Filling Carousel Container Detection Using Load Cell Oscillation
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Solution Overview
Problem
Automatic filling devices often experience incorrect filling due to the lack of container presence detection, leading to soiling of the device and downstream systems, especially with viscous media, and existing solutions fail to reliably identify damaged or misplaced containers during transfer.
Innovation Solution
A method that utilizes the oscillating measurement signal from a weighing device to detect container presence directly during transfer, eliminating the need for settling times and digital filters, allowing for immediate signal evaluation and preventing incorrect fillings by ensuring a container is present before filling commences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If digital filters are used to process load cell signals, then measurement precision is improved, but productivity deteriorates due to required settling time
Solution Approach 1:
The patent applies preliminary action by capturing the measurement signal during the container transfer window before the filling process begins. The control unit evaluates whether a container is present based on signal characteristics during transfer, eliminating the need to wait for settling time after transfer before making the presence determination. This allows the filling process to start immediately once container presence is confirmed.
2Ease of operation
If optical container detection devices are used, then ease of operation is improved, but reliability deteriorates because damaged or lost containers cannot be detected
Solution Approach 1:
The patent replaces optical detection systems with a mechanical measurement approach using load cells. The measurement signal characteristics (amplitude, frequency, pattern) during container transfer provide reliable information about container presence and integrity. This mechanical approach detects faulty transfers, damaged containers, or lost containers through physical weight and vibration characteristics, achieving 100% signal generation for container presence detection.
3Measurement precision
If settling time is implemented for load cell measurements, then measurement precision is improved, but loss of time increases causing production downtime
Solution Approach 1:
The patent performs the measurement signal evaluation during the container transfer window itself, before the container settles into the filling station. The control unit captures and evaluates the measurement signal characteristics during transfer to determine container presence, eliminating the need for a separate settling period. This preliminary evaluation enables immediate transition to filling operations.
Solution Approach 2:
The patent skips the traditional settling time period by rapidly evaluating the measurement signal during the brief container transfer window. The control unit processes the signal characteristics (amplitude, frequency, pattern) in real-time during transfer, rushing through what would traditionally be a delayed evaluation phase and enabling immediate filling operation.
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 nearly eliminates incorrect fillings, allows for early start of filling processes, and enables the downsizing of filling devices by reducing the number of stations, as it reliably identifies faulty transfers and prevents filling without a container being present.
Implementation Method 1
acquiring a measurement signal from a weighing device of a filling station, preferably a filling carousel
Data Source
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AI summary
The invention relates, inter alia, to a method for operating a device (10) for filling containers (12). The method comprises acquiring a measurement signal from a weighing device (30) of one of several filling stations (22) of a filling device (16), preferably a filling carousel, within a predetermined container transfer signal window (CV) for transferring a container (12) between a transport device (14, 18), preferably a feeding device (14), and the filling station (22). The method further comprises detecting whether a container (12) is present in the filling station (22) based on the measurement signal. The invention is based on the finding that the oscillating measurement signal of the weighing device (30) during the container transfer is sufficiently characteristic to detect a correct container transfer into the filling station (22), for example, to prevent incorrect filling.