Determining the functionality of a closed-loop control valve of an apparatus for filling containers

Abstract

To provide a device for filling a container with a filling material.SOLUTION: A device (10) includes: a closed-loop control valve (36) for a filling material; and a diagnostic device (56). The diagnostic device (56) is configured to monitor a control value of a control variable of the closed-loop control valve (36) during closed-loop control, and to determine a state of functionality of the closed-loop control valve (36) as a function of a monitored control value. Advantageously, the device (10) allows for the functionality and thus wear of the closed-loop control valve (36) to be monitored and detected during operation.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to an apparatus for filling containers with a filler material, the apparatus having a closed-loop control valve.The present invention further relates to a method for determining the functionality of a closed-loop control valve of an apparatus for filling containers with a filler material. [Background technology]

[0002]

[0003] Apparatus for filling containers, such as rotary fillers, can use closed-loop control valves in various locations. For example, a closed-loop control valve can be located at the fill material inlet to the fill material container of the filler to regulate the fill level in the fill material container to a constant value. A closed-loop control valve can also be integrated into the filling station of the filler to regulate the flow of fill material as the containers are filled.

[0003] A closed-loop control valve may experience wear over its life. For example, the sealing surface between the valve seat and valve member may wear over time, the sealing elastomer insert may wear over time, and the closed-loop control valve actuator may wear over time. As wear progresses, the closed-loop control valve may suddenly fail (leak).

[0004] Traditionally, closed-loop control valves can be inspected, disassembled, or replaced at specific intervals, for example, after 6000 hours of operation or once a year. A drawback of this technique is that it is not possible to make reliable statements regarding the durability or wear of closed-loop control valves during operation. For example, the selected maintenance intervals may be too long or too short. Only rough information regarding lifespan can be given, as external influences (chemistry, temperature, manufacturing precision, material variations, etc.) can cause large variations.

[0005] The invention is based on the object of improving the monitoring of the functioning of a closed-loop control valve of an apparatus for filling containers. Summary of the Invention

[0006] This object is achieved by the features of the independent claims. Advantageous developments are set out in the dependent claims and the description.

[0007] One aspect of the present disclosure relates to an apparatus for filling a container with a filler material. The apparatus has (at least) one closed-loop control valve for the filler material (e.g., constructed and arranged to regulate the flow of the filler material or to regulate the fill level or pressure in a filler material container of the apparatus). The apparatus has a diagnostic device configured to monitor a control value of a control variable of the closed-loop control valve, preferably a valve lift (e.g., a valve lift specified without dimensions, in percentage units, or in units such as length) or a valve opening (e.g., a valve opening specified without dimensions, in percentage units, or in units such as length or area), during closed-loop control (e.g., closed-loop control of a flow rate, fill level, or pressure). The diagnostic device is further configured to determine a (e.g., normal and / or faulty) functional state, preferably a wear state, of the (e.g., each) closed-loop control valve as a function of the monitored control value.

[0008] Advantageously, the device can enable the functionality, and therefore wear, of the closed-loop control valves to be monitored and determined during operation of the device and during closed-loop control by the closed-loop control valves. When monitoring the control values, for example, anomalies can be detected, and the state of function of the closed-loop control valves can then be inferred. This makes it possible to individually determine when replacement or maintenance is required for each closed-loop control valve. This determination can also be performed in advance, allowing action to be taken not only after a closed-loop control valve has failed, but also when there is a risk of the closed-loop control valve failing. This allows preventative maintenance to be planned, thus avoiding unnecessary premature replacement. Monitoring can be performed automatically, even during manufacturing, without removal or disassembly. Furthermore, this allows each closed-loop control valve in the device to be individually monitored, which is a significant improvement over conventional random disassembly and testing. For example, if a pushrod on a closed-loop control valve were to come loose, it could be detected and addressed immediately.

[0009] For example, the diagnostic device may be further configured to receive a control value from a signal output of a closed-loop control valve or from a signal output of a closed-loop control controller / device associated with the closed-loop control valve.

[0010] The closed-loop control variable (process variable, regulating variable) for the closed-loop control may preferably be the detected flow rate through the closed-loop control valve, or the detected fill level in the fill material container of the device, or the detected pressure in the fill material container of the device.

[0011] The reference variable (desired variable, set point variable) for the closed-loop control may preferably be the desired flow rate through the closed-loop control valve, or the desired filling level in the filling material container of the device, or the desired pressure in the filling material container of the device.

[0012] In one exemplary embodiment, the diagnostic device is further configured to determine the state of functionality of the closed-loop control valve as a function of an acceptable control value range (e.g., an acceptable control value range specified by a user interface of the apparatus), and preferably the state of functionality of the closed-loop control valve is determined as an impaired state of functionality if the monitored control value is outside the acceptable control value range, and / or as a normal state of functionality if the monitored control value is within the acceptable control value range. This allows for easy detection of abnormalities in the operation of the closed-loop control valve, such as when the control value fluctuates more than normal or in a range different from normal.

[0013] Preferably, the impaired state may indicate that the closed loop control valve is still functioning but is expected to fail (eg, due to wear).

[0014] Preferably, the impaired condition may indicate a predicted failure of the closed loop control valve.

[0015] In another exemplary embodiment, the acceptable control value range is greater than or equal to 50%, greater than or equal to 55%, or greater than or equal to 60% and / or less than or equal to 75%, less than or equal to 70%, or less than or equal to 65% of the maximum value of the controlled variable. Thus, the closed-loop control valve is advantageously designed so that during normal operation and when no abnormalities are occurring, there is sufficient power reserve for fast-responding closed-loop control.

[0016] In one embodiment, the acceptable control value range is: - the output of the device (e.g., vessel output per unit time), - the container format and / or filling volume, the filling level in the filling material container of the device, - the pressure in the filling container of the device, - pre-pressure of the fill material upstream of the fill material container of the device, and - the temperature of the filler.

[0017] Advantageously, different acceptable control value ranges may thus be specified for different operating parameters and conditions, e.g., a first acceptable control value range for a first output of the device and a second, lower acceptable control value range for a second, smaller output of the device.

