Filling System Calibration via Reference-Point Deviation Transfer
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Solution Overview
Problem
Existing filling systems require complex and time-consuming process calibration due to numerous filling points, which are often not under actual process conditions, leading to insufficient measurement accuracy.
Innovation Solution
A method where a first control and evaluation unit at one filling point calibrates a parameter under process conditions, determines deviations, and transmits these to a second unit via a communication channel for adjustment, reducing the need for individual calibration of each device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If process calibration is performed at all filling points to ensure measurement accuracy, then measurement precision is improved, but calibration time and complexity increase significantly
Solution Approach 1:
The patent applies the copying principle by creating a virtual copy of the calibration process. Instead of physically calibrating each filling point individually, the system copies the calibration data from a reference filling point and transmits it to other filling points via communication channels. This allows all filling points to be calibrated without performing the actual calibration operation at each location, thereby maintaining measurement accuracy while significantly reducing calibration time.
Solution Approach 2:
The patent uses an intermediary approach by introducing a reference filling point that performs the calibration and then shares this calibration information with other filling points through communication channels. The reference filling point acts as a mediator that consolidates the calibration effort, allowing the entire system to be calibrated through a single calibration event rather than multiple separate calibration operations at each filling point.
2Measurement precision
If individual calibration is performed at each filling point, then measurement accuracy is improved, but device complexity and calibration effort increase
Solution Approach 1:
The patent applies universality by making the calibration process applicable to all filling points through a single reference calibration. The reference filling point's calibration data serves multiple filling points simultaneously, allowing the same calibration procedure to be universally applied across the entire system without requiring separate calibration operations at each location. This reduces overall system complexity while maintaining accuracy.
Solution Approach 2:
The system copies calibration parameters from the reference filling point to other filling points via communication channels, eliminating the need for individual calibration operations at each device. This copying approach reduces calibration complexity from multiple separate calibration procedures to a single reference calibration that can be replicated across the entire system.
3Loss of time
If factory calibration uses few calibration points to minimize effort, then calibration time is reduced, but measurement accuracy under process conditions deteriorates
Solution Approach 1:
The patent applies preliminary action by performing comprehensive calibration at the reference filling point before the calibration data is copied to other filling points. The reference filling point undergoes thorough calibration with multiple calibration points and extended dwell times under actual process conditions, preparing accurate calibration data in advance that can then be efficiently distributed to other filling points without requiring them to repeat the time-consuming calibration process.
Data Source
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AI summary
A method (100) for calibrating a filling plant (1) is presented and described, in which, in a first calibration step (101), a calibration of a calibration parameter of the first flow or level measuring device (4) is carried out under process conditions at a first calibration point, in a first deviation determination step (102), the first control and evaluation unit (5) of the first flow or level measuring device (4) determines an average deviation of the calibration parameter measured by the first flow or level measuring device (4) from a target value of this calibration parameter at the first calibration point, and in a first correction step (103), the first control and evaluation unit (5) corrects at least one calibration parameter taking into account the determined deviation.In a first transmission step (104), the first control and evaluation unit (5) transmits the determined deviation in the first calibration point and/or the at least one corrected calibration parameter via the communication channel (8) to the second control and evaluation unit (7), and in a first adjustment step (105), the second control and evaluation unit (7) corrects at least one calibration parameter in a first calibration point, taking into account the deviation or calibration parameter transmitted by the first control and evaluation unit (5).