EP4324783A1 - Filling device and method for operating a filling device - Google Patents

Abstract

The invention relates, among other things, to a method for operating a filling device (10), comprising pre-stressing a container (12) with a tension gas for a pre-stressing period by means of a filling element (14) of the filling device (10). The method further comprises filling the prestressed container (12) with a filling material by means of the filling element (14), detecting a flow of the filling material during the filling of the prestressed container (12) by means of a flow measuring device (22) of the filling device (10) and Adjusting the preload duration for at least one subsequent container (12) depending on the detected flow by means of a control device of the filling device (10). The method can advantageously enable the pre-stressing duration to be set as optimally as possible, which allows the performance of the filling device (10) to be increased.

Description

Technical area

The invention relates to a method for operating a filling device and a filling device.

Technical background

In filling systems for filling carbonated drinks, for example, a filling process can take place under a certain pressure (filling pressure). This must be higher than the saturation pressure of the drink (rule of thumb approx. 1 bar higher). For this purpose, certain valves are used with which pressure filling can be carried out. The filling process can have several process steps, such as pressing, pre-stressing, filling, pause, first relief, calming, second relief, removal.

The duration of a respective process step can be defined differently. Depending on the situation, this can be processed via the angular position of a filling element (e.g. in a filler carousel), via a sensor value (e.g. end of filling) or over a firmly defined time. Particularly when it comes to time-controlled process steps, it is important to make them as short as possible without endangering the process on the one hand (if too short) or wasting too much time on the other (if too long). These times are usually determined in advance.

One of these predetermined process times is the prestressing period or the prestressing time for which a container is prestressed with a clamping gas before filling. For example, this can be the time period that is given to the filling element to equalize the pressure between a filling material tank and the pressed container.

Conventionally, this lead time is a fixed time, e.g. B. for a respective variety, stored in a control device. Influencing factors for determining this preload duration can be the container size, the filling pressure and the switching times of the filling element.

The disadvantage of this technology can be that the preload time for all filling valves is identical and therefore may not be ideal. It is not conventionally possible to directly check whether the preload duration is sufficient, so that the preload duration is usually set with a significant reserve in order to avoid a preload duration that is too short.

If the pre-stressing time is too short, the filling process will start when the container is not yet completely pre-stressed. Due to the higher pressure in the filling tank compared to the insufficiently pre-stressed container, the filling speed may be too high. Over-foaming occurs with loss of product, contamination, etc. If the pre-tensioning time is too long, the performance of the filler is reduced and process time is wasted. The machine is not operating efficiently.

Another disadvantage of the fixed preload duration can be that there is no reaction to changes. Would e.g. For example, if the filling pressure changes, the pre-tensioning time is not usually changed. Even if the switching time of the filling valve of the filling element changes, e.g. B. due to aging, wear, changes in working pressure, etc., the preload duration is not adjusted.

The EP 1127 835 A1 discloses a system for filling bottles, cans or similar containers with a liquid filling material, with several filling positions, each of which has a filling element. At least one pressure sensor is provided on each filling element, which detects the pressure in the interior of the container connected to the filling element during the filling process and delivers an electrical signal corresponding to this pressure to electronics common to all filling elements. Will e.g. For example, if the required filling or preloading pressure is not quite reached during the preloading time on a filling element, the electronics can extend the preloading time accordingly during the next filling process.

The invention is based on the object of creating an improved technology for operating a filling device, with which the performance of the filling device can preferably be increased and/or the risk of contamination of the filling device can be reduced.

Summary of the invention

The task is solved by the features of independent claim 1. Advantageous developments are specified in the dependent claims and the description.

One aspect of the present disclosure relates to a method of operating a filling device. The method comprises pre-stressing a container with a tension gas (e.g. from a headspace of a filling material tank of the filling device) for a pre-stressing period by means of a filling element of the filling device. The method involves filling the prestressed container with a filling material (e.g. from a filling material tank of the filling device) by means of the filling element. The procedure shows detecting a flow (e.g. a flow rate or a flow rate) of the filling material during the filling of the prestressed container by means of a flow measuring device of the filling device. The method includes adjusting the preload duration for at least one subsequent container depending on the detected flow by means of a control device of the filling device.

The method is advantageously based on the knowledge that a quality or quality of the setting of the prestressing duration can be determined based on an analysis of the flow of the filling material during filling. Depending on how well the preload duration is set, characteristic curves for the recorded flow can arise. Insufficient preload can manifest itself, for example, in an overshoot of the flow at the start of filling and/or in a drop in the flow during filling. The insufficient pressure in the container at the end of prestressing or at the beginning of filling can lead to an undesirably high filling speed, at least at the beginning of filling, since the pressure differences between the pressure inside the container and the filling pressure are too large.