[0018] In a further embodiment, the diagnostic device is further configured to monitor the control value of the closed-loop control valve during closed-loop control, such that the control value is monitored within a specified time window and / or at a steady state (of the control value). Preferably, the diagnostic device may be further configured to determine the state of functionality of the closed-loop control valve as a function of the monitored control value, such that the state of functionality of the closed-loop control valve is determined as a function of (e.g., only) the monitored control value in the specified time window and / or at the steady state. This may advantageously result in anomaly detection being performed when anomalies may be particularly significant, i.e., preferably when the control value is stable.

[0019] In one embodiment variant, the specified time window is: -Starting after the start-up stage of the device (e.g., container filling), and / or -Starting after 1 minute, 2 minutes, or 3 minutes after starting the device (e.g., filling the container); and / or - Finishing before the shutdown phase of the device (e.g., container filling), and / or - Finished within 3 minutes, 2 minutes, or 1 minute before stopping the device (e.g., filling the container); and / or - It can end before the change in the power output of the device and / or start after the change in the power output of the device.

[0020] In another embodiment variant, the diagnostic device is further configured to monitor the control value of the closed-loop control valve during closed-loop control, such that the control value is monitored under substantially constant operating conditions of the apparatus. Preferably, the diagnostic device may be further configured to determine the state of functionality of the closed-loop control valve as a function of the monitored control value, such that the state of functionality is determined as a function of (e.g., only) the control value monitored at the substantially constant operating conditions. This can advantageously result in abnormality detection being performed when anomalies may be particularly significant, i.e., when all other key parameters of the apparatus remain substantially the same.

[0021] In one exemplary embodiment, the diagnostic device comprises: - The output of the device is within the specified output range; - the container locking device of the device is open; - the fill level in the filling material container of the device is within the specified fill level range; - the pressure in the filling material container of the device is within the specified pressure range; - the valve of the cullet removal system of the device is closed; - the pre-compression of the filler material when it is fed into the filler material container of the device is within the specified pre-compression range; and / or - The temperature of the filler is within the specified temperature range; is further configured to determine that a substantially constant operating condition exists when at least one of applies.

[0022] In one exemplary embodiment, the apparatus includes a flow detection device configured to detect a flow rate of filler material through the closed-loop control valve. Preferably, the diagnostic device may be further configured to determine the state of functionality of the closed-loop control valve as a function of the filler material flow rate detected by the flow detection device, preferably by comparing the detected filler material flow rate with a theoretical filler material flow rate through the closed-loop control valve, which is determined as a function of the monitored control value. This makes it possible to easily detect when the actual (detected) flow rate differs significantly from the theoretical flow rate, which may be due to progressive wear of the closed-loop control valve.

[0023] Preferably, the diagnostic device measures the functional status by: - as impaired functionality when the deviation between the measured filler flow rate and the theoretical filler flow rate is greater than a limit value; and / or It may further be configured to determine as a normal state of function when the deviation between the measured filler flow rate and the theoretical filler flow rate is less than the above-mentioned limit value.

[0024] In another exemplary embodiment, the apparatus further comprises an output device (e.g., visual, acoustic, and / or tactile) for outputting information to a user. Preferably, the diagnostic device may further be configured to operate the output device to output information regarding the determined functional status. This advantageously makes it possible to issue instructions and warnings regarding the functionality of the closed-loop control valve and / or to request that the closed-loop control valve be replaced at the next opportunity.

[0025] A further aspect of the present disclosure relates to a method for determining functionality of a closed-loop control valve of an apparatus for filling a container with a filler material, preferably as disclosed herein. The method includes closed-loop control by the closed-loop control valve (e.g., a flow rate of the filler material, a fill level in a filler material container of the apparatus, or a pressure in a filler material container of the apparatus). The method includes monitoring a control variable of the closed-loop control valve, preferably a control value of the valve lift or valve opening, during the closed-loop control by a diagnostic device. The method includes determining, by the diagnostic device, a state of functionality of the closed-loop control valve as a function of the monitored control value. Optionally, the method can further include outputting the determined state of functionality to a user by an output device. Advantageously, the method can achieve the same advantages as already described herein with reference to the apparatus. The same applies to the following preferred exemplary embodiments of the method.

[0026] In one exemplary embodiment, determining the state of functionality of the closed-loop control valve further depends on an acceptable control value range (e.g., as specified by a user interface of the device). Preferably, the state of functionality of the closed-loop control valve may be determined as impaired if the monitored control value is outside the acceptable control value range. Alternatively or additionally, the state of functionality of the closed-loop control valve may be determined as normal if the monitored control value is within the acceptable control value range.

[0027] Preferably, the allowable control variable ranges (e.g., ranges before or during commissioning of the apparatus) can be determined empirically and / or by simulation, preferably for different outputs of the apparatus, different filling levels of the filler container of the apparatus, different pressures of the filler container of the apparatus, different pre-pressures of the filler when fed to the filler container of the apparatus, and / or different temperatures of the filler.

[0028] In another exemplary embodiment, the control value is monitored within a specified time window at steady state (of the control value) and / or under substantially constant operating conditions of the apparatus. Preferably, the state of functionality of the closed-loop control valve can be determined as a function of (e.g., only) the control value monitored during the specified time window at steady state and / or under substantially constant operating conditions.

[0029] In another exemplary embodiment, the method further includes detecting a filler flow rate through the closed-loop control valve by a flow detection device. Preferably, the state of function of the closed-loop control valve can also be determined as a function of the detected filler flow rate, preferably by comparing the detected filler flow rate with a theoretical filler flow rate through the closed-loop control valve, the theoretical filler flow rate being determined as a function of the monitored control value.

[0030] Preferably, an impaired functioning state can be determined when the deviation between the measured filler flow rate and the theoretical filler flow rate is greater than a limit value. Alternatively or additionally, a normal functioning state can be determined when the deviation between the measured filler flow rate and the theoretical filler flow rate is less than a limit value.

