Filling Machine Contour Detection for Volume Accuracy
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Solution Overview
Problem
Existing methods for inspecting and filling containers, such as bottles, face challenges in accurately determining the fill level due to variations in container expansion and contour, leading to inconsistent fill volume measurements and potential underfilling or overfilling, especially with beverages containing CO2.
Innovation Solution
A container treatment device with a container detection element upstream of the fill level monitor captures the container's partial or entire contour, allowing for independent volume determination and fill level control, decoupling the contour detection from the fill level check, and enabling dynamic adaptation of the fill volume based on the container's real external configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a fill level probe is used to check the fill level, then the fill level can be monitored, but the measurement is affected by container expansion and contour variations leading to inaccurate volume determination
Solution Approach 1:
The patent extracts the contour detection function from the fill level monitoring system by introducing a separate container detection element upstream. This separation allows the fill level probe to focus solely on measuring liquid level while the detection element independently captures container contour data, eliminating the interference between contour variations and fill level measurements.
Solution Approach 2:
The container detection element is positioned upstream of the fill level probe to capture the container's external configuration before the filling process begins. This preliminary detection of container contour and volume allows the system to pre-calculate correction factors that compensate for container expansion and shape variations during subsequent fill level measurements.
2Productivity
If the fill level is checked after filling, then the inspection can be performed, but container expansion during filling causes the fill level to fluctuate even with correct volume
Solution Approach 1:
The system performs preliminary detection of container volume and external configuration before the filling process. By capturing the container's initial state upstream, the system can predict how the container will expand during filling and pre-adjust the target fill level accordingly, ensuring consistent volume despite container expansion fluctuations.
Solution Approach 2:
The patent implements a feedback mechanism where the container detection element continuously monitors container expansion during the filling process. The control unit uses this real-time feedback data to dynamically adjust the fill level probe's measurements, compensating for container expansion and maintaining accurate volume determination throughout the filling process.
3Quantity of substance
If different container contours are filled to the same volume, then the filling quantity is correct, but the fill level varies leading to inconsistent inspection results
Solution Approach 1:
The container detection element captures the external contour and calculates the internal volume of each container before filling. This preliminary measurement allows the control unit to determine the specific fill level required for each container based on its unique geometry, ensuring that containers with different contours are filled to appropriate levels that all correspond to the correct volume.
Solution Approach 2:
The system applies local quality by customizing the fill level target for each individual container based on its detected contour characteristics. Instead of using a universal fill level setting, the control unit calculates container-specific fill levels that account for variations in shape, size, and internal volume, ensuring accurate volume filling across diverse container geometries.
Data Source
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AI summary
The invention relates to a container handling device, in particular a filling machine (1) for filling containers (5), wherein the filling machine (1) is connected downstream of a filling level control unit. Advantageously, at least one container detection element (9) is provided, which is disposed separately from the filling level control unit, upstream thereof, wherein both the filling level control unit and the at least one container detection element (9) guide respective inspection data of the containers (5) inspected independently of one another to a control and regulating device (6), wherein the at least one container detection element (9) detects and forwards at least one partial contour of the relevant container (5) as inspection data. The invention also relates to an inspection and filling process of the filling machine (1).