Method for the automated adjustment of process parameters of a filling process and container treatment system with filling device

Abstract

The invention relates to a method for the automated adjustment of process parameters (P, Pa - Pm) of a filling process in a filling device (1) for filling containers (2) with a liquid and / or free-flowing material. In this method, a foam pattern in the containers (2) filled with the material is optically detected by means of a first optical sensor system (3) arranged downstream of the filling device (1). Furthermore, the filling and / or foam formation within the containers (2) is optically monitored during and / or at the end of the filling process by means of a second optical sensor system (4) arranged upstream of the first optical sensor system (3).In a first stage (S1), a control device (10) that is connected to at least the filling device (1) and the first and second optical sensor systems (3, 4) automatically sets, in particular modifies, a power (P) of the filling device (1) as a process parameter based on measurement data (M1) of the first optical sensor system (3), and in a second stage (S2), one or more other process parameters (Pa - Pm) of the filling process are automatically set, in particular varied, based on measurement data (M2, M2', M2") of the second optical sensor system (4).

Description

[0001] The invention relates to a method for the automated adjustment of process parameters of a filling process in a filling device for filling containers with a liquid and / or flowable material, and to a container treatment system with a filling device for filling containers with a liquid and / or flowable material.

[0002] Filling devices or systems and methods for filling containers with a liquid and / or free-flowing substance are known in various designs from the prior art. In particular, filling systems or devices and methods for filling bottles with beverages are also known, as used, for example, in the beverage industry or beverage processing.

[0003] As is well known, such filling systems or filling devices are implemented in the form of filling machines, especially those of a rotating design, wherein the filling machines have a multitude of filling stations or filling positions or filling points, each of which is usually equipped with a filling element or filling device with a filling valve or liquid valve, through whose dispensing opening the liquid or flowable material is dispensed into the container in a controlled manner via a predetermined filling process.

[0004] The filling elements or filling devices are fluidically connected to a storage container or a source of the liquid material (e.g., a filling tank) via appropriate fluid lines, namely material feeds or lines. The material is generally dispensed into the containers by the controlled opening and closing of the respective filling valves provided in the filling elements or filling devices. It is also known that in such filling systems, the filling process, and in particular its control, depends on the material being filled, and the filling system or filling device must therefore be adjusted according to the specific application.

[0005] In current systems, a filling valve for the filling device is selected based on the beverage being filled, and the filling device is designed and adjusted according to the duration of the filling process. Subsequently, the filling process is optimized during commissioning through various manually implemented or initiated changes. Such changes include, for example, modifications and adjustments to process parameters such as pressures, times, and flow rates, as well as mechanical modifications and adjustments to components.

[0006] In practice, adjusting the filling device is complex and requires trained personnel. In particular, specialists are needed on-site during commissioning to adjust the filling device, especially for the first time, to bring a delivered machine up to operating condition by modifying components and optimizing process parameters, and to adapt it to the desired application. Therefore, there is a need to automate the adjustment of the filling device and the optimization of process parameters in a simple, cost-effective, and labor-saving manner.

[0007] One object of the invention is to demonstrate a method for the automated adjustment of process parameters of a filling process in a filling device, which enables an automatic, efficient, time-saving and optimized adjustment of the filling device in a systematic and, in particular, self-optimizing manner.

[0008] This problem is solved by a method for the automated adjustment of process parameters of a filling process according to the features of independent claim 1. Furthermore, a container treatment system according to the features of claim 14 is proposed to solve the problem. The dependent claims relate to particularly advantageous embodiments of the invention.

[0009] The present invention provides a method for the automated adjustment of process parameters of a filling process in a filling device for filling containers with a liquid and / or free-flowing material. In this method, a first optical sensor system arranged downstream of the filling device optically detects the foam pattern of the containers filled with the material. Furthermore, a second optical sensor system arranged upstream of the first optical sensor system optically monitors the filling process and / or foam formation within the containers during and / or at the end of the filling process.This includes a control device that communicates with at least the filling device and with the first and second optical sensor systems, by which, in a first stage, the performance of the filling device is automatically set, in particular modified, as a process parameter depending on measurement data from the first optical sensor system, and in a second stage, one or more other process parameters of the filling process are automatically set, in particular varied, depending on measurement data from the second optical sensor system.

[0010] The present method enables the automatic adjustment and setting of important process parameters via optimization algorithms, parameters which in conventional systems previously had to be set manually based on the knowledge-based experience of the operating personnel. The automatic setting of the process parameters is achieved, for example, via machine learning using a self-learning algorithm. The method according to the invention can therefore also be described as a self-optimizing filling process and, within the meaning of the invention, is also to be understood as a self-setting filling system.