[0031] In another exemplary embodiment, the apparatus has a preferably annular filler container, and the closed-loop control valve is arranged upstream of the filler container (in the direction of filler movement) for closed-loop control of the fill level or pressure in the filler container. Alternatively, the closed-loop control valve may be a fill valve, for example, capable of supplying filler material to a container for filling the container for closed-loop control of the filler material flow. Alternatively, the closed-loop control valve may be connected to a fill valve, for example, capable of delivering filler material to a container for filling the container for closed-loop control of the filler material flow.

[0032] In another exemplary embodiment, the apparatus includes at least one filling station for filling the containers, and the closed-loop control valve is included in or connected to the at least one filling station. Alternatively or additionally, the apparatus includes a rotary filler with the closed-loop control valve.

[0033] Another aspect of the present disclosure relates to a container processing facility for manufacturing, washing, coating, inspecting, filling, closing, labeling, printing, and / or packaging containers for liquid media, preferably beverages or liquid foods, which can include the apparatus disclosed herein.

[0034] For example, the container may be configured as a bottle, can, canister, carton, vial, or the like.

[0035] Preferably, the term "diagnostic device" may refer to an electronic system (e.g., embodied as a driver circuit or with microprocessor(s) and memory) that, depending on the configuration, can perform processing tasks. Optionally, the diagnostic device may be part of a closed-loop control device that can perform closed-loop control tasks. The closed-loop control device may include electronics, mechanical controls, pneumatic controls, and / or hydraulic controls. The closed-loop control device may be part of a closed-loop control and control device that can also perform control tasks.

[0036] The preferred embodiments and features of the present invention described above can be combined with each other as required. [Brief explanation of the drawings]

[0037] Further details and advantages of the invention are explained below with reference to the accompanying drawings, in which: [Figure 1] 1 illustrates an apparatus for filling a container according to an exemplary embodiment of the present disclosure. [Figure 2]FIG. 1 illustrates an exemplary filling station. [Figure 3] FIG. 10 illustrates another exemplary filling station. [Figure 4] FIG. 1 illustrates a time-control value / control variable diagram for a closed-loop control valve of an exemplary device. [Figure 5] FIG. 1 illustrates a time flow diagram of a closed loop control valve of an exemplary apparatus.

[0038] The embodiments shown in the drawings correspond at least in part, so that similar or identical parts are given the same reference numerals and, to avoid repetition, reference is made to the description of other embodiments or drawings for their description. DETAILED DESCRIPTION OF THE INVENTION

[0039] Figure 1 shows an apparatus 10 for filling containers 12. For clarity, only a few containers 12 are shown in Figure 1. Figure 2 shows an exemplary filling station 38 of the apparatus 10. Figure 3 shows an exemplary alternative embodiment of filling station 38'.

[0040] The device 10 is configured to fill a container 12 with a filler material, preferably in liquid or paste form, which may be carbonated.

[0041] The apparatus 10 comprises at least closed-loop control valves 36, 44, 52 and a diagnostic device 56. Optionally, the apparatus 10 may comprise, for example, a container conveyor 14, a (further) container conveyor 20, a container locking device 24, a cullet removal system 26, a filling machine 28, at least one filling station 38, and / or a user interface 54.

[0042] The container conveyor 14 may be positioned upstream (in the direction of container movement) of the filler 28 or at least one filling station 38. For example, the container conveyor 14 may include an infeed starwheel 16 and / or a conveyor section 18.

[0043] The infeed starwheel 16 can transport the containers 12 to the filling machine 28 or to at least one filling station 38, preferably individually or in separate transports.

[0044] Conveyor section 18 may preferably be a single track section and / or may be configured for individual transport of containers 12. Conveyor section 18 may, for example, be located upstream (in the direction of container movement) of infeed starwheel 16. Containers may be transferred to infeed starwheel 16 at one end of conveyor section 18, preferably individually or in individual transport. Conveyor section 18 may, for example, be a conveyor section of a linear conveyor.

[0045] The container conveyor 20 can be arranged downstream (in the direction of container movement) of the filler 28 or at least one filling station 38. For example, the container conveyor 20 can have an outfeed starwheel 22. The outfeed starwheel 22 can take over filled containers 12 from the at least one filling station 38, preferably individually or in individual transports.

[0046] Preferably, the containers 12 can be closed after being filled. For example, the container conveyor 20 can transport the filled containers 12 to a closing device, such as a carousel closing machine.

[0047] The container locking device 24 may be located upstream (in the direction of container movement) of the filling machine 28 or at least one filling station 38. For example, the container locking device 24 may be located on the container conveyor 14, preferably on the conveyor portion 18 thereof.

[0048] The container locking device 24 can lock (or block) and unlock the transport of the container 12. For example, the container locking device 24 can extend or pivot a locking element to block the transport of the container 12. The blocking element can, for example, extend above the container conveyor 14. The container 12 can be stacked on the blocking element, for example, standing on the container conveyor 14. Preferably, the locking element can retract or pivot to unlock the transport of the container 12.

[0049] It is also possible to integrate the container locking device 24, for example, in the infeed starwheel 16.

[0050] The cullet removal system 26 can remove cullet from broken containers in the filling machine 28 or at least one filling station 38. The cullet removal system 26 is preferably located in the area of ​​the outlet of the filling machine 28 and / or adjacent to the delivery starwheel 22. The cullet removal system 26 can be fluid-actuated and / or fluid-dispensing. Preferably, the cullet removal system 26 can include a valve for blocking, releasing, and / or regulating fluid flow. Preferably, the cullet removal system 26 can be controlled, for example, by a valve, to deliver a fluid, such as sterile air or sterile water, to the container-receiving space of the at least one filling station 38. Preferably, the cullet removal system 26 can be configured as a cullet spray system for spraying cullet from the container-receiving space of the at least one filling station 38.

[0051] The filling machine 28 may preferably be configured as a rotary or carousel filling machine. For example, several filling stations 38 may be distributed around the filling machine 28.

[0052] The filling machine 28 can be configured as a linear filling machine, for example, with multiple filling stations 38 (not shown) arranged in parallel and / or behind each other. It is also possible for the device 10 or filling machine 28 to have only one filling station 38.

