Filling System Speed Control via Liquid Product Reservoir
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Solution Overview
Problem
Filling systems face challenges in maintaining consistent filling speed independent of geodetic height and pressure differences, leading to inefficiencies and complex control systems, especially in pressure or counter-pressure filling processes.
Innovation Solution
A control loop regulates filling speed using a volume flow control element and sensor device, independent of geodetic height and pressure differences, allowing for precise control of filling pressure and flow rate, enabling filling material to be supplied under optimal pressure conditions without a gas cushion, thus simplifying system design and reducing contamination risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a throttle is arranged in a return gas path to adjust filling speed, then the filling speed can be regulated, but the system complexity increases and requires additional control components
Solution Approach 1:
The patent extracts the filling speed control function from the gas path system and relocates it to the liquid product feed line. By placing a throttle directly in the liquid supply path to the filling point, the system eliminates the need for complex gas path throttling mechanisms and their associated control systems, thereby reducing overall device complexity while maintaining filling speed regulation capability
Solution Approach 2:
The patent introduces a liquid product as an intermediary medium to transmit pressure and control filling speed. Instead of using gas path pressure modulation which requires complex control systems, the liquid product itself serves as the pressure transmission medium, simplifying the control mechanism while achieving precise filling speed regulation
2Ease of operation
If the filling material level in the filling material tank is not precisely regulated, then the system operation is simpler, but the filling speed varies due to geodetic height changes
Solution Approach 1:
The patent segments the filling system into separate functional zones: a filling material storage tank (where level regulation is not critical) and a liquid product reservoir (where precise level control maintains constant geodetic height). The liquid product acts as a pressure transmission medium that decouples the filling material supply from the filling speed control, allowing simple operation while maintaining consistent filling speed
Solution Approach 2:
The patent maintains a constant liquid product level in the reservoir to create an equipotential pressure source. This constant level ensures that the geodetic height from the liquid product surface to the filling point remains constant, thereby maintaining steady filling pressure and speed without requiring complex level regulation of the filling material itself
3Reliability
If a gas cushion is maintained in the filling material tank, then the filling material level can be stabilized, but the system requires additional pressure control mechanisms
Solution Approach 1:
The patent extracts the pressure stabilization function from the filling material tank and relocates it to the liquid product reservoir. The liquid product serves as the pressure-stabilizing medium with its level precisely controlled, while the filling material tank can operate without complex pressure control mechanisms, thereby reducing device complexity while maintaining reliability
Solution Approach 2:
The liquid product acts as an intermediary pressure transmission medium between the filling material tank and the filling point. It absorbs pressure fluctuations and maintains stable filling pressure through its controlled level, eliminating the need for complex pressure control mechanisms in the filling material supply system
4Ease of manufacture
If the filling material is supplied from a partially filled tank, then the system design is simpler, but the geodetic height varies leading to filling speed fluctuations
Solution Approach 1:
The patent segments the supply system into two independent parts: a simple filling material tank (partially filled, no level control needed) and a controlled liquid product reservoir (level precisely maintained). This segmentation allows simple system design for the filling material supply while using the liquid product reservoir to ensure stable geodetic height and consistent filling speed
Solution Approach 2:
The patent creates an equipotential pressure source using the liquid product reservoir with its precisely controlled level. This constant level maintains steady geodetic height to the filling point, ensuring stable filling speed. The filling material tank can remain simply designed as a partial storage vessel without level control mechanisms
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 solution ensures precise and consistent filling performance, independent of geodetic height and pressure fluctuations, improving filling efficiency and eliminating the need for pressure sensors, while allowing for various filling methods and container types, and reducing contamination risks.
Implementation Method 1
the filling speed, i.e. the flow rate at which the filling material flows into the respective container during filling or in the filling phase, is regulated using a control loop
Implementation Method 2
a sensor device with which the volume flow of the filling material actually supplied to the at least one filling point is detected
Data Source
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AI summary
The invention relates to a method for filling containers (2) with a liquid filling good fed by means of a product supply means (7), by using at least one filling point (4), via which, during a filling phase, the filling good is introduced into the container (2) arranged at the filling point (4) in a controlled manner by means of at least one valve (8, 10), wherein the flow velocity of the filling good flowing to the particular container (2) during the filling phase and thus the filling speed are controlled by means of a control circuit, namely by processing a target value of the filling speed or comparing said target value with a measured value, which corresponds to the actual flow velocity of the filling good and is determined by a sensor system (9), which senses the flow velocity of the filling good flowing to the container (2), wherein, for a filling operation, a shut-off or liquid valve (10) is opened and, at the same time or with a slight delay, a volumetric-flow-rate control element (8), which is arranged before the shut-off or liquid valve (10) with respect to the flow direction of the filling good, is opened in order to initiate the filling phase, wherein the volumetric-flow-rate control element (8) is controlled in such a way that the flow velocity is independent of the pressure difference between the pressure of the filling good in the product supply means (7) and the filling pressure set in the container (2) to be filled.