Vehicle Filling Console Layout for Independent Vacuum and Pressure Testing
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Solution Overview
Problem
Existing filling systems on assembly lines face challenges in maintaining functional safety and efficiency when multiple consoles are operated simultaneously, leading to issues with process quality and speed, as well as interference between separate consoles.
Innovation Solution
The solution involves relocating essential process steps such as pressure testing, evacuation, and vacuum pump protection to a console with integrated assemblies like a separator, vacuum pump, and control assemblies, allowing the basic unit to focus solely on media supply, thereby making each console functionally self-sufficient and reducing inter-console interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple consoles are operated simultaneously in existing filling systems, then filling capacity is increased, but functional safety and process quality deteriorate due to inter-console interference
Solution Approach 1:
The system is segmented into independent console units, each with its own vacuum pump and control assemblies. This segmentation allows multiple consoles to operate simultaneously without interfering with each other, as each console is a self-contained system that maintains its own vacuum environment and control processes.
Solution Approach 2:
The vacuum pump and separator are integrated into the console before the filling operation begins. This preliminary arrangement ensures that each console is pre-prepared with its own vacuum generation capability, eliminating the need for shared vacuum resources and preventing inter-console interference during simultaneous operations.
2Device complexity
If process steps are distributed between base unit and console, then system complexity is reduced, but process quality and filling speed depend on line lengths and system design
Solution Approach 1:
The vacuum pump and separator are extracted from the base unit and relocated to the console. This extraction allows the console to perform vacuum-related operations independently, eliminating dependence on line lengths and base unit configuration, thereby improving filling speed and process quality while maintaining manageable system complexity.
Solution Approach 2:
The separator acts as an intermediary component between the vacuum pump and the filling process. It is integrated into the console to mediate the vacuum generation and transmission, ensuring that vacuum pressure is maintained independently of base unit distance and configuration, thus improving filling performance.
3Reliability
If vacuum pump protection steps are distributed across multiple consoles, then each console requires its own vacuum pump, but system complexity and cost increase
Solution Approach 1:
The vacuum pump and separator are merged into a single integrated console unit. This combination ensures that each console has its own dedicated vacuum pump for protection and operation, while the separator consolidates the vacuum management function. This approach maintains reliable vacuum pump protection without requiring separate vacuum pumps for each console, as the integrated design optimizes resource utilization.
4Adaptability or versatility
If essential process steps are relocated to the console, then each console becomes functionally self-sufficient, but console complexity increases
Solution Approach 1:
The console is designed as a universal, multi-functional unit that integrates the filling adapter, separator, vacuum pump, and control assemblies. This multi-functionality allows the console to perform all essential filling operations independently, making it adaptable to different filling requirements while managing complexity through standardized integration of components.
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 design ensures consistent process parameters, improved performance in pressure reduction and suction back times, and independent operation of consoles, reducing the impact of component failures and eliminating the need for multiple vacuum pumps, resulting in a functionally safe and efficient filling system.
Implementation Method 1
arranging in the console a separator (4), a vacuum pump (5), a first assembly (6) for controlling process steps for emptying the separator (4), a second assembly (7) for controlling a vacuum application and/or filling with liquids and/or back suction or venting
Implementation Method 2
a vacuum pump (5), a first assembly (6) for controlling process steps for emptying the separator (4), a second assembly (7) for controlling a vacuum application
Implementation Method 3
process steps for pressure testing and/or evacuating and/or filling and/or protecting a vacuum pump and/or absorbing gases for pressure reduction
Data Source
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AI summary
The invention relates to a technical solution for filling vehicle tanks and circuits with at least one liquid operating fluid using a filling system comprising at least one console with at least one filling adapter, wherein the at least one operating fluid is fed into the tanks and circuits to be filled via the at least one filling adapter. The object of the invention is to design the main process and the ancillary processes necessary for filling, both in terms of process engineering and equipment engineering, in such a way that, particularly when several consoles are operating simultaneously, a functionally reliable operating mode for the entire filling system is achieved.The problem is solved process-wise by carrying out several process steps in the console (2) for pressure testing and/or evacuation and/or filling and/or protecting a vacuum pump (5) and/or receiving gases for pressure reduction and/or receiving liquids for back-suction. Device-wise, the problem is solved by arranging in the console (2) a separator (4), a vacuum pump 5, a first assembly (6) for controlling the process steps for emptying the separator (4) and/or a second assembly (7) for controlling vacuum application and/or filling with liquids and/or back-suction or aeration and/or a hydraulic supply to the filling adapter (3) and/or a third assembly (8) for the pneumatic and electrical control of the filling adapter (3). (Fig. 5).