Filling Station Cleaning Flow Control to Prevent Pressure Surges
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Solution Overview
Problem
Existing cleaning processes for filling devices are prone to errors and do not guarantee adequate cleaning, particularly for gas paths, leading to potential damage and inconsistent cleaning medium flow rates.
Innovation Solution
A method that utilizes existing flow meters to measure cleaning medium flow rates through material and gas paths, adjusting valve actuation parameters to maintain a constant total flow rate, prevent pressure surges, and ensure optimal cleaning by setting a target number of open valves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual on-site setting of cleaning process is used, then operator flexibility is maintained, but cleaning adequacy deteriorates and errors increase
Solution Approach 1:
The system performs self-adjustment of valve actuation parameters by automatically analyzing cleaning medium flow rate measurements and modifying valve timing and synchronization accordingly, eliminating the need for manual operator intervention while maintaining optimal cleaning parameters
Solution Approach 2:
The system continuously measures cleaning medium flow rates through flow meters and uses this feedback information to automatically adjust valve actuation parameters, creating a closed-loop control system that ensures adequate cleaning while reducing manual setting complexity
2Productivity
If multiple material paths are cleaned simultaneously, then cleaning productivity increases, but pressure surges increase causing damage
Solution Approach 1:
The system dynamically adjusts valve actuation parameters based on real-time flow rate measurements, modifying the timing and synchronization of valve openings to maintain optimal cleaning flow rates while preventing pressure surges that could damage bellows or other components
Solution Approach 2:
The system changes operational parameters (valve actuation timing, synchronization) based on measured flow rates to optimize the balance between cleaning productivity and pressure control, preventing harmful pressure surges while maintaining efficient cleaning
3Reliability
If cleaning medium flow rate is increased, then cleaning effectiveness improves, but system pressure stability deteriorates
Solution Approach 1:
The system modifies valve actuation parameters based on flow rate measurements to maintain optimal cleaning effectiveness while preventing pressure surges, dynamically adjusting the balance between flow rate and pressure stability
Data Source
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AI summary
The invention relates, inter alia, to a method for setting up a cleaning operation of a device (10) for filling containers (12) with a fill material. The device (10) has several filling stations (36), each with a fill material path (46), a fill material path valve (48) arranged in the respective fill material path (46), and a flow meter (50) arranged for measuring a flow rate through the respective fill material path (46). A cleaning medium is passed through at least some of the fill material paths (46) by opening the respective fill material path valves (48). Cleaning medium flow rates through the opened fill material paths (46) are measured by means of the respective flow meters (50). At least one valve actuation parameter of the cleaning operation of the device (10) is set depending on the measured cleaning medium flow rates.