Filling process

The filling system adjusts the initial position of the position sensor above the drive cylinder in each metering cylinder module unit according to the preset micro-adjustment value, which is used as the reference benchmark for the micro-adjustment of the filling volume of each metering cylinder module unit; the controller starts each metering cylinder module unit to carry out the filling work; the controller detects the position sensor's output signal of each metering cylinder module unit, and starts the corresponding timer accordingly. The controller detects the micro-adjustment information of each metering cylinder module unit, and controls the driving cylinder of the corresponding metering cylinder module unit to return to the suction; for the detection and calculation of the filling error of each metering cylinder module unit, after the micro-adjustment of each metering cylinder module unit, the controller collects and receives the filling amount of each metering cylinder module unit, and calculates the error based on the currently required filling amount; for the filling error, the controller collects and receives the filling amount of each metering cylinder module unit according to the current error calculation of filling amount; for the qualified judgment, the controller collects and receives the filling amount based on the current filling amount obtained. Qualified judgment, the controller analyzes and determines the filling volume error of each metering cylinder module unit based on the filling volume error obtained from the calculation in step 5, so that the filling volume error of each metering cylinder module unit meets the qualified requirements.

Principle of Filling Volume Adjustment

Multihead filling machine a number of metering cylinder module unit set up in the drive cylinder above the position of the sensor position, is the drive cylinder piston upward movement of the return point. At the beginning of each filling cycle, first by the controller (the controller can be used programmable controller PLC or microcontroller system) at the same time drive each group of metering cylinder module unit of the drive cylinder piston upward, driven metering cylinder piston began to material filling operations. Then the controller constantly detects the driving cylinder above the position sensor output signal, once found that a group of driving cylinder piston to reach the return point, it will make its return downward movement, driven by the metering cylinder piston for the suction operation, until all the metering cylinder module unit have completed the suction operation, a complete filling cycle that is the end. Through repeated, fine-tuning the position of the position sensor on the drive cylinder in each metering cylinder module unit by hand, it can realize the fine-tuning of the filling volume of the winter metering cylinder module unit. The output signal from the position sensor below the drive cylinder (which can also not be installed) reflects the initial position of the drive cylinder, and this signal can be collected by the controller for control purposes.

Recyclables Detection

For the efficiency of the recycled bottle filling machine, the recyclables detection equipment plays a decisive role. With the increasing number of bottle types on the market and the mixing of recycled bottles, the empty bottles must be accurately inspected to avoid malfunctions during unloading and too high a proportion of foreign bottles on the conveyor belt. Empty bottle inspection equipment examines crates with different criteria to determine their unloadability, the percentage of foreign bottles and the mix of glass and plastic bottles. Ultrasonic methods can be used to determine the height of bottles and to identify foreign objects inside the bottles. For example, PET bottles can be identified by different residual rings. If the bottles have the same shape but differ in color, they can be differentiated using a color camera.

Empty case inspection

Empty boxes need to be tested after unloading to determine if they can be used directly in the production of the batch. The boxes must not be damaged, must not have foreign objects, and the color and markings must be consistent with the product. These three characteristics are now generally inspected with a camera system. A new trend in current foreign object detection is the increased use of sturdy ultrasonic measurements when identifying plastic bottles that are fixedly inserted in a grid. Since other foreign objects generally fall out when turned over, this low-cost approach is also a good alternative.

Sorting empty bottles

Due to the very high mixing ratios nowadays, it is not possible to separate all foreign bottles in the box conveyor area. Therefore, crates containing a small number of foreign bottles are also unloaded. These foreign bottles are sorted on a bottle conveyor. The most important part of the bottle sorting is a camera system with image processing, which measures the shape of the bottles and compares it with the standard shape of the batch. Depending on the requirements, this can be supplemented by color measurements and checking for the presence of caps. For the evaluation of the results, a proven fuzzy logic system is used. With this technology, a comprehensive evaluation of individual identifications is possible, which improves the accuracy of bottle shape identification.

