APPARATUS AND METHOD FOR FILLING A CONTAINER WITH A FILLING PRODUCT

Abstract

An apparatus and method for handling a container, comprising filling the container with a filling product, for example with a beverage in a beverage bottling plant, wherein the apparatus has: a valve main body with an outlet for introducing the filling product into the container and with a swirl chamber which is fluidically connected to the outlet and is configured to induce a swirling motion in the filling product as the latter is being introduced into the container; a valve cone which is at least partially arranged in the valve body, defines an axial direction and through which a gas duct penetrates in the axial direction; and a sensor device with a sensor head which is configured to detect at least one signal and is arranged in the gas duct.

Claims

1. An apparatus for filling a container with a filling product, comprising: a valve main body comprising: an outlet configured to introduce the filling product into the container, and a swirl chamber fluidically connected to an outlet and configured to induce a swirling motion in the filling product as the filling product is introduced into the container; a valve cone that is at least partially arranged in the valve main body, defines an axial direction, and through which a gas duct penetrates in the axial direction; and a sensor device comprising a sensor head that is configured to detect at least one signal and is arranged in the gas duct.

2. The apparatus of claim 1, wherein the valve cone is configured to be displaceable in the axial direction to enable flow control of the filling product through the outlet.

3. The apparatus of claim 1, wherein the sensor head comprises a transmit/receive surface that is configured to emit a transmit signal in a direction of the container and to receive a receive signal initiated by the transmit signal.

4. The apparatus of claim 3, wherein the transmit signal comprises an ultrasonic signal, an optical signal, a radar wave, or a microwave.

5. The apparatus of claim 1, further comprising an evaluation device that communicates with the sensor device and is configured to infer one or more measured variables from the at least one signal detected by the sensor device, wherein the one or more measured variables comprises a filling height of the filling product in the container, a gas pressure, a gas composition or a gas concentration in the gas duct and container, a froth quantity/height and/or froth composition in the container, a container position, and/or a structural state of the container.

6. The apparatus of claim 5, further comprising a filling member controller that communicates with the evaluation device and is configured to control and/or to regulate handling of the container, wherein the handling comprises one or more of: positioning the container, pressing the container against a mouth section of the valve main body, introducing a gas through the gas duct into the container, drawing off a gas out of the container through the gas duct, generating a positive pressure in the container, generating a negative pressure in the container, introducing the filling product into the container, relieving the container of load, or removing the container from the mouth section of the valve main body.

7. The apparatus of claim 1, wherein the swirl chamber comprises an annular shape, a cross-sectional contour of which has a round shape in a direction of extent and perpendicularly to the direction of extent.

8. The apparatus of claim 7, wherein the swirl chamber extends substantially axially symmetrically about the valve cone.

9. The apparatus of claim 1, wherein the valve main body further comprises a main inlet that opens tangentially into the swirl chamber and is configured to introduce the filling product or a main component of the filling product into the swirl chamber in such a manner that a swirling motion is induced in the filling product in the swirl chamber.

10. The apparatus of claim 9, wherein at least an axial outer wall of the swirl chamber merges continuously and differentiably into the main inlet, and/or the main inlet in a region of a mouth leading into the swirl chamber has substantially the same cross-sectional contour perpendicularly to a direction of extent as the swirl chamber.

11. The apparatus of claim 1, wherein the outlet is annular, and the swirl chamber tapers towards the outlet, resulting in the filling product, after exiting from the outlet, flowing downward in a spiral movement in the container.

12. The apparatus of claim 1, wherein: the valve main body further comprises a valve seat, and the valve cone and the valve seat are configured such that, in a shut-off position, the valve cone is sealingly in contact with the valve seat for sealing the outlet.

13. The apparatus of claim 1, wherein the valve main body further comprises one or more secondary inlets that open into the swirl chamber and are configured to correspondingly introduce one or more additional components of the filling product into the swirl chamber in such a manner that the additional components are mixed therein with a main component of the filling product.