The method can therefore advantageously be used to improve the setting of the preload duration. The adjusted preload duration can therefore preferably be neither too short nor too long. By avoiding a pre-tensioning time that is too short, there is advantageously no or at least less over-foaming and corresponding contamination, which has to be cleaned with great effort and thus reduces the efficiency of the filling device due to the downtime. The efficiency can preferably indicate how long the corresponding machine can be operated without stopping, whereby downtimes due to malfunctions, format changes and maintenance can be taken into account. By avoiding a pre-tensioning period that is too long, process time can be advantageously saved, which can be used to increase the performance (output) of the system. Preferably, the output can be stated in (treated) containers per unit of time (e.g. hour). As mentioned, improving the rinsing process can lead to an increase in performance, so that, for example, instead of 50,000 containers per hour, 55,000 containers per hour can now be processed.

Advantageously, the method can also enable the preload duration to be automatically adapted to changing conditions, e.g. B. due to a changed filling pressure or changed, aging-related switching times of the filling element.

In contrast to the state of the art according to the EP 1 127 835 A1 Advantageously, no additional pressure sensors are required to adjust the preload duration. Instead, the device technology that is preferably already available in the form of the flow measuring device can be used for the method. This means that the method can preferably be implemented in a particularly cost-effective and structurally simple manner.

Preferably, the control device can be spatially assigned to the filling device. However, it is also possible for the control device to be a remote control device, for example.

The term “control device” can preferably refer to electronics (e.g. designed as a driver circuit or with microprocessor(s) and data memory) and/or a mechanical, pneumatic and/or hydraulic control, which, depending on the training, carries out control tasks and/or or can take on control tasks and/or processing tasks. Even if the term “control” is used here, it can also expediently include or mean “rules” or “control with feedback” and/or “processing”.

For example, adjusting the header duration may include applying a mathematical operation (e.g., addition or subtraction) to the header duration or replacing the header duration with a header duration with a different value.

In one exemplary embodiment, the method is initially used to adjust the filling device. Alternatively or additionally, the method for adjusting (e.g. adjusting or calibrating) the filling device can be used during normal operation of the filling device. Advantageously, the preload duration can be automatically set as optimally as possible initially and, on the other hand, automatically adapted to changing conditions, e.g. B. due to a changed filling pressure or changed, aging-related switching times of the filling element.

In a further embodiment, the bias time during adjustment is reduced if the sensed flow remains substantially constant during filling. Alternatively or additionally, the preload duration can be increased during adjustment, for example, if the detected flow overshoots at the start of filling and/or drops during filling. In this way, one can advantageously approach an optimal bias value iteratively.

In a further exemplary embodiment, when adjusting, the preload duration is adjusted, preferably reduced or increased, by a predetermined period of time, preferably in the two-digit ms range, or by a predetermined percentage value, preferably in the single-digit % range.

In a further embodiment, to iteratively adjust the bias duration, biasing, filling, capturing and adjusting are repeated until a termination criterion is met.

In a further exemplary embodiment, the preload duration can be successively reduced during iterative adjustment until the termination criterion is met. In this way, one can advantageously approach an optimal preload value iteratively without the containers foaming over and thus contaminating the system.

In one embodiment, the amount is successively reduced by a predetermined period of time, preferably in the two-digit ms range, or by a predetermined percentage value, preferably in the single-digit % range. Advantageously, the successive reduction or shortening of the preload duration can be easily implemented in terms of control technology.

In a further embodiment, if the termination criterion is met, the preload duration during adjustment is increased by a predetermined safety value, preferably in a range between ≥ 20 ms and ≤ 80 ms, particularly preferably between ≥ 35 ms and ≤ 65 ms, for example around 50 ms. This can advantageously ensure sufficient process reliability so that, if there are any tolerances, the containers do not foam over and thus contaminate the system.

In one embodiment variant, the termination criterion requires that the detected flow decreases during filling and/or overshoots at the start of filling. In this way it can advantageously be recognized that the container has not yet been sufficiently prestressed. The drop and overshoot can be indications that there is a significant increase in pressure in the container at the start of filling, which can be recognized by the increased flow. The increase in pressure can be caused, for example, by insufficient pressure equalization at the end of prestressing.

In a further embodiment variant, the termination criterion may require that a predetermined number of iteration steps be reached. In this way, for example, the accuracy of adjusting the preload duration can be set advantageously or the process can be repeated endlessly, e.g. B. in the event of a malfunction, can be prevented.

