Filling Valve Dynamics for Free Jet Deflection Control
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Solution Overview
Problem
At high rotary speeds of the filler carousel, the exit speed of the filling product from the filling valve is reduced, leading to unfavorable steering of the free jet, which can result in the filling product passing the container mouth.
Innovation Solution
A device with a filler carousel and a filling organ that includes a control valve and a filling valve. The control device adjusts the volume flow through the control valve and synchronizes the filling valve to maintain a constant exit speed of the filling product, ensuring it is directed into the container effectively even at high speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the filler carousel operates at high rotational speeds to improve productivity, then the filling speed increases, but the exit velocity of the product from the filling valve decreases significantly, causing unfavorable centrifugal deflection of the jet and potential missing of the container opening
Solution Approach 1:
The filling valve is designed with a movable valve cone that can dynamically adjust the opening cross-section of the product channel during the filling process. This dynamic adjustment allows the system to adapt to changing operational conditions, specifically maintaining appropriate product exit velocity even when the filler carousel operates at high rotational speeds. The valve cone's position can be modified in real-time to compensate for the reduced exit velocity caused by high rotation speeds, thereby preventing jet deflection issues and ensuring accurate filling.
Solution Approach 2:
The invention changes the geometric parameters of the product channel by adjusting the opening cross-section through the movable valve cone. By modifying the channel geometry dynamically, the system can maintain optimal flow characteristics and exit velocity despite changes in carousel rotation speed. This parameter adjustment allows the filling system to operate effectively across a range of rotational speeds without sacrificing filling accuracy or product velocity.
2Speed
If the opening cross-section of the product channel is increased to maintain product velocity at high speeds, then the exit velocity is preserved, but the volume flow regulation becomes more complex
Solution Approach 1:
The movable valve cone serves multiple functions simultaneously: it regulates the volume flow of the filling product, maintains the desired exit velocity, and compensates for the effects of varying carousel rotation speeds. This multi-functional design eliminates the need for separate control mechanisms for each function, thereby reducing overall system complexity despite the dynamic adjustment capabilities. The single valve cone integrates flow control and velocity maintenance into one component.
3Productivity
If the filling valve is designed with multiple opening positions to regulate volume flow, then the filling profile can be optimized, but the device complexity increases
Solution Approach 1:
The filling valve employs a dynamically adjustable valve cone that can assume multiple opening positions during the filling process. This dynamic capability allows the system to optimize the filling profile by adjusting the opening cross-section at different stages of filling, while avoiding the complexity of multiple discrete valves or complex mechanical positioning systems. The continuous adjustability of the valve cone provides flexible control with simpler overall architecture.
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 allows for high-speed operation of the filler carousel without unfavorable steering, ensuring efficient filling of containers and improving productivity in the bottling process.
Implementation Method 1
the filling product exits the product channel with a certain velocity, bridges a free jet area, and experiences jet deflection in this free jet area due to the rotation of the filling carousel
Implementation Method 2
a control valve, wherein the control device is set up to change the volume flow of the filling product in the product channel during a filling process by means of the control valve
Data Source
Figure 1~2
AI summary
Apparatus and method for filling a container with a filling product, preferably a beverage, using a free jet method, wherein the method comprises: transporting the container along a partial circle by means of a filler carousel (10) rotating about a rotation axis (11); during the transport of the container, introducing the filling product into the container via a product channel (22) of a filling element (20), wherein the filling product leaves the product channel (22) at an outlet section (21) of the filling element (20) with an exit velocity (V0), bridges a free jet area (Fb) and thereby experiences a jet deflection (8) in the free jet area (Fb) due to the rotation of the filler carousel (10);During the introduction of the filling product into the container, the volume flow rate of the filling product in the product channel (22) is changed by means of a control valve (28) of the filling device (20) and, concurrently, a filling valve (30) arranged downstream of the control valve (28) is actuated, so that it counteracts the change in the outlet velocity (V0) of the filling product caused by the change in volume flow rate.