Countercurrent Shutter Filling Valve Stabilizes Flow
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Solution Overview
Problem
Rotary-type filling machines face hydrodynamic instabilities and inefficiencies in controlling the flow rate of pourable products due to the Venturi effect and Bernoulli forces, limiting the precision and stability of the shutter movement, especially when approaching the full closing position, which leads to increased costs and reduced regulation of the flow rate.
Innovation Solution
The filling valve is designed with a shutter that moves countercurrently towards the full closing position, using a magnetic actuator system with a ferromagnetic core and a plunger to engage with the flow channel, which reduces Bernoulli forces and stabilizes the shutter, allowing precise control of the flow rate without mechanical interfaces entering the aseptic environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the shutter moves towards the full closing position in a conventional filling valve, then the flow rate is reduced, but hydrodynamic instabilities occur due to the Venturi effect and Bernoulli forces
Solution Approach 1:
The shutter is configured to move countercurrently towards the full closing position, opposite to the conventional flow direction. This inversion of movement direction counteracts the Venturi effect and Bernoulli forces that cause hydrodynamic instabilities, allowing the shutter to maintain stability while controlling flow rate reduction.
Solution Approach 2:
The patent changes the movement parameter of the shutter from conventional (with flow) to countercurrent (against flow). This parameter change fundamentally alters the hydrodynamic interaction, eliminating the instability-causing effects while maintaining flow control capability.
2Reliability
If a magnetic actuator system is used to control the shutter, then mechanical interfaces are avoided in the aseptic environment, but control precision is reduced due to hydrodynamic instabilities
Solution Approach 1:
By inverting the shutter movement direction to move countercurrently, the patent eliminates the hydrodynamic instabilities that would otherwise compromise control precision. This allows the magnetic actuator system to maintain both aseptic conditions and precise flow rate control without mechanical interfaces.
3Adaptability or versatility
If the shutter is controlled to intermediate positions for flow modulation, then the flow rate can be regulated, but hydrodynamic instabilities increase near the full closing position
Solution Approach 1:
The countercurrent movement configuration allows the shutter to achieve intermediate positions for flow modulation while moving against the flow direction. This eliminates the Venturi effect that causes instability near the closing position, enabling stable flow rate regulation across all intermediate positions.
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 configuration enhances the stability and precision of the shutter movement, preventing hydrodynamic instabilities and enabling effective modulation of the flow rate, while maintaining aseptic conditions and reducing energy consumption by using a single energy spike for the auxiliary shutter's on-off operation.
Implementation Method 1
the shutter is controlled by magnetic actuator means comprising a magnetic actuator including a magnetic stator, i.e. a coil, which is arranged in a fixed position around the flow channel, and an inner core, which is made of a ferromagnetic material and is movable within the flow channel
Implementation Method 2
as the shutter approaches the full closing position, the intermediate opening passage shrinks more and more, thereby causing a Venturi effect on an end portion of the shutter configured to engage the outlet opening
Implementation Method 3
due to this phenomenon, the pressure decreases around the intermediate opening passage when this latter is shrinking, i.e. when the shutter is controlled near the full closing position, due to the high speed of the pourable product through the same intermediate opening passage. Therefore, Bernoulli forces arise
Data Source
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AI summary
There is described a filling valve (5; 105) for a filling machine (1) configured to fill a receptacle (2) with a pourable product; the filling valve (5; 105) comprises a flow channel (11; 111) having an inlet opening (15) for receiving the pourable product and an outlet opening (18) for feeding the pourable product into the receptacle (2); the filling valve (5; 105) comprises a closing member (12) arranged within the flow channel (11; 111) and configured to be controlled at least between a full closing position, in which the closing member (12) is configured to prevent a fluid connection between the inlet opening (15) and the outlet opening (18), a full opening position, in which the closing member (12) is configured to allow the fluid connection between the inlet opening (15) and the outlet opening (18) through a full opening passage, and at least one intermediate position, defining a respective intermediate opening passage for the pourable product; the closing member (12) is configured to be controlled towards the full closing position in a direction against the flow direction (D) of the pourable product within the flow channel (11; 111).