Filling Level Sensor Detects Leaky Containers in Bottling
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Solution Overview
Problem
Conventional bottling plants face challenges in detecting defective glass containers that are not completely intact but leak during the filling process with carbonated beverages, leading to potential rupture at later stages, resulting in additional costs and contamination risks.
Innovation Solution
A device and method utilizing a filling level sensor to detect the target filling level after the filling valve is closed, initiating an ejection process if the level is undershot, allowing for the detection of container faults without additional sensors, and ensuring only intact containers are transferred to subsequent processing stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical detection method is used to detect container rupture during filling, then complete container fractures can be detected, but leaky containers with small holes or cracks cannot be detected and may rupture later causing contamination and additional costs
Solution Approach 1:
The filling level sensor performs a preliminary check of the container's sealing integrity by detecting whether the filling level is maintained after the filling valve closes. This preliminary detection identifies leaky containers before they are transferred to subsequent processing stations, preventing future rupture and contamination.
Solution Approach 2:
The system uses feedback from the filling level sensor to determine whether a container is leaking. After the filling valve closes, the sensor continuously monitors the filling level, and if the level drops indicating a leak, the system triggers an ejection mechanism to remove the defective container from the production line.
2Manufacturing precision
If the filling valve remains open to ensure complete filling, then the target filling level is achieved, but leaky containers will show incorrect filling levels and cannot be distinguished from properly filled containers
Solution Approach 1:
The system performs a preliminary filling to the target level, then closes the filling valve and waits for a settling period. After this preliminary action, a second filling level measurement is taken to verify whether the level is maintained, which indicates container integrity. This two-stage approach ensures both precise filling and reliable defect detection.
Solution Approach 2:
The system incorporates a time delay or settling period between closing the filling valve and taking the second filling level measurement. This cushioning period allows any immediate filling variations to stabilize, ensuring that the second measurement accurately reflects whether the container is leaking rather than just being in the process of filling.
3Reliability
If additional sensors are added to detect container faults, then detection capability is improved, but device complexity and cost increase
Solution Approach 1:
The existing filling level sensor is made multi-functional by using it for both its primary purpose (controlling the filling process and ensuring target filling level) and a secondary purpose (detecting container leaks by monitoring filling level changes after valve closure). This eliminates the need for additional dedicated detection sensors, reducing device complexity and cost.
Solution Approach 2:
The filling level sensor serves itself by utilizing its own measurement capability for dual purposes. The sensor's existing function of measuring filling level is extended to also detect container integrity, allowing the system to perform self-diagnosis of container defects without requiring external detection devices.
Data Source
AI summary
A device for filling a container with a filling product, preferably for filling a glass container with a beverage in a bottling plant, comprising a filling valve for introducing the filling product into the container to be filled, a control device for controlling the filling valve, and a filling level sensor which communicates with the control device for detecting the presence of a target filling level (HS) of the filling product in the container, the control device being configured to close the filling valve upon detection of the target filling level (HS), the control device being configured to determine the presence of the target filling level (HS) by means of the filling level sensor again after the filling valve has been closed and to initiate an ejection process for the container if it is detected that the target filling level (HS) has been undershot.