Flowmeter Predictive Shutdown for Beverage Filling Precision
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Solution Overview
Problem
In beverage filling applications, the limited sampling rate of flowmeters and data transmission delays lead to non-deterministic overfilling, as the precise timing of shutting off the filling process is compromised, resulting in inaccuracies in reaching the target volume.
Innovation Solution
The method involves a flowmeter's computing unit predicting when the target fill volume will be reached and sending an additional message to the control unit to terminate the filling process, allowing the actuator to shut off closer to the target volume, even outside the regular transmission frequency, taking into account process variables like viscosity and pressure, and prioritizing this message to ensure accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the sampling rate of the flowmeter and data transmission frequency are increased to reduce overfilling, then the filling precision improves, but the hardware costs and system complexity increase disproportionately
Solution Approach 1:
The flowmeter's computing unit predicts the target volume arrival time in advance and sends an early warning message to the control unit before the actual target volume is reached. This preliminary action allows the control unit to prepare for shutdown timing, compensating for system delays without requiring higher sampling rates or more complex hardware.
Solution Approach 2:
The patent transitions from a time-based sampling approach (regular intervals) to a prediction-based approach by adding a temporal dimension. The flowmeter calculates not just current volume but also predicts future arrival at target volume, enabling proactive control decisions that overcome transmission delays without increasing hardware complexity.
2Ease of manufacture
If the sampling rate is reduced to lower hardware costs, then the system becomes more economical, but non-deterministic errors in reaching target volume increase
Solution Approach 1:
The system implements a feedback mechanism where the flowmeter continuously monitors flow rate, calculates current fill volume, and predicts remaining time to target volume. This feedback loop enables the control unit to adjust shutdown timing dynamically, maintaining accuracy even with lower sampling rates and reducing overall system costs.
Solution Approach 2:
By calculating and communicating the predicted arrival time at target volume in advance, the system compensates for lower sampling rates. The early warning message allows the control unit to plan shutdown execution, ensuring accurate target volume achievement without requiring expensive high-speed sampling hardware.
3Reliability
If the data transmission run time is increased to allow more comprehensive data processing, then the control decisions become more accurate, but the delay in shutting off the filling process increases causing more overfilling
Solution Approach 1:
The flowmeter performs comprehensive data processing and sends the predicted target volume arrival time message in advance, before the actual target volume is reached. This early communication allows the control unit to account for its own processing time and actuator response delay, executing shutdown at the optimal moment without overfilling.
Solution Approach 2:
The system dynamically adjusts the timing of shutdown commands based on real-time flow conditions and predicted arrival times. Rather than using fixed timing intervals, the control unit adapts its shutdown decision to the current process state, maintaining accuracy despite variable transmission and response times.
Data Source
AI summary
A method for filling a target volume into a container by means of a measuring arrangement is described and illustrated. The measuring arrangement includes at least one flowmeter for measuring the flow of a medium flowing into the container, at least one actuator and at least one control unit. The flowmeter includes a computing unit. The filling process can be started and ended by actuating the actuator. The control unit is connected to the actuator and the flowmeter via a communication system. The control unit is set up in such a way that, during operation, it sends a control command to the actuator to end the filling process when a defined limit value of the fill volume, which correlates with the target volume, is reached.