In one exemplary embodiment, the filling device is involved in preloading after adjusting the preloading duration or after iteratively adjusting the preloading duration in normal operation the adjusted preload duration is operated by means of the control device. Advantageously, the adjusted preload duration can be used in normal operation and the performance of the system can thus be increased.

In a further exemplary embodiment, the method further comprises determining a wear state of the filling element, preferably a filling valve and/or a biasing valve of the filling element, depending on a historical development of recorded flows and/or a historical development of adjusted preloading durations by means of the control device. In this way, it can advantageously be determined, for example, whether the filling element should be serviced or replaced due to wear or due to a malfunction. In this way, an impending malfunction of the filling element can advantageously be recognized and a corresponding predictive response can be made.

In one embodiment, the method is applied to a plurality of filling elements of the filling device on an individual basis for each filling element in order to adapt the respective preload duration to the individual filling element. In this way, all filling elements of the filling device can advantageously be adjusted as optimally as possible with regard to the preload duration. Advantageously, conclusions can also be drawn about their functionality and state of wear by comparing the pre-stressing time between the filling elements, which is adapted to each individual filling element.

In a further embodiment, the method further comprises determining an average value from the pre-stressing durations adapted to the individual filling element by means of the control device and checking whether one of the pre-stressing durations adapted to the individual filling element is increased by at least a predetermined value (e.g. 50 ms) or by at least a predetermined percentage ( B. deviates between 5% and 20%) from the determined mean value by means of the control device. Optionally, the method can further include outputting information about the testing to a user using a user interface of the filling device. In this way, worn filling elements can advantageously be identified and, for example, serviced or replaced.

Another aspect of the present disclosure relates to a filling device, preferably a rotary filling device or linear filling device, for filling containers. The filling device has at least one filling element for pre-stressing a container with a tension gas (e.g. from a headspace of a filling material tank) and filling the pre-stressed container with a filling material (e.g. from a filling material tank). The filling device has at least one flow measuring device for measuring a flow of the filling material to the at least one filling element (e.g. one flow measuring device per filling element). The filling device has a control device which is configured to operate the filling device according to a method as disclosed herein. Advantageously, the same advantages can be achieved with the device that have already been explained with reference to the method.

Optionally, the filling device can also have at least one filling material tank for storing filling material and optionally clamping gas in the head space of the filling material tank (e.g. with a filling material tank for one or more filling elements).

The filling device can preferably be installed in a container treatment system, e.g. B. for producing, cleaning, coating, testing, filling, sealing, labeling, printing and / or packaging containers for liquid (e.g. carbonized) media, preferably drinks or liquid food.

For example, the containers can be designed as bottles, cans, canisters, cartons, bottles, etc.

The previously described preferred embodiments and features of the invention can be combined with one another in any way.

Short description of the characters

Figur 1

eine schematische Darstellung einer Vorrichtung gemäß einem Ausführungsbeispiel der vorliegenden Offenbarung;

Figur 2

einen idealisierten Verlauf eines Behälterinnendrucks p in Abhängigkeit von der Zeit t während eines Vorspannens eines Behälters;

Figur 3

ein exemplarischer Verlauf einer Füllgutdurchflussmenge Q in Abhängigkeit von der Zeit t während eines Füllens eines Behälters mit dem Füllgut;

Figur 4

ein weiterer exemplarischer Verlauf einer Füllgutdurchflussmenge Q in Abhängigkeit von der Zeit t während eines Füllens eines Behälters mit dem Füllgut;

Figur 5

ein Flussdiagramm eines Verfahrens gemäß einem Ausführungsbeispiel der vorliegenden Offenbarung; und

Figur 6

ein Flussdiagramm eines Verfahrens gemäß einem weiteren Ausführungsbeispiel der vorliegenden Offenbarung.

Further details and advantages of the invention are described below with reference to the accompanying drawings. Show it:

Figure 1

a schematic representation of a device according to an embodiment of the present disclosure;

Figure 2

an idealized course of an internal container pressure p as a function of time t during prestressing of a container;

Figure 3

an exemplary course of a filling material flow rate Q as a function of the time t while a container is being filled with the filling material;

Figure 4

a further exemplary course of a filling material flow rate Q as a function of the time t while a container is being filled with the filling material;

Figure 5

a flowchart of a method according to an embodiment of the present disclosure; and

Figure 6

a flowchart of a method according to a further exemplary embodiment of the present disclosure.

The embodiments shown in the figures are at least partially the same, so that similar or identical parts are provided with the same reference numerals and for their explanation reference is also made to the description of the other embodiments or figures in order to avoid repetitions.