14. The apparatus of claim 1, wherein the valve main body further comprises: a valve housing that forms at least part of a wall bounding the swirl chamber and the outlet, and a membrane made of a deformable material, the membrane forming a further part of the wall bounding the swirl chamber and the outlet, and being attached at an outer contour to the valve housing.

15. The apparatus of claim 1, further comprising at least one gas path that opens laterally into the gas duct, wherein the least one gas path opens into the gas duct directly below the sensor head.

16. The apparatus of claim 15, wherein the at least one gas path is in a form of a flexible hose, and the at least one gas path opens tangentially into the gas duct.

17. A method for filling a container, comprising: providing an apparatus comprising: a valve main body comprising: an outlet configured to introduce a filling product into the container, and a swirl chamber fluidically connected to an outlet and configured to induce a swirling motion in the filling product as the filling product is introduced into the container, a valve cone that is at least partially arranged in the valve body, and defines an axial direction and through which a gas duct penetrates in the axial direction, and a sensor device comprising a sensor head that is configured to detect at least one signal and is arranged in the gas duct; introducing the filling product into the swirl chamber of the valve main body; inducing a swirling motion in the filling product in the swirl chamber; discharging the swirling filling product from the swirl chamber via the outlet of the valve main body into the container, resulting in the filling product flowing along a container inner wall into the container; and detecting at least one signal that propagates from the container through the gas duct by the sensor head of the sensor device.

18. The method of claim 17, further comprising inferring one or more measured variables from the at least one signal detected by the sensor device.

19. The method of claim 18, wherein the one or more measured variables comprise a filling height of the filling product in the container, a gas pressure, a gas composition or a gas concentration in the gas duct and the container, a froth quantity/height and/or a froth composition in the container, a container position, and/or a structural state of the container.

20. The method of claim 17, further comprising one or more of the following: positioning the container; pressing the container against a mouth section of the valve main body; introducing a gas through the gas duct into the container; drawing off a gas out of the container through the gas duct; generating a positive pressure in the container; generating a negative pressure in the container; introducing the filling product into the container; relieving the container of load; or removing the container from the mouth section of the valve main body.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0061] Further embodiments of the invention will be described in more detail by the following description of the figures.

[0062] FIG. 1 shows a schematic cross section of a filling member with a sensor device, an evaluation device and a filling member controller;

[0063] FIG. 2 shows a perspective sectional view of a valve main body of the filling member with swirl chamber, valve cone and membrane;

[0064] FIG. 3 shows a cross-sectional view of the valve main body from FIG. 2;

[0065] FIG. 4 shows a cross-sectional view of a valve main body with swirl chamber, valve cone and membrane according to a further exemplary embodiment; and

[0066] FIG. 5 shows the valve main body from FIG. 4 in a top view.

DETAILED DESCRIPTION

[0067] Exemplary embodiments will be described below with reference to the figures. Elements which are identical, similar or act in an identical manner are provided with identical reference signs in the figures, and a repeated description of these elements is dispensed with in some cases in order to avoid redundancies.

[0068] FIG. 1 is a schematic cross-sectional view of an apparatus 1 for filling a container 100 with a filling product. The apparatus 1 is also referred to herein as “filling member” or comprises such a filling member. Products to be bottled include in particular beverages, for example water, soft drinks, beer, mixed drinks and the like. In some embodiments, carbonated beverages are bottled by the filling member 1.

[0069] The filling member 1 comprises a valve main body 10. FIG. 2 is a perspective view of the valve main body 10. FIG. 3 shows the valve main body 10 in a cross-sectional view.

[0070] The valve main body 10 has a swirl chamber 11 designed as an annular duct or torus. The valve main body 10 furthermore has a main inlet 12 which is not visible in the perspective view in FIGS. 1, 2 and 3 and opens tangentially or substantially tangentially into the swirl chamber 11. The main inlet 12 is shown in the exemplary embodiment of FIGS. 4 and 5.

[0071] In the lower region of the valve main body 10, the swirl chamber 11 tapers towards an annular outlet 13, from which the filling product exits during the bottling operation and runs into a container 100 placed below the valve main body 10.

