Optical Fill Level Detection in Container Filling Machines
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Solution Overview
Problem
Existing filling machines face challenges in achieving high filling capacity and accuracy, particularly with glass bottles where empty bottle volume fluctuations lead to inconsistent filling heights, affecting quality and requiring lower performance level measurement methods.
Innovation Solution
The implementation of a filling system that uses a light source to illuminate the container from various angles, combined with optical detection means such as cameras and light guides, allows for precise fill level measurement independent of container position, enabling efficient and accurate filling of containers with liquid material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If volumetric measuring method is used to fill containers, then filling speed is improved, but filling accuracy deteriorates because empty bottle volume fluctuations lead to different filling heights
Solution Approach 1:
The patent replaces volumetric/mechanical filling methods with optical measurement and control systems. Optical sensors (cameras, light guides) measure the actual filling level in real-time, and this information is fed back to control the filling process, enabling both high speed and high precision simultaneously.
Solution Approach 2:
The patent implements a feedback control system where optical sensors continuously monitor the filling level, and this information is used to adjust the filling process in real-time. This ensures that each container receives the correct amount of product despite variations in container size or shape.
2Manufacturing precision
If optical measuring methods are used to determine fill level, then filling accuracy is improved, but filling performance (capacity) deteriorates
Solution Approach 1:
The patent employs continuous optical measurement during the filling process, allowing real-time monitoring and control without interrupting the filling operation. This enables high-precision measurement to be achieved at full operating speed, eliminating the trade-off between accuracy and productivity.
3Manufacturing precision
If level filling systems with probes or return gas tubes are used, then filling accuracy is improved for glass bottles, but filling performance decreases
Solution Approach 1:
The patent replaces mechanical probes and return gas tubes with optical measurement systems. Optical sensors can measure filling levels through the container wall without physical contact, eliminating the need for intrusive mechanical elements that slow down the filling process while maintaining high accuracy.
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 approach enables high filling capacity with precise level measurement, maintaining quality by ensuring consistent fill levels across containers, regardless of their size or material, and allows for continuous measurement during the filling process.
Implementation Method 1
a light source (3) is provided, by means of which the interior of the container (2) is illuminated
Implementation Method 2
the fill level in the container (2) is detected by optical detection means (4)
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a filling machine for filling containers (2) with a fluid filling material, wherein the fill level in the container (2) to be filled can be determined by optical detection means, characterised in that the internal space of the container is at least partially illuminated by a light source (3), and in that the fill level is detected by optical detection means (4) provided laterally adjacent to the container (2), or a camera (6) or a light-guide (5) connected to a camera (6) is provided in the region of the filling element (1), and in that at least one computer unit having image processing program means is provided, by means of which the fill height (FS) in the container (2) can be determined from the image information provided by the camera (6) by running an image processing program.