[0053] Preferably, the apparatus 10 or filler 28 may comprise a filler material source 30, a (filler material) pipeline system 32 and / or a filler material container 34.

[0054] The filler material source 30 can be configured, for example, as a filler material reservoir. The filler material can be stored in the filler material reservoir. The filler material reservoir can be refillable. Preferably, the filler material source 30 can be located at a higher level than the filler material container 34.

[0055] The pipeline system 32 can connect the filler material source 30 and the filler material container 34 to each other. The pipeline system 32 can have, for example, a main line that can be connected to the filler material source 30 at an upstream end of the main line. A filler material distributor of the pipeline system 32 can be located at a downstream end of the main line. Several distribution lines can branch off from the filler material distributor. The distribution lines can, for example, connect to the filler material container 34 at different circumferential positions.

[0056] The filler container 34 is preferably annular or configured as a ring container. The filler container 34 can be connected to a filling station 38 via several filler lines.

[0057] The closed-loop control valve 36 may be disposed upstream (in the direction of filler movement) of the filler container 34 and configured to provide closed-loop control of the fill level or pressure in the filler container 34. In particular, the closed-loop control valve 36 may, for example, regulate the flow of filler from the filler source 30 to the filler container 34 during closed-loop control.

[0058] The closed-loop control valve 36 may be located, for example, at the outlet of the filler source 30 or within the pipeline system 32. The closed-loop control valve 36 may preferably be located in the main line of the pipeline system 32 or in a filler distributor.

[0059] For example, the closed loop control valve 36 may be continuously or discretely adjustable between a closed position with 0% flow cross section and a maximum open position with 100% flow cross section.

[0060] The closed loop control valve 36 may be, for example, electrically, electromagnetically, pneumatically, hydraulically, or mechanically operated.

[0061] Preferably, the closed-loop control valve 36 may have a movable, preferably displaceable, valve member for opening and closing the closed-loop control valve 36. The valve member may preferably have a conical, and particularly preferably a frusto-conical, portion that may be lifted from a valve seat of the closed-loop control valve 36 to open the closed-loop control valve 36.

[0062] The valve lift or valve opening of the closed-loop control valve 36 is preferably the controlled variable of the closed-loop control valve 36. The controlled variable is the output variable (position) of an actuator (i.e., the closed-loop control valve 36) used in a closed-loop control device, with which a targeted intervention is made in a control process. The actual valve lift or actual valve opening of the closed-loop control valve 36 is preferably the instantaneous value of the controlled value or controlled variable of the closed-loop control valve 36. The valve lift or valve opening may be expressed, for example, in a normalized dimensionless manner, in %, or in units of length or area (e.g., mm or mm 2 It can be specified in units.

[0063] The detected (measured) filling level of the fill material or the pressure in the fill material container 34 may be a closed-loop controlled variable (process variable, regulated variable) of the closed-loop control valve 36. A closed-loop controlled variable is a variable that is kept constant by the closed-loop control or that is intentionally changed. The detected actual filling level of the fill material or the actual pressure in the fill material container 34 may be an actual value / process value of the closed-loop controlled variable. The (actual) filling level may be detected, for example, by a filling level sensor in the fill material container 34. The (actual) pressure may be detected, for example, by a pressure sensor in the fill material container 34.

[0064] The desired filling level or the desired pressure in the filler container 34 can be a reference variable (desired variable, setpoint variable) for the closed-loop control valve 36. The reference variable is the variable towards which the closed-loop control variable should be brought. The reference variable can change over time. The reference variable can be specified by the user, for example, using the user interface 54 or the technical system of the device 10. A control deviation can be calculated as the difference between the reference variable and the closed-loop control variable or actual value / process value. A control value can then be formed accordingly, which can influence the controlled system via the closed-loop control valve 36 (i.e., actuator).

[0065] At least one filling station 38 can fill the container 12, preferably with a liquid or paste-like filler material. The container 12 can also be evacuated, prestressed, and / or rinsed at the at least one filling station 38. Thus, each of the at least one filling station 38 can have a drain channel, a biasing channel, and / or a rinsing channel.

[0066] 2 and 3 show exemplary embodiments of filling station 38 or 38', respectively.

[0067] The filling station 38 may include a receiving space 40 , a container support 42 , a closed-loop control valve 44 , a filler channel 46 , and / or a flow detection device 48 .

[0068] One container 12 at a time can be received or placed within the receiving space 40 for filling.

[0069] The containers 12 may be supported in the receiving space 40 by container supports 42 of the filling station 38. The container supports 42 may, for example, have a base plate for supporting each container 12 at its bottom. Alternatively or additionally, the container supports 42 may support the containers 12, for example, on their shells or necks.

[0070] The closed loop control valve 44 may be configured as a fill valve. Preferably, the closed loop control valve 44 may be configured as a so-called proportional flow closed loop control valve.

[0071] The closed-loop control valve 44 can release the fill material into a container 12 disposed in the receiving space 40 of the filling station 38. For example, the closed-loop control valve 44 can be continuously or discretely adjustable between a closed position having a 0% flow cross-section and a maximum open position having a 100% flow cross-section.

[0072] The closed loop control valve 44 may be, for example, electrically, electromagnetically, pneumatically, hydraulically, or mechanically operated.

[0073] Preferably, the closed-loop control valve 44 may have a movable, preferably displaceable, valve member for opening and closing the closed-loop control valve 44. The valve member may preferably have a conical, and particularly preferably a frusto-conical, portion that may be lifted from the valve seat of the closed-loop control valve 44 to open the closed-loop control valve 44.

[0074] The outlet of the closed-loop control valve 44 and the container opening of the container 12 in the receiving space 40 can be pressed against each other for filling. For this purpose, the filling station 38 can have a preferably vertical adjusting device (not shown separately in the figures). The adjusting device can move the container support 42 (together with the supported container 12) toward and away from the outlet of the closed-loop control valve 44. Alternatively or additionally, the adjusting device can move the closed-loop control valve 44 toward and away from the container support 42 (or the supported container 12). The adjusting device can be electrically, electromagnetically, pneumatically, hydraulically, or mechanically operated.

