Beverage Filling Distribution Line Pressure Stabilization
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Solution Overview
Problem
Existing filling systems in beverage bottling plants face challenges in maintaining consistent filling volume flow due to pressure fluctuations, requiring complex and costly product tanks with level control, which limits flexibility and increases maintenance.
Innovation Solution
A device with a pressure maintaining device in the distribution line, such as a directional control valve, ensures constant pressure across filling elements, eliminating the need for a pressurized product tank and allowing flexible adjustment of filling volume flow, using a product pump to maintain excess pressure and a flow meter to regulate excess product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a product tank with level control system is used to minimize pressure fluctuations, then filling consistency is improved, but device complexity and maintenance effort increase
Solution Approach 1:
The patent extracts the pressure stabilization function from the complex product tank with level control system and implements it through a simple membrane element in the distribution line. The membrane acts as a pressure buffer without requiring active control systems, thereby achieving filling consistency while eliminating device complexity
Solution Approach 2:
The membrane element serves as an intermediary component that absorbs pressure fluctuations in the distribution line. It acts as a passive pressure buffer between the product supply and filling valves, stabilizing pressure without requiring complex control mechanisms
2Reliability
If a product tank with level control system is used to minimize pressure fluctuations, then filling consistency is improved, but maintenance effort increases
Solution Approach 1:
The patent removes the complex level control system from the product tank and replaces it with a simple membrane element in the distribution line. This passive pressure stabilization component requires no maintenance while maintaining filling consistency
Solution Approach 2:
The membrane element provides self-regulating pressure stabilization without requiring external control systems or maintenance. It automatically absorbs pressure fluctuations through its physical properties, eliminating the need for active maintenance
3Reliability
If a product tank with level control system is used to minimize pressure fluctuations, then filling consistency is improved, but costs increase
Solution Approach 1:
The patent extracts the essential pressure stabilization function from the expensive product tank with level control system and implements it through a simple, inexpensive membrane element in the distribution line, achieving the same reliability at lower cost
Solution Approach 2:
The membrane element is a simple, inexpensive component that provides pressure stabilization without the high costs associated with active level control systems. It offers a cost-effective solution for maintaining filling consistency
4Reliability
If control valves with adjustable flow coefficients are used to compensate for pressure fluctuations, then filling consistency is improved, but device complexity increases
Solution Approach 1:
The patent replaces the mechanical control valves with adjustable flow coefficients with a passive membrane element that provides pressure stabilization through its physical properties. This eliminates the need for complex control mechanisms while maintaining filling consistency
Solution Approach 2:
The membrane element provides automatic pressure stabilization without requiring control valves or active control systems. It self-regulates pressure fluctuations through its elastic properties, eliminating device complexity
5Device complexity
If simple shut-off valves with fixed flow coefficient are used, then device complexity is reduced, but filling consistency deteriorates due to pressure fluctuations
Solution Approach 1:
The membrane element serves as an intermediary in the distribution line that absorbs pressure fluctuations before they reach the simple shut-off valves. This allows the use of simple valves while maintaining filling consistency through passive pressure stabilization
6Reliability
If a product tank is used to maintain static level for constant pressure difference, then filling consistency is improved, but adaptability to change filling volume flow is reduced
Solution Approach 1:
The patent replaces the static level control in the product tank with a dynamic membrane element in the distribution line. The membrane can adapt to changing pressure conditions and filling requirements, providing both consistency and adaptability
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
The solution provides a mechanically compact, low-maintenance, and cost-effective system that maintains consistent pressure and volume flow, reducing product losses and enabling flexible filling volume adjustments without the need for complex tank regulation.
Implementation Method 1
a product pump (12) which is configured to transport the filling product from the product supply (20) to the distribution line (13)
Implementation Method 2
a pressure-maintaining device (30) configured to keep the pressure in the distribution line (13) constant
Data Source
Figure 1
AI summary
Device (1) and method for filling containers with a filling product, preferably in a beverage filling plant, wherein the device comprises: a product feed (20) configured to provide the filling product; one or more filling devices (10) configured to introduce the filling product into the containers; a distribution line (13) to which the filling devices (10) are connected and from which the filling devices (10) obtain the filling product to be filled; a product pump (12) configured to transport the filling product from the product feed (20) to the distribution line (13); and a pressure maintenance device (30) configured to keep the pressure in the distribution line (13) constant.