METHOD FOR OPERATING A FILLING PLANT AND FILLING PLANT

Description

[0001] The invention relates to a method for operating a filling plant, wherein the filling plant has at least one first filling point and at least one second filling point, wherein the first filling point has at least one first filling valve, at least one first flow or level sensor and at least one first control and evaluation unit for regulating and monitoring the filling process of the first filling point, and wherein the second filling point has at least one second filling valve, at least one second flow or level sensor and at least one second control and evaluation unit for regulating and monitoring the filling process of the second filling point.wherein a valve characteristic curve of the first filling valve is stored in the first control and evaluation unit and wherein a valve characteristic curve of the second filling valve is stored in the second control and evaluation unit, and wherein the first control and evaluation unit and the second control and evaluation unit are connected to each other via a communication channel. The invention also relates to a corresponding filling system.

[0002] Filling systems are known in large numbers from the prior art and are used to fill various media into containers. For this purpose, filling systems generally have multiple filling points, each of which has at least one filling valve for adjusting the flow opening, a flow or level sensor for determining a flow rate, flow velocity, or level, and a control and evaluation unit for regulating and monitoring the filling processes of the filling point. DE 10 2013 100702 A1 discloses such a filling system and a corresponding method according to the preamble of claim 1. Another filling system is known from EP 2 460 761 A1.

[0003] The present invention is described with reference to at least two filling points, and some aspects of the invention are described with reference to at least three filling points. However, the invention is readily applicable to filling systems with more than two or three filling points.

[0004] The control and evaluation units of the filling system store valve characteristic curves for the respective filling valves at the filling stations. A valve characteristic curve shows the flow rate or flow velocity as a function of the valve opening or the degree of opening of the filling valve. A valve characteristic curve is recorded under constant process conditions – within reasonable tolerances. If the process conditions change, for example, if the pressure conditions in the filling system change, the valve characteristic curve also changes. Accordingly, it is advantageous to keep the valve characteristic curves stored in the control and evaluation units as up-to-date as possible. Preferably, the valve characteristic curves are stored in the control and evaluation units immediately before the start of the process according to the invention, or it is checked whether the process conditions – which are decisive for the valve characteristic curve – have changed.

[0005] To ensure reliable operation of the filling system, it is necessary to perform regular diagnostic checks of the filling points or individual components thereof. Common diagnostic checks include zero-point monitoring, conductivity monitoring, and – when using magnetic-inductive flow meters – monitoring of the electrode noise of the measuring electrodes.

[0006] Some necessary diagnostics can only be performed when there is no flow. This includes, for example, zero-point monitoring, which verifies that a true zero flow is indeed measured as zero flow. A deviation from the zero point in an individual flow meter can be caused, for example, by a valve leak or a sensor malfunction.

[0007] Other necessary diagnostics can only be performed while the filling system is in operation, as a certain flow rate is required for diagnostic procedures. For example, conductivity monitoring requires at least a small flow rate. Conductivity monitoring serves to detect deposits on the measuring lines, contamination of the medium, or changes in the medium's composition. Electrode noise monitoring, for instance, must be performed during a flow measurement. A deviation from the expected electrode noise value at multiple filling points can indicate, for example, a changed flow profile or contamination of the medium.

[0008] A disadvantage of performing diagnostics is that doing so can disrupt the filling process. Firstly, it may be necessary to stop the filling process if zero flow is required for the diagnostic procedure. Even if the filling process can continue, the diagnostics can still disrupt the operation. This can lead to inaccuracies in the filling quantities or a slowdown in the flow measurement during filling. Therefore, current best practices include performing diagnostics only when the filling system is shut down, for example, during maintenance work, or foregoing diagnostics altogether.

[0009] The invention is therefore based on the objective of providing a method for operating a filling plant and a corresponding filling plant with which a diagnostic operation can be carried out reliably during the filling operation.

[0010] The problem is solved in the inventive method with the features of the characterizing part of claim 1.

[0011] The method according to the invention is therefore characterized, firstly and essentially, by the fact that, during the operation of the filling system, i.e., during filling operation, the first filling station switches to a diagnostic mode. According to the invention, the first control and evaluation unit signals the start of the diagnostic mode to the second control and evaluation unit. Furthermore, the first control and evaluation unit outputs substitute flow or substitute fill level values ​​during the diagnostic mode; however, a filling process continues at the first filling station during this time.