[0011] The present method advantageously enables the commissioning and operation of a filling system according to a "plug-and-play" principle. Both initial commissioning and recommissioning (resumption of operation), for example after a production stoppage due to maintenance or repair, and / or a product changeover or production changeover, are reliably, quickly, and efficiently possible with the present method according to the invention, without the need for operating or commissioning personnel. Compared to known solutions from the prior art, the method according to the invention thus leads in particular to faster, more efficient, and cost- and personnel-saving commissioning of a filling device. The present method can also automate the filling process.This significantly accelerates the filling process during ongoing production, leading to faster filling times and ultimately increased efficiency. The process also offers high flexibility and low susceptibility to errors.

[0012] The method according to the invention is based on a multi-stage approach to setting and optimizing process parameters, whereby optical measurements and monitoring, as well as classifying assessments and evaluations of the measurement results, are automatically carried out in at least two stages after and / or during the filling process in order to automatically adjust process parameters accordingly. The method thus offers a scheme for a multi-stage procedure to automate the commissioning and operation of a filling plant by making decisions at at least two stages, based on which changes to process parameters are automatically effected.

[0013] In accordance with the present invention, the filling process carried out by means of the filling device can also be part of a comprehensive container treatment process, which, in addition to the filling process, may include further treatments, in particular, for example, pretreatment of the containers before the filling process and / or sealing of the containers already filled during the filling process in a sealing device located downstream of the filling device, i.e., arranged downstream of the filling device, which can also be referred to as a capper. The filling process or the entire container treatment process can be carried out, in particular, in a beverage bottling plant or beverage processing plant.

[0014] If a capper is located downstream of the filling device, the first optical sensor system can advantageously be arranged at the transition from the filling device to the capper or in or on a transfer star arranged between the filling device and the capper for transferring the filled containers from the filling device to the capper.

[0015] According to the invention, the performance of the filling device in the first stage is automatically adjusted depending on measurement data from the first optical sensor system.

[0016] If necessary, the performance of the filling device can also be adjusted and / or varied depending on measurement data from the second optical sensor system.

[0017] In general, the "capacity of the filling device" is understood here as a measure of the number of containers to be processed, or processed, per unit of time, and in particular, the number to be filled. The capacity of the filling device can thus be understood as synonymous with the container throughput, especially the throughput of containers through the filling device.

[0018] In accordance with the present invention, the second stage of the automated adjustment of process parameters, namely the automatic adjustment or variation of (other and / or further) process parameters of the filling process depending on measurement data from the second optical sensor system, is carried out, in particular, after the first stage. The first and second stages of the automated adjustment of process parameters can thus also be considered successive, preferably sequential, process steps. Although there may be a temporal overlap between the two stages, the first stage is preferably started or initiated before the second stage.

[0019] In the present understanding, the filling process is considered optimally adjusted, or rather, optimized, when a flawless filling result is achieved at every filling point of the filling device. Such a flawless filling result generally exists when a target fill quantity is filled with sufficient accuracy (standard deviation), when no excessive foam forms at the respective filling point while still compressed, which could rise into the filling valve and negatively affect the next filling and lead to underfilling, and when no foam or fill material escapes from the transfer star to the capper via the container opening and could lead to underfilling.

[0020] For example, achieving the target fill quantity can be achieved via a volume setpoint, which is controlled by means of a flow measurement, and achieving a target fill level can be achieved via a fill level setpoint, which is controlled by means of a fill level measurement.

[0021] The present method allows the filling process to be optimized automatically and a flawless filling result to be achieved.

[0022] The expression "a foam pattern of the containers filled with product is optically detected" means, in this context, that it is detected, particularly in the transfer area from the filling device to the capper, whether and to what extent a foam crown is present in the filled container. That is, it is observed whether the product foams up in the container or whether foam has formed above the liquid level of the product during the filling process.

[0023] In the present understanding, "monitoring of filling and / or foam formation" includes observing whether and with what proportion, for example, (air) bubbles are contained in the filling material and what size any bubbles may be. Furthermore, it also includes observing whether turbulence occurs when the filling material enters the container, whether the filling stream flows straight and smoothly (laminarly), and / or whether the filling process is "uneven" or the filling stream is turbulent. For example, optical sensor systems can acquire image data, namely measurement data, containing information about the filling film thickness, the filling stream thickness and shape profile in the case of free-jet filling, the number of bubbles, the bubble size, and the foam height along the filling path (e.g.,...).in %), foam intensity and foam consistency over the course of filling, foam formation, foam increase and foam type in the settling and unloading phase, foam behavior when lowering the containers from the filling element and / or foam formation during the transfer to the capper.

[0024] According to a preferred embodiment of the method, the power of the filling device is increased from a starting value, depending on the measurement data of the first optical sensor system, particularly stepwise in predetermined increments. Depending on the application and / or specific circumstances, the power can also be decreased from a starting value, again particularly stepwise in the aforementioned increments. The increase or decrease in power can, for example, be carried out in increments of 0.01%, whereby smaller or larger increments may also be appropriate and can be selected, for example, depending on the machine design or machine power, the rated power of the filling device, and / or the computing power, particularly the computing power of the control unit.The gradation is generally the same over time and preferably occurs in the smallest possible steps, but it can also occur in initially larger and then increasingly smaller steps, which can, for example, save time.