[0072] It should be mentioned that spatial terms, such as “under”, “below”, “over”, “above”, etc., refer to the installed position of the filling member 1, which is clearly determined by the direction of gravity. Furthermore, the annular outlet 13 means that the filling member 1 or the valve main body 10 thereof has a clearly defined axial direction which, in the installed state, coincides at least substantially with the direction of gravity.

[0073] The tangential supplying of the filling product from the main inlet 12 into the swirl chamber 11 induces a swirling motion in said filling product, as a result of which the filling product is driven outwards due to centrifugal force and, after exiting the valve main body 10, passes further outwards and flows downwards on the container wall. The tapering or constriction of the swirl chamber 11 towards the outlet 13 firstly leads to a uniform, well-defined swirling motion across the periphery and, secondly, is a significant determining factor for the flow rate. If the degree of tapering, in particular the size of the annular gap at the outlet 13, is adjustable, an integrated flow control can therefore be realised, optionally including the shutting-off thereof

[0074] The aforementioned flow control can be implemented as follows: according to the exemplary embodiment of FIGS. 1, 2 and 3, the valve main body 10 for this purpose has a valve cone 14 which has a cylindrical shape tapering towards the outlet 13. The annular gap adjoining the swirl chamber 11 is at least partially formed on the inside by the outer peripheral surface of the valve cone 14. On the outside, the annular gap is defined and/or formed by a valve housing 15. According to the present exemplary embodiment, the valve cone 14 is configured to be displaceable in the axial direction, i.e. upwards and downwards. The annular gap can thereby be enlarged and reduced at the outlet 13. The height adjustment of the valve cone 14 is undertaken, for example steplessly, within a working region, i.e. between a fully open position and a closed position or a position of minimum flow. If, by the internal shape of the valve housing 15, a valve seat 16 is formed which is in sealing contact with the valve cone 14 in a closed position of the filling member 1, the outlet 13 can be completely closed, as a result of which a shutting-off function is realised.

[0075] The lateral main inlet 12, i.e. opening tangentially into the swirl chamber 11, also provides space above the swirl chamber 11, in addition to the aforementioned technical effects. The space is unobstructed and can be used for mounting a membrane 17, which seals the swirl chamber 11 in the upper region.

[0076] The membrane 17 has a circular outer contour which is attached directly or indirectly via a fastening means to the valve housing 15. The membrane 17 is fastened radially on the inside to the valve cone 14. The membrane 17 is produced from a flexible material, for example Teflon, as a result of which it can follow the axial movement of the valve cone 14 and at the same time ensures hygienic sealing of the swirl chamber 11. The symmetry of the membrane 17 also permits an embodiment with a high load cycle, as is generally required for filling members 1.

[0077] The valve main body 10 furthermore has a gas duct 18 which centrally penetrates the valve cone 14 in the axial direction. The gas duct 18 serves for introducing a gas, such as, for example, flushing gas, pressurising gas and the like, and acts at the same time as a return gas duct in order to divert any gas which has to be removed during gas exchange and/or is displaced out of the container 100 during the filling operation. However, the gas duct 18 can also be realised as a multi-duct construction, for example a pipe-in-pipe construction, for example in order to provide separate supply and exhaust gas paths.

[0078] Opening laterally into the gas duct are one or more gas paths 18a, 18b, for example a gas feed line 18a, in order to supply the gas—pressurising gas, flushing gas, etc.—to the gas duct 18, and a gas-diverting line 18b in order to divert gas out of the container 100. The gas paths 18a, 18b are in some embodiments each designed as a flexible hose, as a result of which they can compensate for the axial movement of the valve cone 14.

[0079] The valve cone 14 ends essentially directly below a throttle point, i.e. the narrowest point of the annular gap forming the outlet 13, as a result of which a defined change from a single-phase separated flow to a wall film flow is realised in the container 100. Thus, a well-defined uniform separation edge of the liquid is formed, specifically at the point with the greatest flow rate. The valve seat 16, i.e. the shut-off point, is in several embodiments located in the immediate vicinity of the separation edge, as a result of which the surfaces which could lead to dripping are minimised.