[0012] The second filling station is in "normal" filling operation when the first filling station is in diagnostic operation. According to the invention, it is further provided that the second control and evaluation unit transmits a deviation message to the first control and evaluation unit if it detects a deviation of the current flow rate or fill level from the flow rate or fill level expected based on the valve characteristic curve.

[0013] The first control and evaluation unit receives the deviation message. According to the invention, two alternative variants are provided. In a first variant, the first control and evaluation unit terminates the diagnostic operation after receiving the deviation message and switches to normal operation. In normal operation, the first filling station can then react to the changed process conditions and adapt the filling process accordingly.

[0014] In a second variant, the first control and evaluation unit outputs corrected substitute flow or level values ​​after receiving the deviation message. In this second variant, the diagnostic operation is therefore not interrupted; instead, corrected substitute flow or level values ​​are output, on the basis of which the filling process at the first filling station continues.

[0015] The method according to the invention offers the advantage that diagnostic operation can take place at the filling point during the filling process. The filling process is therefore not affected by the diagnostic procedure. The output of the substitute level or flow rate values ​​is based on the assumption that the process conditions are constant within predefined tolerances. The method according to the invention detects changes in the process conditions, namely those detected by the second filling point and reported to the first filling point, enabling the latter to react to the changing process conditions in order to prevent or at least minimize disruptions to the filling process.

[0016] This makes it possible to perform diagnostics even during the filling process. Overall, this results in a more precise filling process, as any errors identified during the diagnostics can be rectified immediately, or the diagnostics can uncover errors without having to wait until the next scheduled maintenance interval for the filling system to detect existing problems. By performing diagnostics and filling simultaneously, maintenance times for the filling system can be reduced, as diagnostics do not need to be carried out during the same process, as is usually the case with current technology.

[0017] According to the invention, there are various variants with which the substitute flow rate or substitute level values ​​can be determined or ascertained.

[0018] In a first variant, the method according to the invention is characterized in that the substitute flow rate or substitute level values ​​are determined by the first control and evaluation unit on the basis of the current valve position of the first filling valve and the valve characteristic curve stored in the first control and evaluation unit.

[0019] In a second embodiment, the method according to the invention is characterized in that the second control and evaluation unit transmits current flow rate or fill level values ​​to the first control and evaluation unit, and the first control and evaluation unit outputs these values ​​as substitute flow rate or fill level values. The first control and evaluation unit thus outputs the same flow rate or fill level values ​​as the second control and evaluation unit. This is particularly advantageous when the first control and evaluation units are arranged adjacent to each other or at least in close proximity, since the process conditions at both filling points are then approximately identical.

[0020] In a third variant, the method according to the invention is characterized in that flow rate or fill level values ​​from at least one past filling cycle are stored in the first control and evaluation unit and that the first control and evaluation unit outputs these stored flow rate or fill level values ​​as substitute flow rate or substitute fill level values.

[0021] In a fourth variant, the method according to the invention is characterized in that flow rate or fill level values ​​from at least one past filling cycle are stored in the second control and evaluation unit and that the second control and evaluation unit transmits these stored flow rate or fill level values ​​to the first control and evaluation unit and the first control and evaluation unit outputs these values ​​as substitute flow rate or substitute fill level values.

[0022] A particularly preferred embodiment of the method according to the invention is used in a filling system that has at least one third filling point, wherein the third filling point has at least one third filling valve, at least one third flow or level sensor, and at least one third control and evaluation unit for regulating and monitoring the filling process of the third filling point, wherein a valve characteristic curve of the third filling valve is stored in the third control and evaluation unit, and wherein the third control and evaluation unit is connected to at least the second control and evaluation unit via a communication channel. The third control and evaluation unit can also be connected to the first control and evaluation unit via a communication channel. All of the communication channels of the filling system can be wireless or wired.All control and evaluation units can also be connected to each other via the same communication channel.

[0023] According to the invention, a particularly preferred embodiment of the method is characterized in that, during diagnostic operation of the first filling point, the second control and evaluation unit compares its currently measured flow rate or level value with the flow rate or level value expected based on the valve characteristic curve stored in the second control and evaluation unit. Furthermore, the third control and evaluation unit also compares its currently measured flow rate or level value with the flow rate or level value expected based on the valve characteristic curve stored in the third control and evaluation unit.

