Filling Condition Generation Device for Opaque Containers
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Solution Overview
Problem
Existing filling devices face challenges in setting the optimum filling condition, leading to overflowing, foaming, or insufficient ejection of filling liquid due to the difficulty in accurately positioning the nozzle and controlling the ejection amount, especially when filling opaque containers.
Innovation Solution
A filling condition generation device that includes a nozzle with a liquid surface sensor and a control system to automatically adjust the nozzle position and ejection amount based on detected liquid surface proximity and predetermined distances, allowing for precise setting of filling conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the nozzle position is manually adjusted and filling condition is set by operator, then the filling device can operate, but the optimum filling condition is difficult to set and requires skilled manual manipulation
Solution Approach 1:
The system performs self-diagnosis and self-adjustment by automatically detecting the liquid surface position using the liquid surface sensor and autonomously determining the optimal nozzle position and ejection amount, eliminating the need for skilled manual manipulation while maintaining easy operation
Solution Approach 2:
The liquid surface sensor provides real-time feedback on the liquid surface position, and the control unit uses this feedback to automatically adjust the nozzle position and ejection amount, creating a closed-loop control system that simplifies operation while optimizing filling conditions
2Productivity
If the ejection amount is increased to improve productivity, then filling speed increases, but overflowing and foaming occur when the nozzle is not close to the liquid surface
Solution Approach 1:
The liquid surface sensor continuously monitors the liquid surface position and provides feedback to the control unit, which automatically adjusts the ejection amount based on the detected position, enabling high productivity while preventing overflowing and foaming through real-time control
Solution Approach 2:
The system dynamically adjusts the ejection amount based on the real-time liquid surface position detected by the sensor, allowing the filling device to adapt to varying liquid levels and maintain optimal filling conditions throughout the process
3Reliability
If the nozzle is positioned close to the liquid surface to prevent foaming, then filling quality improves, but the ejection amount per unit time decreases
Solution Approach 1:
The system dynamically adjusts the ejection amount based on the real-time liquid surface position, allowing the nozzle to maintain close proximity to the liquid surface for high filling quality while compensating for reduced ejection distance by increasing the ejection rate, thus achieving both quality and productivity
4Ease of operation
If manual manipulation is used to set filling condition, then the device can be operated, but the process requires skilled operation and time-consuming adjustments
Solution Approach 1:
The system performs self-diagnosis and self-adjustment by automatically detecting the liquid surface position using the liquid surface sensor and autonomously determining the optimal nozzle position and ejection amount, eliminating the need for skilled manual manipulation and significantly reducing setup time
Solution Approach 2:
The system performs preliminary detection of the liquid surface position and pre-calculates the optimal filling parameters before actual filling begins, allowing for rapid setup and eliminating time-consuming manual adjustments while maintaining ease of 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
Enables easy and accurate generation of optimum filling conditions, preventing overflowing and foaming while ensuring sufficient ejection of filling liquid, even for opaque containers.
Implementation Method 1
a liquid surface sensor that detects a position of a liquid surface of the filling liquid
Data Source
Figure 1
Figure 2(A)~2(B)
Figure 3(A)~3(B)
AI summary
The problem to be addressed by the present invention is to provide a filling condition generation device which is capable of easily generating optimal filling conditions set in a filling device. The filling device includes, as the filling condition generation device 1 which generates filling conditions that are conditions when the filling device consecutively fills a filling liquid into a plurality of containers 2, : a nozzle 6 which ejects the filling liquid into the containers 2; a driving device 5 which moves the nozzle 6; and a control device 22, wherein the control device 22 ejects the filling liquid 3 from the nozzle 6, moves the nozzle 6 from a side of the bottom surfaces 2a of the containers 2 to a side of opening parts 2b of the containers 2 by means of the driving device 5, and generates the filling conditions for filling the filling liquid 3 into the containers 2 in a state where a tip end part of the nozzle 6 is close to the liquid surface 3a of the filling liquid 3.