to 1.0mm. This parameter range causes the material in the vibrating feeding device 13 to be subjected to fine excitation. Microbubbles burst and escape under the repeated action of high-frequency excitation force, while preventing the stable conveying of materials from being affected by excessive amplitude. The frequency ratio f2 / f1 is controlled within the range of 1.5 to 3.0 to ensure that the two levels of vibration effectively complement each other in frequency, avoiding overlapping defoaming effects due to excessively close frequencies.

[0065] By adopting the above technical solution, the frequency and amplitude parameters of the two-stage vibration unit are optimized so that low-frequency large-amplitude vibration and high-frequency small-amplitude vibration can achieve the best defoaming effect for bubbles of different sizes, and the frequency ratio is controlled within a reasonable range to ensure the complementarity of the two-stage defoaming.

[0066] In some embodiments of this application, a method of using a multi-stage defoaming filling machine includes the following steps: S1: Start the filling machine. The first vibrating unit 101a generates low-frequency, large-amplitude vibration with frequency f1 and amplitude A1, which is transmitted to the first hopper 11 through the first vibration connecting section 102a. At the same time, the second vibrating unit 101b generates high-frequency, small-amplitude vibration with frequency f2 and amplitude A2, which is transmitted to the vibrating feeding device 13 and the anti-turbulence guiding structure 21 of the hopper 15 through the second vibration connecting section 102b.

[0067] S2: The material to be filled enters the first hopper 11 through the feed connector 17. Under the combined effect of low-frequency, large-amplitude vibration and a slightly negative pressure environment within the first hopper 11, large bubbles in the material coalesce, rise, break, and escape, completing the first stage of defoaming. The negative pressure inside the first hopper 11 is adaptively adjusted according to the material viscosity: when the material viscosity is ≥500 mPa·s, the negative pressure is adjusted to -0.03 MPa to -0.05 MPa; when the material viscosity is <500 mPa·s, the negative pressure is adjusted to -0.01 MPa to -0.03 MPa.

[0068] S3: The material after primary defoaming enters the vibrating feeding device 13 through the first hopper control valve 12. During the conveying process, it is continuously subjected to high-frequency, small-amplitude vibration. At the same time, the baffle 131 applies multi-directional disturbance to the material. The remaining micro-bubbles are broken and escaped by the combined action of the high-frequency excitation force and the baffle 131, completing the secondary defoaming. The ratio of the frequency f2 of the second vibrating unit 101b to the frequency f1 of the first vibrating unit 101a, f2 / f1, is controlled within the range of 1.5 to 3.0.

[0069] S4: The bubble detection sensor 19 detects the residual bubble rate in the material in real time. When the residual bubble rate exceeds a preset threshold, the controller 20 automatically increases the frequency f2 of the second vibrating unit 101b and reduces the opening degree of the first silo control valve 12 until the residual bubble rate drops below the threshold. The bubble rate threshold is set to 0.5% to 1.0%.

[0070] S5: The defoamed material is discharged through the hopper 15 and flows downstream along the inner wall of the filling container via the anti-turbulence guiding structure 21 into the filling station of the multi-station rotating mechanism 2 for filling. After filling, the liquid level detection sensor 22 detects the liquid level height in the filling container, and the controller 20 compensates and corrects subsequent fillings based on the liquid level deviation signal. When the liquid level deviation direction of three consecutive filling containers is consistent and the deviation value exceeds ±0.5mm, the controller 20 starts the compensation and correction program.

[0071] S6: The multi-station rotating mechanism 2 sequentially drives each filling station through the filling, can delivery, cap delivery and cap sealing processes, and finally outputs the finished product through the output mechanism 4.

[0072] By employing the above-mentioned method, and through the coordinated use of multiple technical means such as two-stage vibration defoaming, micro-negative pressure synergy, bubble closed-loop detection, anti-turbulence guidance, and liquid level compensation correction, bubble control and liquid level accuracy control can be achieved throughout the entire process from material feeding to filling, significantly improving the quality and consistency of filled products.

[0073] This invention effectively solves the technical problems of incomplete bubble removal and low filling level accuracy in existing filling machines when filling materials containing gas or prone to generating bubbles. It achieves efficient defoaming of materials and precise control of filling level by combining technical solutions such as dual-frequency vibration synergistic defoaming, micro-negative pressure environment assisted defoaming, bubble detection closed-loop control, anti-turbulence guiding to prevent secondary bubbles, vibration reduction and isolation to ensure the accuracy of the mechanism, turbulence ribs to enhance defoaming, and liquid level detection compensation correction.

