Time-Controlled Filling Process with Flow Measurement Compensation
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Solution Overview
Problem
Existing filling control methods are negatively influenced by short filling times and disturbances such as pressure and temperature fluctuations, which affect the accuracy and reliability of the filling process.
Innovation Solution
A time-controlled filling method that involves measuring the flow before and during filling, adjusting the filling time interval based on comparisons between actual and target values, and using filters to account for fluctuations, allowing for precise control and compensation of disruptive factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If time-controlled filling is used to achieve very short filling times, then productivity increases, but measurement precision deteriorates due to disturbances from pressure and temperature fluctuations
Solution Approach 1:
The patent performs multiple flow measurements during the filling process (at start, middle, and end) to predict the total filling quantity before the filling operation completes. This preliminary prediction allows the system to compensate for disturbances and adjust subsequent fillings even when individual filling times are very short, thus maintaining measurement precision while enabling high productivity
Solution Approach 2:
The system uses feedback from multiple flow measurements taken during each filling operation to calculate a predicted total filling quantity. This feedback mechanism allows real-time compensation for pressure and temperature fluctuations, maintaining accurate filling control even at very short filling times where disturbances would normally degrade measurement precision
2Manufacturing precision
If integrated batching control is used to automatically correct overrun quantities, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The patent combines multiple flow measurements (start, middle, end) and integrates them into a single predictive calculation for total filling quantity. This merging of measurement data and control functions into one integrated system achieves accurate overrun correction while avoiding the complexity of separate control mechanisms for each measurement point
Solution Approach 2:
The control system performs multiple functions using a unified approach: it conducts flow measurements, predicts total filling quantity, calculates overrun, and adjusts subsequent fillings all through one integrated control algorithm. This multi-functionality achieves precise manufacturing control without requiring separate dedicated systems for each control task
Data Source
Figure 1~2
AI summary
A method for carrying out a filling process in a time-controlled manner with the following steps: A beginning a first flow measurement before or during the start of filling a first container; B starting the filling of the first container at a first time (to); C ending the filling of the first container at a second time (tE), wherein the second time (tE) is predefined by a first interval of time (totr) which has been set; D repeating steps B and C once or a plurality of times for filling a second container or a plurality of further containers; E ending the first flow measurement with the determination of a total flow (qMeas) of the preceding filling operations; F comparing an actual value determined from the total flow (qMeas) with a predefined desired value, and G adapting the first interval of time (toff) on the basis of the comparison according to step F, and an apparatus comprising a control loop (1) for controlling the filling quantity in a time-controlled manner, and a flowmeter, in particular for carrying out the method according to one of the preceding claims.