Filling Valve Assembly With Optical Probe and Independent Flow Control
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Solution Overview
Problem
Existing filling machines face challenges in accurately regulating bottle levels due to the rigidity of multiple point probes and inefficiencies in flow rate partialization, leading to overfilling and operational complexities.
Innovation Solution
A valve assembly with a filling level regulation probe that uses independent electric motors to control the position of a shutter and a refractive optic fiber probe, allowing precise flow rate partialization adaptable to varying bottle formats.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed support structure with a rotating turret is used, then the filling machine structure is stable and reliable, but the adaptability to different bottle formats is limited
Solution Approach 1:
The support structure for the adduction conduit is made movable along the valve axis rather than fixed, allowing dynamic adjustment of the conduit position. This enables the filling valve to adapt to different bottle formats while maintaining structural reliability through controlled motion along a defined path.
Solution Approach 2:
The support structure is divided into separate components: a movable support that can translate along the valve axis and a fixed mounting structure. This segmentation allows the movable portion to adapt to different bottles while the fixed portion maintains overall structural stability.
2Measurement precision
If multiple point probes are used for level detection, then the filling level can be detected at multiple positions, but the device complexity increases
Solution Approach 1:
The mechanical multiple point probe system is replaced with an optical fiber probe that uses light refraction principles. This substitution reduces mechanical complexity while maintaining or improving measurement precision through optical detection of the liquid meniscus.
Solution Approach 2:
A single optical fiber probe performs the function previously requiring multiple mechanical probes by detecting the liquid level through optical refraction at the meniscus. This multi-functional approach reduces the number of components while achieving accurate level detection.
3Manufacturing precision
If flow rate partialization is implemented, then the filling precision can be improved, but the operational complexity increases
Solution Approach 1:
The system automatically adjusts the shutter position along the valve axis based on real-time feedback from the optical fiber probe detecting the liquid level. This self-regulating mechanism achieves precise flow rate partialization without requiring complex manual operation or intervention.
Solution Approach 2:
The optical fiber probe provides continuous feedback on the liquid level and meniscus position, which is used to automatically control the shutter position and flow rate. This feedback loop simplifies operation while maintaining high filling precision through automatic adjustment.
4Adaptability or versatility
If a movable support structure is used, then the adaptability to different bottle formats is improved, but the device complexity increases
Solution Approach 1:
The support structure is designed with controlled mobility along the valve axis, allowing it to adapt to different bottle formats through simple translational motion. This dynamic design provides versatility while maintaining relative structural simplicity compared to fully adjustable mechanisms.
Solution Approach 2:
Only the specific portion of the support structure that needs to adapt to different bottles is made movable, while the rest of the structure remains fixed. This localized mobility provides the necessary adaptability without requiring the entire support structure to be complex and adjustable.
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
Enables flexible and precise bottle level regulation, reducing overfilling and operational complexities while maintaining efficient filling control across different bottle sizes.
Implementation Method 1
a refractive optic fiber probe (40)
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present invention refers to a valve assembly (1) for a filling machine and comprises: an adduction conduit (10) that extends along a valve axis (X) and that is fluidically connectable to the tank (110) of said filling machine (100) to allow the inflow of said liquid from the tank (110) to the container (B) to be filled through a discharge mouth (10a); a shutter (20) suitable to regulate the inflow of said liquid in said container (B), which shutter is movably placed inside said adduction conduit (10) to be moved along the valve axis (X) between a closing position and one or more opening positions; a tubular control stem (30) of the shutter, which internally defines a conduit axially extended along the valve axis (X); a probe (40) for detecting the filling level of the container, which probe is provided with a single detection point near the tip and is coaxially inserted inside the axial conduit defined by the stem to be moved between at least one extracted position and a retracted position. The valve assembly comprises: a first electric motor (50) which is kinematically connected to said tubular control stem (30) to move the shutter (20) between the closing position and said one or more opening positions, and - a second electric motor (60) which is kinematically connected to said probe (40) to move it with respect to said stem between said at least one extracted position and said retracted position. Said first (50) and said second electric motor (60) are controllable independently from each other.