Detailed description of exemplary embodiments

The Figure 1 shows a filling device 10 for filling containers 12. The filling device 10 can pre-stress the containers 12 and then fill them with a liquid or pasty filling material. The filling material is preferably carbonized. Preferably, the filling device 10 can additionally evacuate and/or rinse the containers 12 before prestressing.

The filling device 10 can be included in a container treatment system. For example, the filling device 10 can be arranged downstream of a cleaning device for cleaning the containers 12 and/or a manufacturing device for producing the containers 12. Alternatively or additionally, the filling device 10 can be arranged upstream of a container for closing the containers 12.

The filling device 10 has at least one filling element 14, at least one filling material tank 20 and at least one flow measuring device 22.

In the Figure 1 Filling device 10 shown has only one filling element 14, only one filling material tank 20 and only one flow measuring device 22. However, it is preferred that the filling device 10 has a plurality of filling elements 14 and a plurality of flow measuring devices 22 as well as one or more filling material tanks 20.

The filling device 10 is particularly preferably designed as a rotary filling device or a filler carousel or a linear filling device. The rotary filling device can have a plurality of filling stations arranged around a circumference of the rotary filling device. The linear filling device can have several filling stations arranged next to one another and/or one behind the other. Each filling station can have a filling element 14 and a flow measuring device 22. Several filling stations can each share a filling material tank 20 or each filling station can be assigned its own filling material tank 20. The filling device 10 can Using the multiple filling stations, preferably fill multiple containers 12 at the same time or with a time overlap.

The filling element 14 can bias and fill the container 12. The filling element 14 can preferably additionally evacuate, rinse and/or relieve the container 12.

Before the container 12 is treated by means of the filling element 14, the container 12 can be pressed against the filling element 14. During treatment of the container 12, a container mouth of the container 12 and the filling element 14 can be pressed together, preferably essentially gas-tight. The pressing together can be done, for example, by means of at least one lifting device (not shown in the figures). The at least one lifting device can, for example, completely or partially lower the filling element 14 to press it onto the container 12 and/or raise the container 12 to press it onto the filling element 14, e.g. B. via a lifting plate.

For example, the filling element 14 can have a contact surface, preferably a sealing surface, against which the container 12 can be pressed with its container mouth. The contact surface can be arranged on the underside of the filling element 14. The contact surface can be ring-shaped. For example, a pressure rubber can have the pressure surface. The contact surface can serve as a seal between the filling element 14 and the container 12. The internal atmosphere of the container 12 can thus be separated from the external atmosphere or an environment outside the container 12.

The filling element 14 can have a filling valve 16 and a biasing valve 18. The filling device 10 can also have a control device (not included). Figure 1 shown) which can control an actuation of the filling valve 16 and the biasing valve 18.

The filling valve 16 is used to fill the container 12. When filling, the container 12 can be pressed against the filling element 14. The filling valve 16 can be in fluid communication with the filling material tank 20. For example, a fluid line can connect the filling valve 16 to the filling material tank 20. The filling valve 16 can receive a liquid or pasty filling material from the filling material tank 20. In an opening state, the filling valve 16 can fill the filling material into the container 12. In a closed state, the filling valve 16 can block the container 12 from being filled with the filling material.

The biasing valve 18 is used to bias the container 12. When biasing, the container 12 can be pressed against the filling element 14. The biasing valve 18 can receive a tensioning gas or production gas. The clamping gas or production gas is preferably an inert gas (for example CO2) or an inert gas mixture. The biasing valve 18 can be connected to a headspace of the filling material tank 20 and/or to a tension gas source or production gas source. For example, a tension gas line can fluidly connect the head space of the filling material tank 20 and/or the tension gas source and the preload valve 18 to one another. In an open state, the biasing valve 18 can direct the tensioning gas into the container 12. In a closed state, the biasing valve 18 can block the introduction of the tensioning gas into the container 12.

It is possible that the biasing valve 18 may be used in addition to flushing the container 12 prior to biasing the container 12, for example to reduce an oxygen concentration in the container 12.

It is also possible for the filling element 14 to have a relief channel (possibly with a relief valve) (not separately in Figure 1 shown). A fluid connection between the container 12 and an environment of the device 10 or the container 12 can be established via the relief channel. For example, the relief channel can be used to relieve the container 12 after filling. Alternatively or additionally, the relief channel can be used when flushing the container 12 to drain the air from the container 12 into the environment.

It is also possible for the filling element 14 to have a vacuum channel (possibly with a vacuum valve) (not separately in Figure 1 shown). The vacuum channel can be connected to a vacuum source, for example a vacuum pump. A fluid connection can be established between the container 12 and the vacuum source via the vacuum channel. For example, the vacuum channel can be used to evacuate the container 12. Alternatively or additionally, the vacuum channel can be used when flushing the container 12 to suck the air out of the container 12 into the environment.