Empty bottle inspection

The washed and sorted bottles are checked again for their specifications before entering the empty bottle inspection machine. For example, incoming bottle sorting equipment recognizes bottles with broken necks in the bottle washer and separates them before the empty bottle inspection machine to avoid equipment malfunction and damage. Thereafter, the bottles undergo different inspections within the empty bottle inspection machine. According to the structure of the equipment and the internal conveyor, empty bottle inspection can be divided into two types: in the past, only so-called rotary equipment was available; more recently, linear equipment has also been used on many occasions. Most of the empty bottle inspection technology consists of a camera system. The various areas of the bottle are usually imaged using a CCD camera. For bottle bottom and bottle top inspection, only one picture is usually needed. For transparent foreign objects, e.g. transparent films, special optics are often required and a secondary inspection of the bottle bottom is needed. Sidewall inspection is more complex based on the shape of the surface to be inspected. Images have to be taken in different positions so that the entire circumference can be inspected, which can be accomplished either by taking multiple photographs of the bottle as it rotates or by using a mirror system that extends the viewing angle of the camera. For high-performance empty bottle inspection equipment, a combination of both methods is used. Another important item is residual liquid detection with the aid of high frequency and far infrared technology to identify residual bases, oils and paints on the bottom of the bottle.

The management of automatic fillers and cappers checks different characteristics during the filling process and directly after the end of filling with samples taken from the production line. During the filling process, the bottles are checked for bursting due to back pressure or filling. If it is recognized that a bottle has burst, its adjacent or subsequent bottles may contain broken glass, which can be punched out in a subsequent level detection device. In order to avoid bottles that may contain broken glass being put back on the liquid filler line (because it is not visible to the operator, who assumes it is a certified product), these bottles are forced to be filled to a low liquid level. Similarly, the flushing of the associated filling guns can be controlled by a detection system. At the exit of the filling and capping machine, other indicators are checked, such as bottle neck air (especially for beer) and sealing. The technology used for level measurement depends on the product and container, the simplest method being photocells. The most commonly used method is radiation absorption, such as roentgen rays or yah rays. This technique has the advantage of being particularly low maintenance, but it requires approval from special authorities and specialized personnel to ensure compliance with radiation protection regulations. As a result of this problem, high-frequency measurement techniques have been promoted, based on the principle that when a container passes through a high-frequency electromagnetic field, the liquid in the neck of the bottle influences and alters that field. This influence can be detected and assessed using measurement. Only with this technique is it possible to measure the volume of a liquid containing foam. For this, specialized software is required to measure several parameters of the electromagnetic field and compare them with statistical benchmark values.

Modernized testing systems

Modern inspection instruments not only have to be able to exclude low and high level products, but also require statistical functions, e.g. which filling gun is experiencing low levels at what intervals. This data can simplify repair and maintenance work, help maintenance personnel to recognize failure trends early, and thus improve the efficiency of the equipment. For cap detection, a light scanner or metal detector can be used to determine if a cap is present, or a more sophisticated imaging system can be used to determine the location of the cap and whether the cap is sealing properly. The latter is more relevant for crown caps, where it can be determined whether the outer teeth of the cap were crushed during capping. Imaging systems are also often used for screw caps to check that the cap is correctly positioned and that the safety ring is not damaged. Recently, there has been a discussion on the safety of product handling, making this issue even more relevant. In the case of glass bottles, the sealing is checked by the condition of the cap, while in the case of plastic bottles, the bottle needs to be checked as a whole. New products are now being introduced in the market that apply pressure on the side walls of the bottle while measuring the reaction of the bottle. If the level rises significantly under pressure, the bottle is not sealed. A high-performance dosing and filling machine management system should include a sampling program. In this way, even the product filled by a particular filling gun can be punched out, as well as the entire circle of products starting from filling gun #1.

Trademark Inspection

After the trademark machine and before boxing, a final look is needed. First, it must be checked that all trademarks are present. This is usually done with an optical scan inside the labeling machine or after the labeling machine. As the demands on product quality and product liability increase, there is a need to add these features to the tester. The use of imaging systems is spreading so that not only is it possible to check for the presence of the logo, but also to check that the printing is correct and that the coding is working properly. In addition to these guidelines in terms of product reliability, the relative positional relationship between the labels has to be scrutinized. Capping inspection can be after the filling machine or installed in this position. Maintenance can be simplified if multiple photo units are housed in a single inspection unit. Frequently, a second level detection device is installed after the trademark machine. By repeating the test, on the one hand, reliability can be increased and on the other hand the measurement is more accurate in this position because the product is fully stabilized here.

Summarizing

Which testing device is more suitable can only be determined on a case-by-case basis. We must clearly see the trend in product liability law and must pay attention to the scalability of each instrument when acquiring filling equipment.