Filling Valve Characteristic Monitoring for Fault Localization
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Solution Overview
Problem
Existing bottling plant monitoring systems require external test equipment, leading to additional costs and maintenance efforts, and fail to accurately identify the source of filling process errors.
Innovation Solution
A method where a control and evaluation unit determines and compares current valve characteristic curves of filling valves with stored reference curves, allowing for real-time identification of deviations and localization of errors within the bottling plant, using sub-units to exchange and compare data on valve status and perform adjustments or signaling as needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external test equipment is used to monitor filling processes, then filling level can be monitored, but additional costs and maintenance effort increase
Solution Approach 1:
The filling system monitors its own operation using existing internal sensors (flow sensors, level sensors, valve position sensors) rather than requiring external test equipment. The control unit evaluates sensor signals to detect filling errors, making the system self-diagnostic and eliminating the need for separate monitoring equipment.
Solution Approach 2:
The control unit performs multiple functions: it controls the filling valves, processes sensor signals, and detects filling errors. By integrating these functions into a single control unit, the system eliminates the need for separate external test equipment while maintaining comprehensive monitoring capability.
2Reliability
If external test equipment is used to monitor filling processes, then filling errors can be detected, but the source of errors cannot be localized
Solution Approach 1:
The monitoring system is divided into separate monitoring paths for different filling points, each with its own sensors and evaluation logic. This segmentation allows the control unit to identify which specific filling point or valve is experiencing an error by evaluating signals from individual sensors associated with each filling location.
Solution Approach 2:
The control unit continuously receives feedback signals from flow sensors, level sensors, and valve position sensors during the filling process. By analyzing these real-time feedback signals, the system can detect deviations and trace them back to specific filling points or valve characteristics, enabling precise error localization.
3Manufacturing precision
If valve characteristic curves are monitored in real-time, then filling accuracy is maintained, but system complexity increases
Solution Approach 1:
Reference valve characteristic curves are pre-determined and stored in the control unit before the filling process begins. During operation, the control unit compares real-time valve characteristics against these pre-stored references to detect deviations, eliminating the need for complex real-time characterization while maintaining filling accuracy.
Solution Approach 2:
The system creates a simplified digital representation (copy) of the valve characteristic curve by storing key parameters and reference values in the control unit. This digital copy allows for rapid comparison during filling operations without requiring complex real-time measurement and analysis equipment.
Data Source
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AI summary
The invention relates to a method (100) for operating a filling plant (1) with at least one first filling station (2), at least one second filling station (3), and at least one control and evaluation unit (4) for regulating and monitoring the filling processes, wherein the first filling station (2) has a first filling valve (5) and a first flow or level sensor (6), and wherein the second filling station (3) has a second filling valve (7) and a second flow or level sensor (8), and wherein reference valve characteristics of the first filling valve (5) and the second filling valve (7) are stored in the control and evaluation unit (4). The objective of providing a method (100) with which fault monitoring of a filling plant (1) can be implemented in a simplified manner is achieved by determining the current valve characteristics of the filling valves (5, 7) in a determination step (101).that in a comparison step (102) the current valve characteristics of the filling valves (5, 7) are compared with the corresponding reference valve characteristics, that in a calibration step (103) it is determined at how many of the filling points (2, 3) a deviation of the current valve characteristic from the associated reference valve characteristic occurs, and that in a signaling step (104) in the event of a deviation of the valve characteristic from the reference valve characteristic at one filling point (2, 3) a filling point error of the corresponding filling point (2, 3) is detected and signaled (104'), and in the event of a deviation of the valve characteristic from the reference valve characteristic at both filling points (2, 3) a process error is detected and signaled (104").