The filling material tank 20 can store a liquid or pasty filling material (e.g. beverage or liquid/pasty food) with which the containers 12 are to be filled. The filling material tank 20 is preferably designed as a product vessel. For example, the filling material tank 20 can have a volume of between 100 l and 300 l for the filling material, e.g. B. around 200 l. The filling material tank 20 can be connected to a filling material source. The filling material can be supplied to the filling material tank 20 via the filling material source.

The filling material tank 20 can also be fluidly connected to a production gas source, e.g. B. via a production gas line. Specifically, a headspace of the filling material tank 20 can contain the production gas source be fluidly connected. The production gas source can provide compressed production gas, which can also be used or referred to as tension gas and/or as purge gas, and supply it to the filling material tank 20. During operation, production gas with, for example, a pressure between 5 and 6 bar can be stored in the head space of the filling material tank 20.

The flow measuring device 22 is designed to measure a flow of the filling material. For example, the flow measuring device 22 can measure a flow rate and/or a flow quantity or a flow volume flow. The flow measuring device 22 can output information about the measured flow to a control device of the device 10.

The flow measuring device 22 can be arranged in a fluid connection between the filling valve 16 and the filling material tank 20. The flow measuring device 22 can be arranged upstream of the filling valve 16. Flow measuring device 22 can be arranged downstream of the filling material tank 20.

The flow measuring device 22 can use any known measuring principle. For example, the flow measuring device 22 can be designed as a magnetic-inductive flow measuring device, as a mass flow measuring device or as an ultrasonic flow measuring device.

The Figure 2 shows an idealized pressure curve within the container 12 when the container 12 is preloaded. The dotted curve A indicates a switching signal of the preload valve 18. The solid curve B indicates a pressure curve in the container 12.

Preloading can begin by opening the preload valve 18 (see curve A).

As already explained, a fluid connection can exist between the container 12 and the filling material tank 20 during prestressing and filling. A fluid connection can exist during prestressing through the opened prestressing valve 18 for introducing tensioning gas from the headspace of the filling material tank 20 (and/or from a production gas source) into the container 12. The fluid connection can exist during filling through the opened filling valve 16 for introducing filling material from the filling material tank 20 into the container 12.

A (working) pressure p4, e.g. B. approx. 5 bar. During prestressing and possibly during filling, pressure equalization can occur between the container 12 and the filling material tank 20. During pressure equalization, the pressure p in the container 12 can essentially correspond to the pressure p4 in the product tank 20 can be increased. The pressure p in the container 12 can increase approximately according to a so-called restricted growth function. The pressure p can asymptotically approach the pressure p4. The pressure p4 can be a bound of the restricted growth function.

Filling can preferably be started at a time when there is already a pressure p close to the pressure p4 in the container 12. An example of this is in Figure 2 the time t2 is shown. At time t2 there can be a pressure p2 in the container 12. A differential pressure between p2 and p4 can be comparatively small, e.g. B. ≤ 0.3 bar, ≤ 0.2 bar or ≤ 0.1 bar.

The Figure 3 shows in this context a flow rate Q measured by means of the flow measuring device 22 as a function of the time t. If the filling valve 16 is opened at time t2, i.e. when the pressure p2 prevails in the container 12, after a steep increase in the flow rate Q at the start of filling, a substantially constant flow rate Q can be established during filling. This constant flow preferably corresponds to the desired nominal flow. In particular, there can be no undesirable overshoot of the flow rate Q at the start of filling and/or a drop in the flow rate Q after the steep rise at the start of filling.

In Figure 2 a time t1 is also shown, which lies before the time t2. At time t2 there can be a pressure p1 in the container 12, e.g. B. approx. 4.2 bar. The differential pressure between p1 and p4 can be comparatively high, e.g. B. approx. 0.8 bar. If a switch is made from prestressing to filling at time t1, filling can be significantly negatively affected.

The Figure 4 In this context, again shows a flow rate Q measured by means of the flow measuring device 22 as a function of the time t. If the filling valve 16 is opened at time t1, i.e. when the pressure p1 prevails in the container 12, the initially steep increase in the flow Q can lead to a significant overshoot of the flow Q at the start of filling.

The flow Q may be too high at the start of the filling process. The filling speed can therefore be higher than desired at the start of filling. The filling material can foam over, resulting in product loss and contamination of the system. Any necessary cleaning of the system reduces the efficiency of the system.