[0024] In the event of a deviation between the current flow rate or fill level values ​​and the flow rate or fill level values ​​expected based on the valve characteristics at both filling points, the second and third control and evaluation units determine the magnitude and / or direction of the deviations. According to the invention, the magnitude and / or direction of the deviations are also compared. This comparison can be performed, for example, by one of the two control and evaluation units, i.e., by the second control and evaluation unit, or by the third control and evaluation unit – for which the necessary data has been previously transmitted to the respective control and evaluation unit. The comparison can also be performed in both control and evaluation units, i.e., in both the second and the third control and evaluation units.In the event of a similar deviation, the magnitude and / or direction of the deviation is / are transmitted to the first control and evaluation unit. Preferably, the control and evaluation unit that also performed the comparison transmits the magnitude and / or direction of the deviation. A similar deviation exists when the deviations are identical within a predefined tolerance range.

[0025] According to the invention, the method is further characterized in that the first control and evaluation unit corrects the valve characteristic curve of the first filling valve – in particular, corrects it by the magnitude and / or direction of the deviation – and that the first control and evaluation unit outputs a corrected substitute flow rate or substitute level value determined using the corrected valve characteristic curve. Thus, the first filling point can react to changes in process conditions without having to interrupt the diagnostic operation.

[0026] In the second variant of the method according to the invention, i.e., the variant in which the first control and evaluation unit does not terminate the diagnostic operation but outputs corrected substitute flow or level values, one embodiment provides that both the substitute flow or level values ​​and the corrected substitute flow or level values ​​are determined using the same method, i.e., in the same way. Alternatively, it is provided that the substitute flow or level values ​​and the corrected substitute flow or level values ​​are determined using different methods.

[0027] During diagnostic operation, the first control and evaluation unit can perform various diagnoses. If the first control and evaluation unit detects a fault condition during diagnostic operation, further embodiments of the method according to the invention provide for additional process steps.

[0028] In a particularly preferred embodiment of the method according to the invention, the first control and evaluation unit, after detecting a fault condition, sends a request for a diagnostic result of a similar diagnosis to the second control and evaluation unit and / or – if present – ​​to the third control and evaluation unit. Thus, if the first filling station, for example, performs zero-point monitoring and detects a deviating zero point, the control and evaluation unit requests the result of a zero-point monitoring performed by the second and / or third control and evaluation unit. According to the invention, the second control and evaluation unit and / or the third control and evaluation unit – if present – ​​also transmit their diagnostic result for the similar diagnosis to the first control and evaluation unit.

[0029] The method according to the invention is further characterized in that the diagnostic result of the first control and evaluation unit is compared with the diagnostic result of the second control and evaluation unit and / or – if present – ​​the third control and evaluation unit. Preferably, the first control and evaluation unit performs the comparison of the diagnostic results.

[0030] The method according to the invention is further characterized in that, in the case of an identical diagnostic result, a conclusion is drawn that there is a process error in the filling system, and in the case of a different diagnostic result, a conclusion is drawn that there is a filling point error at the first filling point.

[0031] In an alternative variant, after detecting a fault condition, the first control and evaluation unit transmits the diagnostic result justifying the fault condition to the second control and evaluation unit and / or the third control and evaluation unit - if present.

[0032] The method according to the invention is further characterized in that the diagnostic result of the first control and evaluation unit is compared with the diagnostic result of the second control and evaluation unit and / or – if present – ​​the third control and evaluation unit. Preferably, the second control and evaluation unit performs the comparison of the diagnostic results, or the third control and evaluation unit – if present – ​​performs the comparison of the diagnostic results. More preferably, if three control and evaluation units are present, both the second and the third control and evaluation units perform the comparison of the diagnostic results. In a particularly preferred embodiment, all similar diagnostic results from all control and evaluation units are compared with each other, i.e., the diagnostic results of the first, second, and third control and evaluation units.

[0033] The inventive method according to the alternative variant is now further characterized in that, in the case of an identical diagnostic result, a conclusion is drawn that there is a process error in the filling system and, in the case of a different diagnostic result, a conclusion is drawn that there is a filling point error at the first filling point.

[0034] The two variants described above have the advantage of providing a particularly elegant way to distinguish between a filling point error and a process error. The method is based on the assumption that a process error affects the filling points in the same way. If a filling point error is determined according to the inventive method, the affected filling point can, for example, be taken out of service and serviced. If, on the other hand, a process error is determined, the filling system can, for example, be stopped.

[0035] In addition to the method for operating a filling plant, the invention also relates to a filling plant for filling media into containers according to claim 7.

