Multi-Component Filling Device with Optical Detection for Mixed Batches
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Solution Overview
Problem
Existing systems for producing mixed containers of different beverage types require large storage and picking areas, generate packaging waste, and are prone to errors due to mismatched container labeling or missing containers, leading to incorrect fillings.
Innovation Solution
A filling device with a main filler for a primary component and a secondary filler that adjusts based on container properties detected by an optical reader, allowing flexible production of mixed containers without pre-sorting, combined with a system for immediate packaging into mixed bundles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If containers are pre-sorted and stored in large batches before filling, then the filling process can be simplified, but storage requirements increase and packaging waste is generated
Solution Approach 1:
The system performs preliminary identification of container types and product requirements using optical readers and sensors before the filling process. This allows the filling device to be pre-configured for each specific container type, eliminating the need for large-scale pre-sorting and storage while maintaining filling simplicity and accuracy.
Solution Approach 2:
The filling device automatically identifies and adapts to different container types through integrated sensors and optical readers. The system self-configures its filling parameters based on detected container properties, eliminating the need for manual pre-sorting and reducing storage requirements while maintaining ease of operation.
2Manufacturing precision
If containers are pre-sorted by type before filling, then filling accuracy can be improved, but the system becomes more complex and error-prone due to labeling mismatches
Solution Approach 1:
The system replaces complex mechanical pre-sorting mechanisms with optical and sensor-based detection systems. Optical readers and sensors automatically identify container types and properties, eliminating the need for mechanical sorting while improving accuracy and reducing complexity through automated recognition and adaptation.
Solution Approach 2:
The filling device incorporates feedback mechanisms through optical readers and sensors that continuously monitor container properties and adjust filling parameters in real-time. This closed-loop control ensures high filling accuracy without requiring complex pre-sorting systems, as the system adapts dynamically to each container type.
3Ease of operation
If containers are fed to the filler in a fixed order matching labels, then the filling process is straightforward, but errors occur when containers are missing or mislabeled
Solution Approach 1:
The system incorporates optical readers and sensors that provide real-time feedback on container identification and properties. This feedback mechanism allows the filling device to verify container match with product requirements and adjust operations accordingly, maintaining simplicity while significantly improving reliability by detecting and responding to missing or mislabeled containers.
Solution Approach 2:
The filling system transitions from a static, fixed-order operation to a dynamic process that adapts to each container's actual properties. The system dynamically adjusts filling parameters and operations based on real-time detection of container type, size, and other properties, ensuring reliable operation regardless of container ordering or labeling status.
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
Eliminates the need for complex pre-sorting, reduces storage requirements, and ensures accurate filling of diverse containers without waste, enhancing overall equipment effectiveness and flexibility.
Implementation Method 1
a product determination device (17) which is configured to determine at least one property of the container to be filled
Data Source
Figure 1
Figure 2
AI summary
Filling device (10) for filling a container (100) with a multi-component filling product, preferably in a beverage filling plant, wherein the filling device (10) comprises: a main filler (12) which is configured to introduce a main component of the filling product into the container (100), wherein the main filler (12) is preferably designed as a rotary type, in which the containers (100) to be filled are fed to a filler carousel and, during transport along a partial circle, are filled with the main component of the filling product via filling elements mounted on the outer circumference of the filler carousel; a secondary filler (14) which is configured to introduce different secondary components into the container (100);and a product determination device (17), preferably comprising a camera, which is configured to determine at least one property of the container (100) before the container (100) is filled by the secondary filler (14), wherein the secondary filler (14) is configured to select one or more secondary components and introduce them into the container (100) depending on the container property thus determined.