Filling Valve Flow Control Using Pre-Stored Opening Positions
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Solution Overview
Problem
Conventional filling systems using continuously variable filling valves suffer from overshoots and oscillations due to suboptimal control, particularly when transitioning between different flow rates, leading to inefficient and unstable filling processes.
Innovation Solution
A method and device utilizing a pre-stored opening position of the filling valve, determined during a previous control process, to quickly achieve and maintain the target flow rate, minimizing overshoots by using a control system that learns and adapts to individual filling valve characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a continuously variable filling valve is used to control flow rate, then the filling process can be optimized for speed and precision, but overshoots and oscillations occur due to suboptimal control when transitioning between flow rates
Solution Approach 1:
The control system stores the last opening position of the filling valve for each target flow rate in advance. When a target flow rate is selected, the stored corresponding opening position is immediately set, providing a head start that prevents overshoot and oscillation during transitions between flow rates.
Solution Approach 2:
The control system continuously monitors the actual flow rate and compares it with the target flow rate. Based on this feedback, the control system adjusts the filling valve opening position, using pre-stored positions to guide adjustments and minimize deviations, thereby maintaining flow rate stability.
2Ease of operation
If conventional control methods are used, then the system is simple to operate, but the control response is slow and inefficient when adjusting flow rates
Solution Approach 1:
The control system pre-stores the opening positions of the filling valve corresponding to different target flow rates during the initial phase. This preliminary action enables the control system to quickly retrieve and apply the appropriate opening position when a target flow rate is selected, significantly improving control response speed without complicating the operation interface.
3Measurement precision
If the filling valve opening position is continuously adjusted to reach target flow rate, then precise flow control is achieved, but excessive time is consumed and oscillations occur during the adjustment process
Solution Approach 1:
The control system determines and stores the optimal opening position for each target flow rate in advance. When a target flow rate is selected, the system immediately sets the pre-determined opening position, eliminating the need for time-consuming continuous adjustments and oscillations, thus achieving both precision and speed.
Data Source
Figure 1~2
Figure 3~4
AI summary
The present invention relates to a method for filling a container with a filling product by means of a continuously adjustable filling valve and a device for determining an actual volume flow rate (2), wherein a target volume flow rate (1) is specified, wherein for a specified value of the target volume flow rate (12) a pre-stored opening position (32, 32') of the filling valve is controlled, wherein the pre-stored opening position (32, 32') was determined by a previous control process for the specified target volume flow rate (12).