[0036] The filling system has at least one first filling point and at least one second filling point, wherein the first filling point has at least one first filling valve, at least one first flow or level sensor and at least one first control and evaluation unit for controlling and monitoring the filling process of the first filling point, and wherein the second filling point has at least one second filling valve, at least one second flow or level sensor and at least one second control and evaluation unit for controlling and monitoring the filling process of the second filling point, wherein a valve characteristic curve of the first filling valve is stored in the first control and evaluation unit and wherein a valve characteristic curve of the second filling valve is stored in the second control and evaluation unit, and wherein the first control and evaluation unit and the second control and evaluation unit are connected to each other via a communication channel.

[0037] The problem is solved in the filling system according to the invention, firstly and essentially, by the features of the characterizing part of claim 8, namely that the first control and evaluation unit is designed such that, after transitioning to a diagnostic mode, it reports the start of the diagnostic process to the second control and evaluation unit; that the first control and evaluation unit is further designed such that it outputs substitute flow rates or substitute fill levels during the diagnostic mode; that the second control and evaluation unit is designed such that, in the event of detecting a deviation of the current flow rate or fill level from the flow rate or fill level expected based on the valve characteristic curve, it transmits a deviation message to the first control and evaluation unit; and that the first control and evaluation unit is further designed such thatthat upon receiving the deviation message, it either aborts the diagnostic operation and switches to normal operation or outputs corrected substitute flow or substitute level values.

[0038] In a further preferred embodiment of the filling system according to the invention, the filling system has at least one third filling point, wherein the third filling point has at least one third filling valve, at least one third flow or level sensor, and at least one third control and evaluation unit for controlling and monitoring the filling process of the third filling point, wherein a valve characteristic curve of the third filling valve is stored in the third control and evaluation unit, and wherein the third control and evaluation unit is connected to at least the second control and evaluation unit via a communication channel. The filling system according to the invention is further characterized in that the second control and evaluation unit and the third control and evaluation unit are configured such thatthat in diagnostic mode of the first filling point, the second control and evaluation unit compares its currently measured flow rate or level value with the flow rate or level value expected based on the valve characteristic curve stored in the second control and evaluation unit, that the third control and evaluation unit compares its currently measured flow rate or level value with the flow rate or level value expected based on the valve characteristic curve stored in the third control and evaluation unit,that in the event of a deviation of the current flow rate or level values ​​from the flow rate or level values ​​expected based on the valve characteristic curves, the second control and evaluation unit and the third control and evaluation unit determine the magnitude and / or direction of the deviations and compare them with each other, and in the event of a similar deviation, the second control and evaluation unit and / or the third control and evaluation unit transmit the magnitude and / or direction of the deviation to the first control and evaluation unit, that the first control and evaluation unit corrects the valve characteristic curve of the first filling valve - in particular corrects it by the magnitude and / or direction of the deviation - and that the first control and evaluation unit outputs a corrected substitute flow rate or substitute level value determined with the corrected valve characteristic curve.

[0039] Particularly preferred embodiments of the filling system according to the invention are characterized in that the first control and evaluation unit, the second control and evaluation unit and - if provided - the third control and evaluation unit are further designed to implement one or more of the variants of the method according to the invention described above.

[0040] All variants described in connection with the inventive method, with their corresponding advantages, can be transferred analogously to the inventive filling plant and apply accordingly.

[0041] In detail, there are numerous possibilities for designing and further developing the inventive method for operating a filling plant and the inventive filling plant itself. Reference is made to the claims following the dependent claims and to the description of preferred embodiments in conjunction with the drawing. The drawing shows Fig. 1 a block diagram of a first variant of a method for operating a filling plant, Fig. 2 a block diagram of a first preferred embodiment of process steps of the Fig. 1 The method described in Fig. 3 is a block diagram of a second preferred embodiment of the process steps described in Fig. 3. Fig. 1 The method shown in Fig. 4 is a block diagram of a third preferred embodiment of the process steps of the method described in Fig. 4. Fig. 1 The method shown in Fig. 5 is a block diagram of a fourth preferred embodiment of the process steps described in Fig. 5. Fig. 1 The method shown in Fig. 6 is a block diagram of a second variant of a method for operating a filling plant, Fig. 7 is a first embodiment of a filling plant and Fig. 8 is a second embodiment of a filling plant.

[0042] Fig. 1 A block diagram of a first variant of a method 100 for operating a filling plant 1 is shown. A filling plant 1, which is designed to fill the in Fig. 1 The procedure described in 100 is to be carried out in Fig. 7 The filling system 1 has a first filling station 2 and a second filling station 3. The first filling station 2 has a first filling valve 4, a first flow or level sensor 5, and a first control and evaluation unit 6. The first control and evaluation unit 6 is configured to regulate and monitor the filling process of the first filling station 2. The second filling station 3 has a second filling valve 7, a second flow or level sensor 8, and a second control and evaluation unit 9, the second control and evaluation unit 9 being configured to regulate and monitor the filling processes of the second filling station 3. The first control and evaluation unit 6 of the first filling station 2 and the second control and evaluation unit 9 of the second filling station 3 are connected to each other via a communication channel 10.