[0080] The valve cone 14 is in one or more embodiments produced from Teflon, as a result of which the outflow behaviour is improved owing to the low surface energy. If, in addition, the valve housing 15 is produced from stainless steel, a full seal can also be ensured by such a material pairing, even in the event of high pressure differences.

[0081] Apart from the valve cone 14, the valve main body 10 does not require swirl bodies, for example guide vanes or swirl ducts, or additional flow guides, and is therefore highly hygienic and tolerant to disperse solid/liquid mixtures which contain, for example, pieces of fruit, slurry, fruit fibres or the like. Furthermore, the size of the pieces in the flow is scarcely restricted because of the lack of swirl bodies. In order to bottle large pieces, for example having volumes of 5×5×5 mm or more, the valve cone travel during the filling operation can be flexibly increased.

[0082] The valve main body 10 is particularly suitable for the aforementioned wall bottling, in which the filling product runs downwards spirally on the inner wall of the container. However, a filling member 1 provided with the valve main body 10 can also be used as a free-jet valve. In this case, the valve main body 10 can be used as a hygienic control valve, by the latter being installed in a corresponding filling product line with an adjoining steadying section and optionally a gas barrier at the outlet. If required, the swirling motion can be removed through a radial main inlet 12, instead of a tangential one.

[0083] The valve main body 10 permits complete flushing out of the valve interior, in particular the swirl chamber 11 and the outlet 13 adjoining the latter in the filling direction, with a minimum quantity of flushing fluid, owing to the high turbulence that can be achieved in the swirl chamber 11, and a comparatively small surface area. For this reason, the valve main body 10 is particularly suitable for a frequent change of filling product, for example including the container, in particular of components to be metered in. Owing to the particularly effective capacity for flushing out, the valve main body 10 can also be used in aseptic filling machines.

[0084] The integration of control and shut-off function in the valve main body 10 permits a reduction in the number of components and a simplification of the product path. This leads to lower pressure losses and contributes to a more careful handling of the product and to reduced frothing during the filling operation.

[0085] The compact design of the valve main body 10 additionally permits a hygienic integration of the valve cone drive and optionally of further control functions in the valve head, i.e. above the swirl chamber 11, for example an integration of gas valves for pressurising the containers 100, return gas lines, depressurising lines, solenoid valves for further separate control functions in the region of the filling member 1, such as lifting and lowering a valve, metering in components, and the like. Similarly, for example, a control circuit board for realising non-central control architectures can be installed in the valve head.

[0086] Since the filling member 1 with the valve main body 10 can be extended modularly and, in addition, can be used for wall bottling and for free-jet filling or for products to be bottled at atmospheric pressure, the multiplicity of variants of filling members for different applications is reduced. Therefore, the effort in terms of care and maintenance and the number of machine variants are reduced. Bottling plants which are equipped with filling members 1 of the type described herein are universally useable. A great diversity of different beverages, container formats and container materials (PET, glass, can, still, carbonated, etc.) can be bottled with them.

[0087] FIG. 4 is a cross-sectional view of a valve main body 10 with swirl generation according to a further exemplary embodiment. A plan view of the valve main body 10 is shown in FIG. 5. The basic construction and the technical functions associated therewith are similar to the exemplary embodiment of FIGS. 1, 2 and 3. However, the valve main body 10 according to FIGS. 4 and 5 has a functional scope which is extended in relation to the above-described embodiment variants.

[0088] The valve main body 10 thus has two further inlets which are denoted herein as first and second secondary inlets 12a, 12b. The number of two secondary inlets 12a, 12b is only by way of example and can vary depending on the intended use.

[0089] The secondary inlets 12a, 12b permit the supply of further components, which are also referred to herein as additional component(s), directly into the swirl chamber 11. In order to be able to meter the quantities of additional components, the secondary inlets 12a, 12b can be provided in each case with a metering valve 19a. The metering valve associated with the secondary inlet 12b cannot be seen in the perspective view of FIG. 4 but can be designed in the same way as the metering valve 19a.

