Radar Antenna in Gas Pipe for Filling Level Detection
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Solution Overview
Problem
Existing filling systems face challenges in accurately determining the target filling level in containers of varying sizes and volumes, especially when the filling machine's performance changes, leading to inconsistent filling heights and potential non-compliance with minimum filling quantities.
Innovation Solution
A filling system equipped with a radar level measuring device that uses radar signals to determine the filling level within the container, integrated into the flow path, allowing for precise filling regardless of container shape or volume, and a control circuit to adjust the filling process to reach the target level.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a stationary sensor device is used to detect fill level, then the detection position is fixed, but the filling endpoint shifts relative to the sensor when machine output changes
Solution Approach 1:
The patent applies the dynamics principle by making the radar antenna movable rather than stationary. The antenna is coupled to the container conveying mechanism and moves synchronously with the containers through the filling position. This dynamic positioning ensures the antenna remains aligned with the container opening regardless of machine output variations, maintaining measurement precision across different operating speeds.
Solution Approach 2:
The patent uses the container conveying mechanism as an intermediary to transfer the positioning information from the moving container to the radar antenna. The antenna is coupled to the conveying mechanism, which acts as a mediator to synchronize the antenna's position with the container's position, eliminating the need for a stationary sensor that would require complex tracking systems.
2Productivity
If volume filling is used for glass bottles with varying empty volumes, then different filling levels occur, but adjusting for each bottle individually increases complexity
Solution Approach 1:
The patent implements feedback control by using the radar level gauge to continuously measure the actual fill level in each container and comparing it with the target fill level. The control system processes this feedback information and automatically adjusts the filling process to correct any deviations, ensuring consistent fill levels across containers with varying empty volumes while maintaining high productivity.
Solution Approach 2:
The patent replaces complex mechanical adjustment mechanisms with a radar-based measurement and control system. Instead of using mechanical devices to physically adjust filling parameters for each container, the system uses electromagnetic radar signals to detect fill levels and electronically controls the filling process, simplifying the overall system while improving precision.
3Device complexity
If the antenna is positioned outside the flow path, then the structure is simpler, but the radar signals may be blocked or interfered with by the filling element housing
Solution Approach 1:
The patent applies the nested doll principle by placing the radar antenna inside the flow path, specifically within the gas tube that is already part of the filling element structure. The antenna is nested within the existing gas tube component, allowing it to be positioned in an optimal location for signal transmission without adding significant external structural complexity. This internal positioning ensures reliable signal transmission to the liquid surface while utilizing the existing structural space.
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
Ensures reliable and precise filling of containers of different shapes and volumes, maintaining consistent filling heights and compliance with minimum filling quantities, regardless of the filling machine's performance.
Implementation Method 1
at least one antenna (21) of a radar level measuring device (22) is provided in this flow path (20) to determine the fill level of the liquid material which is being filled into the container (2)
Implementation Method 2
for determining the correct time of reception and thus the path traveled
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
The invention relates to a filling system (1) for filling containers (2) with a fluid filling material. According to a first embodiment, the invention relates to a filling system for filling containers with a fluid filling material, comprising at least one filling material tank (5) providing the filling material, and at least one filling element (1.1) for the controlled output of the filling material into the containers arranged in a sealing position on the filling element in a filling phase. In a filling element housing (6), the filling element also comprises a fluid channel (7) through which the fluid filling material can flow, and in which a fluid valve (9) is provided, wherein the valve body (9.1) thereof can be shifted in a controlled manner along a filling element axis (FA) for opening and/or closing the fluid valve, and is formed on a gas pipe (13) that is axially aligned with the filling element axis and acting as a valve tappet. In addition, with the inclusion of the gas pipe, at least one flow path (20) is formed for a liquid and/or gaseous medium, which is connected to an interior of the container to be filled during the filling phase, wherein at least one antenna (21) of a radar fill level measuring device (22) is provided in the flow path for determining the fill level of the fluid filling material filled in the container.