[0043] The in Fig. 1 The described method for operating a filling plant 1 is characterized by various process steps. In a first process step 101, the first filling station 2 switches to a diagnostic mode while the filling plant 1 is in operation. In a second process step 102, the first control and evaluation unit 6 of the first filling station 2 signals the start of the diagnostic phase to the second control and evaluation unit 9 of the second filling station 3. This signal is transmitted via communication channel 10. During the diagnostic phase, the first control and evaluation unit 6 outputs substitute flow rate or substitute level values ​​(process step 103).In a further process step 104, if the second control and evaluation unit 9 detects a deviation of the current flow rate or fill level from the flow rate or fill level expected based on the valve characteristic curve stored in the second control and evaluation unit 9, it transmits a deviation message to the first control and evaluation unit 6. After receiving the deviation message 105, the first control and evaluation unit 6 terminates the diagnostic operation in a process step 106 and switches to normal operation. In an alternative variant, after receiving the deviation message 105, the control and evaluation unit 6 outputs corrected substitute flow rate or substitute fill level values ​​to the first filling point 2 (process step 107).

[0044] The described method is particularly suitable for performing a diagnostic operation at least at one filling station during the ongoing filling operation of the filling plant. During the diagnostic operation, a filling process also takes place at the filling station undergoing diagnostics. In addition to the possibility of integrating the diagnostic operation into the filling operation, the described method also offers the advantage of ensuring significantly more precise filling at the filling stations. This is because, firstly, the filling station undergoing diagnostics outputs substitute values ​​for the flow rate or fill level, which are used to monitor and control the filling process. Secondly, any errors that may occur can be detected immediately during the diagnostic operation and thus rectified promptly.

[0045] The Fig. 2 bis 5 show individual excerpts from the in Fig. 1 The procedures shown are presented in different variations. Only the process steps between process steps 102 and 103 are shown. All other steps in Fig. 1 The process steps described are performed before or after the steps described in Fig. 2 bis 5 The described procedural steps were nevertheless carried out.

[0046] Fig. 2 shows a block diagram of a first preferred further development of process steps of the in Fig. 1 The procedure 100 shown is as follows: After the communication of the diagnostic start 102 from the first filling point 2 to the second filling point 3, in a procedure step 108 the first control and evaluation unit 6 of the first filling point 2 determines the substitute flow rate or substitute level values ​​based on the current valve position of the first filling valve 4 and the valve characteristic curve stored in the first control and evaluation unit 6. Subsequently, in a procedure step 103, the substitute values ​​are output by the first control and evaluation unit 6.

[0047] An alternative method for determining the substitute flow rate or substitute level values ​​is in Fig. 3 This differs from the one shown in Fig. 2 In the illustrated embodiment, the second control and evaluation unit 9 transmits current flow or level values ​​to the first control and evaluation unit 6 in a process step 108' and the first control and evaluation unit 6 outputs these current flow or level values ​​to the second control and evaluation unit 9 as substitute flow or level values.

[0048] The in Fig. 4 The variant shown differs from the variants shown previously in that in a process step 108" the first control and evaluation unit 6 determines the substitute flow or substitute level values ​​in such a way that flow or level values ​​previously stored in the control and evaluation unit 6 from at least one past filling cycle are stored and these are output as substitute flow or substitute level values.

[0049] The in Fig. 5 The variant shown is characterized by the fact that in a process step 108‴ the second control and evaluation unit 9 transmits flow or level values, which are stored in it from a previous filling cycle, to the first control and evaluation unit 6 of the first filling point 2 and the first control and evaluation unit 6 outputs these values ​​as substitute flow or level values.

[0050] In Fig. 6 Figure 1 shows a block diagram of a second process 100' for operating a filling plant 1. A corresponding filling plant 1, which is particularly suitable for carrying out this process, is shown in Figure 2. Fig. 8 The filling system 1 has a third filling station 11. The third filling station 11 has a third filling valve 12, a third flow or level sensor 13, and a third control and evaluation unit 14. The third control and evaluation unit 14 is configured to control and monitor the filling processes of the third filling station 11. The third control and evaluation unit 14 of the third filling station 11 is connected via a communication channel 10' to the second control and evaluation unit 9 of the second filling station 3 and to the first control and evaluation unit 6 of the first filling station 2.