[0025] For commissioning and / or production start-up or product changeover, the iteration loops can be completed after a period of approximately 8 to 24 hours following initial use. Subsequently, the automated adjustment and optimization of the process data can, in principle, run continuously during production.

[0026] Preferably, the first optical sensor system quantitatively measures the amount of foam present in the containers after the filling process, increasing the filling device's output as long as the measured amount of foam remains below a predetermined limit. This optical measurement can be used, for example, to quantify the amount of foam by determining or evaluating the ratio of liquid to foam in the container. It is also possible to deduce the fill level and the foam content or proportion from the absolute quantities or volumes of the liquid and foam.

[0027] In this case, namely if no foam is detectable by the first optical sensor system or if the detected amount of foam, that is, the quantity or relative volume of foam, is below the specified limit or below a limit to be determined, the automatic adjustment, in particular variation of the process parameters of the second stage, can also include an unchanged "maintenance" of the process parameters, since in this described case the process parameters can be considered as suitable or as already correctly set.

[0028] To enable automated decision-making based on evaluation results, for example, to change process parameters, the decision-making process can incorporate information on how many filling stations are affected by suboptimal foam formation. For instance, it can be stipulated that a change in process parameters is only initiated if more than one, two, three, four, or five consecutive filling stations are affected. Alternatively or additionally, multiple cycles of the filling device or rotations of the filler carousel can be analyzed to, for example, trace individual filling stations and make station-specific or filling valve-specific adjustments.

[0029] According to a particularly preferred embodiment, the filling and / or foam formation within the containers is monitored by the second optical sensor system during an initial filling phase of the filling process taking place in the filling device. Depending on the measurement data from the second optical sensor system, process parameters such as an evacuation time for evacuating the containers, a filling temperature, gas recirculation from the container, a filling pressure, and / or a pre-pressurization time for pre-pressurizing the containers can be varied. In particular, it is conceivable that one or more of the aforementioned process parameters, for example in different combinations, can be varied. If several process parameters are varied, this can be done simultaneously or sequentially, and the order of the process parameters to be varied is not fixed but, in particular, can be chosen arbitrarily.

[0030] Preferably, the filling and / or foam formation within the containers is monitored by means of the second optical sensor system during a pressure release phase of the filling process taking place in the filling device. Depending on the measurement data of the second optical sensor system, a pre-pressure release, a settling time, a pressure release time, and / or the capacity of the filling device can be varied as process parameters. Analogous to the procedure described above for monitoring the filling and / or foam formation during the initial filling phase, it is also conceivable in this case that one or more of the aforementioned process parameters, for example in different combinations, are varied.When several process parameters are varied, this can, for example, be done simultaneously or sequentially, whereby the order of the process parameters to be varied is not fixed, but in particular can be chosen arbitrarily.

[0031] Preferably, the filling and / or foam formation within the containers can be monitored by means of the second optical sensor system at the end of the filling process taking place in the filling device. Here, for example, a filling pressure, a filling rate, a tank level, and / or a return gas pressure are varied as process parameters depending on the measurement data from the second optical sensor system. Analogous to the procedure described above for monitoring the filling and / or foam formation during the initial filling phase and / or during the discharge phase, it is also conceivable in this case that one or more of the aforementioned process parameters are varied, for example, in different combinations.When several process parameters are varied, this can, for example, be done simultaneously or sequentially, whereby the order of the process parameters to be varied is not fixed, but in particular can be chosen arbitrarily.

[0032] Particularly advantageous is the monitoring of filling and / or foam formation within the containers during different phases of the filling process. For this purpose, measurement data is acquired and evaluated in various zones of the filling device during several phases of the filling process. This acquisition is carried out primarily using multiple sensor units of the second optical sensor system, with the multiple sensor units, or individual units, being assigned to the different zones of the filling device. This enables finely graduated, accurate, and precise adjustments, and thus improved and faster optimization of the filling process.

[0033] According to a preferred embodiment of the method, multiple measurement data points are acquired in successive phases of the filling process in a hierarchical sequence, depending on test criteria. Depending on the respective evaluation results of the measurement data, further measurement data points are acquired in subsequent phases of the filling process. The multiple measurement data points acquired in successive phases of the filling process are evaluated, in particular by means of the control unit. This evaluation is performed, for example, using at least one predefined evaluation algorithm, taking into account or incorporating the test criteria. Depending on the evaluation result, further measurement data points are then acquired in subsequent phases of the filling process. The selection of the measurement data points to be acquired is again preferably made by means of the control unit, depending on the evaluation results.

[0034] The evaluation of the measurement data, taking into account the test criteria, is carried out, for example, as a "yes / no" query in the form of a decision tree. Such possible "yes / no" queries can be used to check, for example: - whether or not foaming can be detected by means of the first optical sensor system arranged downstream of the filling device, - whether the filling process is unstable during an initial filling phase or at the beginning of the filling, - whether the relief or the relief phase is unsettled or not and / or - whether foam is formed at the end of the filling process.

