Filling Machine Sensor Failure Synchronization
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Solution Overview
Problem
Filling machines, especially rotary fillers, face performance issues due to defective filling sensors, leading to overfilled containers and contamination, as existing methods require shutdown of affected elements, resulting in lost productivity and additional defective containers.
Innovation Solution
Implementing a method where a filling element with a defective sensor is controlled synchronously with a following element having an intact sensor, allowing for immediate reintegration and maintaining performance by synchronizing opening and closing times and flow rates, thereby minimizing the production of defective containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the filling element is completely shut down when the filling sensor fails, then overfilled containers are avoided, but filling performance is lost and empty containers are produced
Solution Approach 1:
A control unit acts as an intermediary between the filling sensor and the filling element. When sensor failure is detected, the control unit takes over control of the filling element, using data from other sensors (flow sensor, level sensor, weight sensor) to determine when to close the filling element, thereby maintaining both reliability and productivity
Solution Approach 2:
The system changes the control parameters from relying solely on the defective filling sensor to using alternative parameters from other sensors (flow rate, liquid level, weight). The control unit monitors these alternative parameters and adjusts the filling element closure timing accordingly to prevent overfilling while maintaining productivity
2Productivity
If the filling element is operated with delayed valve opening signal, then filling time can be controlled, but complex calculations and timing adjustments are required
Solution Approach 1:
The control unit continuously receives feedback from multiple sensors (flow sensor, level sensor, weight sensor) and adjusts the filling element operation in real-time. This feedback mechanism eliminates the need for complex pre-calculated timing delays, as the system automatically adapts to actual filling conditions
Solution Approach 2:
The control unit serves multiple functions: it monitors the defective filling sensor, processes data from alternative sensors, makes closure decisions, and coordinates with the filling element. This multi-functional approach simplifies the overall system by consolidating control logic in a single intelligent unit rather than requiring complex timing mechanisms
Data Source
AI summary
The present invention relates to a method for the control of a filling machine (A) for the filling of containers (C) with liquid filling material, wherein the filling machine comprises at least two controllable filling elements (1, 2, 30, 31) each having at least one filling sensor, and wherein by way of the filling sensors the termination of filling of the respective filling element is controlled. According to the invention a first filling element (1) will, in case of failure of its filling sensor, be controlled synchronously to a following second filling element (2).