Only in the course of filling, when the pressure equalizes, does the flow equalize and reach a desired nominal flow, as in Figure 3 . After the initial overshoot, the flow Q can drop accordingly (see Figure 4 ). The decay can be approximated as a bounded growth function with negative growth or as a bounded shrinkage. The barrier can correspond to the nominal flow.

In Figure 2 A time t3 is also shown at which a pressure of approximately p4 can prevail in the container 12. The time t3 is later than the time t2. If a switch is made from pre-stressing to filling at time t3, the measured flow of the filling material can essentially correspond to that of Figure 3 are equivalent to. The filling is therefore no better than if it had already started at the earlier time t2. The loss of time, i.e. the time between t2 and t3, can lead to losses in production and performance.

The methods proposed here make use of the knowledge explained above that, based on the measured flow of the filling material during filling, a conclusion can be drawn as to how well the pre-tensioning duration is set or how the setting of the pre-tensioning duration can be improved.

The Figure 5 shows an exemplary method for operating a filling device, e.g. B. the filling device 10 as described below.

In a step S10, the container 12 is pre-tensioned for a pre-tensioning period by means of the filling element 14. The pre-tensioning valve 18 of the filling element 14 can be open for the pre-tensioning period. Opening of the preload valve 18 can be controlled by the control device of the filling device 10. Clamping gas can flow into the container 12 through the opened preload valve 18. At the end of the preload period, the preload valve 18 can be closed. Closing of the bias valve 18 can be controlled by the control device of the filling device 10. The preload duration can, for example, be stored in the control device. The filling valve 16 can be closed during prestressing.

In a step S12, the prestressed container 12 is filled with the filling material by means of the filling element 14. Step S12 can take place directly after step S14. Filling can take place immediately after the pre-tensioning period. The filling valve 16 of the filling element 14 can be open during filling. Opening of the filling valve 16 can be controlled by the control device of the filling device 10. Filling material from the filling material tank can flow into the container 12 through the opened filling valve 16. At the end of filling, the filling valve 16 can be closed. A closing of the Filling valve 16 can be controlled by the control device of the filling device 10. Closing can take place, for example, after reaching a predetermined filling level or after reaching a predetermined flow rate of the filling material in the container 12. The filling valve 16 can be closed during filling.

In a step S14, a flow is detected, e.g. B. a flow rate or a flow rate, of the filling material during filling, i.e. during step S12. Step S14, i.e. capturing, can be carried out in parallel with step S12, i.e. filling. Step S14 can take place directly after step S10. The flow is recorded or measured using the flow measuring device 22. The flow measuring device 22 can output information regarding the detected flow to the control device.

In a step S16, the preload duration for one or more, preferably all, subsequent containers 12 is adjusted depending on the flow recorded in step S14 by means of the control device. Step S16 may follow steps S12 and S14. The control device can, for example, change (e.g. reduce or increase) or replace the stored preload duration. The method can optionally include prestressing at least one further or subsequent container 12 for the adjusted prestressing duration by means of the filling element 14 and filling the prestressed further container 12 with the filling material by means of the filling element 14.

Adjusting the preload duration can, for example, include reducing or shortening the preload duration if the detected flow remains essentially constant during filling, as exemplified in Figure 3 is shown. This situation can, for example, indicate that the opening duration is too long. In the case of detecting a substantially constant flow, there is also the possibility that the preload duration is already set close to the optimum, so that a shortening of the preload duration would lead to an overshoot of the flow when filling a subsequent container 12, as exemplified in Figure 4 is shown. If the described change from essentially constant flow to flow with overshoot occurs due to a reduction when adjusting the pre-stressing duration, the adjusted pre-stressing duration can, for example, be increased again, e.g. B. to the last value at which the flow did not overshoot during filling, and/or to a predeterminable safety value or safety value surcharge in order to position the preload duration close to the optimum and to enable sufficient process reliability to compensate for tolerances.

Adjusting the preload duration can, for example, involve increasing or extending the preload duration if the detected flow rate overshoots at the start of filling (e.g. by a percentage value ≥ 5% compared to a desired flow rate or a flow rate that occurs at the end of filling or a nominal flow) and/or decreases during filling (e.g. by a percentage value ≥ 5% compared to a desired flow or a flow that occurs at the end of filling or a nominal flow), as exemplified in Figure 4 is shown.

Reducing the preload duration and/or increasing the preload duration can be done by a predetermined period of time, preferably in the two-digit ms range (e.g. between 10 ms and 50 ms). Reducing the preload duration and/or increasing the preload duration can also be done by a predetermined percentage value, preferably in the single-digit °/range (e.g. between 1% and 9%).