[0035] Depending on the query result, process parameters are then varied and, if necessary, further measurement data is recorded in subsequent phases of the filling process.

[0036] In the present method, the automated adjustment of process parameters is particularly preferred when the filling device is put into operation, when the machine is started and / or when the production is changed.

[0037] The automated adjustment of process parameters is also preferred in the continuous production operation of the filling device.

[0038] According to a particularly preferred embodiment of the present method, the automatic adjustment of the process parameters is carried out by means of control and / or calculation algorithms running in the control device, in particular using “machine learning” algorithms.

[0039] In this way, the filling device can be operated as an autonomous system using the present method. It also makes it possible to achieve improved automated monitoring and / or optimization of the filling process through methods such as data mining. New patterns and regularities can thus be automatically identified and used, for example, with the help of semi-supervised learning for the filling process or the bottling of beverages. This "machine learning" can be based on parameters, structures, or hidden concepts.

[0040] Preferably, the automatic adjustment of process parameters takes into account material-specific parameters, whereby material-specific parameters include, in particular, the type of material, its CO2 content, its temperature, and / or its electrical conductivity. This offers the advantage of efficient and, above all, application-specific adjustment and optimization of the filling process, resulting in application-optimized process control.

[0041] Further advantages of the present method arise from the classification of the measurement data from the first and / or second optical sensor system, particularly using deep learning methods. The measurement data acquired by the first and / or second optical sensor systems, namely the data from the camera surveillance, can be classified for evaluation, for example, using deep learning methods such as regression, and / or a support vector machine (SVM), and / or similar techniques. Such classification can be helpful and / or necessary to initiate automated decision-making.

[0042] The present invention further provides a container treatment system with at least one filling device for filling the containers with a liquid and / or flowable material. In the container treatment system, at least one first optical sensor system is provided downstream of the filling device for optically detecting foam in containers filled with the material. Upstream of the first optical sensor system, a second optical sensor system is provided for optically monitoring the filling process and / or foam formation within the containers during and / or at the end of a filling process taking place in the filling device.Furthermore, a control device is provided which communicates with the filling device as well as with the first and second optical sensor systems and which is designed to perform an automated adjustment of process parameters of the filling process in the container treatment system according to the method according to one of the preceding claims.

[0043] Preferably, the first optical sensor system and / or the second optical sensor system comprise at least one camera, in particular an electronic camera.

[0044] Furthermore, the second optical sensor system preferably has several sensor units, wherein the several sensor units are assigned to different zones of the filling device and wherein each sensor unit is preferably formed by a camera, in particular an electronic camera.

[0045] The invention will be explained in more detail below with reference to exemplary embodiments shown in the figures. The figures show: Fig. 1. A roughly schematic and highly simplified representation of an embodiment of a container treatment system and Fig. 2 A roughly schematic flow diagram of an advantageous embodiment of the method for the automated adjustment of process parameters.

[0046] The Fig. Figure 1 shows, purely by way of example and in a highly simplified and only roughly schematic sketch, a preferred embodiment of a container treatment system 9 with a filling device 1 for filling containers 2, in particular bottles, with a flowable or liquid filling material, in particular with a beverage, which may be, for example, a CO2-containing and / or foaming beverage.

[0047] The depicted container handling system 9 can also be understood as a filling system or bottling system and is, in particular, part or component of a complex beverage bottling or beverage processing plant. The filling device 1, which is also referred to synonymously as a filling machine, filler, or filling star, is designed, for example, as a continuously rotating filling device 1 and comprises a plurality of filling positions or filling points arranged circumferentially around a machine rotor, each of which is equipped with a filling element (not shown in the figures) and an associated filling valve.

[0048] Although not shown in the figures, each filling element is fluidically connected to a filling vessel via a material supply line connected to it, so that the liquid material held in the filling vessel is fed to the respective filling element via the material supply line, in particular in a controlled manner, and is then discharged by the filling element, again in a controlled manner, into the container 2 to be filled, the container preferably being in a sealing position against the filling element. A flow meter may be provided in the material supply line.

[0049] During the filling process, the containers 2 to be filled are fed to the filling device 1 in the area of ​​a container inlet 7, for example via an inlet star wheel 7.1, with each filling station being equipped with one container 2. The containers 2 held at the respective filling stations are rotated along a circular path of the filler, rotating with the rotating machine rotor, and thus pass through different zones Z1, Z2, Z3 of the filling device 1, in which the successive phases F1, F2, F3 of the filling process take place or are carried out.

[0050] The container handling system 9 of the illustrated example has a capping device 5, designed as a rotating capping carousel, downstream of the filling device 1. This capping device 5 can also be referred to as the capper 5 and is connected to the filling device 1 by means of a transfer star 6 arranged between the filling device 1 and the capper 5. After completion of the filling process in the filling device 1, i.e., after completion of a final phase F3 of the filling process, the containers 2 filled in the filling device 1 are taken over by the transfer star 6 and transferred to the capper 5. From the capper 5, the sealed containers 2 are discharged via a discharge star 8.1 in the area of ​​a container outlet 8 after completion of the closing process.

