Filling Gas-Permeable Containers via Dynamic Vacuum and Pressure Control
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Solution Overview
Problem
Filling gas-permeable receptacles, such as valve sacks and FIBCs, with bulk materials is inefficient due to reduced filling speed as the filling material compacts and clogs the receptacle, especially with low-density and fine-grained materials, leading to prolonged filling times and potential overloading of the receptacle walls.
Innovation Solution
A two-stage filling method is implemented, initially using vacuum filling to quickly fill the receptacle and then assisted by pressure subjection of the filling material conduit, gradually increasing pressure to maintain filling speed without overloading the receptacle, utilizing a differential pressure closed-loop control to manage the filling process and prevent material leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If vacuum filling is used to fill gas-permeable receptacles with low-density fine-grained materials, then filling speed is initially high, but filling speed decreases as the receptacle fills and gas permeability reduces
Solution Approach 1:
The patent applies dynamic switching between vacuum filling and pressure filling modes. The system transitions from vacuum filling (high initial speed) to pressure filling (maintained speed) as the receptacle fills, adapting the filling method to the changing gas permeability conditions to maintain optimal filling speed throughout the process
Solution Approach 2:
The patent changes the pressure parameter in the filling material conduit from negative pressure (vacuum) to positive pressure. This parameter change compensates for the reducing gas permeability of the receptacle wall, maintaining adequate filling speed even as the receptacle becomes less permeable
2Productivity
If pressure filling is used to maintain filling speed, then filling speed is maintained, but the receptacle wall may be overloaded
Solution Approach 1:
The system dynamically adjusts the pressure level in the filling material conduit based on the filling state of the receptacle. Pressure is gradually increased from vacuum level to a controlled positive pressure level, maintaining filling speed while preventing excessive pressure that would overload the receptacle wall
Solution Approach 2:
The system uses feedback control to monitor the filling process and adjust the pressure in the filling material conduit accordingly. This ensures pressure is increased only to the extent needed to maintain filling speed, preventing overloading of the receptacle wall
3Reliability
If vacuum filling is used for fine-grained materials, then material containment is improved, but filling time increases due to reduced gas permeability
Solution Approach 1:
The system maintains vacuum containment conditions while dynamically switching to pressure filling mode to overcome the reducing gas permeability. This allows the benefits of vacuum containment to be retained while the filling speed is maintained through pressure assistance
4Reliability
If pump supply is provided in the filling material conduit, then material damming is prevented, but device complexity increases
Solution Approach 1:
The vacuum pump serves multiple functions: it provides vacuum containment to prevent material leakage, creates the initial vacuum filling flow, and assists in material transport. By making the vacuum pump multi-functional, the patent avoids adding separate dedicated components for each function, thereby reducing overall device complexity
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
This method significantly accelerates the filling process by a factor of 2 or more compared to pure vacuum or pressure filling, ensuring efficient and accurate filling without material leakage, by maintaining underpressure and controlled pressure assistance throughout the filling procedure.
Implementation Method 1
the receptacle at the outer side is subjected to an underpressure, in order to generate a feed of filling material through a filling material conduit into the inside of the receptacle
Implementation Method 2
transport the filling material into the receptacle by way of a pressurized air flow, wherein the pressurized air passes through the gas-permeable wall of the receptacle
Data Source
AI summary
A method for filling a receptacle (7), which is at least partly gas-permeable with bulk filling material (2), includes subjecting the receptacle (7) at the outer side to an underpressure, in order to generate a feed of filling material through a filling material conduit (4) into the inside of the receptacle (7). The filling procedure is assisted by way of subjecting the filling material conduit (4) to pressure after completion of a first filling time.