[0075] The closed-loop control valve 44 may receive the filler material via a filler material channel 46. The filler material channel 46 may connect the closed-loop control valve 44 to the filler material reservoir 34 (see FIG. 1).

[0076] The flow detection device 48 may be configured to detect the flow rate of filler material into the closed-loop control valve 44. For example, the flow detection device 48 may detect the flow rate through the filler material channel 46. For example, the flow detection device 48 may measure the flow rate, for example, in terms of amount and / or volume. The flow detection device 48 may output a measurement signal indicative of the detected flow rate, for example, to a diagnostic device 56.

[0077] The flow detection device 48 may include any suitable flow measurement principle for detecting the flow rate. Particularly preferably, the flow detection device 48 may be a magnetic induction flow detection device or an ultrasonic flow detection device.

[0078] FIG. 3 shows a filling station 38' which has been modified compared to FIG.

[0079] The filling station 38' may have a fill valve 50 instead of the closed-loop control valve 44. The fill valve 50 may be configured, for example, to selectively open or block the fill material channel 46. The fill valve 50 may release fill material into a container 12 disposed within the receiving space 40 of the filling station 38'. The fill valve 50 may be operated, for example, electrically, electromagnetically, pneumatically, hydraulically, or mechanically.

[0080] The filling valve 50 may have a movable, preferably displaceable, valve member for opening and closing the filling valve 50. The valve member may preferably have a conical, particularly preferably frusto-conical, portion that can be lifted from a valve seat of the filling valve 50 to open the filling valve 50. As already described for the closed-loop control valve 44, the outlet of the filling valve 50 and the container opening of the container 12 in the receiving space 40 can be pressed against each other for filling.

[0081] The filling station 38' may include a closed-loop control valve 52. The closed-loop control valve 52 may be disposed, for example, within the filler channel 46. The closed-loop control valve 52 may be disposed upstream (in the direction of filler movement) of the fill valve 50. The closed-loop control valve 52 may be disposed upstream (in the direction of filler movement) or downstream (in the direction of filler movement) of the flow detection device 48.

[0082] Additionally, the closed loop control valve 52 may be configured as previously described for the closed loop control valve 44 .

[0083] The valve lift or valve opening of the closed-loop control valve 44, 52 is preferably the control variable of the closed-loop control valve 44, 52. The control variable is the output variable (position) of the actuator (i.e., the closed-loop control valve 44, 52) used in the closed-loop control device, and is used to effect targeted intervention in the control process. The actual valve lift or actual valve opening of the closed-loop control valve 44, 52 is preferably the control value or instantaneous value of the control variable of the closed-loop control valve 44, 52. The valve lift or valve opening may be expressed, for example, in a normalized dimensionless manner, in %, or in units of length or area (e.g., mm or mm 2 It can be specified in units.

[0084] The detected (measured) flow rate of the filler material through the filler material channel 46 (or the closed-loop control valve 44, 52) may be the closed-loop controlled variable (regulated variable, process variable) of the closed-loop control valve 44, 52. A closed-loop controlled variable is a variable that is kept constant by the closed-loop control or that is intentionally changed. The recorded actual flow rate of the filler material through the filler material channel 46 may be the actual value / process value of the closed-loop controlled variable. The (actual) flow rate may be detected, for example, by the flow detection device 48.

[0085] The desired flow rate through the closed-loop control valve 44, 52 or the filler channel 46 can be the reference variable (desired variable, setpoint variable) of the closed-loop control valve 44, 52. The reference variable is the variable towards which the closed-loop control variable should be brought. The reference variable can change over time. The reference variable can be specified by the user, for example, using the user interface 54 or the technical system of the device 10. The control deviation can be calculated as the difference between the reference variable and the closed-loop control variable or the actual value / process value. A control value can then be formed accordingly, which can influence the controlled system via the closed-loop control valve 44, 52 (i.e., the actuator).

[0086] In Figure 2, filling station 38 includes closed-loop control valve 44, and in Figure 3, filling station 38' includes closed-loop control valve 52. It is also possible for filling station 38 or filling machine 28 of apparatus 10 to have no closed-loop control valve at all. Apparatus 10 or filling machine 28 could, for example, include only closed-loop control valve 36 (see Figure 1).

[0087] At least one closed-loop control valve 36, 44, 52 can be connected to a closed-loop control device (not shown) of the apparatus 10. The closed-loop control device can receive signals from and / or output signals to the at least one closed-loop control valve 36, 44, 52. The actual closed-loop control can be implemented electronically and / or programmatically within the closed-loop control device. It is also possible for the closed-loop control device to be at least partially contained within the at least one closed-loop control valve 36, 44, 52.

[0088] The closed-loop control of the at least one closed-loop control valve 36, 44, 52 may be, for example, a closed-loop control having proportional behavior (P element), integral behavior (I element) and / or derivative behavior (D element).

[0089] The user interface 54 may include output devices and / or input devices.

[0090] The output device may be, for example, an acoustic output device, a visual output device, and / or a tactile output device. Information may be output to a user via the output device. The output device may include, for example, a (e.g., touch-sensitive) display, a speaker, and / or at least one signal light.

[0091] For example, information regarding the state of functionality of at least one closed-loop control valve 36, 44, 52 as determined by the diagnostic device may be output to a user by an output device, such as a warning or alarm, when an impaired state of functionality is detected.

[0092] The input device may be, for example, an acoustic input device, a visual input device, and / or a tactile input device. Information, preferably an input command, may be entered by a user via the input device. The input device may include, for example, a touch-sensitive display, a keyboard, at least one button or switch, a camera, and / or a microphone. The input information may be stored, for example, in a data memory of the diagnostic device 56.

[0093] The diagnostic device 56 is configured to monitor the function of at least one closed-loop control valve 36 , 44 , 52 .

[0094] The diagnostic device 56 may be connected to any of the components described herein to send and / or receive signals. In particular, the diagnostic device 56 may be connected to at least one closed-loop control valve 36, 44, 52 and / or its closed-loop control device to send and / or receive signals.

