Filling-Sealing Unit Tightness Control via Third Seal Segmentation
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Solution Overview
Problem
Existing methods for checking the tightness of filling-closing units in beverage filling machines are inefficient, as they require extensive inspection of all seals when a pressure drop occurs, making it difficult to identify which seal is responsible for the leak.
Innovation Solution
A method involving a third seal that temporarily replaces the sealing function around the container's mouth, neck, and shoulder areas, using an external attachment to create overpressure or underpressure and measure pressure curves, allowing for the detection of deviations from predetermined curves to identify seal malfunctions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If all seals are inspected when a pressure drop occurs, then the leak source can be identified, but the inspection time and system downtime increase significantly
Solution Approach 1:
The sealing system is segmented into multiple independent seals (first seal around product inlet, second seal around sealer, third seal around container mouth/neck/shoulder). Each seal can be independently tested by temporarily replacing the third seal with a sealing attachment that has a known good sealing function, allowing isolation and identification of which specific seal is defective without inspecting all seals simultaneously.
Solution Approach 2:
A sealing attachment is introduced as an intermediary component to temporarily replace the third seal during testing. This attachment provides a known good sealing interface that allows the system to test the functionality of the first and second seals independently, acting as a mediator between the pressure chamber and the container to isolate specific seal components for diagnosis.
2Loss of information
If pressure monitoring is used to detect leaks, then the location of the leak can be identified, but the system complexity increases
Solution Approach 1:
The complex electronic pressure monitoring system is replaced with a simpler mechanical test method. Instead of using pressure sensors and electronic evaluation units to continuously monitor and locate leaks, the system uses a mechanical sealing attachment replacement approach where a known good seal temporarily substitutes the suspected seal, and pressure testing is performed mechanically to identify the defective seal location.
3Reliability
If the third seal is permanently replaced with a sealing attachment, then the first and second seals can be tested, but the container sealing function is lost
Solution Approach 1:
The sealing attachment is designed to be dynamically replaceable - it can be temporarily installed during testing phases to verify seal functionality, and then removed or replaced with the actual third seal when container sealing is required. This dynamic configuration allows the system to switch between testing mode and operational mode, maintaining both diagnostic capability and production functionality.
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
This approach simplifies the leak detection process, enabling quicker identification of seal issues and reducing downtime by attributing pressure losses to specific seals, thus improving the operational efficiency of filling machines.
Implementation Method 1
an overpressure and/or underpressure is created in the pressure chamber
Implementation Method 2
a pressure curve is then measured in the pressure chamber
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A method for tightness control (30, 40, 50, 60) of a filling-sealing unit (1) for containers (9) is described. According thereto, a pressure chamber (2) formed on the filling-sealing unit is sealed by a sealer (3) which is movable therein and has a first seal (6), and is sealed with respect to a product inflow (4) which is movable therein with a second seal (7). According to the invention, a third seal (8) designed for sealing the pressure chamber around a container mouth (9a) is sealed from the outside with a cap (14), a positive pressure and/or negative pressure is generated in the pressure chamber, the pressure line (11, 12) used for this purpose is closed and then a pressure profile (DV) is measured in the pressure chamber. A leakage at the first and/or second seal can thereby be identified specifically and differentiated from a leakage of the third seal.