[0051] The in Fig. 6 The depicted procedure 100' is characterized by the following process steps: In a first process step 101, the first filling station switches to diagnostic mode. In a process step 102', the first filling station 2 reports the start of the diagnostic procedure to the third filling station 11 via communication channel 10, 10'. In a process step 103, the first filling station 2 outputs substitute flow or substitute level values ​​while the diagnostic mode is running. The filling operation is maintained at the first filling station using these substitute flow or substitute level values.In process step 104', the third control and evaluation unit 14 of the third filling station 11 detects a deviation of a flow rate or level value expected based on the valve characteristic curve stored in the third control and evaluation unit from the actually determined flow rate or level value and reports a deviation message to the first control and evaluation unit 6 of the first filling station 2. During the process steps described so far, filling processes are also carried out at the second filling station 3.In process step 109, the second control and evaluation unit 9 and the third control and evaluation unit 14 compare the magnitude and direction of the deviations of the current flow rate or level values ​​from the flow rate or level values ​​expected based on the valve characteristic curves stored in the respective control and evaluation units 9 and 14, and transmit the deviations to the first control and evaluation unit 6 if they are of the same magnitude and / or direction. In process step 110, the first control and evaluation unit 6 corrects the valve characteristic curve of the first filling valve 4 stored in the first control and evaluation unit 6. In particular, this correction is made based on the values ​​for the magnitude and / or direction of the deviation transmitted by at least one of the other control and evaluation units 9 and 14.In process step 107, the corrected substitute flow or substitute level values ​​determined using the corrected valve characteristic curve are then output by the first control and evaluation unit 6.

[0052] If the first control and evaluation unit 6 detects a fault condition in diagnostic mode, which is determined by procedure step 111 in Fig. 6 As shown, the first control and evaluation unit 6 sends a request for a diagnostic result of a similar diagnosis to the second control and evaluation unit 9 of the second filling station 3 and / or to the third control and evaluation unit 14 of the third filling station 11. The second control and evaluation unit 9 and / or the third control and evaluation unit 14 transmit the requested diagnostic result to the first control and evaluation unit 6 of the first filling station 2. In a process step 112, a comparison of the diagnostic results is performed. In the case of an identical diagnostic result, a process filler of the filling system is identified in a process step 113, and the corresponding filler is output. In the case of a different diagnostic result, a filling station error at the first filling station 2 is identified in a process step 114, and this error is output. The in Fig. 6The described method is therefore particularly suitable for distinguishing a process error from a level error. Reference sign

[0053] 1 Filling system 2 First filling point 3 Second filling point 4 First filling valve 5 First flow or level sensor 6 First control and evaluation unit 7 Second filling valve 8 Second flow or level sensor 9 Second control and evaluation unit 10 Communication channel 10' Communication channel 11 Third filling point 12 Third filling valve 13 Third flow or level sensor 14 Third control and evaluation unit 100 Procedure 101 Start of diagnostic operation first filling point 102 Notification of start to second filling point 103 Output of substitute values ​​first filling point 104 Detection of a deviation second filling point and notification of the deviation to first filling point 104' Detection of a deviation third filling point and notification of the deviation to first filling point 105 Receipt of the deviation message first filling point 106 Termination of diagnostic operation, transition to normal operation first filling point 107 Output of corrected substitute values ​​first filling point 108 Determination of replacement values ​​first filling point based on currentValve position and valve characteristic curve 108'Determination of substitute values ​​for the first filling point by transmitting current flow or fill level values ​​from the second filling point to the first filling point 108"Determination of substitute values ​​based on past filling cycles of the second filling point 108‴Determination of substitute values ​​based on past filling cycles of the third filling point 109Comparison of the magnitude and / or direction of the deviation from the valve characteristic curve of the second and third filling points and transmission of the deviation to the first filling point 110Correction of the valve characteristic curve of the first filling point based on the transmitted values ​​111Detection of a fault condition at the first filling point in diagnostic mode and request of diagnostic result to the second and / or third filling point 112Comparison of the diagnostic results 113Detection of a process error with identical diagnostic results 114Detection of a filling point error with different diagnostic results

