Electric Clamping Drive Monitoring for Container Breakage Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for detecting container breakage during filling operations are prone to errors due to contamination, incorrect settings, and reliance on external sensors, making precise detection of breakage location challenging and disruptive to system operation.
Innovation Solution
An integrated system using electrically actuated clamping devices with monitoring of electrical operating parameters, such as current consumption, to diagnose container anomalies like breakage or loss, eliminating the need for external sensors and allowing precise location of the anomaly within the treatment carousel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external sensors (optical sensors, cameras, ultrasonic sensors, light barriers) are used to detect container breakage, then the detection capability is improved, but the system becomes more complex and more prone to errors due to contamination, water drops, and incorrect settings
Solution Approach 1:
The patent extracts the detection function from external sensors and integrates it into the clamping device itself. The clamping device's electric drive unit now serves dual purposes: both actuating the clamping action and providing diagnostic information about container integrity through monitoring its operating parameters (current, power, speed, torque). This eliminates the need for separate external sensor systems.
Solution Approach 2:
The electric drive unit of the clamping device is given multiple functions: it actuates the clamping mechanism to hold and transport containers, and simultaneously serves as a sensor by providing diagnostic information about container breakage or loss through monitoring its operating parameters. This multi-functionality reduces system complexity while maintaining detection reliability.
2Measurement precision
If external sensors are used to monitor container flow and detect breakages, then detection coverage is improved, but the response time increases and system disruption occurs during cleaning operations
Solution Approach 1:
The detection system is segmented by clamping device position. Each clamping device on the transport carousel independently monitors its own container through its electric drive unit parameters. This allows precise localization of breakages to specific clamping device positions, enabling targeted cleaning of only the affected section rather than shutting down the entire system.
Solution Approach 2:
The clamping device detects container breakage or loss immediately when it occurs during the holding or transport phase, before the container reaches the filling station. This preliminary detection allows the system to identify and isolate affected containers early, minimizing the need for extensive system shutdowns and cleaning operations.
3Reliability
If monitoring of electric drive unit parameters is implemented in the clamping device, then the detection reliability is improved, but the device complexity increases
Solution Approach 1:
The diagnostic function is merged with the actuation function in the clamping device. The same electric drive unit that provides mechanical actuation also serves as the sensing element. By monitoring the drive unit's operating parameters (current, power, speed, torque) during normal operation, the system detects container anomalies without adding separate sensing components, thus avoiding increased device complexity.
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
Enables rapid, precise detection of container breakage or loss without external sensors, reducing false alerts, minimizing system disruption, and enabling real-time cleaning of affected units, thus enhancing system efficiency and reducing maintenance costs.
Implementation Method 1
the clamping device comprises at least one electric drive unit configured to actuate the clamping device, including gripping and releasing the container
Implementation Method 2
the processing device is configured to monitor at least one electrical operating parameter, preferably a current consumption and/or electrical power, of the electric drive unit
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Device (1) for treating containers, preferably for filling containers with a filling product in a beverage filling plant, and method for detecting a container anomaly, preferably a container breakage or a container loss, in such a device (1).The device (1) comprises: an electrically actuatable clamping device (50) for holding a container, wherein the clamping device (50) has at least one electrical drive unit (53) configured to actuate the clamping device (50), including gripping and releasing the container; and a processing device (100) that is in communication with the clamping device (50) and configured to monitor at least one electrical operating parameter, preferably a current consumption and/or an electrical power, of the electrical drive unit (53); wherein the processing device (100) is further configured to generate a container signal from the monitoring of the operating parameter, which indicates whether or not the clamping device (50) is holding a container, and to determine a container anomaly, preferably a container breakage or a container loss, depending on the container signal.