Dual Flow Meter Filling System Composition Monitoring
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Solution Overview
Problem
Conventional flexible filling systems face challenges in ensuring independent quality control over the composition of filling materials in containers, as the mixture is only combined shortly before or during filling, making it difficult to guarantee the desired composition, especially in opaque containers where post-filling composition measurement is not feasible.
Innovation Solution
A filling system with a main and additional filling material source, connected via a filling material line with series flow measuring devices and a control device that compares measurements for error detection, ensuring accurate composition monitoring and potentially omitting post-filling composition checks by detecting deviations and triggering maintenance as needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If flexible filling systems combine or mix filling material shortly before or during filling, then filling flexibility is improved, but independent quality control of composition becomes difficult
Solution Approach 1:
The patent applies preliminary action by measuring the flow rates of filling materials before they are mixed and filled. Two flow measuring devices are positioned upstream to independently monitor the composition components before mixing occurs, allowing quality control to be performed in advance rather than after mixing.
Solution Approach 2:
The control device receives measurements from both flow measuring devices and compares them to determine if the composition is correct. This feedback mechanism allows the system to verify composition accuracy in real-time and trigger alerts or corrections when deviations are detected, ensuring quality control despite the flexible mixing approach.
2Measurement precision
If post-filling composition measurement is used, then composition verification is improved, but it only works for transparent containers
Solution Approach 1:
The patent performs composition measurement before filling occurs, using flow measuring devices that monitor the filling materials upstream. This preliminary measurement approach eliminates the need for post-filling optical inspection, making the system compatible with both transparent and opaque containers.
Solution Approach 2:
The patent introduces flow measuring devices as intermediary measurement tools that indirectly assess composition by measuring the flow rates of individual filling material components before mixing. This intermediary approach avoids the need for direct optical measurement of the final mixture in the container, enabling verification for all container types.
3Device complexity
If single flow measuring device is used, then device complexity is reduced, but measurement reliability deteriorates due to undetected errors
Solution Approach 1:
The patent applies local quality by positioning two flow measuring devices at different locations upstream in the filling material lines. Each device measures a specific component's flow rate at its local position, providing distributed measurement coverage that enhances overall measurement reliability through spatial redundancy.
Solution Approach 2:
The control device compares measurements from both flow measuring devices to detect errors. This feedback comparison mechanism identifies inconsistencies or failures in individual sensors, allowing the system to maintain measurement reliability even with the added complexity of dual measurement devices.
Data Source
Figure 1
AI summary
The invention relates, inter alia, to a filling system (10) for a tank treatment plant. The filling system (10) comprises a filling valve (14) and a main material source (18) which is connected to the filling valve (14) via a material line (20). A first flow meter (22) and a second flow meter (24) are arranged in series in the material line (20). An additional material source (30), to which a metering valve (34) is assigned, is connected to the material line (20). A control device (50) is configured to compare a measurement of the first flow meter (22) and a measurement of the second flow meter (24) for fault detection.