Container Filling Device with Shape Detection
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Solution Overview
Problem
Existing container filling systems face challenges in achieving consistent filling heights due to varying container shapes and sizes, leading to complex and expensive technology requirements, hygiene issues, and reduced performance, especially in implementing aseptic fillers and CO2 purging processes.
Innovation Solution
A device with a container detection system that determines the internal shape of each container and adjusts filling valves to achieve precise filling volumes and heights, eliminating the need for lifting devices and probe or return air pipe systems, allowing for optimized filling processes and improved hygiene.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If lifting devices are used to insert return air tubes or probes into containers, then filling can be achieved, but device complexity and cost increase significantly
Solution Approach 1:
The patent removes the lifting device entirely from the system. Instead of mechanically lifting containers to insert probes or return air tubes, the invention uses a valve that opens and closes based on a schedule while containers pass through a carrier. This extraction of the lifting mechanism eliminates the associated complexity and cost while maintaining filling functionality.
Solution Approach 2:
The patent replaces the mechanical lifting system with a temporal control system. The valve operation is controlled by a schedule based on container position and volume, substituting mechanical action (lifting) with a timed sequence of valve openings and closings. This substitution eliminates the need for complex lifting mechanisms while achieving the same filling result.
2Ease of manufacture
If lifting devices and long stroke mechanisms are implemented to achieve proper container positioning, then filling can be performed, but hygiene standards become difficult to meet
Solution Approach 1:
The patent removes the probe that would need to be inserted into the container, eliminating the primary source of contamination risk. By using a valve-based system that operates externally while containers pass through the carrier, the invention eliminates the need for components that would require sterile insertion and removal, thereby meeting hygiene standards more easily.
Solution Approach 2:
The patent introduces a carrier as an intermediary between the valve and the container. The carrier transports containers through the filling zone, allowing the valve to dispense filling material into containers without direct mechanical contact or insertion of components into the container interior. This intermediary system maintains hygiene by preventing contamination pathways.
3Ease of operation
If complex lifting mechanisms with stroke curves and height adjustments are used, then container positioning can be achieved, but manufacturing cost increases
Solution Approach 1:
The patent eliminates the entire lifting mechanism, including stroke curves and height adjustment systems. Containers are positioned and filled while passing through the carrier at a consistent level, removing the need for complex positioning mechanisms. This extraction dramatically reduces manufacturing cost while maintaining adequate positioning for filling.
Solution Approach 2:
The system allows containers to be filled in their natural position within the carrier without requiring external lifting or positioning adjustments. The valve and carrier system are designed to work with containers at a fixed height, allowing the filling process to occur automatically as containers pass through, eliminating the need for expensive positioning infrastructure.
4Ease of manufacture
If long stroke mechanisms are implemented to position containers properly, then filling can be achieved, but process time increases and productivity decreases
Solution Approach 1:
The patent removes the time-consuming lifting and positioning stroke from the filling process. Containers are filled while passing through the carrier without interruption for lifting or positioning adjustments. The valve operates in synchronization with container passage, eliminating idle time and maximizing filler throughput and productivity.
Solution Approach 2:
The filling process operates continuously as containers pass through the carrier. The valve opens and closes in a scheduled sequence that matches the continuous flow of containers, ensuring that the filling action occurs without interruption. This continuous operation eliminates the start-stop cycles associated with lifting mechanisms, thereby increasing productivity.
5Ease of manufacture
If probes or return air pipes are used for filling control, then filling can be performed, but installation space is blocked and CO2 purge process cannot be improved
Solution Approach 1:
The patent removes the probe and return air pipe from the system, freeing up installation space. The valve-based filling mechanism operates externally, allowing the interior space previously occupied by these components to be available for CO2 purge system implementation. This extraction enables greater system versatility and improved purge capability.
Solution Approach 2:
The carrier and valve system are designed to accommodate multiple functions within the same space. The carrier not only transports containers for filling but also provides space for CO2 purge operations. The valve system can be configured to support both filling and purge functions, creating a multi-functional system that improves versatility without requiring additional space.
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates, inter alia, to a device (10) for filling containers (12), comprising a container detection device (24), several filling stations (32), and a control unit (48) configured to determine a filling volume for each container (12) up to a target filling level (5) based on a detected internal shape of the respective container (12), and to operate filling valves (40) based on the determined filling volume and a detected flow rate of the filling material to the respective filling valve (40). Advantageously, the device (10) enables very precise filling of containers (12) to a specific height based on a determination of the filling volume for each individual container (12).