Container Filling System with Real-Time Product and Layer Count Control
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Solution Overview
Problem
The beverage processing industry faces high reject rates and inefficiencies when changing product types or exhausting stock, particularly when containers are supplied in layers, leading to unnecessary losses due to the inability to reuse or recycle partially filled containers.
Innovation Solution
A filling system with a control unit that manages the supply of containers to the transport device based on real-time product quantity measurements, allowing for precise calculation of the number of layers needed, and includes inspection devices to divert faulty containers, thereby minimizing rejects and optimizing container usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If containers are supplied in layers on the transport device, then the transport capacity is increased, but the ability to control the exact number of containers to be filled is reduced, leading to rejects when product stock is exhausted
Solution Approach 1:
The system performs preliminary counting of containers on the transport device before the filling process begins. The counter determines the exact number of containers (K) present on the transport device, and this information is stored in the control unit in advance. This preliminary measurement enables precise control of the filling process even when containers are supplied in layers, resolving the contradiction between high transport capacity and precise container quantity control.
2Productivity
If a large number of containers remain on the transport device when product stock is exhausted, then the transport device utilization is high, but the reject rate increases due to inability to reuse or dispose of containers efficiently
Solution Approach 1:
The control unit continuously receives feedback from two sources: the product quantity sensor that monitors remaining product stock, and the container counter that tracks the number of containers on the transport device. Based on this real-time feedback, the control unit calculates the optimal number of containers to supply and controls the container task accordingly. This feedback mechanism ensures that containers are supplied only when needed, maximizing transport device utilization while minimizing container waste when product stock is exhausted.
Solution Approach 2:
The system dynamically changes the parameter of container supply quantity based on the relationship between product quantity and container count. The control unit adjusts the number of containers to be supplied according to the formula that considers product quantity (M), container volume (V), and current container count (K). This parameter change enables the system to adapt to different filling scenarios, optimizing both transport utilization and reducing waste.
3Measurement precision
If sensors are added for real-time product quantity measurement, then the precision of container supply control is improved, but the device complexity increases
Solution Approach 1:
The control unit is designed with multi-functionality, serving both as the controller for the container task and as the processor for product quantity measurements and container count data. By integrating these functions into a single control unit, the system achieves precise product quantity measurement and container supply control without proportionally increasing device complexity. The control unit universally handles multiple tasks: receiving sensor signals, counting containers, calculating optimal supply quantities, and controlling the container task.
Data Source
Figure 1
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Figure 3b~3c
AI summary
The invention relates to a filling system (100) for filling containers (130), such as cans in the drinks-handling industry, said system comprising: at least one filling station (110) connected to a product storage container (105); a transport device (101) by means of which containers are transported to the filling station; and a container feeding means (102) that supplies, in layers, the containers of the transport device, wherein a counter that can determine the number (K) of containers in the transport device is arranged on the transport device, characterised in that a control unit (180) is provided that controls the container feeding means (102) depending on the amount of product available in the product storage container (105), and the number of containers in the transport device (101). The invention also relates to a corresponding method.