[0095] During closed-loop control, the diagnostic device 56 monitors the respective control values ​​of the control variables of the at least one closed-loop control valve 36, 44, 52. The diagnostic device 56 can monitor the respective control values ​​of the at least one closed-loop control valve 36, 44, 52 simultaneously with the closed-loop control. In other words, closed-loop control is performed by the at least one closed-loop control valve 36, 44, 52, and the diagnostic device 56 monitors the respective control values ​​of the at least one closed-loop control valve 36, 44, 52.

[0096] In particular, the diagnostic device 56 can monitor the control values ​​during the period in which closed-loop control is being exercised by the respective closed-loop control valves 36 , 44 , 52 .

[0097] As a function of the monitoring, the diagnostic device 56 determines the state of function of each closed-loop control valve 36, 44, 52. For example, the diagnostic device 56 may determine a state of normal function or a state of impaired function.

[0098] Different variants of monitoring and determining the status of the functions, which can be combined with each other, are described below: For ease of understanding, an exemplary normal operation of the closed-loop control valve 36 will first be described with reference to FIG.

[0099] FIG. 4 shows an example of the control value or control variable u(t) (ie, valve lift or valve opening) of the closed-loop control valve 36 with respect to time t in a normal functioning state of the closed-loop control valve 36.

[0100] Start-up of the apparatus 10 may occur at time t0. At this point, for example, filling of the container 12 and / or the filler container 34 may begin. Accordingly, the closed-loop control valve 36 may open to allow (re)filling of the filler container 34. A transient response of the control value of the closed-loop control valve 36 may occur from time t0 to time t1. Between times t1 and t2, the control value may be at a steady state. The control value may be substantially constant or may fluctuate slightly. Here, the apparatus 10 may exhibit substantially constant operating conditions. At time t2, a decrease in the output of the apparatus 10 or the filling machine 28 may occur, for example, from 60,000 containers per hour to 40,000 containers per hour. A transient response of the control value of the closed-loop control valve 36 may occur again from time t2 to time t3. Between times t3 and t4, the control value may again be at a steady state. The control value may be substantially constant or may fluctuate slightly. Again, the apparatus 10 may exhibit substantially constant operating conditions. Shutdown of the apparatus 10 can begin at time t4. Between time t4 and time t5, less and less fill material needs to be dispensed into the fill material container 34. The closed-loop control valve 36 can be closed until time t5. The control value can be reduced to 0 until time t5.

[0101] Preferably, the control value of the closed-loop control valve 36 can be monitored over a specified time window, and the state of function of the closed-loop control valve 36 can be determined as a function of the control value monitored over the specified time window.

[0102] Referring to FIG. 4 , the specified time window may be between t1 and t2 and / or between t3 and t4. Generally, the specified time window may be determined by one or more conditions. For example, the specified time window may begin after a startup phase (e.g., of filling a container) of the apparatus 10. For example, the specified time window may begin one minute or more, two minutes or more, or three minutes or more after starting (e.g., filling a container) of the apparatus 10. For example, the specified time window may end before a shutdown phase (e.g., of filling a container) of the apparatus 10. For example, the specified time window may end within three minutes, two minutes, or one minute before stopping (filling a container) of the apparatus 10. For example, the specified time window may end before an output change of the apparatus 10 and / or begin after an output change of the apparatus 10.

[0103] Preferably, the control value of the closed-loop control valve 36 can be monitored at a steady state of the control value, and the state of function of the closed-loop control valve 36 can be determined as a function of the monitored control value at the steady state.

[0104] Referring to Figure 4, the control value may be steady between t1 and t2 and / or between t3 and t4. Generally, a steady state may exist when the control value fluctuates around a mean value over time. In the steady state, the control value may fluctuate around the mean value within a range of, for example, ±5%, preferably ±3%. In the steady state, the progression of the control value may be trendless. In the steady state, the control value may fluctuate by, for example, 7% or less, 6% or less, or 5% or less.

[0105] Preferably, the control value of the closed-loop control valve 36 can be monitored such that the control value is monitored under certain operating conditions of the apparatus 10. The state of function of the closed-loop control valve 36 can be determined as a function of the monitored control value under certain operating conditions.

[0106] Referring to FIG. 4 , a substantially constant operating condition of the apparatus 10 may exist between t1 and t2 and / or between t3 and t4. Generally, the diagnostic device 56 can determine that a constant operating condition exists when one or more conditions are met. For example, the output of the apparatus 10 may be substantially constant and within a specified output range. For example, the container locking device 24 may be open. For example, the fill level in the fill material container 34 may be substantially constant and within a specified fill level range. For example, the pressure in the fill material container 34 may be substantially constant and within a specified pressure range. For example, the valve of the cullet removal system 26 may be closed. For example, the pre-pressure of the fill material when delivered to the fill material container 34 may be substantially constant and within a specified pre-pressure range. For example, the temperature of the fill material may be substantially constant and within a specified temperature range.

[0107] Preferably, the state of functionality of the closed-loop control valve 36 can also be determined as a function of an acceptable control value range. If the monitored control value is, for example, within the acceptable control value range, it can be determined that the functionality of the closed-loop control valve 36 is normal, i.e., the closed-loop control valve 36 is functioning normally. For example, if the monitored control value is outside the acceptable control value range, it can be determined that the functionality of the closed-loop control valve 36 is impaired, e.g., the closed-loop control valve 36 is not functioning, is not functioning at all, is functioning abnormally, or is expected to fail due to wear.

[0108] 4, the first acceptable control value range may be, for example, between u2 and u3. For example, the first acceptable control value range may be specified for a steady state between t1 and t2, for certain operating conditions between t1 and t2, and / or for a specified time window between t1 and t2.

[0109] 4, the second acceptable control value range may be, for example, between u1 and u2. For example, the second acceptable control value range may be specified for a steady state between t3 and t4, for certain operating conditions between t3 and t4, and / or for a specified time window between t3 and t4.