[0074] The embodiments of this application have been described above with reference to the accompanying drawings. However, this application is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of this application without departing from the spirit and scope of the claims, and all of these forms are within the protection scope of this application.

Claims

1. A multi-stage defoaming filling machine, characterized in that, The system includes a feeding device, a multi-station rotating mechanism, a can feeding mechanism, an output mechanism, a cap feeding mechanism, and a capping device. The feeding device includes a vibrating feeding mechanism, a first hopper, a first hopper control valve, a vibrating feeding unit, a metering hopper, and a hopper. The vibrating feeding mechanism includes a vibrating base and a vibrating machine mounted on the vibrating base. The vibrating machine includes a first vibrating unit and a second vibrating unit. The output of the first vibrating unit transmits vibration to the first hopper via a first vibrating connecting section, and the output of the second vibrating unit transmits vibration to the first hopper via a second vibrating connecting section. A vibrating feeding device; the first vibrating unit operates at a frequency of f1 and an amplitude of A1, and the second vibrating unit operates at a frequency of f2 and an amplitude of A2, wherein f1 < f2 and A1 > A2; the first hopper is a sealed structure, and its top is connected to a negative pressure source through a negative pressure pipeline connector; the first hopper is connected to the inlet end of the vibrating feeding device through the first hopper control valve, the outlet end of the vibrating feeding device is connected to the quantitative hopper, the hopper is located below the quantitative hopper, and the outlet of the hopper corresponds to the filling station of the multi-station rotating mechanism.

2. The filling machine according to claim 1, characterized in that, The first hopper is equipped with a bubble detection sensor, the signal output of which is connected to a controller. Based on the residual bubble rate signal fed back by the bubble detection sensor, the controller independently adjusts the frequency f1 and amplitude A1 of the first vibrating unit, the frequency f2 and amplitude A2 of the second vibrating unit, and the opening degree of the first hopper control valve. The bubble detection sensor is any one of a photoelectric bubble sensor, an ultrasonic bubble sensor, or a conductivity bubble sensor. The controller is a PLC or industrial computer with a preset bubble rate threshold. When the detected residual bubble rate exceeds the threshold, the controller automatically increases the frequency f2 of the second vibrating unit and decreases the opening degree of the first hopper control valve.

3. The filling machine according to claim 1, characterized in that, A pressure regulating valve is provided between the negative pressure source and the first silo to adjust the negative pressure inside the first silo according to the material viscosity; the gauge pressure inside the first silo is -0.01MPa to -0.05MPa.

4. The filling machine according to claim 1, characterized in that, The lower discharge port of the hopper is equipped with an anti-turbulence guiding structure. The anti-turbulence guiding structure is connected to the vibrator through a guide rod. The anti-turbulence guiding structure is any one or a combination of a spiral guide vane, an umbrella-shaped guide hood, or a stepped buffer plate.

5. The filling machine according to claim 1, characterized in that, A vibration damping component is provided between the vibrating base and the frame of the filling machine. The vibration damping component is any one or a combination of vibration damping rubber pads, vibration damping springs, or air springs. The feeding device is installed on the frame as an independent module.

6. The filling machine according to claim 2, characterized in that, A liquid level detection sensor is provided above the filling station of the multi-station rotary mechanism. The signal output terminal of the liquid level detection sensor is connected to the controller. The controller adjusts the discharge volume of the quantitative hopper or the opening degree of the control valve of the first hopper according to the filling liquid level signal fed back by the liquid level detection sensor, forming a closed loop of liquid level accuracy for filling, detection and compensation.

7. The filling machine according to claim 1, characterized in that, The vibrating feeding device is a downwardly inclined vibrating square tube with turbulence ribs on its inner wall. The turbulence ribs work in synergy with the vibration of the second vibrating unit to subject the material to multi-directional disturbance forces during the conveying process, thereby accelerating the separation of bubbles from the material.

8. The filling machine according to claim 7, characterized in that, The turbulence ribs are arranged vertically on the bottom inner wall of the vibrating square tube, horizontally on the upper inner wall of the vibrating square tube, or in a staggered arrangement. In the staggered arrangement, some of the baffles are vertically installed at the bottom of the square tube, and some of the baffles are horizontally suspended on the upper inner wall of the square tube. The upper and lower baffles are staggered and alternately arranged along the material conveying direction. The cross-section of the baffles is rectangular, semi-circular or trapezoidal. The baffles and the inner wall of the vibrating square tube are integrally welded or integrally cast.

