Displacement Pump Filling System for Solid-Liquid Mixes
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Solution Overview
Problem
Existing filling systems cause mechanical damage to solid constituents in liquid products due to product-damaging fittings like adjustment and control valves, and result in high energy consumption and material wastage from inefficient by-pass volume flow control.
Innovation Solution
The system employs a by-pass pump and an overflow pump, both operated as displacement pumps, to maintain a constant and reduced by-pass volume flow, and uses frequency converters for infinitely variable control, avoiding product-damaging fittings and optimizing filling material flow to minimize mechanical stress and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If adjustment and control valves are used in the filling system, then the by-pass volume flow can be controlled, but mechanical damage to solid constituents occurs due to shearing forces from product-damaging fittings
Solution Approach 1:
The patent removes adjustment and control valves from the filling system entirely, extracting the harmful fittings that cause mechanical damage to solid constituents. The by-pass volume flow control is achieved through a different mechanism that does not require these product-damaging valves.
Solution Approach 2:
The patent introduces a level control device as an intermediary mechanism to manage the by-pass volume flow without using traditional valves. This mediator controls the filling material flow while avoiding direct mechanical contact with solid constituents through shearing forces.
2Reliability
If traditional control valves are used to maintain filling material level, then the filling tank level can be controlled, but energy consumption increases and material wastage occurs
Solution Approach 1:
The level control device operates autonomously to maintain the filling material level in the filling tank without requiring continuous energy input or complex control systems. The device self-regulates the by-pass volume flow based on the actual filling needs, eliminating unnecessary energy consumption and material wastage.
Solution Approach 2:
The system dynamically adjusts the by-pass volume flow parameters based on the actual filling rate and tank level requirements. This parameter optimization ensures that filling material is not wasted and energy is consumed only when necessary for maintaining the correct level.
3Productivity
If high pump speeds are used to maintain by-pass volume flow, then the filling material can be circulated, but mechanical damage to solid constituents increases
Solution Approach 1:
The system dynamically adjusts the pump speed based on actual filling requirements rather than operating at constant high speed. The pump speed is optimized to maintain the necessary by-pass volume flow while minimizing mechanical stress on solid constituents, adapting to changing operational conditions.
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 ensures the integrity of solid constituents during filling by reducing mechanical stress and energy consumption, achieving a product-kind filling with minimal material wastage and improved filling system efficiency.
Implementation Method 1
using a by-pass pump embodied as a displacement pump, actively drawing the residual quantity from one of the filling element and the filling tank
Implementation Method 2
The overflow pipe returns an unneeded quantity of filling material to the processing unit
Implementation Method 3
uses frequency converters for infinitely variable control
Implementation Method 4
For hot filling or hot aseptic filling of products
Data Source
AI summary
A method for filling containers with a fill of liquid material and solids using a container-filling machine having a tank, a filling element, a processing unit, a bypass pipe and pump, and an overflow pipe. The tank holds the fill. The filling element controls delivery of fill from the tank into the container. The processing unit provides the fill to the tank. The by-pass pipe connects to the filling element. The pump returns a residual quantity from the tank to the processing unit. The residual quantity is a quantity of one of the fill and a by-pass volume flow from the filling element. The overflow pipe returns an unneeded quantity of fill to the processing unit. The method includes, using a by-pass pump embodied as a displacement pump, actively drawing the residual quantity from the filling element or tank.