[0051] For the automated adjustment of process parameters P, Pa - Pm of the filling process, the container handling system 9 of the illustrated example has both a first optical sensor system 3 in the form of an electronic camera 3.1, arranged downstream of the filling device 1 in the area of ​​the transfer star 6, and a second optical sensor system 4, arranged upstream of the first optical sensor system 3, which in the illustrated example comprises three sensor units 4.1, 4.2, 4.3, each also designed as an electronic camera. Furthermore, a control unit 10, communicating with the filling device 1 as well as with the first and second optical sensor systems 3, 4, is provided for the automated adjustment of process parameters P, Pa - Pm of the filling process. The sequence of the automated adjustment of process parameters P, Pa - Pm of the filling process is described in connection with Fig. 2 below, described in more detail.

[0052] The first optical sensor system 3, or the electronic camera 3.1, is designed, arranged, and aligned in such a way that it captures measurement data M1 as image data in the form of a respective foam image of the filled containers 2 in the transfer area between filler 1 and capper 5, i.e., after filling or after completion of the filling process. This data can be used to detect whether the filling material in the container 2 foams up during the filling process, or whether the filling process leads to foam formation, in particular to excessive foam formation above a predetermined limit value.

[0053] The three sensor units 4.1, 4.2, 4.3 of the second optical sensor system 4 are provided in the area of ​​the filling device 1 and are designed, arranged and aligned in such a way that they are assigned to different zones Z1, Z2, Z3 of the filling device 1 and in this way acquire measurement data M2, M2', M2'' as respective image data of the containers 2 in the filling process in the zones Z1, Z2, Z3 in order to be able to monitor the filling and / or foam formation within the containers 2 in different phases F1 - F3 of the filling process.

[0054] For example, sensor unit 4.1 is located in or assigned to a first zone Z1 of the filling device 1, in which an initial filling phase F1 of the filling process takes place. Sensor unit 4.2 is located in or assigned to a second zone Z2 of the filling device 1, in which, for example, the unloading phase F2 of the filling process takes place, so that the second zone Z2 can also be referred to as unloading zone Z2. Sensor unit 4.3 is located in or assigned to a third zone Z3 of the filling device 1, in which the final phase F3 of the filling process takes place and the filling process is completed.

[0055] By combining the first and second sensor systems 3, 4, a diagnosis regarding foam formation in the container 2 – and thus consequently regarding optimized process control with a flawless filling result – can be efficiently carried out thanks to the stationary cameras 3.1, 4.1, 4.2, 4.3 arranged at various positions. In this multi-stage process, the presence of a foam crown in the transfer area from filler 1 to capper 5 can be observed, and additionally, foam formation and filling can be monitored at the beginning of the filling process in the first zone 2 of filler 1, at the end of the relief zone Z2 of filler 1, and / or at the end of the third zone 3 of filler 1.

[0056] The measurement data M1, M2, M2', M2" from the first and second optical sensor systems 3, 4, namely the image data or camera data, can be evaluated with regard to foam formation in the containers 2. For example, the absolute quantity of liquid and foam allows conclusions to be drawn about both the fill level and the amount of foam, and the ratio of liquid to foam can also be determined and evaluated. Based on the evaluation of the image data or camera data M1 - M2", automated decisions can be made and measures or actions initiated accordingly. Specifically, adjustments, changes, and variations of the process parameters P, Pa - Pm can be made to optimize the filling process.

[0057] Even if in Fig. Not shown in Figure 1, it is alternatively possible that a specific, predetermined filling point of the filler 1 is equipped with a preferably rotating camera, and that the monitoring of the filling and / or foam formation is carried out zone- and phase-independently by the camera belonging to the filling point. In this case, an integrated circuit with a logic circuit, preferably a so-called "Field Programmable Gate Array" (FPGA), can also be provided at the filling point, whereby, for example, the actions or decisions triggered by the acquired data through appropriate evaluation and decision-making for adjusting the process parameters can be transferred to all other filling points.

[0058] With reference to now Fig. Section 2 explains in more detail the automated adjustment of process parameters P, Pa - Pm of the filling process. Fig. Figure 2 shows, using a roughly schematic flow diagram, an advantageous embodiment of the present method in which the power P and / or various (other) process parameters Pa to Pm of the filling process are automated or automatically set as process parameters P.

[0059] In this process, multiple measurement data points M1, M2, M2', M2" are recorded in successive phases F1-F3 of the filling process in a hierarchical sequence, depending on test criteria. Based on the respective evaluation results A-M1, A-M2, A-M2', A-M2" of the measurement data M1, M2, M2', M2" further measurement data M1, M2, M2', M2' are recorded in subsequent phases of the filling process, and / or the power output P or process parameters Pa to Pm are changed. The adjustment or change of the power output P or process parameters Pa to Pm can be considered the measure to be taken or implemented, depending on the respective evaluation results A-M1, A-M2, A-M2', A-M2".

