Sterilizing Solution Volume Measurement Arrangement
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Solution Overview
Problem
Existing packaging machines face challenges in accurately measuring and controlling the consumption of hydrogen peroxide or other sterilizing solutions, leading to potential contamination risks due to either insufficient or excessive sterilization.
Innovation Solution
An arrangement comprising a measuring tank and a level tank connected to the sterilizing solution bath, with a control unit that manages the transfer of sterilizing solution based on level tank data, allowing for precise measurement and control of solution consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the web path in the hydrogen peroxide bath is increased to reduce the risk of insufficient sterilization, then the sterilization reliability is improved, but the machine stop losses increase and productivity decreases
Solution Approach 1:
The patent replaces the mechanical approach of extending the web path (physical dimension) with an electronic/control system approach. A weighing device continuously monitors the weight of hydrogen peroxide in the bath, and a control unit calculates consumption based on weight change over time. This substitution allows sufficient sterilization to be achieved through precise measurement and control rather than simply increasing the physical path length, thereby maintaining productivity while ensuring reliability.
2Object-affected harmful factors
If the web path in the dryer is extended to assure adequate removal of excessive hydrogen peroxide, then the safety is improved, but the machine stop losses increase and productivity decreases
Solution Approach 1:
The patent replaces the mechanical approach of extending the dryer web path with a control system that monitors hydrogen peroxide consumption. By continuously measuring the weight of hydrogen peroxide in the bath and calculating consumption rates, the system can determine when sufficient sterilization has occurred without needing to extend the physical drying path. This ensures hydrogen peroxide residues are adequately controlled while maintaining productivity.
3Loss of information
If a weighing device is used to monitor hydrogen peroxide consumption, then information about consumption is provided, but the measurement accuracy is insufficient for high-speed varying web speeds
Solution Approach 1:
The patent implements a feedback system where the weighing device continuously monitors hydrogen peroxide weight, and the control unit calculates consumption based on weight change over time. The system receives web speed signals and uses this feedback to adjust consumption calculations dynamically. This feedback mechanism enables accurate measurement even at high speeds with varying web velocities, as the system continuously adapts to changing conditions rather than relying on fixed assumptions.
Solution Approach 2:
The patent makes the measurement system dynamic by continuously updating consumption calculations based on real-time weight measurements and web speed variations. Rather than using static measurement intervals or fixed consumption rates, the system dynamically adjusts its calculations to match the actual operating conditions, including speed changes. This dynamic approach ensures measurement precision is maintained across varying operational parameters.
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 solution provides a more accurate and reliable measurement of sterilizing solution consumption, reducing the risk of contamination by ensuring sufficient sterilization without excessive residue in the packages.
Implementation Method 1
a level tank fluidly connected to the sterilizing solution bath in at least two points such that the level tank and the sterilizing solution bath constitute communicating vessels
Data Source
Figure 1A
Figure 1B~1C
Figure 2
AI summary
An arrangement (100) for measuring a volume (VOL) of sterilizing solution (102) used per time unit in a roll-based packaging machine (104), said arrangement (100) comprising a measuring tank (106) fluidly connected to a sterilizing solution bath (108), a measuring tank level detection device (110) arranged to generate measuring tank level data (112) representing a measuring tank level (MT-L), a level tank (114) fluidly connected to the sterilizing solution bath (108) in at least two points (116, 118) such that the level tank (114) and the sterilizing solution bath (108) constitute communicating vessels, a level tank level detection device (120) arranged to generate level tank level data (122) representing a level tank level (LT-L), a measuring tank valve (124) placed on a lower measuring tank pipe (126) connecting the measuring tank (106) to the bath (108), wherein in an open state (OS) the sterilizing solution in the measuring tank (106) is allowed to pass into the bath (108), and in a closed state (CS) the sterilizing solution in the measuring tank (106) is hindered to pass, and a control unit (128) configured to retrieve the level tank level data (122), in case the level tank level (LT-L) is equal to or below a lower reference level (LOW-REF), to open the measuring tank valve (124) such that at least part of the sterilizing solution (102) in the measuring tank (106) is transferred to the bath (108), and to register a time point for opening the measuring tank valve (124) as a filling start time point, in case the level tank level (LT-L) is equal to or above an upper reference level (UPP-REF), to close the measuring tank valve (124) such that the sterilizing solution (102) from the measuring tank (106) is hindered from being transferred to the bath (108), and to register a time point for closing the measuring tank valve (124) as a filling end time point to determine a filling start measuring tank level by retrieving the measuring the level tank level (LT-L) for the filling start time point, to determine a filling end measuring tank level (MT-L) by retrieving the measuring tank level data (112) for the filling end time point, to determine the volume of sterilizing solution used between the filling start time point and the filling end time point by using the measuring tank level data (112) for the filling start time point and the filling end time point, and a cross-sectional area of the measuring tank (106), and to determine the volume of sterilizing solution used per time unit by dividing the volume of sterilizing solution determined with a number of time units between the filling start time point and the filing end time point.