Filling Device for Heterogeneous Products with Rotary Mixing
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Solution Overview
Problem
Weight filling systems struggle with heterogeneous products having solid or semi-solid suspended elements, leading to spillage, aggregation, and inconsistency in filling due to pressure from the product's geodetic head, which is incompatible with weight measurement systems, resulting in over-filling and increased production costs.
Innovation Solution
A filling device with a hollow body and a movable shutter member, actuated by compressed air, that ensures accurate and efficient filling by maintaining product homogeneity through continuous mixing and precise control of the dispensing opening, integrated with a loading cell for weight measurement and a motorized dispensing member for volumetric systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pressurization is applied to ensure continuity of filling operation, then filling continuity is improved, but weight measurement accuracy deteriorates and over-filling occurs
Solution Approach 1:
The filling system is segmented into two independent parts: a pressurized volumetric filling system for maintaining continuous operation, and a separate weight measurement system for accurate monitoring. This allows both functions to operate simultaneously without interference, resolving the contradiction between filling continuity and weight measurement accuracy.
Solution Approach 2:
A feedback control mechanism acts as an intermediary between the pressurized filling system and the weight measurement system. The loading cell continuously monitors the actual weight and provides feedback signals to adjust the pressurization, enabling both continuous operation and accurate weight control.
2Productivity
If volumetric piston systems are used for pressurized filling, then filling speed is improved, but filling accuracy deteriorates due to physical variable changes
Solution Approach 1:
The system incorporates real-time weight measurement feedback from loading cells to continuously monitor and adjust the volumetric filling process. This feedback loop compensates for variations caused by temperature changes and suspended piece distribution, maintaining filling accuracy while preserving the high speed of volumetric piston systems.
Solution Approach 2:
The system dynamically adjusts filling parameters based on real-time monitoring of physical variables such as temperature and product density. By changing operational parameters in response to measured conditions, the system maintains accurate filling despite variations in product physical properties.
3Stability of the object's composition
If constant mixing is applied to avoid stratification, then product homogeneity is improved, but energy consumption increases
Solution Approach 1:
Instead of continuous mixing, the system applies periodic or intermittent mixing actions that are sufficient to maintain product homogeneity. This periodic approach reduces energy consumption while still preventing stratification of solid parts, as the mixing is applied only when necessary to maintain uniform distribution.
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
The solution allows for accurate net weight filling of heterogeneous products, ensuring product quantities match label declarations, reducing over-filling and associated costs, while maintaining product homogeneity and consistency.
Implementation Method 1
actuated by compressed air
Implementation Method 2
integrated with a loading cell for weight measurement
Data Source
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Figure 2
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AI summary
The present invention relates to a filling device for heterogeneous products or products which have solid or semi-solid suspended elements with variable dimensions and compactness. The valve of the invention can be used in net weight filling machines. In particular, the invention relates to a filling device (1) for filling machines, comprising a hollow body (2) in which a shutter member (3) is movably fitted and acts in cooperation with a dispensing member (4), which is coaxial to said shutter member (3), to close or open a dispensing opening (5) for a product (P) to be dispensed into a container (C), characterized in that said dispensing member (4) comprises a rotatable shaft (10) comprising a screw portion (14) adapted to impart a dispensing pressure and a mixing to the product (P).