Filling Machine Valve Calibration via Reference Flow Measurement
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Solution Overview
Problem
Filling machines with time-controlled dosing valves face recalibration challenges due to fluid dynamic and wear factors, leading to variations in flow rate affected by viscosity, density, temperature, and other parameters, requiring complex setups with master valves and throttling diaphragms.
Innovation Solution
A filling machine with reference valves and flow-rate measurement devices connected to a controlling unit, using a calibration station with a tray and weighing device to determine and adjust the open time of dosing valves, allowing for automatic correction coefficients to maintain consistent liquid dispensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If time-controlled dosing valves are used for liquid filling, then filling speed and productivity are improved, but flow rate variations occur due to fluid dynamic factors and wear, requiring recalibration
Solution Approach 1:
The system performs preliminary calibration operations to determine the relationship between valve open time and liquid quantity dispensed. The computer unit stores reference values that allow the dosing valves to operate accurately without continuous adjustment, addressing flow rate consistency while maintaining high filling speed.
Solution Approach 2:
The system incorporates feedback mechanisms where the computer unit monitors and adjusts valve operation timing based on stored reference calibration data. This feedback loop compensates for flow rate variations caused by fluid dynamic factors and wear, ensuring consistent dosing while maintaining productivity.
2Manufacturing precision
If recalibration is performed frequently to maintain flow rate accuracy, then dosing precision is improved, but production time is lost and productivity decreases
Solution Approach 1:
Comprehensive calibration operations are performed preliminarily to establish reference values for multiple valve positions. These pre-determined reference values enable the system to maintain dosing precision throughout production without frequent interruptions for recalibration, thus preserving productivity.
Solution Approach 2:
The system performs calibration for multiple different open times (excessive action) covering the full range of dosing requirements. This comprehensive approach ensures that any valve position used during production has pre-established reference values, eliminating the need for intermediate recalibration and maintaining both precision and productivity.
3Productivity
If flow resistances are reduced to improve liquid flow, then filling speed increases, but flow rate becomes more sensitive to parameter variations requiring complex control systems
Solution Approach 1:
The system compensates for flow rate variations by adjusting the open time parameter of the dosing valves based on stored reference calibration data. This parameter adjustment approach maintains accurate dosing with high flow rates without requiring complex control hardware, achieving both productivity and simplicity.
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
The solution enables practical, reliable, and cost-effective calibration management, ensuring consistent liquid dispensing by automatically adjusting valve operation times based on measured discrepancies, reducing the need for complex setups and frequent recalibrations.
Implementation Method 1
a flow-rate measurement device 3b which is functionally connected to the managing and controlling device 10 in order to determine the open time of the reference valve 3a that corresponds to the dispensing of a predetermined quantity of liquid
Implementation Method 2
a device for weighing the liquid discharged into the tray 20 by the valve to be calibrated 3c
Data Source
Figure 1
Figure 2
AI summary
A filling machine (1) comprising a containment tank which is connected, by way of supply ducts, to a plurality of dosing valves (3) which are functionally connected to a device (10) for managing and controlling the opening and the closure of the dosing valves (3); the dosing valves (3) comprise at least one reference valve (3a) which is associated with a flowrate measurement device (3b) which is functionally connected to the managing and controlling device (10) in order to determine the open time of the reference valve (3a) that corresponds to the dispensing of a predetermined quantity of liquid, and at least one valve to be calibrated (3c). The filling machine (1) has a calibration station which comprises at least one tray (20), into which the liquid dispensed by each valve to be calibrated (3c) can be discharged, the tray (20) being associated with a device for weighing the liquid discharged in a time that corresponds to the open time of the reference valve (3a) determined by the managing and controlling device (10), the managing and controlling means (10) being adapted to detect the difference between the quantity of liquid contained in the tray and the predetermined quantity of liquid, and being adapted to generate a correction coefficient for the time that the valve to be calibrated (3c) is to remain open as a function of such difference in order to allow the dispensing, by the valve to be calibrated (3c), of the predetermined quantity of liquid.