Filling Line Segmentation for Homogeneous Product Distribution
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Solution Overview
Problem
The distribution of a second component in a product consisting of a first liquid component becomes non-homogeneous over time due to segregation processes, where particles may float or settle depending on the specific weight of the components, posing a challenge in storing products like emulsions or fruit juices with chunky portions.
Innovation Solution
The filling line between the receptacle and the filling valve is divided into sections with throttle valves, with the section between the filling valve and the adjacent throttle valve dimensioned to match the internal volume of the container to be filled, and the filling line is oriented vertically to prevent segregation, with a conveying device inside the receptacle to mix the product and ensure the inside diameter of the filling line is 1.3 times the size of the average particle diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the filling line is long to connect the receptacle to the filling valve, then the device can handle larger containers, but segregation of components occurs during filling
Solution Approach 1:
The filling line is divided into multiple sections by inserting throttle valves at specific positions. Each section has a controlled length and volume, preventing segregation while allowing the overall system to handle large containers. The segmentation creates multiple short filling paths instead of one long path.
Solution Approach 2:
The internal diameter of the filling line is specifically dimensioned to be 1.3 times the average particle size of solid components. This parameter optimization ensures smooth flow of particles through the line without segregation, while the throttle valves adjust flow rate to maintain homogeneity throughout the filling process.
2Ease of operation
If the filling line diameter is large to accommodate particles, then particle flow is improved, but the line volume increases and causes more segregation
Solution Approach 1:
The filling line internal diameter is precisely set to 1.3 times the average particle size. This optimized parameter allows particles to flow smoothly without excessive line volume that would cause segregation. The specific ratio ensures adequate clearance for particles while minimizing the volume where segregation could occur.
Solution Approach 2:
By dividing the filling line into multiple smaller sections with throttle valves, each section has reduced volume despite maintaining adequate diameter for particle flow. This segmentation prevents the accumulation of segregated components that would occur in a single large-volume line.
3Stability of the object's composition
If throttle valves are added to divide the filling line, then segregation is prevented, but device complexity increases
Solution Approach 1:
The filling line is divided into multiple sections by inserting throttle valves at specific positions. Each section has a controlled length and volume, preventing segregation while allowing the overall system to handle large containers. The segmentation creates multiple short filling paths instead of one long path.
4Productivity
If the filling line is oriented vertically to improve filling, then filling efficiency increases, but segregation may occur due to gravity
Solution Approach 1:
The vertical filling line is divided into multiple sections by throttle valves, creating several short vertical segments rather than one long vertical path. This segmentation prevents gravity-induced segregation while maintaining the vertical orientation for efficient filling.
Solution Approach 2:
The internal diameter of the vertical filling line is specifically dimensioned to be 1.3 times the average particle size. This parameter ensures that particles can flow vertically without segregation, counteracting the gravitational effect while maintaining filling efficiency.
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 configuration effectively counteracts segregation by ensuring a uniform distribution of components during filling, maintaining the intended quantity ratio and preventing separation, allowing for a homogeneous product fill.
Implementation Method 1
Separation of the product can be prevented by moving the product inside the receptacle by a conveyor
Implementation Method 2
the line section between the filling valve and a throttle valve arranged adjacent to the filling valve is dimensioned in such a way that the internal volume of this part of the line section in the Essentially corresponds to a filling volume of a container to be filled
Data Source
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AI summary
The invention relates to a method and device used to fill a container with a product. The product consists of a first liquid component and at least one second component. The product is supplied to the container to be filled via at least one filling line (21) and at least one filling valve (24). The filling line (21) is sub-divided into line sections between the receiving container (2) and the filling valve (24) by at least one throttle valve (23). The line section (25) between the filling valve (24) and a throttle valve (23) arranged adjacent to the filling valve is dimensioned such that the interior volume of said part of the filling line substantially corresponds to a filling volume of a container (27) to be filled.