Method for operating a filling system and filling system

Patent metadata

Field	Value
Publication number	US-12535836-B2
Application number	US-202217934718-A
Country	US
Kind code	B2
Filing date	Sep 23, 2022
Priority date	Sep 24, 2021
Publication date	Jan 27, 2026
Grant date	Jan 27, 2026

Abstract

A method for operating a filling system includes: determining a current valve curve of a first filling valve and a current valve curve of a second filling valve; comparing the current valve curve of the first filling valve with a reference valve curve of the first filling valve and comparing the current valve curve of the second filling valve with a reference valve curve of the second filling valve; adjusting a number of filling points at which the current valve curve differs from the associated reference valve curve; detecting and signaling a filling point error in the event of a deviation of the valve curve from the reference valve curve at one filling point; and detecting and signaling a process error in the case of deviation of the valve curve from the reference valve curve at both filling points.

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, at least one second filling point and at least one control and evaluation unit for controlling and monitoring the filling processes, wherein the first filling point has at least one first filling valve and at least one first flow or fill level sensor and wherein the second filling point has at least one second filling valve and at least one second flow or fill level sensor, and wherein a reference valve curve of the first filling valve and a reference valve curve of the second filling valve are stored in the control and evaluation unit, the method comprising:
a determination step, in which the control and evaluation unit determines a current valve curve of the first filling valve and a current valve curve of the second filling valve in an operating state of the filling system; a comparison step, in which the control and evaluation unit compares the current valve curve of the first filling valve with the reference valve curve of the first filling valve and compares the current valve curve of the second filling valve with the reference valve curve of the second filling valve; an adjustment step, in which the control and evaluation unit adjusts the number of filling points at which the current valve curve differs from the associated reference valve curve; and a signaling step, in which the control and evaluation unit detects and signals a filling point error at the corresponding filling point in the event of a deviation of the valve curve from the reference valve curve at one filling point, and detects and signals a process error in the case of deviation of the valve curve from the reference valve curve at both filling points.

2 . The method according to claim 1 , wherein the control and evaluation unit has at least a first sub-unit and a second sub-unit;
wherein the first sub-unit implements the control and monitoring of the first filling point and the second sub-unit implements the control and monitoring of the second filling point; wherein the first sub-unit and the second sub-unit are connected to one another via a communication channel; and wherein, in the adjustment step, the first sub-unit and the second sub-unit exchange and adjust deviation information of the current valve curves from the corresponding reference valve curves.

3 . The method according to claim 1 , wherein in the adjustment step, at least one of the measure and the direction of the deviation of the valve curves from the reference valve curves of the filling valves of the filling points is/are adjusted; and
wherein in the signaling step, a process error is then detected and signaled, when at least one of: (i) the degree of deviation of the valve curves from the reference valve curves of both filling valves is within a predetermined tolerance range; and (ii) the direction of deviation of the valve curves from the reference valve curves of both filling valves is the same.

4 . The method according to claim 1 , wherein in the case of a deviation of the valve curves from the reference valve curves beyond a predetermined first tolerance range, the filling valves are recalibrated by adapting the valve curves of the respective filling valves.

5 . The method according to claim 1 , wherein in the event of a deviation of the valve curves from the reference valve curves beyond a predetermined second tolerance range, a serious process error is at least one of: (i) detected and signaled; and (ii) operation of the filling system is stopped.

6 . The method according to claim 1 , wherein a reference valve speed for at least one of the first filling valve and the second filling valve is stored in the control and evaluation unit; and
wherein, in an additional step, the control and evaluation unit determines the valve speed of at least one of the first filling valve and the second filling valve and compares it with the reference valve speed of the corresponding filling valve, and that, in the event of a deviation of the valve speed from the reference valve speed, the corresponding filling valve is recalibrated.

7 . The method according to claim 1 , wherein, in the event of a filling point error being detected, the control and evaluation unit actuates the filling valve of the faulty filling point with a predetermined number and type of control commands and monitors the reaction of the filling valve to the control commands; and
wherein, if the reaction of the filling valve deviates from the expected reaction, a valve error of a first type is detected at least one of: (i) with the filling point being put out of operation; and (ii) with a request for replacement of the filling valve being issued; or wherein, if the reaction of the filling valve does not deviate from the expected reaction, a valve error of a second type or a sensor error is detected at least one of: (i) with the filling point being put out of operation; and (ii) with a request for replacement of the filling valve and of the flow or level sensor being issued.

8 . The method according to claim 1 , wherein, in the event of a filling point error being detected, the faulty filling point is checked with the aid of an external testing means;
wherein the fill level of the filled container is determined with the aid of an external testing means in order to check the filling point after a container has been filled and that a valve error or a sensor error is concluded on the basis of the degree of filling and the direction of the deviation of the valve curve from the reference valve curve; wherein at least one of: (i) the faulty filling point is put out of operation; and (ii) a request to replace the filling valve or to replace the flow or level sensor is issued.

9 . A filling system, comprising:
at least one first filling point; at least one second filling point; and at least one control and evaluation unit for controlling and monitoring the filling processes; wherein the first filling point has at least one first filling valve and at least one first flow or fill level sensor; wherein the second filling point has at least one second filling valve and at least one second flow or fill level sensor; wherein a reference valve curve of the first filling valve and a reference valve curve of the second filling valve are stored in the control and evaluation unit; wherein the control and evaluation unit is designed in such a way that, in a determination step, it determines a current valve curve of the first filling valve and a current valve curve of the second filling valve; wherein, in a comparison step, it compares the current valve curve of the first filling valve with the reference valve curve of the first filling valve and compares the current valve curve of the second filling valve with the reference valve curve of the second filling valve; wherein, in an adjustment step, it adjusts at how many of the filling points a deviation of the current valve curve from the associated reference valve curve occurs; and wherein, in a signaling step, in the event of a deviation of the valve curve from the reference valve curve at one filling point, it detects and signals a filling point error of the corresponding filling point, and in the case of a deviation of the valve curve from the reference valve curve at both filling points, it detects and signals a process error.

10 . The filling system according to claim 9 , wherein the control and evaluation unit has at least a first sub-unit and a second sub-unit;
wherein the first sub-unit implements the controller of the first filling point and the second sub-unit implements the controller of the second filling po

Assignees

• Krohne Messtechnik Gmbh

Inventors

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

Classifications

• G05D9/12

  characterised by the use of electric means · CPC title

• G05D7/0623 Primary

  characterised by the set value given to the control element · CPC title

• B67C3/287

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

• B67C3/007 Primary

  Applications of control, warning or safety devices in filling machinery (flow-control B67C3/28) · CPC title