Container Filling Control via Real-Time Parameter Polling
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Solution Overview
Problem
Existing filling devices and methods struggle to maintain consistency in filling operations due to variations in tank level, temperature, pressure, and filler speed, as well as deviations among individual filling valves, which are not adequately accounted for by prior control methods.
Innovation Solution
A method and device for filling containers that involves incremental polling of influencing variables, accounting for the variability of individual filling elements, using a control device that calculates the filling operation based on parameters like temperature, pressure, and rotation frequency, and includes a calibration process to determine and store characteristic parameters for each filling element, allowing for independent control and correction of filling rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If time-controlled dosing is used for filling operations, then filling speed and productivity are improved, but deviations among individual filling elements cause inconsistency in filling accuracy
Solution Approach 1:
The patent applies local quality by determining and storing individual characteristic parameters for each filling element (such as filling time, flow rate, or valve position) that are specific to each element's performance. This allows each filling element to be controlled according to its unique characteristics rather than using a uniform control approach, thereby maintaining high filling speed while ensuring consistent filling accuracy across all elements.
Solution Approach 2:
The patent implements feedback by continuously monitoring the actual filling process and comparing it against the target filling amount. The control device adjusts the filling operation based on real-time data from sensors that measure parameters like liquid level, pressure, or flow rate, enabling dynamic correction of deviations and ensuring consistent filling accuracy while maintaining productivity.
2Manufacturing precision
If individual filling elements are controlled independently, then filling accuracy for each element is improved, but the complexity of the control system increases
Solution Approach 1:
The patent applies segmentation by dividing the control system into modular components: a control device that manages multiple filling elements, individual sensors for each element, and a memory device for storing characteristic parameters. This segmented architecture allows independent control of each filling element for high accuracy while distributing complexity across manageable modules rather than requiring a single complex centralized system.
Solution Approach 2:
The patent implements preliminary action by determining and storing the characteristic parameters of each filling element before the actual filling operation begins. This calibration or characterization step is performed in advance, allowing the control system to use pre-stored data during operation, thereby reducing real-time computational complexity while maintaining high filling accuracy for each individual element.
3Manufacturing precision
If real-time monitoring of liquid parameters is implemented, then filling consistency is improved, but the frequency of polling and data processing increases system complexity
Solution Approach 1:
The patent applies periodic action by implementing time-controlled polling of liquid parameters (such as level, temperature, or pressure) at predetermined intervals rather than continuous monitoring. This periodic sampling approach maintains filling consistency by capturing relevant parameter changes while reducing the frequency of data processing operations, thereby balancing filling consistency with acceptable system complexity.
Data Source
AI summary
Method for filling containers with liquids, wherein the containers are filled using a plurality of controllable filling elements and the liquid is fed to these filling elements starting from a reservoir, common to the filling elements, for storing the liquid, wherein during the filling the containers are transported at least in sections along a circular track and wherein the filling of the containers by at least one filling element is controlled as a function of at least one first parameter characteristic of the liquid in the reservoir and this parameter is determined repeatedly at given intervals of time during the filling operation.