The absolute value or the percentage value by which to increase or decrease can be specified by means of a user interface of the filling device 10 and, for example, stored in the control device.

The control device can, for example, carry out the adjustment automatically or suggest it to the filling device 10 using a user interface and carry it out after user confirmation.

The Figure 6 shows an extended exemplary method for operating a filling device, e.g. B. the filling device 10 as described below.

In the process of Figure 6 The lead time can be adjusted iteratively. For this purpose, preloading (S10), filling (S12), detecting (S14) and adapting (S16.1 or S16.2) can be repeated until a termination criterion for ending the iterative adapting is met. During iterative adaptation, the preload duration is preferably successively reduced in each iteration step, starting from a predetermined (e.g. comparatively large) preload duration, until the termination criterion is met. In each iteration step, the preload duration can preferably be increased by a predetermined time period, preferably in the two-digit ms range (e.g. between 10 ms and 50 ms), or by a predetermined percentage value, preferably in the single-digit °/-range (e.g. between 1% and 9%), gradually reduced.

In step S15 it can be checked whether the termination criterion is met. The termination criterion may preferably require that the detected flow overshoots at the start of filling (e.g. by a percentage value ≥ 5% compared to a desired flow or a flow that occurs at the end of filling or a nominal flow) and / or drops during filling (e.g. by a percentage value ≥ 5% compared to a desired flow rate or a flow rate that occurs at the end of filling or a nominal flow rate), as exemplified in Figure 4 is shown. It is also possible that the termination criterion requires, for example, that a predetermined number of iteration steps be reached.

If the termination criterion is not met in step S15 (-), the preload duration can be adjusted by the control device in a step S16.1. Preferably, the preload duration can be reduced when adjusting, e.g. B. by a predetermined period of time or by a predetermined percentage, as explained above. After the adjustment in step S16.1, the method can begin again with step S10, this step S10 taking place with the adjusted preload duration for a further or subsequent container 12.

If the termination criterion is met in step S15 (+), the preload duration can be increased by the control device in a step S16.2 by a predetermined safety value, preferably in a range between ≥ 20 ms and ≤ 80 ms, particularly preferably between ≥ 35 ms and ≤ 65 ms, for example around 50 ms.

In a step S18, which can follow step S16.2, the filling device 10 can be operated in a normal operating mode, with the containers 12 being preloaded by the filling element 14 during prestressing for the prestressing duration adjusted in step S16.2 and then by the filling element be filled with the filling material.

It is also possible that in normal operating mode it is checked continuously or at predetermined time intervals whether the preload duration needs to be adjusted (again), e.g. B. due to continuous wear of the filling element 14, such as on the movable valve member of the filling valve 16. For this purpose, for example, the method according to Figure 5 or Figure 6 are applied, whereby if the termination criterion is directly met in step S15, there is preferably no adjustment of the preload duration.

The referring to the Figures 5 and 6 The methods described can be carried out separately for each filling element 14 of the filling device 10, if desired and to the extent that the filling device 10 has several filling elements 14. The process can therefore be used for several filling organs 14 of the filling device 10 is applied individually to the filling element for adjusting the respective preload duration to the individual filling element.

In an extension of the method, a state of wear of the filling element 14 can also be determined. The determined state of wear can preferably relate to wear of the filling valve 16 or the preload valve 18. For example, the state of wear can be deduced based on a historical development of recorded flows, which are recorded, for example, during normal operation of the filling device 10, or a historical development of adjusted preload durations. If the flow changes historically for the same adjusted preload value by a certain value, e.g. B. ≥ 10%, this can be an indication of advanced wear of the filling element 14. For example, a movable valve member of the filling valve 16 or the biasing valve 18 can be difficult to move and therefore have a longer switching time or dead time.

Information regarding the determined state of wear can, for example, be output by the control device via a user interface of the filling device 10.

It is also possible that, if several filling elements 14 are present, these several filling elements 14 are compared with one another with regard to their respective adjusted preload duration, e.g. B. from the control device. For example, an average value of the pre-stressing durations adapted to the filling element can be determined using the control device, e.g. B. be calculated. It can then be checked whether one (or more) of the pre-stressing times adapted to the individual filling element has been increased by at least a predetermined value, e.g. B. 50 ms, or by at least a percentage, e.g. B. between 5% and 20%, deviates from the determined mean. If, for example, the adjusted preload duration of a filling element 14 is significantly longer than for other filling elements 14, the movable valve member of the filling valve 16 or the preloading valve 18 may be stiff in this filling element 14, opens more slowly and therefore has a longer dead time or switching time . Preventive maintenance may be recommended. You can also react to external changes, e.g. B. when the working pressure is changed or the filling pressure changes.