Claims

1. Method (100) for operating a filling system (1), wherein the filling system (1) comprises at least one first filling point (2) and at least one second filling point (3), wherein the first filling point (2) comprises at least one first filling valve (4), at least one first flow or fill level sensor (5), and at least one first control and evaluation unit (6) for controlling and monitoring the filling process at the first filling point (2), and wherein the second filling point (3) comprises at least one second filling valve (7), at least one second flow or fill level sensor (8), and at least one second control and evaluation unit (9) for controlling and monitoring the filling process at the second filling point (3), wherein a valve characteristic curve of the first filling valve (4) is stored in the first control and evaluation unit (6), and wherein a valve characteristic curve of the second filling valve (3) is stored in the second control and evaluation unit (9), and wherein the first control and evaluation unit (6) and the second control and evaluation unit (9) are connected to each other via a communication channel (10), characterized in that, during operation of the filling system (1), the first filling point (2) switches to diagnostic mode (101), wherein during diagnostic mode, a filling operation also takes place at the filling point (2) that is in diagnostic mode, that the first control and evaluation unit (6) signals (102) the start of the diagnosis to the second control and evaluation unit (9), that during diagnostic mode, the first control and evaluation unit (6) outputs (103) substitute flow or substitute fill level values, based on which the filling is controlled or regulated, that, if the second control and evaluation unit (9) detects a deviation of the current flow or fill level value from the flow or fill level value expected based on the valve characteristic curve, it sends (104) a deviation message to the first control and evaluation unit (6) and that the first control and evaluation unit (6), upon receiving (105) the deviation message, • exits diagnostic mode and returns (106) to normal operation • or outputs (107) corrected substitute flow or substitute fill level values.

2. Method (100) according to claim 1, characterized in that the substitute flow or substitute fill level values are determined by the first control and evaluation unit (6) based on the current valve position of the first filling valve (4) and the valve characteristic curve stored in the first control and evaluation unit (6).

3. Method (100) according to claim 1, characterized in that the second control and evaluation unit (9) transmits current flow or fill level values to the first control and evaluation unit (6), and the first control and evaluation unit (6) outputs these current flow or fill level values as substitute flow or substitute fill level values.

4. Method (100) according to claim 1, characterized in that • that flow or fill level values from at least one previous filling cycle are stored in the first control and evaluation unit (6), and that the first control and evaluation unit (6) outputs these stored flow or fill level values as substitute flow or substitute fill level values, • or that flow or fill level values from at least one previous filling cycle are stored in the second control and evaluation unit (9), that the second control and evaluation unit (9) sends these stored flow or fill level values to the first control and evaluation unit (6), and that the first control and evaluation unit (6) outputs these flow or fill level values sent by the second control and evaluation unit (9) as substitute flow or substitute fill level values.

5. Method (100) according to any one of claims 1 to 4, wherein the filling system (1) comprises at least a third filling point (11), wherein the third filling point (11) comprises at least a third filling valve (12), at least one third flow or fill level sensor (13), and at least one third control and evaluation unit (14) for controlling and monitoring the filling process at the third filling point (11), wherein a valve characteristic curve of the third filling valve (12) is stored in the third control and evaluation unit (14), and wherein the third control and evaluation unit (14) is connected at least to the second control and evaluation unit (9) via a communication channel (10'), characterized in that, during diagnostic mode at the first filling point (2), the second control and evaluation unit (9) compares its currently measured flow or fill level value with the expected flow or fill level value based on the valve characteristic curve stored in the second control and evaluation unit (9) with the expected flow or fill level value, that the third control and evaluation unit (14) compares its currently measured flow or fill level value with the expected flow or fill level value based on the valve characteristic curve stored in the third control and evaluation unit (14), that, in the event of a deviation of the current flow or fill level values from the flow or fill level values expected based on the valve characteristic curves, the second control and evaluation unit (9) and the third control and evaluation unit (14) determine the magnitude and / or direction of the deviations and compare them with each other, and in the event of a similar deviation, the second control and evaluation unit (9) and / or the third control and evaluation unit (14) transmit the magnitude and / or direction of the deviation to the first control and evaluation unit (6), that the first control and evaluation unit (6) corrects the valve characteristic curve of the first filling valve (4) - specifically, by correcting the magnitude and / or direction of the deviation - and that the first control and evaluation unit (9) outputs a corrected substitute flow or substitute fill level value determined using the corrected valve characteristic curve.

6. Method (100) according to any one of claims 1 to 5, characterized in that the corrected substitute flow or substitute fill level value is determined using the same method as that used to determine the substitute flow or substitute fill level value.

7. Method (100) according to any one of claims 1 to 5, characterized in that different methods are used to determine the substitute flow rate or substitute fill level value and the corrected substitute flow rate or substitute fill level value.

