Solid Immersion Body Load Cell for Viscous Filling Level Measurement
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Solution Overview
Problem
Existing methods for determining the filling level in beverage bottling plants, such as capacitive probes, resistive probes, microwave sensors, and buoyancy bodies, face challenges with precise measurement in pasty or viscous products and are not suitable for hygienic designs required in the food industry, leading to inaccuracies and hygiene issues.
Innovation Solution
A device with an immersion body made of solid material, connected to a load cell, which measures the weight force acting on it, allowing for precise filling level determination independently of the filling product's dielectric constant and permittivity, and is designed for hygienic use with smooth surfaces to prevent contamination and facilitate cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If capacitive probes are used to determine filling level, then filling level can be determined in a quasi-continuous manner, but precise measurement is difficult for pasty or viscous products and products containing solids
Solution Approach 1:
The patent replaces capacitive sensing (electrical field-based) with a mechanical buoyancy-based system. An immersion body physically displaces the filling product, and this mechanical displacement is transmitted through a coupling rod to a deflection sensor, eliminating dependence on dielectric properties of the product.
Solution Approach 2:
The patent changes the measurement parameter from electrical capacitance (which depends on dielectric constant) to mechanical buoyant force (which depends on density and displaced volume). This parameter change makes the measurement independent of dielectric properties, enabling accurate measurement of pasty, viscous, and solid-containing products.
2Reliability
If multi-part devices are used for level measurement, then measurement functionality can be achieved, but hygienic design cannot be provided due to dead spaces
Solution Approach 1:
The patent merges the immersion body and coupling rod into a single integrated mechanical transmission system. The immersion body is directly connected to the coupling rod, which transmits deflection directly to the sensor, eliminating intermediate components and dead spaces that would compromise hygiene.
Solution Approach 2:
The patent employs a thin-walled immersion body that can be made from hygienic materials. The immersion body acts as a flexible yet rigid enough structure to transmit buoyant force while maintaining smooth surfaces without dead spaces, complying with hygiene requirements for food and beverage industries.
3Measurement precision
If buoyancy bodies with multi-part design are used, then filling level can be determined, but hygienic design cannot be provided for food industry use
Solution Approach 1:
The patent replaces complex multi-part buoyancy mechanisms with a simple direct mechanical coupling system. The immersion body's buoyant force is directly transmitted through a single coupling rod to a deflection sensor, eliminating multiple parts and potential dead spaces while maintaining measurement accuracy.
Solution Approach 2:
The patent segments the device into only two essential functional parts: the immersion body (which experiences buoyancy) and the coupling rod (which transmits deflection). This minimal segmentation achieves both measurement precision and hygiene compliance by eliminating unnecessary components.
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
The device provides a reliable and hygienic means to measure filling levels in beverage bottling plants, ensuring accurate measurements and compliance with food industry standards, including FDA and EHEDG approvals, without requiring precise knowledge of the filling product's properties.
Implementation Method 1
the weight force acting on the immersion body, which is determined by the load cell, is understood here to mean the weight force that is exerted by the immersion body on the load cell. In a vacuum, the weight would be equal to the weight of the immersion body. In a medium, on the other hand, the weight force corresponds to the weight of the immersion body reduced by the buoyancy of the displaced medium according to the Archimedean principle.
Data Source
Figure 1~2
Figure 3~5
AI summary
The present invention relates to a device (1) for determining the filling level of a filling product in a filling product reservoir (2) of a filling product filling system, preferably a beverage reservoir in a beverage filling system, comprising an immersible body (4) arranged in the filling product reservoir (2) for immersion into the filling product and a force-measuring cell (3) connected to the immersible body (4) for determining the weight force acting on the immersible body (4), the immersible body (4) being completely formed from a full material.