Filling Nozzle Piston Valve Water Hammer Control
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Solution Overview
Problem
Filling machines face issues in maintaining consistent filling conditions and preventing water hammer due to variations in flow rate and quick valve closure, leading to inconsistent weight and volume delivery in containers.
Innovation Solution
A filling nozzle with a movable piston and valve system that controls the flow rate and prevents water hammer by isolating the dispensing opening from the supply duct, allowing for controlled dispensing and modulation of fluid flow, ensuring consistent filling and reducing pressure spikes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the filling valve closes quickly to interrupt dispensing, then the filling cycle time is reduced and productivity is improved, but water hammer occurs causing pressure spikes that can damage the filling system
Solution Approach 1:
The filling valve begins closing before the dispensing nozzle is fully obstructed by the container rim. This preliminary closure action reduces the flow rate gradually rather than abruptly, preventing water hammer while maintaining efficient filling cycles. The valve closure timing is coordinated with the container positioning to achieve smooth flow reduction.
Solution Approach 2:
The system anticipates the water hammer problem by implementing a controlled valve closure sequence that cushions the pressure buildup. The valve closes in a manner that absorbs the pressure surge before it can propagate through the supply system, protecting pumps and piping from damage.
2Productivity
If the flow rate is increased to improve filling speed, then productivity is improved, but the consistency of weight and volume delivery deteriorates due to variations in flow rate conditions
Solution Approach 1:
The filling process uses periodic adjustment of flow rate based on detected weight or volume. The system operates at high speed initially, then periodically reduces flow rate as the container approaches the target fill level, ensuring precise delivery while maintaining overall productivity.
Solution Approach 2:
Detection devices (scales or flow measurers) provide real-time feedback on the filling status. This feedback enables dynamic adjustment of the valve closure timing and flow rate, allowing the system to maintain consistent weight and volume delivery even when operating at high speeds. The control unit modifies valve behavior based on detected parameters.
3Measurement precision
If the valve closure timing is advanced based on previous filling data, then the precision of target weight achievement is improved, but the system becomes sensitive to flow rate variations that cause inconsistent filling results
Solution Approach 1:
The valve closure timing is made dynamic rather than fixed. The control unit adjusts the advance time based on real-time detection of flow rate conditions and filling status. This dynamic adjustment allows the system to maintain precision across varying operating conditions, preventing the reliability problems associated with fixed timing based on historical data alone.
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
Ensures consistent filling conditions and eliminates water hammer, ensuring accurate weight and volume delivery while preventing damage to the filling system by managing fluid flow and pressure.
Implementation Method 1
each valve associated with the respective filling nozzle totally and quickly closes the respective pipe generating upstream thereof the undesired phenomenon of water hammer that causes a significant increase in pressure along the pipe
Data Source
Figure 1~4
Figure 5~6
Figure 7~8
AI summary
The present invention concerns a filling nozzle (1) for filling machines, in particular weight-grading machines, for containers such as drums, bottles, cans and/or the like, comprising: a hollow body (2) defining an inner channel (3) for the transit of a fluid (4), the hollow body (2) being provided with at least one supply duct (6) of the fluid (4) and a dispensing opening (7) of the fluid (4) coming from the supply duct (6); a valve member (8) operatively associated with the dispensing opening (7) of the hollow body (2), being switchable between a first condition, wherein it sealingly obstructs the dispensing opening (7) of the hollow body (2) to prevent the fluid (4) outflow through the latter and a second condition, wherein it disengages the dispensing opening (7) of the hollow body (2) to allow the fluid (4) outflow from the latter. The nozzle (1) further comprises a piston (9) operatively engaged in the inner channel (3) defined by the hollow body (2). The piston (9) is controllable as for movement and/or switching for isolating the dispensing opening (7) of the hollow body (2) with respect to the supply duct (6) of the fluid (4) and for determining the controlled outflow, from the dispensing opening (7) of the hollow body (2), of the fluid (4) present between the latter and the piston (9).