Filling Machine Probe and Filtered Gas Path for Precise Fill Level Correction
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Solution Overview
Problem
Existing methods for precise filling of containers, such as the Trinox and vacuum filling methods, face issues like additional costs due to inert gases and contamination from ambient air, respectively, during the fill level correction phase.
Innovation Solution
A filling machine design that uses a height-adjustable probe and controlled gas paths with a filter unit to maintain a sealed position during fill level correction, either using vacuum pressure or a filtered pressure medium to remove excess filling material without introducing unfiltered air into the container's headspace.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the Trinox method is used to remove overfilled material, then filling precision is improved, but additional costs due to inert gas are incurred
Solution Approach 1:
The patent replaces expensive inert gas with ambient air that is filtered through a filter unit. The filtered air is used temporarily during the fill level correction phase and then discharged, effectively using a cheap, disposable medium instead of expensive reusable inert gas while maintaining filling precision.
Solution Approach 2:
The patent introduces a filter unit as an intermediary between ambient air and the container headspace. This filter unit mediates the interaction by cleaning the ambient air before it contacts the filling material, thereby eliminating the need for expensive inert gas while preventing contamination.
2Manufacturing precision
If vacuum filling method is used to remove overfilled material, then filling precision is improved, but contamination from ambient air enters the container
Solution Approach 1:
The filter unit acts as an intermediary that allows ambient air to contact the container headspace during fill level correction while preventing harmful contaminants from entering. The filter unit is positioned in the gas path between the container and the environment, mediating the interaction to allow necessary pressure equalization while blocking contaminants.
Solution Approach 2:
The patent creates a protected environment by filtering ambient air to remove contaminants before it contacts the filling material. This filtered air environment serves as a protective atmosphere during the fill level correction phase, preventing contamination while allowing pressure-driven material removal.
3Manufacturing precision
If the container is removed from sealed position during fill level correction, then overfilled material can be removed, but unfiltered air enters the headspace
Solution Approach 1:
The filter unit is positioned in the gas path to mediate between the container headspace and ambient air. During fill level correction, the filter unit allows pressure equalization and material removal while continuously filtering the air that contacts the headspace, preventing contamination without requiring the container to remain sealed.
4Object-affected harmful factors
If a filter unit is introduced to prevent contamination, then quality is improved, but device complexity increases
Solution Approach 1:
The filter unit is integrated into the existing gas path structure of the filling machine, serving multiple functions: filtering ambient air during fill level correction, maintaining pressure differential for material removal, and preventing contamination. This multi-functionality reduces the need for separate systems and minimizes overall device complexity.
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
Enables precise filling with minimal losses and optimal quality at reduced costs, ensuring operational reliability and preventing contamination by maintaining a sealed environment during the fill level correction phase.
Implementation Method 1
A filling machine design that uses a height-adjustable probe and controlled gas paths with a filter unit to maintain a sealed position during fill level correction
Implementation Method 2
using vacuum pressure or a filtered pressure medium to remove excess filling material without introducing unfiltered air into the container's headspace
Implementation Method 3
a negative pressure prevails in the filling-material tank... due to the pressure difference between the pressure in the filling-material tank and the pressure of the ambient air
Data Source
AI summary
A filling machine includes a filling element that has a liquid channel, a liquid valve, controlled gas paths, and a probe having a channel and an opening. The channel connects to a tank of filling material. A filter in a gas path traps contaminants. During filling, the liquid valve introduces filling material into a container, the first gas path connects to an interior space of the container, and the probe's position determines a fill level in the container.