8. Method (100) according to any one of claims 1 to 4 and 6 to 7, or, if the filling system (1) has a third filling point (11), according to any one of claims 5 to 7, characterized in that the first control and evaluation unit (6), in diagnostic mode, upon detecting an error condition, • sends a request for a diagnostic result to the second control and evaluation unit (9) and / or - if present - to the third control and evaluation unit (14), and that the second control and evaluation unit (9) and / or the third control and evaluation unit (14) - if present - transmit a diagnostic result to the first control and evaluation unit (6), • which transmits the diagnostic result indicating the error condition to the second control and evaluation unit (9) and / or the third control and evaluation unit (14), if present, that the diagnostic result of the first control and evaluation unit (6) is compared with the diagnostic result of the second control and evaluation unit (9) and / or - if present - the third control and evaluation unit (14), that, in the event of an identical diagnostic result, a process error in the filling system (1) is inferred, and that, in the event of a differing diagnostic result, a filling point error at the first filling point (2) is inferred.

9. Filling system (1) for filling containers with media, comprising at least one first filling point (2) and at least one second filling point (3), wherein the first filling point (2) comprises at least one first filling valve (4), at least one first flow or fill level sensor (5), and at least one first control and evaluation unit (6) for controlling and monitoring the filling process at the first filling point (2), and wherein the second filling point (3) comprises at least one second filling valve (7), at least one second flow or fill level sensor (8), and at least one second control and evaluation unit (9) for controlling and monitoring the filling process at the second filling point (3), wherein a valve characteristic curve of the first filling valve (4) is stored in the first control and evaluation unit (6), and a valve characteristic curve of the second filling valve (7) is stored in the second control and evaluation unit (9), and the first control and evaluation unit (6) and the second control and evaluation unit (9) are connected to each other via a communication channel (10), characterized in that the first control and evaluation unit (6) is designed such that, after switching to diagnostic mode, wherein during the diagnostic mode a filling operation also takes place at the filling point that is in diagnostic mode, it signals the start of the diagnostic process to the second control and evaluation unit (9), that the first control and evaluation unit (6) is further designed such that, during diagnostic mode, it outputs substitute flow or substitute fill level values based on which the filling process is monitored or controlled, that the second control and evaluation unit (9) is designed such that, if it detects a deviation of the current flow or fill level value from the flow or fill level value expected based on the valve characteristic curve, it transmits a deviation message to the first control and evaluation unit (6) and that the first control and evaluation unit (6) is further designed such that, upon receiving the deviation message, • exits diagnostic mode and returns to normal operation • or outputs corrected substitute flow or substitute fill level values.

10. Filling system (1) according to claim 9, characterized in that the filling system (1) comprises at least a third filling point (11), wherein the third filling point (11) comprises at least a third filling valve (12), at least one third flow or fill level sensor (13), and at least one third control and evaluation unit (14) for controlling and monitoring the filling process of the third filling point (11), wherein a valve characteristic curve of the third filling valve (12) is stored in the third control and evaluation unit (14), and wherein the third control and evaluation unit (14) is connected to at least the second control and evaluation unit (9) via a communication channel (10'), that the second control and evaluation unit (9) and the third control and evaluation unit (14) are configured such that, during diagnostic mode of the first filling point (2), the second control and evaluation unit (9) compares its currently measured flow or fill level value with the expected flow or fill level value based on the valve characteristic curve stored in the second control and evaluation unit (9), that the third control and evaluation unit (14) compares its currently measured flow or fill level value with the expected flow or fill level value based on the valve characteristic curve stored in the third control and evaluation unit (14), that, in the event that the current flow or fill level values deviate from the flow or fill level values expected based on the valve characteristic curves, the second control and evaluation unit (9) and the third control and evaluation unit (14) determine the magnitude and / or direction of the deviations and compare them with one another, and in the event of a similar deviation, transmit the magnitude and / or direction of the deviation to the first control and evaluation unit (6), and that the first control and evaluation unit (6) is further designed such that it corrects the valve characteristic curve of the first filling valve (4) - in particular, by correcting the magnitude and / or direction of the deviation - and that the first control and evaluation unit (9) is further configured to output a corrected substitute flow or substitute fill level value determined using the corrected valve characteristic curve.

11. Filling system (1) according to claim 9 or 10, characterized in that the first control and evaluation unit (6), the second control and evaluation unit (9), and - if present - the third control and evaluation unit (14) are further configured to carry out the method according to at least one of claims 2 to 5 or 8.