Filling Unit Actuator Using Smart Materials for Fluid Path Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The high cost and complexity of electro-pneumatic actuators in beverage bottling plants necessitate the development of a more cost-effective and durable actuator solution for controlling fluid paths in filling units.
Innovation Solution
The use of actuator elements made from materials such as magnetorheological elastomers, dielectric elastomers, thermal shape memory alloys, magnetic shape memory alloys, and piezoceramics, which can change shape in response to control signals to achieve defined positions and forces for fluid path control, allowing for efficient and reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electro-pneumatic actuators are used for controlling fluid paths, then reliable operation and sufficient actuating force can be achieved, but the cost and device complexity increase significantly
Solution Approach 1:
The patent replaces electro-pneumatic actuators with a purely mechanical actuator system consisting of a shape memory alloy element and a return spring. This substitution eliminates the need for complex pneumatic components (cylinders, valves, hoses) while maintaining reliable actuation through the intrinsic properties of the shape memory alloy that responds to temperature changes to generate the required actuating force of 200-400 N
Solution Approach 2:
The actuator utilizes parameter changes in the shape memory alloy material, which undergoes a phase transformation when heated, causing it to change shape and generate actuating force. The material transitions from an austenitic phase (actuated state) to a martensitic phase (relaxed state) through temperature control, enabling reliable operation without complex mechanical systems
2Force
If electro-pneumatic actuators are used for controlling fluid paths, then sufficient actuating force can be achieved, but the manufacturing cost increases
Solution Approach 1:
The patent employs a cost-effective actuator design using shape memory alloy and spring elements that are simpler and cheaper to manufacture than electro-pneumatic actuators. The design accepts that the actuator may need replacement over time but reduces initial manufacturing cost and complexity, with the shape memory alloy element and spring providing sufficient actuating force of 200-400 N at lower cost
Solution Approach 2:
By replacing expensive electro-pneumatic components with simpler mechanical elements (shape memory alloy and spring), the patent achieves the required actuating force while significantly reducing manufacturing cost. The mechanical system requires fewer precision-manufactured parts and eliminates costly pneumatic infrastructure
3Device complexity
If actuator elements made from shape memory alloys are used, then device complexity and cost are reduced, but the actuating force and stroke must be sufficient for sealing fluid paths at working pressures
Solution Approach 1:
The shape memory alloy element is designed to undergo significant parameter changes in the form of large shape transformations during phase transition. This allows the actuator to generate sufficient actuating force of 200-400 N and adequate stroke to reliably seal fluid paths at working pressures, overcoming the limitation of simpler actuator designs
Solution Approach 2:
The actuator uses a composite system combining shape memory alloy with a return spring to achieve the required force output. The shape memory alloy provides the actuating force in one direction while the spring provides the return force, creating a composite mechanical system that delivers sufficient bidirectional force for sealing applications at working pressures
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
These materials enable the actuator elements to provide the necessary forces and strokes for sealing or opening fluid paths, reducing costs and increasing the service life of the filling units while maintaining operational efficiency.
Implementation Method 1
the material of the actuator element is or includes a magnetorheological elastomer. In particular, it can be provided that the magnetorheological elastomer can be activated by an externally applicable magnetic field, for example by a toroidal coil
Implementation Method 2
the magnetorheological elastomer can be activated by an externally applicable magnetic field, for example by a toroidal coil
Implementation Method 3
the material of the actuator element is or comprises an electrorheological liquid or a gel. Here, by applying a voltage, the liquid or gel can be expanded
Implementation Method 4
the material of the actuator element is or includes a dielectric elastomer. When an electrical voltage is applied between the electrodes, the elastomer film contracts in thickness and expands in area
Implementation Method 5
the material of the actuator element is or comprises a thermal shape memory alloy
Implementation Method 6
Thermal shape memory alloys (SMA) are metallic compounds that deform when the temperature increases, with the material changing from a martensitic to an austenitic crystal structure
Implementation Method 7
the material of the actuator element is or includes a magnetic shape memory alloy. Here, too, the deformation can take place through a crystal transformation of the MSMA, which, in contrast to the thermal shape memory alloy, is triggered by the application of a magnetic field
Implementation Method 8
the deformation can take place through a crystal transformation of the MSMA, which, in contrast to the thermal shape memory alloy, is triggered by the application of a magnetic field
Implementation Method 9
the material of the actuator element is or comprises a piezoceramic
Data Source
Figure 1
Figure 2a~2b
Figure 2c~2d
AI summary
The invention relates to an actuator (14) for controlling at least one fluid path (20) of a filling unit (12) for a beverage filling system (10), having at least one control unit (22) and at least one actuator element (24), by means of which an actuating force can be provided, wherein at least one first control signal and at least one second control signal can be provided by means of the control unit (22) and wherein the actuator element (24) consists of a material that assumes a first elongation in accordance with a first control signal, in which first elongation the actuator element (24) assumes a first resting position, and that assumes an elongation, in which the actuator element (24) assumes a second activation position, in accordance with the second control signal.