[0060] In the example shown, the Fig. 2. The evaluation of the measurement data M1, M2, M2', M2" and the associated decisions regarding the measures to be taken, namely the setting or changing of the power P or process parameters Pa to Pm, are carried out by means of the control unit 10 in the form of a decision tree as a "yes / no" query ("yes / no" (Y / N) - in Fig. 2 indicated by the reference symbol y for "yes" and by the reference symbol n for "no").

[0061] For the filling process taking place in the filling device 1, the first optical sensor system 3, arranged downstream of the filling device 1, is used, for example (as in Fig. 1 shown) is formed by a camera 3.1, in particular by an electronic camera, and measurement data M1 is acquired. These first measurement data M1 of the first optical sensor system 3 reflect an optically acquired foam image of the containers 2 filled with material after the actual filling process.

[0062] Depending on the measurement data M1 of the first optical sensor system 3, namely depending on the evaluation result A-M1, the power P of the filling device 1 is automatically adjusted in a first stage S1. In the example of the Fig. 2. As part of the evaluation of the measurement data M1 from the first optical sensor system 3, a query is performed to determine whether no foam, or only a quantity of foam below a predefined limit, can be detected in the container 2 filled with the material after it has left the filling device 1 following the completion of the filling process and is located in the area of ​​a downstream transfer star 6. If the evaluation result A-M1 is "yes" to this query based on the evaluation of the measurement data M1, the power P of the filling device 1 is automatically increased. The evaluation of the measurement data M1 and the increase in power P are controlled and performed automatically by the control unit 10. The evaluation of the measurement data M1 from the first optical sensor system 3 and the increase in power P of the filling device 1 can be automatically repeated iteratively.

[0063] If the evaluation of the measurement data M1 of the first optical sensor system 3, carried out with the aid of the control unit 10, results in the evaluation outcome A-M1 that the query posed during the evaluation must be answered with "no" n because foam can be detected in a quantity exceeding the specified limit value, then in the example of the Fig. 2 the filling and / or foam formation within the containers 2 is additionally monitored during an initial filling phase F1 of the filling process, by means of the second optical sensor system 4, in particular with the sensor unit 4.1 of the second optical sensor system 4 designed as an electronic camera, which is assigned to a partial circle or the first zone Z1 in the area of ​​the filling device 1, in which the initial filling phase F1 of the filling process takes place, for example including an evacuation and / or pressure control and / or a pre-pressurization of the containers as well as a filling start with the beginning of the flow of filling material into the container 2.

[0064] Depending on the measurement data M2 of the sensor unit 4.1 of the second optical sensor system 4, process parameters Pa - Pe of the initial filling phase F1 can be automatically adjusted or varied and / or the acquisition of further additional measurement data M2', M2" in further phases of the filling process can be automatically initiated.

[0065] In the example of the Fig. 2. During the evaluation of the measurement data M2 from sensor unit 4.1 of the second optical sensor system 4, a query is performed to determine whether the start of the filling process is unstable. If the evaluation result A-M2 is "yes" to this query, one or more of the process parameters Pa - Pe of the initial filling phase F1 are automatically adjusted or varied. These process parameters Pa - Pe include, for example, an evacuation time Pa for evacuating the containers 2, a filling temperature Pb, a gas recirculation Pc from the container 2, a filling pressure Pd, and / or a pre-pressurization time Pe for pre-pressurizing the containers 2. The evaluation of the measurement data M2, as well as the adjustment and variation of the process parameters Pa - Pe, and / or the initiation of monitoring the filling and / or foam formation in further phases of the filling process, is carried out automatically and controlled by the control unit 10.

[0066] In the exemplary execution variant outlined, according to Fig. 2 as evaluation result A-M2, that the query which is posed within the framework of the evaluation of the measurement data M2 carried out with the aid of the control unit 10 is to be answered with “no” n because the filling start runs smoothly, the filling and / or foam formation within the containers 2 is additionally monitored during a relief phase F2 of the filling process, namely again by means of the second optical sensor system 4, in particular with the sensor unit 4.2 of the second optical sensor system 4 designed as an electronic camera, which is arranged in the area of ​​the filling star 1 and is assigned to the second zone Z2 or a partial circle of the filling device 1 in which the relief is carried out.

[0067] Depending on the measurement data M2' of the sensor unit 4.2 of the second optical sensor system 4, process parameters Pf - Pi of the unloading phase F2 can be automatically adjusted or varied and / or the acquisition of further additional measurement data M2" in further phases of the filling process can be automatically initiated.

