Filling System Negative Geodetic Height Integration
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Solution Overview
Problem
Existing filling systems for pressure filling of containers require a filling material container with a gas space above the filling material level, leading to complex piping and increased costs, as well as independent operation of mixing and filling machines, which are inefficient and costly.
Innovation Solution
A filling system where the discharge opening of the liquid valve is arranged above the filling material level, allowing for a negative geodetic height, eliminating the need for a gas space buffer in the filling material container and integrating the mixing and filling machines into a single process engineering unit, using control circuits to regulate pressure and filling speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a filling material container with a gas space above the filling material level is used, then the filling system can operate with positive geodetic height, but the system requires complex piping and increased costs
Solution Approach 1:
The patent inverts the traditional arrangement by positioning the discharge opening above the filling material level, creating a negative geodetic height scenario. This inversion eliminates the need for a gas space buffer and complex piping systems, as the liquid filling material flows downward under gravity and pressure differential into the container
Solution Approach 2:
The patent extracts and eliminates the gas space buffer from the filling material container, removing this intermediate component entirely. By doing so, the system simplifies the piping structure and reduces the number of components required, while maintaining reliable filling operation through direct pressure-controlled delivery
2Ease of manufacture
If mixing and filling machines operate as independent process units, then each machine can be optimized independently, but the system requires additional connecting lines and increased costs
Solution Approach 1:
The patent merges the mixing and filling machines into a single integrated process engineering unit. The mixing chamber is directly connected to the filling element, eliminating the need for separate connecting lines and intermediate storage. This integration reduces system complexity and costs while maintaining the ability to optimize each function
3Device complexity
If the discharge opening is arranged above the filling material level, then the geodetic height becomes negative and eliminates the need for gas space buffer, but pressure control precision is required
Solution Approach 1:
The patent implements a feedback control system with a pressure sensor that continuously monitors the pressure in the filling material container and adjusts the throttle valve accordingly. This closed-loop control ensures precise pressure regulation despite the negative geodetic height arrangement, maintaining filling speed and pressure within desired limits
Solution Approach 2:
The patent changes the pressure parameter dynamically during the filling process. By adjusting the throttle valve position based on real-time pressure feedback, the system maintains optimal pressure differential for filling, compensating for the negative geodetic height and ensuring consistent filling performance
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 reduces manufacturing costs, eliminates complex piping, and integrates the mixing and filling systems, allowing for efficient and precise filling operations while minimizing space requirements.
Implementation Method 1
a preload pressure is generated in the container during the preload phase at least before the start of the subsequent filling phase, which is at a pressure level below the overpressure of the gas space of the product container of the mixer
Implementation Method 2
the container located in a sealing position with a filling element of the filling system is at least temporarily prestressed with a gas to a prestressing pressure in a prestressing phase, the gas used for prestressing being taken from a gas space under excess pressure
Implementation Method 3
in which at least during the filling phase the return gas displaced from the container by the incoming filling material is discharged into an annular channel via a return gas path of the filling element
Data Source
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AI summary
The invention relates to a method for filling containers (2) with a fluid filling material, and to a filling system (1). The significant aspect of the invention is providing a method for filling containers with a fluid filling material using a filling system, wherein a discharge opening of a fluid valve (9) of a filling element (1.1) is arranged above a fill level of a fluid compartment (50.2) of a filling material container (50) of a mixer by a height (H1), wherein the container positioned in a sealing position with the filling element of the filling system is at least periodically pressurised in a pressurising phase with a pressurising gas at a positive pressure (P Kessel) of a gas compartment of the filling material container of the mixer to a pressurising pressure (P Spann), and in a subsequent filling phase with an open fluid valve, same is filled with the filling material from the fluid compartment of the filling material container via a product line of the filling system that is completely filled with the fluid filling material, wherein, at least during the filling phase, the return gas displaced out of the container by the in-flowing filling material is discharged into a ring channel via a return gas path of the filling element, and wherein, during the pressurising phase, at least before the subsequent filling phase starts, a pressurising pressure is generated in the container which is at a pressure level below the positive pressure in the gas compartment of the filling material container of the mixer.