Controllable Choke Arrangement for Low-Pressure Purging in Filling Machines
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Solution Overview
Problem
Existing filling machines face inefficiencies in purging and pre-loading containers due to limitations in gas flow dynamics, leading to suboptimal pressure and throughput during the filling process.
Innovation Solution
The method involves using a controllable choke arrangement to switch between constricted and unconstricted gas paths, allowing purgative gas to enter the container with low pressure and high throughput by reducing pressure through a choke and draining it via a larger cross-sectional path, ensuring rapid pre-loading and filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If purgative gas is introduced through a constricted gas path with reduced flow cross-section, then gas pressure is reduced to low purge pressure (0-2 bar), but gas throughput is limited
Solution Approach 1:
The gas path is segmented into two distinct paths: a first controlled gas-path with a controllable choke arrangement for introducing purgative gas at reduced pressure, and a second controlled gas-path with a larger flow cross-section for draining purgative gas. This segmentation allows each path to be optimized for its specific function, resolving the contradiction between pressure reduction and throughput maintenance
Solution Approach 2:
Different sections of the gas path are given different flow cross-sections and control characteristics. The first gas-path includes a choke arrangement to create localized pressure reduction, while the second gas-path provides an unconstricted drainage path. This local differentiation enables simultaneous achievement of low pressure introduction and high throughput drainage
2Productivity
If purgative gas is introduced through an unconstricted gas path with full flow cross-section, then gas throughput is high, but gas pressure remains high (above atmospheric pressure)
Solution Approach 1:
The drainage function is separated into a dedicated second controlled gas-path with a larger flow cross-section and no choke arrangement, allowing purgative gas to be drained at high throughput without pressure restriction, while the introduction path maintains pressure control through its choke arrangement
Solution Approach 2:
The controllable choke arrangement acts as an intermediary element that selectively restricts flow in the first gas-path during purging operations, creating the pressure differential needed to introduce gas at low pressure while the second path provides an unrestricted drainage route
3Device complexity
If a single gas-path is used for both introducing and draining purgative gas, then device complexity is reduced, but filling speed and efficiency are compromised
Solution Approach 1:
The gas path system is divided into two controlled paths with different characteristics: the first path with choke arrangement for controlled introduction, and the second path with larger cross-section for efficient drainage. This segmentation enables simultaneous optimization of both purging and filling operations, achieving high filling speeds while maintaining manageable device complexity through modular control
4Productivity
If high pressure is used to introduce purgative gas, then gas throughput is maintained, but vortex formation increases and gas consumption rises
Solution Approach 1:
The pressure parameter of the introduced purgative gas is changed from high pressure to low pressure (0-2 bar above atmospheric) through the choke arrangement. This parameter change reduces the kinetic energy of the incoming gas, thereby minimizing vortex formation and gas consumption while the unconstricted drainage path maintains adequate throughput
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 results in faster container filling and reduced gas consumption by maintaining high gas throughput at reduced purge pressures, enhancing the efficiency of the filling process while minimizing vortex formation and gas usage.
Implementation Method 1
conducting purgative gas via a first controlled gas-path from a first ring channel common to all filling elements of the filling machine to the container's interior via a controllable choke arrangement that can switch between a first choke-state in which the controllable choke arrangement chokes gas flow and a second choke-state in which the controllable choke arrangement allows free gas flow, the controllable choke arrangement being in the first choke-state, thereby reducing pressure of the purgative gas to a purge pressure
Implementation Method 2
draining the purgative gas from the container, which is flowing at a purge pressure of between 0 bar and 2 bar above ambient pressure, out of the container's interior through first and second return-gas openings of the filling element and into first and second return-gas channels of a second controlled gas-path of the filling element
Data Source
AI summary
A method for operating a filling machine includes conducting purgative gas via a first controlled gas path from a first ring channel common to all filling elements to the interior of a container sealed against a filling element via a controllable choke arrangement that switches between choking state and non-choking states, draining the purgative gas out of the container's interior through return-gas openings and into return-gas channels of a second controlled gas path, the first and second return-gas channels being controlled by corresponding first and second control valves that are operable independently of each other, and pressure-filling the container with the liquid contents.