Method for operating a filling system and filling system

Patent metadata

Field	Value
Publication number	US-11952253-B2
Application number	US-202218068820-A
Country	US
Kind code	B2
Filing date	Dec 20, 2022
Priority date	Dec 21, 2021
Publication date	Apr 9, 2024
Grant date	Apr 9, 2024

Abstract

A method for operating a filling system with first and second filling points is disclosed. The first filling point has a first unit for controlling and monitoring the filling of the first filling point. The second filling point has a second unit for controlling and monitoring the filling of the second filling point. The first and second units are connected via a communication channel. In an operating state, the first filling point switches to diagnostic mode. The first unit reports the diagnostic start to the second unit. The first unit outputs substitute flow rate or level values. The second unit transmits a deviation message to the first unit in the event of a deviation of the current flow or level value from an expected value. After receipt of the deviation message, the first unit interrupts diagnostic mode and switches to normal operation or outputs corrected substitute flow or level values.

First claim

The invention claimed is:

1. A method for operating a filling system, wherein the filling system has at least one first filling point and at least one second filling point, wherein the first filling point has at least one first filling valve, at least one first flow or fill level sensor and at least one first control and evaluation unit for controlling and monitoring the filling process of the first filling point, and wherein the second filling point has at least one second filling valve, at least one second flow or fill level sensor and at least one second control and evaluation unit for controlling and monitoring the filling process of the second filling point, wherein a valve curve of the first filling valve is stored in the first control and evaluation unit, and wherein a valve curve of the second filling valve is stored in the second control and evaluation unit, and wherein the first control and evaluation unit and the second control and evaluation unit are connected to one another via a communication channel, the method comprising:
in the operating state of the filling system, switching the first filling point to diagnostic mode;
reporting, by the first control and evaluation unit, the diagnostic start to the second control and evaluation unit;
outputting, by the first control and evaluation unit, substitute flow rate or substitute filling level values during the diagnostic mode;
transmitting, by the second control and evaluation unit, a deviation message to the first control and evaluation unit in the event of detection of a deviation of the current flow or level value from the flow or level value expected on the basis of the valve curve; and
after receipt of the deviation message, interrupting diagnostic mode and switching to normal operation, or outputting corrected substitute flow or substitute level values, by the first control and evaluation unit.

2. The method according to claim 1 , wherein the substitute flow or substitute filling level values are determined by the first control and evaluation unit on the basis of the current valve position of the first filling valve and the valve curve stored in the first control and evaluation unit.

3. The method according to claim 1 , wherein the second control and evaluation unit transmits current flow or fill level values to the first control and evaluation unit and the first control and evaluation unit outputs these current flow or fill level values as substitute flow or substitute fill level values.

4. The method according to claim 1 , wherein flow rate or fill level values from at least one past filling cycle are stored in the first control and evaluation unit, and the first control and evaluation unit outputs these stored flow rate or fill level values as substitute flow rate or substitute fill level values; or
wherein flow or fill level values from at least one past filling cycle are stored in the second control and evaluation unit, and the second control and evaluation unit transmits these stored flow or fill level values to the first control and evaluation unit and the first control and evaluation unit outputs these flow or fill level values transmitted by the second control and evaluation unit as substitute flow or substitute fill level values.

5. The method according to claim 1 , wherein the filling system has at least one third filling point, wherein the third filling point has at least one third filling valve, at least one third flow or fill level sensor, and at least one third control and evaluation unit for controlling and monitoring the filling process of the third filling point, wherein a valve curve of the third filling valve is stored in the third control and evaluation unit, and wherein the third control and evaluation unit is connected via a communication channel at least to the second control and evaluation unit;
wherein, in the diagnostic mode of the first filling point, the second control and evaluation unit compares a currently measured flow or fill level value with the flow or fill level value expected on the basis of the valve curve stored in the second control and evaluation unit;
wherein the third control and evaluation unit compares a currently measured flow or fill level value with the flow or fill level value expected on the basis of the valve curve stored in the third control and evaluation unit;
wherein, in the event of a deviation of the current flow or fill level values from the flow or fill level values expected on the basis of the valve curves, the second control and evaluation unit and the third control and evaluation unit determine and compare with one another the degree and/or the direction of the deviations and, in the event of a similar deviation, the second control and evaluation unit and/or the third control and evaluation unit transmit or communicate the degree and/or the direction of the deviation to the first control and evaluation unit; and
wherein the first control and evaluation unit corrects the valve curve of the first filling valve by the measure and/or the direction of the deviation and the first control and evaluation unit outputs a corrected substitute flow rate or substitute filling level value determined with the corrected valve curve.

6. The method according to claim 1 , wherein in diagnostic mode, in the event of detection of a error state, the first control and evaluation unit:
transmits an inquiry about a diagnostic result to the second control and evaluation unit and/or—if present—to the third control and evaluation unit, and wherein the second control and evaluation unit and/or the third control and evaluation unit—if present—transmits a diagnostic result to the first control and evaluation unit; and
transmits the diagnostic result justifying the error state to the second control and evaluation unit and/or the third control and evaluation unit—if present;
wherein the diagnostic result of the first control and evaluation unit is compared with the diagnostic result of the second control and evaluation unit and/or—if present—the third control and evaluation unit;
wherein in the case of an identical diagnostic result, a process error of the filling system is concluded; and
wherein in the case of a different diagnostic result, a filling point error of the first filling point is concluded.

7. A filling system for filling media into containers, comprising:
at least one first filling point; and
at least one second filling point;
wherein the first filling point has at least one first filling valve, at least one first flow or fill level sensor and at least one first control and evaluation unit for controlling and monitoring the filling process of the first filling point;
wherein the second filling point has at least one second filling valve;
wherein the first filling point has at least one second flow or fill level sensor and at least one second control and evaluation unit for controlling and monitoring the filling process of the second filling point, at least one second flow or fill level sensor and at least one second control and evaluation unit for controlling and monitoring the filling process of the second filling point;
wherein a valve curve of the first filling valve is stored in the first control and evaluation unit;
wherein a valve curve of the second filling valve is stored in the second control and evaluation unit, and wherein the first control and evaluation unit and the second control and evaluation unit are connected to one another via a communication channel;
wherein the first control and evaluation unit is designed to report the diagnostic start to the second control and evaluation unit after transition to a diagnostic mode;
wherein the first control and evaluation unit is further designed to output substitute flow rate or substitute fill lev

Assignees

• Krohne Messtechnik Gmbh

Inventors

• Kuschnerus Dirk
• Walbrecker Sven
• Mucke Hansjörg
• Krawczyk-Becker Martin

Classifications

• B67C3/287 Primary

  related to flow control using predetermined or real-time calculated parameters · CPC title

• B65B3/26

  Methods or devices for controlling the quantity of the material fed or filled · CPC title

• B67C3/282 Primary

  related to filling level control (B67C3/2617, B67C3/2625 take precedence) · CPC title

• B67C3/286

  related to flow rate control, i.e. controlling slow and fast filling phases · CPC title

• B67C3/288

  using leader-follower controls · CPC title