Container Filling Apparatus Using Optical Sensor Valve Control
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Solution Overview
Problem
Existing container filling machinery is expensive, difficult to clean, and inefficient in handling flowable products with particulate matter, as it relies on intricate pumps and sensitive electronics that are affected by viscosity, temperature, and composition, leading to inaccurate metering and wear.
Innovation Solution
A container filling apparatus that incorporates a valve, nozzle, and sensors to dynamically control the filling process, allowing the material to participate in the filling process, with sensors determining fill levels and controlling the valve to stop or adjust flow, independent of product properties like viscosity and particulate content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If expensive and intricate pumps and control electronics are used to meter product by weight or volume, then filling accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces complex mechanical metering systems (pumps, flow meters, weight sensors) with a simple optical sensing system. The sensor detects the presence or absence of product at a specific location to trigger valve closure, eliminating the need for expensive metering equipment while maintaining filling accuracy.
Solution Approach 2:
The patent extracts the metering function entirely from the system by using a different approach - instead of measuring and controlling the amount of product dispensed, the system simply detects when the container reaches the desired fill level and stops dispensing. This removes pumps, flow meters, and complex control electronics from the system.
2Manufacturing precision
If intricate pumps and piping are used for metering, then filling accuracy is improved, but ease of cleaning deteriorates
Solution Approach 1:
The patent removes intricate pumps, flow meters, and complex piping from the system by replacing them with a simple valve-controlled dispensing system. The product flows through minimal piping and is stopped by a valve actuated by sensor feedback, dramatically simplifying the system structure and making it much easier to clean.
Solution Approach 2:
The system uses the product itself and the container as active participants in the filling process. The sensor detects product presence directly in the container, and the valve controls flow based on this feedback, eliminating the need for complex metering infrastructure that would require extensive cleaning.
3Manufacturing precision
If sensitive electronic control systems are used, then filling precision is improved, but tolerance to product variations deteriorates
Solution Approach 1:
The patent replaces sensitive electronic control systems with a simple optical sensor and valve actuation system. The sensor detects product presence or absence at a specific fill level and triggers valve closure, providing precise fill control without being affected by product viscosity, temperature, or composition variations.
Solution Approach 2:
The system uses simple, robust components (optical sensor, valve) that are not sensitive to product variations. These components can handle a wide range of products including those with particulate matter, and do not require the sophisticated electronics that would be affected by product property changes.
4Manufacturing precision
If pump-based metering systems are used, then filling control is improved, but productivity deteriorates due to wear and maintenance
Solution Approach 1:
The patent removes pumps from the system entirely, replacing them with a gravity-fed or pressure-fed dispensing system controlled by a valve. This eliminates the moving parts and mechanical components that wear out, allowing continuous operation without maintenance and improving productivity.
Solution Approach 2:
The system uses the product flow itself and container position as the basis for control, rather than requiring active pump metering. The sensor detects fill level and the valve responds automatically, creating a self-regulating system that operates continuously without wear or maintenance.
Data Source
AI summary
Apparatus and methods are provided for controlling flow of a flowable material. The flowable material passes from a product supply through one or more valves which are coupled to a controller. The controller is also coupled to one or more sensors operable to generate a signal indicating whether flowable product is present or not present at a specific level within a container. The controller is programmed to operate the valves based on signals received from the sensors. The sensors may be associated with the feed container and used to control metering of flowable product out of the feed container, or they may be associated with a container and used to control filling of the container with flowable product.