[0068] In the example of the Fig. 2. During the evaluation of the measurement data M2' from sensor unit 4.2 of the second optical sensor system 4, a query is performed to determine whether the unloading process is uneven. If the evaluation result A-M2' is "yes" to this query, one or more of the process parameters Pf - Pi of the unloading phase F2 are automatically adjusted or varied. These process parameters Pf - Pi include, for example, a pre-unloading pressure Pf, a settling time Pg, an unloading time Ph, and / or a reduction in power Pi. The evaluation of the measurement data M2', as well as the adjustment and variation of the process parameters Pf - Pi, and / or the initiation of monitoring the filling and / or foam formation in further phases of the filling process, is carried out automatically and controlled by the control unit 10.

[0069] The evaluation result A-M2' is obtained for the exemplary execution variant outlined according to Fig. 2, that the query, which is posed as part of the evaluation of the measurement data M2' carried out with the aid of the control unit 10, is to be answered with “no” n because the discharge is running smoothly, the filling and / or foam formation within the containers 2 is additionally monitored in a final phase F3, namely at the end of the filling process, again by means of the second optical sensor system 4, in particular with the sensor unit 4.3 of the second optical sensor system 4 designed as an electronic camera, which is arranged in the area of ​​the filling star 1 and is assigned to the third zone Z3 or a partial circle of the filling device 1, in which the filling process is terminated.

[0070] Depending on the measurement data M2" of the sensor unit 4.3 of the second optical sensor system 4, process parameters Pj - Pm of the final phase F3 can be automatically adjusted or varied. In the example of the Fig. 2. During the evaluation of the measurement data M2" from sensor unit 4.3 of the second optical sensor system 4, a query is performed to determine whether foaming occurs at the end of the filling process. If the evaluation result A-M2" is "yes" to this query, one or more of the process parameters Pj - Pm of the final phase F3 are automatically adjusted or varied. These process parameters Pj - Pm include, for example, a filling pressure Pj, a filling speed Pk, a boiler level PI, and / or a return gas pressure Pm. The evaluation of the measurement data M2" and the adjustment and variation of the process parameters Pj - Pm are performed automatically and controlled by the control unit 10.

[0071] In the exemplary execution variant outlined, according to Fig. 2. If the evaluation result A-M2" indicates that the query posed during the evaluation of the measurement data M2" performed with the aid of control unit 10 is to be answered with "no" because no foam formation occurs at the end of the filling, the procedure can be considered completed. Fig. Although not shown in section 2, it is also possible to additionally check whether all setpoints and / or process parameter values ​​and / or actual performance values ​​are within a target range. If this is not the case, a signal can be issued indicating that manual intervention is required and, for example, a mechanical adjustment or change must be made by operating personnel.

[0072] It is understood that the respective evaluations of the measurement data M2, M2', M2" of the second optical sensor system 4 and the corresponding adjustments or variations of the process parameters Pa - Pm can also be automatically repeated iteratively.

[0073] The present procedure can take into account that in a beverage bottling plant, other or additional parameters detected by sensors should also be included in the calculation of the control algorithms for automating the settings of the process parameters P, Pa - Pm, for example a type of product or beverage, a CO2 content of the product or beverage, a product temperature and / or a conductivity, etc.

[0074] The measurement data M1 - M2 can be classified for evaluation using deep learning, e.g. with the help of regression, a "support vector machine", etc. Classification can be helpful and / or necessary to initiate automated decisions. Reference symbol list 1 Filling device 2 containers 3 first optical sensor system 3.1 Camera 4 second optical sensor system 4.1, 4.2, 4.3 Sensor units 5. Closing device, capper 6 Transition star 7 Container inlet 7.1 Inlet star 8 Container outlet 8.1 Outflow star 9 Container treatment system 10 Control unit A-M1 - A-M2" Evaluation result F1 Initial filling phase of the filling process F2 Relief phase of the filling process F3 Final phase of the filling process M1, M2 - M2'' Measurement data P Process parameters, performance Pa - Pm process parameters S1 first stage S2 second stage Z1 - Z3 zones of the filling device

