Container treatment machine
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Solution Overview
Problem
Container treatment machines in the beverage industry face inefficiencies in reheating after operational interruptions, leading to unnecessary heat losses and increased energy costs, as current methods do not accurately account for ambient temperatures or the type of containers being processed, resulting in potential failure to reach target temperatures on time.
Innovation Solution
A method and system where the container treatment machine's controller monitors temperature profiles and environmental conditions to calculate the optimal start time for reheating, using adjustable heating power and ancillary units to ensure the treatment fluid reaches the target temperature efficiently and safely before production resumes, while avoiding peak energy usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the treatment fluid is heated continuously to maintain target temperature during operational interruptions, then the temperature is maintained ready for production resumption, but unnecessary heat losses and energy consumption occur
Solution Approach 1:
The heating device operates dynamically by adjusting its output based on real-time temperature measurements and predicted production start times. The controller modulates heating power to match actual thermal needs rather than maintaining constant maximum heating, resolving the contradiction between temperature maintenance and energy efficiency.
Solution Approach 2:
The system continuously monitors treatment fluid temperature and uses this feedback to adjust heating device operation. The controller receives temperature data, compares it with target parameters, and modifies heating output accordingly, preventing unnecessary energy consumption while ensuring temperature readiness.
2Speed
If the heating device operates at maximum power to reach target temperature quickly, then production start time is met, but peak energy usage increases overall costs
Solution Approach 1:
The heating device transitions from static maximum power operation to dynamic power adjustment. The controller varies heating output based on real-time temperature progress and predicted production start time, enabling faster heating when needed while reducing power during slower heating phases, thus lowering peak energy usage and overall costs.
Solution Approach 2:
The heating device operates in periodic cycles with varying power levels rather than continuous maximum power. The controller applies heating in controlled intervals, allowing thermal energy to distribute and accumulate efficiently, reducing peak demand while maintaining heating progress toward the target temperature.
3Reliability
If the heating start time is set based on fixed maximum heating-up time, then the machine is ready for production, but unnecessary heat losses occur when temperature is reached too early
Solution Approach 1:
The heating control system dynamically adjusts the heating start time and duration based on actual temperature measurements and predicted production start times. Rather than using fixed timing, the controller continuously adapts heating parameters to reach the target temperature precisely when needed, eliminating early temperature achievement and associated heat losses.
Solution Approach 2:
The system uses real-time temperature feedback to determine optimal heating cessation timing. The controller monitors temperature progression and stops heating at the precise moment the target temperature is reached or predicted to be reached by production start time, preventing unnecessary heating and subsequent heat losses during extended warm-up periods.
4Device complexity
If ambient temperature variations are not considered in heating calculations, then the heating process is simple, but the target temperature may not be reached on time
Solution Approach 1:
The system performs preliminary assessment of ambient temperature conditions and their impact on heating requirements before initiating the heating process. The controller calculates adjusted heating parameters based on predicted ambient temperature effects, enabling accurate temperature achievement despite varying environmental conditions without significantly increasing operational complexity.
Solution Approach 2:
The heating control system incorporates ambient temperature sensing and uses this feedback to adjust heating power and timing calculations. The controller continuously compares actual ambient conditions with expected conditions, modifying heating parameters in real-time to compensate for thermal losses or gains from the environment, ensuring reliable target temperature achievement.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for rapid and energy-efficient reheating, minimizing heat losses and energy costs by tailoring the heating process to the specific conditions and container types, ensuring the machine is ready for production start times while avoiding unnecessary heat peaks.
Implementation Method 1
a heating device (16) for heating the treatment fluid (24) in the receiving space (23) to a target temperature
Implementation Method 2
the controller (34) is designed to calculate a heating-up time required for the treatment fluid (24) to heat up to a target temperature before a production start time
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a method for operating a container treatment machine (10) for treating containers with a treatment fluid (24), e.g. a container cleaning machine, in which container treatment machine (10) operating parameters, such as the temperature of the treatment fluid and the duration of the treatment of the container with the treatment fluid, can be set. The container type to be treated and/or the degree of soiling of the containers to be treated is or are detected for the treatment of the containers and at least one operating parameter is set in accordance with the container type and/or the degree of soiling of the container.