[0090] By means of the secondary inlets 12a, 12b, additional components are admixed directly in the swirl chamber 11, thus ensuring an effective capacity for flushing out the valve main body 10 and minimising any potential migration of flavourings. Owing to the integration of the supply of metered components into the valve housing 15, no hoses or additional lines are required. The valve main body 10 is thereby particularly suitable for an instant change of product.

[0091] The valve main body 10 is in many respects of modular construction and can thus be functionally extended and adapted in a simple manner. The membrane 17 has a clamping portion 17a which is configured for fastening in the valve housing 15. The clamping portion 17a is an annular structure which can be fastened to the membrane 17 as an integral part thereof or as a separate element. In the radially inner region, the membrane 17 is fastened to the valve cone 14.

[0092] A material pairing of Teflon for the valve cone 14 and for the membrane 17 is suitable in one or more embodiments. The flexibility of the membrane and the composition of the material assist in bottling the filling product with a swirling motion, even in the event of very small filling streams. In addition, any unintended local maximum flow at the start of a bottling operation, before a uniform flow is set with a swirling motion, is counteracted. In combination with a valve cone 14 made of Teflon which optimises the outflow behaviour owing to low surface energy, a uniform, steady and uninterrupted bottling can thus be realised with short filling times.

[0093] The modular construction enables different membranes 17 and/or valve cones 14 with different flow and bottling properties to be used and combined without the entire valve main body 10 having to be redesigned. The remaining valve main body 10, in particular the valve housing 15, can be an invariable, standardised component, while the valve properties can easily be varied by the structural unit consisting of valve cone 14 and membrane 17. In this way, for example, the size of the swirl chamber 11, the shape of the valve cone 14, in particular the outlet contour thereof, the pressurising position and the pressurising force of the valve cone 14 can be modified by the membrane 17 and the like in a simple manner and adapted to the desired application environment.

[0094] Returning to FIGS. 1 and 4, a possible attachment of a bottle-shaped container 100 to a mouth section 15c of the valve housing 15 is shown therein. The container 100 has a container mouth 101 which is in contact with the mouth section 15c in the wall bottling mode, as a result of which the filling product, in which a swirling motion is induced by the swirl chamber 11 during the bottling operation, flows downwards under the action of the centrifugal force in a spiral movement on the container wall.

[0095] The tangential main inlet 12 set forth above leaves the upper side of the valve main body 10 unobstructed in such a way that one or more modular valve components can be attached. In addition, the wall bottling of the filling product means that the space on the axis of the container 100 is filled only with gas, and therefore said central sections of the filling member 1 can be used for a sensor device 20, the construction and function of which are set forth below with respect to FIG. 1.

[0096] The sensor device 20 has a sensor housing 21 which extends upwards in one embodiment centrally as an extension of the valve cone 14 or of the gas duct 18. The sensor device 20 furthermore has a sensor head 22 with a transmit/receive surface 22a.

[0097] The sensor device 20 is in one embodiment designed as an ultrasonic reflex scanner or ultrasonic sensor. In this case, the gas duct 18 and the container wall form a resonance space for the ultrasonic signal. The container base or the liquid surface act as reflection surfaces. However, the sensor device 20 can also implement a different measuring principle or measuring method, such as, for example, an optical measurement or a measuring method based on radar waves or microwaves.

[0098] By means of the compact construction of the filling member 1, the sensor head 21 can be positioned at a very short distance from the container mouth 101, as a result of which a large sensor field of view S can be achieved. This is furthermore assisted by the swirling motion of the filling product, as a result of which a stable “eye” is formed during the bottling operation, through which the sensor head 21 can “look” without disturbance. As a result, there are two possibilities, of either using the sensor device 20 directly as a filling level sensor which detects the removal of the liquid surface of the filling product in the container 100 by the sensor head 22, or of additionally installing a filling level sensor (not shown in the figures).