Claims

[1] Method for the automated adjustment of process parameters (P, Pa - Pm) of a filling process in a filling device (1) for filling containers (2) with a liquid and / or flowable material, wherein a foam pattern of the containers (2) filled with material is optically detected by means of a first optical sensor system (3) arranged downstream of the filling device (1), wherein the filling and / or foam formation within the containers (2) is optically monitored by means of a second optical sensor system (4) arranged upstream of the first optical sensor system (3), wherein a control device (10) is provided which is connected to communicate at least with the filling device (1) and with the first and second optical sensor systems (3, 4),In a first stage (S1), depending on measurement data (M1) of the first optical sensor system (3), a power (P) of the filling device (1) is automatically set, in particular modified, as a process parameter, and in a second stage (S2), depending on measurement data (M2, M2', M2") of the second optical sensor system (4), one or more other process parameters (Pa - Pm) of the filling process are automatically set, in particular varied. [2] Method according to claim 1, characterized by , that depending on the measurement data (M1) of the first optical sensor system (3) the power (P) of the filling device (1) is increased starting from a starting value, in particular stepwise in predetermined increments. [3] Method according to claim 2, characterized by, that by means of the first optical sensor system (3) the foam present in the containers (2) after the filling process is quantitatively detected as a quantity of foam, whereby the power (P) of the filling device (1) is increased as long as the detected quantity of foam is below a predetermined limit value. [4] Method according to any one of the preceding claims, characterized by , that the filling and / or foaming within the containers (2) is monitored by means of the second optical sensor system (4) during an initial filling phase (F1) of the filling process taking place in the filling device (1), wherein, depending on the measurement data (M2, M2', M2") of the second optical sensor system (4), an evacuation time (Pa) for evacuating the containers (2), a filling temperature (Pb), a gas recirculation (Pc) from the container (2), a filling pressure (Pd) and / or a pre-pressurization time (Pe) for pre-pressurizing the containers (2) are varied as process parameters (Pa - Pm). [5] Method according to any one of the preceding claims, characterized by , that the filling and / or foam formation within the containers (2) is monitored by means of the second optical sensor system (4) during a relief phase (F2) of the filling process taking place in the filling device (1), wherein, depending on the measurement data (M2, M2', M2") of the second optical sensor system (4), a pre-relief pressure (Pf), a settling time (Pg), a relief time (Ph) and / or a power (Pi) of the filling device (1) are varied as process parameters (Pa - Pm). [6] Method according to any one of the preceding claims, characterized by, that the filling and / or foam formation within the containers (2) is monitored by means of the second optical sensor system (4) in a final phase (F3) at the end of the filling process taking place in the filling device (1), wherein, depending on the measurement data (M2, M2', M2") of the second optical sensor system (4), a filling pressure (Pj), a filling speed (Pk), a boiler level (Pl) and / or a return gas pressure (Pm) are varied as process parameters. [7] Method according to any one of the preceding claims, characterized by, that the filling and / or foam formation within the containers (2) is monitored during different phases (F1 - F3) of the filling process, wherein for this purpose measurement data (M2, M2', M2") are recorded and evaluated in different zones (Z1 - Z3) of the filling device (1) in several phases (F1 - F3) of the filling process, wherein the recording is carried out in particular by means of several sensor units (4.1, 4.2, 4.3) of the second optical sensor system (4) which are assigned to the different zones (Z1 - Z3) of the filling device (1). [8] Method according to claim 7, characterized by , that the multiple measurement data (M2, M2', M2") are recorded in successive phases (F1 - F3) of the filling process in a hierarchical sequence depending on test criteria, whereby depending on the respective evaluation results (A-M1, A-M2, AM2', A-M2") of the measurement data (M1, M2, M2', M2") further measurement data (M2, M2', M2") are recorded in subsequent phases (F1 - F3) of the filling process. [9] Method according to any one of the preceding claims, characterized by , that the automated setting of process parameters (P, Pa - Pm) is carried out when the filling device (1) is put into operation, when the machine is started and / or when the production is changed. [10] Method according to any one of the preceding claims, characterized by , that the automated adjustment of process parameters (P, Pa - Pm) is carried out in the continuous production operation of the filling device (1). [11] Method according to any one of the preceding claims, characterized by , that the automatic setting of the process parameters (P, Pa - Pm) is carried out by means of control and / or calculation algorithms running in the control unit (10), in particular using “machine learning” algorithms. [12] Method according to any one of the preceding claims, characterized by, that when automatically setting the process parameters (P, Pa - Pm) product-specific parameters are taken into account, whereby product-specific parameters include in particular a type of product, a CO2 content of the product, a product temperature and / or an electrical conductivity of the product. [13] Method according to any one of the preceding claims, characterized by , that the measurement data (M1, M2, M2', M2") of the first and / or second optical sensor system (3, 4) are classified, in particular using deep learning methods. [14] Container handling system (9) with at least one filling device (1) for filling the containers (2) with a liquid and / or flowable material, wherein at least one first optical sensor system (3) is provided downstream of the filling device (1) for optically detecting a foam pattern of the containers (2) filled with material, wherein a second optical sensor system (4) is provided upstream of the first optical sensor system (3) for optically monitoring the filling and / or foam formation within the containers (2) during and / or at the end of a filling process taking place in the filling device (1), and wherein a control device (10) is provided which communicates with the filling device (1) and with the first and second optical sensor systems (3, 4) and which is configured to automatically adjust process parameters (P,Pa - Pm) of the filling process in the container treatment system (1) according to the method according to one of the preceding claims. [15] Container treatment system (9) according to claim 14, characterized by , that the first optical sensor system (3) and / or the second optical sensor system (4) comprise at least one camera (3.1, 4.1, 4.2, 4.3), in particular an electronic camera. [16] Container treatment system (9) according to claim 14 or 15, characterized by , that the second optical sensor system (4) has several sensor units (4.1, 4.2, 4.3), wherein the several sensor units (4.1, 4.2, 4.3) are assigned to different zones (Z1 - Z3) of the filling device (1) and wherein preferably each sensor unit (4.1, 4.2, 4.3) is formed by a camera, in particular an electronic camera.

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