Those filling elements 14 whose adjusted preload duration deviate from the determined mean value by at least the predetermined value or percentage can, for example, be marked in terms of control technology and/or corresponding information can be output by the control device via a user interface of the filling device 10. The affected filling elements 14 can then be serviced or replaced, for example.

The invention is not limited to the preferred embodiments described above. Rather, a large number of variants and modifications are possible, which also make use of the inventive idea and therefore fall within the scope of protection. In particular, the invention also claims protection for the subject matter and features of the subclaims, regardless of the claims referred to. In particular, the individual features of independent claim 1 are each disclosed independently of one another. In addition, the features of the subclaims are also disclosed independently of all features of independent claim 1. All range information herein is to be understood to be disclosed in such a way that all values falling within the respective range are disclosed individually, e.g. B. also as preferred narrower external boundaries of the respective area.

Reference symbol list

10

Filling device

12

container

14

Filling organ

16

Fill valve

18

Bias valve

20

filling tank

22

Flow measuring device

S10 - S18

Procedural steps

p

Pressure

t

Time

Q

flow rate

A

Switching signal

b

Pressure history

Claims (15)

Method for operating a filling device (10), comprising: Pre-stressing a container (12) with a clamping gas for a pre-stressing period by means of a filling element (14) of the filling device (10); Filling the prestressed container (12) with a filling material by means of the filling element (14); Detecting a flow of the filling material during the filling of the prestressed container (12) by means of a flow measuring device (22) of the filling device (10); and Adjusting the preload duration for at least one subsequent container (12) depending on the detected flow by means of a control device of the filling device (10). A method according to claim 1, wherein: the method is initially used to adjust the filling device (10), and/or the method for adjusting the filling device (10) is used during normal operation of the filling device (10). A method according to claim 1 or claim 2, wherein: the bias time during adjustment is reduced if the sensed flow remains substantially constant during filling; and or the bias duration is increased during adjustment if the detected flow overshoots at the start of filling and/or drops during filling. Method according to one of the preceding claims, wherein:
the preload duration is adjusted, preferably reduced or increased, when adjusting by a predetermined period of time, preferably in the two-digit ms range, or by a predetermined percentage value, preferably in the single-digit % range. Method according to one of the preceding claims, wherein:
To iteratively adjust the preload duration, preloading, filling, capturing and adjusting is repeated until a termination criterion is met. A method according to claim 5, wherein:
the preload duration is gradually reduced during iterative adjustment until the termination criterion is met. A method according to claim 6, wherein:
is successively reduced by a predetermined period of time, preferably in the two-digit ms range, or by a predetermined percentage value, preferably in the single-digit % range. Method according to one of claims 5 to 7, wherein:
if the termination criterion is met, the preload duration during adjustment is increased by a predetermined safety value, preferably in a range between ≥ 20 ms and ≤ 80 ms, particularly preferably between ≥ 35 ms and ≤ 65 ms, for example around 50 ms. Method according to one of claims 5 to 8, wherein: the termination criterion requires that the sensed flow decrease during filling; and or the termination criterion requires that the sensed flow overshoots at the start of filling. Method according to one of claims 5 to 9, wherein:
the termination criterion requires that a specified number of iteration steps be reached. Method according to one of the preceding claims, wherein:
the filling device (10) is operated after adjusting the preload duration or after iteratively adjusting the preload duration in normal operation during preloading with the adjusted preload duration by means of the control device. Method according to one of the preceding claims, further comprising:
Determining a wear state of the filling element (14), preferably a filling valve (16) and/or a biasing valve (18) of the filling element (14), depending on a historical development of recorded flows and/or a historical development of adjusted preloading durations by means of the control device . Method according to one of the preceding claims, wherein:
the method is used for several filling elements (14) of the filling device (10) individually for each filling element in order to adapt the respective pre-stressing duration to the individual filling element. The method of claim 13, further comprising: Determining an average value from the pre-stressing durations adapted to each filling element by means of the control device; and Checking whether one of the pre-stressing durations adapted to the individual filling element deviates from the determined mean value by at least a predetermined value or by at least a predetermined percentage, using the control device; and optional outputting information about the testing to a user using a user interface of the filling device (10). Filling device (10), preferably rotary filling device or linear filling device, for filling containers (12), comprising: at least one filling element (14) for pre-stressing a container (12) with a tension gas and filling the pre-stressed container (12) with a filling material; at least one flow measuring device (22) for measuring a flow of the filling material to the at least one filling element (14); and a control device configured to operate the filling device (10) according to a method according to one of the preceding claims.

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