Filling System Calibration for Media-Dependent Volume Accuracy
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Solution Overview
Problem
Filling systems using measuring devices like flowmeters or level measuring devices exhibit increased measurement deviation and poorer repeatability when filling media that differ from the calibration medium, such as water.
Innovation Solution
A method and system that optimize the repeatability of filling point measuring devices by varying parameters, using a control measuring device to determine and adjust settings, ensuring accurate and repeatable filling operations through a computing unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the filling system uses a measuring device calibrated with water to fill other media, then the device can be delivered ready-to-use, but the measurement deviation and repeatability deteriorate when the medium differs from the calibration medium
Solution Approach 1:
The system automatically adapts the measuring device parameters by performing test fillings with the actual medium to be filled. The computing unit calculates correction factors based on the physical properties (density, viscosity) of the medium and adjusts the measuring device parameters accordingly, transforming the device from a fixed calibration state to an adaptive parameter configuration that optimizes measurement precision for each specific medium
Solution Approach 2:
The system implements a feedback mechanism where the control measuring device captures the actual target volume filled, compares it with the measured value from the filling point measuring device, and feeds this information back to the computing unit. The computing unit uses this feedback to automatically optimize parameters and calculate offset values, continuously improving measurement accuracy without manual intervention
2Measurement precision
If the filling system uses a control measuring device to capture target volume, then measurement accuracy can be verified, but the system complexity increases
Solution Approach 1:
The computing unit serves multiple functions: it controls the filling process, calculates physical properties of the medium, optimizes measuring device parameters, determines offset values, and evaluates repeatability. By consolidating these diverse functions into a single multi-functional computing unit, the system achieves high measurement verification capability without proportionally increasing overall system complexity
Solution Approach 2:
The system performs self-calibration and self-optimization automatically. The computing unit autonomously processes data from both measuring devices, calculates optimal parameters, and adjusts the filling process without requiring external calibration equipment or manual intervention, making the added complexity self-justifying through automated operation
3Reliability
If multiple filling routines are performed to determine repeatability, then measurement reliability improves, but the filling time increases
Solution Approach 1:
The system performs repeatability evaluation and parameter optimization during initial test filling routines before actual production filling begins. By conducting these reliability checks in advance and automatically optimizing parameters based on the results, the system ensures high measurement reliability for subsequent production runs without repeatedly interrupting the filling process for checks
Solution Approach 2:
Once the optimal parameters are determined through initial test routines, the system maintains continuous production filling operations using these optimized parameters. The computing unit continuously monitors and maintains parameter optimization, allowing the system to achieve both high reliability through initial testing and high productivity through continuous uninterrupted production filling
Data Source
AI summary
A method for operating a filling system for filling a target volume of a first medium is described and shown. The filling system has at least one filling point measuring device, at least one control measuring device and at least one computing unit. The filling point measuring device controls the filling of the target volume, wherein the control measuring device is arranged in the filling system such that it captures the target volume of the medium to be filled which is controlled by the filling point measuring device, and wherein the filling point measuring device and the control measuring device are connected to the computing unit.