[0110] In general, the acceptable control value range may be, for example, 50% or more, 55% or more, or 60% or more of the maximum value of the controlled variable, and / or 75%, 70%, or 65% or less. The acceptable control value range may be specified as a function of at least one parameter. For example, the acceptable control value range may be specified as a function of the output of the apparatus 10 (see, e.g., FIG. 4 , a first acceptable control value range at 60,000 containers per hour and a second acceptable control value range at 40,000 containers per hour), the format and / or fill volume of the container 12, the fill level of the fill material container 34, the pressure in the fill material container 34, the fill material pre-pressure upstream of the fill material container 34, and / or the fill material temperature. This means that different acceptable control value ranges may be specified for different parameters, if desired.

[0111] The above description of monitoring the control value of the closed-loop control valve 36 and determining its state of function may also be applied to the closed-loop control valves 44 or 52. Preferably, however, monitoring the control value of the closed-loop control valves 44, 52 and determining the state of function of the closed-loop control valves 44, 52 may be performed as described below, by way of example, with reference to FIG.

[0112] FIG. 5 shows an example of the detected flow rate (solid curve A) through the closed loop control valves 44, 52 over time t for the filling process of the container 12.

[0113] At time t6, filling of the container 12 can begin. Between time t6 and time t7, the control value of the closed-loop control valves 44, 52, and therefore the measured flow rate, can stabilize. From time t7 to time t8, the control value of the closed-loop control valves 44, 52, and therefore the detected flow rate, can be substantially constant or steady. Starting at time t8, a fill stop can begin. The closed-loop control valves 44, 52 begin to close. The detected flow rate can decrease. Filling of the container 12 can be completed at time t9. The control value and detected flow rate of the closed-loop control valves 44, 52 can be zero.

[0114] 5 also shows the theoretical flow rate (curve B) through the closed-loop control valves 44, 52 over time t for the filling process of the container 12. In particular, the theoretical flow rate can be determined, e.g., calculated, from the monitored control values ​​of the closed-loop control valves 44, 52. For example, the respective flow cross-sectional areas can be determined from the monitored control values, and the theoretical flow rate can be determined therefrom. The determination can be performed or supported, for example, mathematically, empirically, and / or simulated.

[0115] By comparing the measured filler flow rate with the theoretical filler flow rate, the diagnostic device 56 can determine the state of function of the closed-loop control valves 44, 52 at this time. The comparison can preferably be performed for a constant flow rate step, a specified time window, and / or a steady state of control value / flow rate (see also the discussion regarding FIG. 4). If the deviation x between the measured flow rate (curve A) and the theoretical flow rate (curve B) during the monitored period is greater than a certain limit value, for example, the function of the closed-loop control valves 44, 52 can be determined to be impaired. If the deviation x between the measured flow rate (curve A) and the theoretical flow rate (curve B) during the monitored period is less than a certain limit value, the function of the closed-loop control valves 44, 52 can be determined to be normal.

[0116] The above description of monitoring the control values ​​of the closed-loop control valves 44, 52 and determining their functional status can also be applied to the closed-loop control valve 36. These procedures can also be combined.

[0117] The present invention is not limited to the preferred exemplary embodiments described above. Rather, numerous variations and modifications are possible that similarly utilize the concept of the present invention and thus fall within the scope of protection. In particular, the present invention also claims protection for the subject matter and features of the dependent claims, regardless of the claims to which they refer. In particular, the individual features of independent claim 1 are each disclosed independently of each other. All ranges specified herein should be understood to be disclosed as, for example, each preferred narrower outer limit of each range, just as all values ​​falling within each range are individually disclosed. [Explanation of symbols]

[0118] 10 Equipment for filling containers 12 containers 14 Container conveyor 16 Infeed star wheel 18 Conveyor section 20 Container conveyor 22 Outgoing Star Wheel 24 Container locking device 26 Cullet Removal System 28 Filling machine 30 Filler Source 32 Pipeline System 34 Filler container 36 Closed Loop Control Valve 38 Filling Station 40 Receptive Space 42 Container support 44 Closed Loop Control Valve 46 filler channels 48 Flow Sensing Device 50 Filling valve 52 Closed Loop Control Valve 54 User Interface 56 Diagnostic Devices

Claims

1. An apparatus (10) for filling a container (12) with a filling material, comprising: a closed loop control valve (36, 44, 52) for said fill material; A diagnostic device (56) comprising: - monitoring the control values ​​of the control variables of said closed-loop control valves (36, 44, 52) during closed-loop control; a diagnostic device (56) configured to determine the state of function of the closed-loop control valve (36, 44, 52) depending on the monitored control values; Equipped with a flow detection device (48) configured to detect a filler flow rate through the closed-loop control valve (36, 44, 52); the diagnostic device (56) is further configured to determine the functional state of the closed-loop control valve (36, 44, 52) also depending on the filler flow rate detected by the flow detection device (48). Apparatus (10).

2. The apparatus (10) of claim 1, wherein the control variable is a valve lift or valve opening.

3. The apparatus (10) of claim 1, wherein the state of function of the closed-loop control valve (36, 44, 52) is a state of wear.

4. 2. The apparatus (10) of claim 1, wherein the diagnostic device (56) is further configured to determine the state of the function of the closed-loop control valve (36, 44, 52) also depending on an acceptable control value range.

5. 5. The apparatus (10) of claim 4, wherein the functional state of the closed-loop control valve (36, 44, 52) is determined as an impaired functional state if the monitored control value is outside the acceptable control value range, and / or is determined as a normal functional state if the monitored control value is within the acceptable control value range.

