Filling Machine Flow Meter for Bottle Breakage Detection
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Solution Overview
Problem
Filling machines with short-circuit probes face significant product loss due to bottle breakage, as they can only determine an insufficient fill level after reaching the maximum filling angle or time, and lack accurate measurement of filling quantities during CIP processes.
Innovation Solution
Incorporating flow meters into filling machines to measure actual flow rates through filling elements, allowing for real-time monitoring and premature termination of filling processes in case of irregularities, and using an evaluation unit to assess deviations from reference flow rates for determining faulty processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If short-circuit probes are used to terminate filling processes, then filling speed is improved, but product loss increases due to delayed detection of bottle breakage
Solution Approach 1:
The flow meter measures the actual flow rate of product during filling before the filling process is complete, enabling early detection of bottle breakage. This preliminary measurement allows the control system to terminate filling prematurely when a breakage is detected, preventing the product loss that would otherwise occur after maximum filling angle or time is reached.
Solution Approach 2:
The flow meter provides continuous feedback on the actual flow rate during filling operations. The control system compares this real-time flow rate data against expected values to detect anomalies indicating bottle breakage. This feedback mechanism enables dynamic adjustment of the filling process, allowing termination before completion when breakage is detected, thus resolving the contradiction between high filling speed and product loss prevention.
2Measurement precision
If flow meters are added to measure actual flow rates, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The flow meter serves multiple functions: it measures actual flow rates during filling operations to detect bottle breakage, measures flow rates during CIP processes to monitor cleaning agent consumption, and provides data for process optimization. This multi-functionality justifies the added device complexity by delivering comprehensive measurement capabilities that benefit both filling operations and cleaning processes.
3Loss of substance
If filling processes are terminated early upon detecting bottle breakage, then product loss is reduced, but productivity decreases due to more frequent interruptions
Solution Approach 1:
The flow meter provides continuous real-time feedback on actual flow rates during filling. The control system uses this feedback to detect bottle breakage events and terminates filling only when anomalies are detected, rather than at fixed intervals. This feedback-driven approach minimizes unnecessary interruptions while preventing product loss, thereby maintaining productivity while reducing waste.
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
Minimizes product loss by detecting bottle breakage and leaks before reaching maximum filling conditions, and optimizes CIP processes by accurately measuring and controlling the flow of cleaning agents, reducing overall consumption and ensuring quality.
Implementation Method 1
The flow meters can be, for example, inductive flow meters (IDM)
Implementation Method 2
The flow meters can be, for example, inductive flow meters (IDM), mass flow meters (MDM)
Data Source
Figure 1
Figure 2
AI summary
A filling machine (1, 21) and a method for controlling filling operations and/or CIP processes on a filling machine are described. The filling machine is equipped with a short-circuit probe (5, 25) for level limitation. In addition to the short-circuit probes on the respective filling elements, the filling machine includes flow meters (7, 27) individually assigned to the filling elements for measuring the instantaneous actual flow rate through each filling element. This allows the proper functioning of filling operations and/or CIP processes to be assessed before a predetermined time period or machine angle has elapsed for individual filling operations, in order to minimize product losses in the event of container breakage. Furthermore, CIP processes can be optimized and documented for individual filling elements.