Container Filling Volume Control Without Probes or Lifting
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Solution Overview
Problem
Existing container filling systems, such as return air tube and probe fillers, require complex and expensive lifting devices, struggle with hygiene issues, and are inefficient due to increased process angles and times, leading to potential contamination and reduced output.
Innovation Solution
A method and device that utilize a container detection system to capture the external shape and weight of each container, determining the filling volume based on these measurements, eliminating the need for lifting devices, filling probes, and return air ducts, and ensuring precise level filling through volume calculation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lifting devices are used to insert return air tubes or probes into containers, then the filling process can be controlled, but the device complexity and cost increase significantly
Solution Approach 1:
The patent removes the lifting device, return air tube, and probe from the filling system. Instead of using these complex mechanical components to control the filling process, the invention uses a simplified valve mechanism that opens and closes based on a schedule, eliminating the need for probes to detect fill levels or lifting devices to position components.
Solution Approach 2:
The patent replaces the mechanical lifting device and probe system with a valve-controlled system. The valve opens and closes according to a predetermined schedule without requiring mechanical lifting or probe insertion, substituting a complex mechanical detection and positioning system with a simpler timed valve operation.
2Reliability
If lifting devices and long stroke mechanisms are used, then containers can be pressed against the filling device, but the process angle and process time increase, reducing productivity
Solution Approach 1:
The patent eliminates the lifting device and long stroke mechanism entirely. Containers are positioned and filled without requiring vertical lifting or extended stroke movements, thereby reducing the process angle and process time while maintaining reliable container positioning through the simplified valve system.
3Reliability
If probes or return air ducts are immersed in containers, then filling can be controlled, but hygiene standards become difficult to meet due to contamination risks
Solution Approach 1:
The patent removes the probe and return air duct from the system. By eliminating these components that must be immersed in the container, the invention eliminates the contamination risk associated with probe immersion while maintaining filling control through the scheduled valve operation that does not require internal container components.
Solution Approach 2:
The filling system operates without requiring probes or return air ducts to be placed inside containers. The valve system controls filling based on external scheduling rather than internal container conditions, allowing the system to function without components that could introduce contaminants.
4Manufacturing precision
If complex lifting devices and stroke curves are implemented, then precise filling can be achieved, but the torque on the filler carousel increases
Solution Approach 1:
The patent eliminates the lifting device and stroke curve mechanism. Precise fill level control is achieved through scheduled valve operation rather than mechanical positioning, thereby eliminating the additional torque that would be required to drive complex lifting and positioning mechanisms on the filler carousel.
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates, inter alia, to a method for filling containers (12) with a fill material. The outer shape of a container (12) is detected by means of a container detection device (24), and an outer volume (A) of the container (12) is determined based on the detected outer shape. The weight of the container (12) is detected by means of a weighing device (30). A filling volume (F) is determined based on the determined outer volume (A) and the detected weight. The container (12) is filled with the fill material according to the determined filling volume (F) by means of a filling device (34).