6. the acceptable control value range is greater than or equal to 50%, greater than or equal to 55%, or greater than or equal to 60% of the maximum value of the control variable, and / or is less than or equal to 75%, less than or equal to 70%, or less than or equal to 65% of the maximum value of the control variable; and / or The acceptable control value range is: the output of said device (10), - the format and / or filling volume of said container (12), the filling level in the filling material container (34) of said device (10), the pressure in the filling material container (34) of the device (10), - pre-compression of the filler material upstream of the filler material container (34) of the device (10), and the temperature of the filler, 5. The device (10) of claim 4, wherein the device is specified in dependence on at least one of:

7. The diagnostic device (56) - monitoring the control value of the closed-loop control valve (36, 44, 52) during closed-loop control, so that the control value is monitored within a pre-specified time window and / or in a steady state on the time axis during the closed-loop control; and The device (10) according to claim 1, further configured to determine the functional state of the closed-loop control valve (36, 44, 52) in dependence on the monitored control value, such that the functional state of the closed-loop control valve (36, 44, 52) is determined in dependence on the monitored control value in the specified time window and / or in the steady state.

8. the start of the specified time window is after a start-up phase of the device (10), after 1 minute, after 2 minutes, or after 3 minutes after the device (10) has started, or after a change in the output of the device (10); the end of the specified time window is before a shutdown phase of the device (10), within 3 minutes, within 2 minutes, or within 1 minute before a shutdown of the device (10), or before a change in the output of the device (10); 8. The device (10) according to claim 7.

9. The diagnostic device (56) - monitoring the control value of the closed-loop control valve (36, 44, 52) during closed-loop control, so that the control value is monitored under substantially constant operating conditions of the device (10); and The device (10) according to claim 1, further configured to determine the functional state of the closed-loop control valve (36, 44, 52) in dependence on the monitored control value, such that the functional state is determined in dependence on the monitored control value at the substantially constant operating condition.

10. The diagnostic device (56) further comprises: the output of the device (10) is within a specified output range; the container locking device (24) of the device (10) is open; the fill level in the filler container (34) of said device (10) is within a specified fill level range; the pressure in the filler container (34) of the device (10) is within a specified pressure range; the valve of the cullet removal system (26) of said device (10) is closed; the pre-compression of the filler material when fed into the filler material container (34) of the device (10) is within a specified pre-compression range; and / or the temperature of the filler is within a specified temperature range; 10. The apparatus (10) of claim 9, further configured to determine that a substantially constant operating condition exists when at least one of:

11. and determining the functional status of the closed-loop control valve (36, 44, 52) by comparing the detected filler flow rate with a theoretical filler flow rate through the closed-loop control valve (36, 44, 52) determined in dependence on the monitored control value.

2. The device (10) of claim 1.

12. further comprising an output device for outputting information to a user; The apparatus (10) of claim 1, wherein the diagnostic device (56) is further configured to operate the output device to output information regarding the determined functional status.

13. 1. A method for determining functionality of a closed-loop control valve (36, 44, 52) of an apparatus (10) for filling a container (12) with a filler material, comprising: providing closed-loop control with said closed-loop control valves (36, 44, 52); monitoring, during said closed-loop control, a control value of a control variable of said closed-loop control valve (36, 44, 52) by a diagnostic device (56); determining, by said diagnostic device (56), the state of function of said closed-loop control valves (36, 44, 52) in dependence on said monitored control values; and optionally outputting the determined feature status to a user via an output device; Including, further comprising the step of detecting a filler flow rate through the closed-loop control valve (36, 44, 52) with a flow detection device (48); The functional state of the closed-loop control valve (36, 44, 52) is also determined depending on the detected filler flow rate. method.

14. The device (10) for filling a container (12) with a filling material comprises:

2. The device (10) according to claim 1, The method of claim 13.

15. The method of claim 14, wherein the control variable is a valve lift or valve opening.

16. determining the state of function of the closed-loop control valve (36, 44, 52) further depends on an allowable control value range; The method of claim 13.

17. the functional state of the closed-loop control valve (36, 44, 52) is determined as impaired if the monitored control value is outside the acceptable control value range, and / or is determined as normal if the monitored control value is within the acceptable control value range.

17. The method of claim 16.

18. The control value is monitored within a pre-specified time window on a time axis during the closed-loop control, at a steady state of the control value and / or under substantially constant operating conditions of the device (10); and the state of function of the closed-loop control valve (36, 44, 52) is determined in dependence on the control value monitored within the specified time window at the steady state and / or under the substantially constant operating conditions; The method of claim 13.

19. The functional state of the closed loop control valve (36, 44, 52) is by comparing the detected filler flow rate with a theoretical filler flow rate through the closed-loop control valve (36, 44, 52) determined in dependence on the monitored control value. The method of claim 13.

20. the device (10) comprises a filler container (34), and the closed-loop control valve (36) is arranged upstream of the filler container (34) for closed-loop control of the fill level or pressure in the filler container (34); or the closed-loop control valve (44) is a fill valve, which can be used to deliver the fill material to the vessel (12) for filling the vessel (12) in a closed-loop control of the flow of the fill material; or The closed-loop control valve (52) is connected to a filling valve (50) and can be used to deliver the filler material to the container (12) for filling the container (12) in order to provide closed-loop control of the flow rate of the filler material. The method of claim 13.

21. The filler container (34) is annular.

21. The method of claim 20.

22. the device (10) comprises a filler container (34), and the closed-loop control valve (36) is arranged upstream of the filler container (34) for closed-loop control of the fill level or pressure in the filler container (34); or the closed-loop control valve (44) is a fill valve, which can be used to deliver the fill material to the vessel (12) for filling the vessel (12) in a closed-loop control of the flow of the fill material; or The closed-loop control valve (52) is connected to a filling valve (50) and can be used to deliver the filler material to the container (12) for filling the container (12) in order to provide closed-loop control of the flow rate of the filler material.

2. The device (10) of claim 1.

23. The filler container (34) is annular.

23. The device (10) according to claim 22.

24. the device (10) has at least one filling station (38) for filling the container (12), and the closed-loop control valve (36, 44, 52) is included in or connected to the at least one filling station (38); or the apparatus (10) comprises a rotary filler (28) comprising the closed-loop control valves (36, 44, 52); The method of claim 13.

25. the device (10) has at least one filling station (38) for filling the container (12), and the closed-loop control valve (36, 44, 52) is included in or connected to the at least one filling station (38); or the apparatus (10) comprises a rotary filler (28) comprising the closed-loop control valves (36, 44, 52); 2. The device (10) of claim 1.

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