9. The filling machine according to claim 1, characterized in that, The frequency f1 of the first vibrating unit is 20Hz to 35Hz and the amplitude A1 is 2mm to 5mm; the frequency f2 of the second vibrating unit is 40Hz to 65Hz and the amplitude A2 is 0.3mm to 1.5mm; the frequency ratio f2 / f1 between the first vibrating unit and the second vibrating unit is 1.5 to 3.

0.

10. A method of using a multi-stage defoaming filling machine, characterized in that, The filling machine includes a feeding device, a multi-station rotating mechanism, a can feeding mechanism, an output mechanism, a cap feeding mechanism, and a capping device; the feeding device includes a vibrating feeding mechanism, a first hopper, a first hopper control valve, a vibrating feeding device, a metering hopper, and a hopper; the vibrating feeding mechanism includes a vibrating base and a vibrator mounted on the vibrating base, the vibrator including a first vibrating unit and a second vibrating unit; the output end of the first vibrating unit transmits vibration to the first hopper through a first vibrating connecting section, and the output end of the second vibrating unit transmits vibration to the vibrating feeding device through a second vibrating connecting section; the operating frequency of the first vibrating unit is... The second vibrating unit has a working frequency of f1 and an amplitude of A1, and a working frequency of f2 and an amplitude of A2, where f1 < f2 and A1 > A2; the first hopper is a sealed structure, and its top is connected to a negative pressure source through a negative pressure pipeline connector; the lower end of the hopper has an anti-turbulence guiding structure inside, and the anti-turbulence guiding structure is connected to the vibrating machine through a guide rod; the first hopper has a bubble detection sensor, and the signal output terminal of the bubble detection sensor is connected to a controller; the multi-station rotating mechanism has a liquid level detection sensor above the filling station, and the signal output terminal of the liquid level detection sensor is connected to the controller; the method of use includes the following steps: S1: Start the filling machine. The first vibrating unit generates low-frequency, large-amplitude vibration at frequency f1 and amplitude A1, which is transmitted to the first hopper through the first vibration connecting section. At the same time, the second vibrating unit generates high-frequency, small-amplitude vibration at frequency f2 and amplitude A2, which is transmitted to the vibrating feeding device and the anti-turbulence guiding structure through the second vibration connecting section. S2: The material to be filled enters the first hopper. Under the combined effect of low-frequency large-amplitude vibration and micro-negative pressure environment in the first hopper, large bubbles in the material aggregate, float, break, and escape, completing the first stage of defoaming. The negative pressure inside the first hopper is adaptively adjusted according to the material viscosity: when the material viscosity is ≥500mPa·s, the negative pressure is adjusted to -0.03MPa to -0.05MPa; when the material viscosity is <500mPa·s, the negative pressure is adjusted to -0.01MPa to -0.03MPa. S3: The material after primary defoaming enters the vibrating feeding device through the first hopper control valve. During the conveying process, it is continuously subjected to high-frequency, small-amplitude vibration. The remaining micro bubbles are broken and escaped by the high-frequency excitation force, completing the secondary defoaming. The ratio of the frequency f2 of the second vibrating unit to the frequency f1 of the first vibrating unit, f2 / f1, is controlled within the range of 1.5 to 3.

0. S4: The bubble detection sensor detects the residual bubble rate in the material in real time. When the residual bubble rate exceeds a preset threshold, the controller automatically increases the frequency f2 of the second vibrating unit and reduces the opening degree of the first silo control valve until the residual bubble rate drops below the threshold. The bubble rate threshold is set to 0.5% to 1.0%. S5: The defoamed material is discharged through the hopper and flows down the inner wall of the filling container through the anti-turbulence guiding structure into the filling station of the multi-station rotary mechanism for filling; after filling, the liquid level detection sensor detects the liquid level height in the filling container, and the controller compensates and corrects subsequent fillings according to the liquid level deviation signal; when the liquid level deviation direction of 3 consecutive filling containers is consistent and the deviation value exceeds ±0.5mm, the controller starts the compensation and correction program; S6: The multi-station rotating mechanism sequentially drives each filling station through the filling, can delivery, cap delivery, and cap sealing processes, and finally outputs the finished product through the output mechanism.

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