Filling Element Gas Valve Dynamics for Residue Control
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Solution Overview
Problem
Existing filling systems face challenges in preventing liquid residues from entering containers, leading to bacterial growth and foam formation due to carbon dioxide-rich environments, and struggle to accurately measure fill levels for precise filling.
Innovation Solution
A filling element with a fluid channel and a gas channel equipped with a gas valve that can be configured in multiple states to control gas flow, allowing for reduced flow speeds to prevent residue atomization and facilitate precise filling, while also using the gas channel to convey pressurizing gas and flush out residues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If liquid filling material is discharged rapidly into the container, then filling productivity is improved, but liquid residues splash and enter the gas channel, leading to bacterial growth and foam formation
Solution Approach 1:
The gas channel is extracted from the container interior and repositioned to extend into the container interior only during specific phases, separating the gas flow path from the liquid filling path to prevent residue contamination
Solution Approach 2:
The gas channel is designed to be dynamically adjustable, extending into the container interior when gas flow is active and retracting when liquid filling occurs, allowing the system to adapt its configuration based on the operational phase
2Object-affected harmful factors
If filling speed is reduced to prevent residue splashing, then residue introduction is minimized, but filling productivity decreases
Solution Approach 1:
The gas channel configuration is dynamically changed during the filling process - extended during gas flow phases to prevent residue entry, and retracted during liquid filling phases to maintain high filling speeds without contamination
3Productivity
If liquid filling material enters the container rapidly, then filling productivity is improved, but fill level measurement precision deteriorates due to difficulty in measuring and stopping in time
Solution Approach 1:
The gas channel is positioned to extend into the container interior before liquid filling begins, creating a protective barrier that allows for more gradual and measurable filling while maintaining overall high productivity
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 solution reduces the introduction of residues into containers, minimizes bacterial growth, prevents excessive foam formation, and allows for more accurate determination of fill levels, enabling efficient and precise filling of containers at high production rates.
Implementation Method 1
a gas channel (10) with a gas valve (13) and a gas opening (11)... in which flushing gas, in particular carbon dioxide, is conveyed into the container (4) before the filling of the container (4)
Implementation Method 2
During the filling of fluid filling material, the return gas channel serves to convey the pressurizing gas that is displaced out of the container
Implementation Method 3
this reduced flow contributes to rapid drying of the residue adhering to the gas channel (10)
Data Source
AI summary
A filling element has a gas valve that controls flow of gas through a gas channel that extends into or faces the container during filling thereof. The gas valve transitions between discrete states, which includes a fully-open state, a closed state, and one or more partially-open states.