[0099] One, a plurality of or all of the gas paths 18a, 18b open in various embodiments essentially directly below the sensor head 22 into the gas duct 18. Soiling of the transmit/receive surface 22a can thereby be suppressed or at least reduced by the synergetic effect of the gas flows in the gas duct 18.

[0100] One, a plurality or all of the gas paths 18a, 18b can be guided tangentially into the central gas duct 18. Such a tangential arrangement of the gas paths 18a, 18b upstream of the transmit/receive surface 22a leads, in a cleaning mode, for example with water, to effective cleaning of the transmit/receive surface 22a. In addition, during normal operation without excessive frothing during the bottling operation, the sensor head 22 comes into contact only with gaseous media, but not with liquids. In the event of a possible bursting of the container 100, the sensor head 22 by its position in the gas duct 18 is readily protected from fragments flying around, for example glass shards.

[0101] The sensor device 20 permits monitoring of a plurality of or even all of the steps of the bottling operation. For this purpose, an evaluation device 30 is provided which communicates with the sensor device 20 and is configured to evaluate the analogue or digital detection signals of the sensor device 20. The detection signals of the sensor device 20 can thus be used by the evaluation device 30, for example, in order to infer one or more of the following measured variables: filling height of the filling product in the container 100; gas pressure in the gas duct 18 or container 100; froth quantity/height or froth composition in the container 100; container position relative to the mouth section 15c; structural state of the container 100, i.e. whether the container 100 is intact or damaged.

[0102] The evaluation device 30 can be part of a filling member controller 40 or can be in communication with such in order to control and/or to regulate the bottling operation. The communication can take place in analogue or digital form, and in wired or wireless form. The evaluation device 30 and filling member controller 40 can be realised centrally or decentrally, as part of Internet-based and/or cloud-based applications or in some other way, and recourse can optionally be made to databases. The sensor device 20, evaluation device 30 and filling member controller 40 can be realised integrally or by separate electronic components. By contrast to the illustration in FIG. 1, the evaluation device 30 can be installed, for example, in the sensor housing 21, and the evaluation device 30 and filling member controller 40 can be implemented by a computer unit, for example assisted by software.

[0103] If the position of the container 100 relative to the filling member 1 is changed, for example during the introduction, pressing on and removal of the container 100, the signal received by the sensor device 20 also changes, as a result of which steps which are associated with a position change of the container 100 can be monitored and correspondingly controlled. In this way, for example, the filling operation can be automatically started as soon as a container 100 is present and is located at the correct position.

[0104] Owing to the dependency of the sound speed on gas properties, such as, for example, composition, pressure, temperature, etc., furthermore steps of gas exchange, pressure increase or reduction/evacuation can be monitored and correspondingly controlled by the sensor device 20.

[0105] Similarly, possible frothing during the filling and/or relieving of load of the container 100 can be monitored by the sensor device 20.

[0106] The monitoring and control of the metering of the filling product is possible in all the containers 100. The increase in the filling speed can be used as a control variable.

[0107] Container defects, for example bursting of bottles, can likewise be identified by the sensor device 20.

[0108] The above-described scope of use of the sensor device 20 is provided in the event of a measuring principle which is based on the transmitting and detecting of ultrasonic waves. However, the scope of use can be completely or at least partially also obtained by other measuring methods, for example optical measurements.

[0109] The use of such a sensor device 20 placed in the gas duct 18 of the filling member 1 with swirl chamber 11 permits a simplification in terms of mechanical engineering since previously used sensors, for example for flow, filling level, container detection (Flada) and pressure, can be replaced and at the same time a plurality of or even all of the steps in the filling operation can be monitored continuously with a single sensor.

[0110] Furthermore, steps or sequences during the filling operation that hitherto could only be inadequately monitored, if at all, relating, for example, to the operation of positioning and/or pressing the container 100 against the mouth section 15c of the filling member 1, can be monitored by the sensor device 20.

[0111] The use of a single sensor device 20 in the filling member 1 leads to a lower maintenance effort and a cost saving because of there being fewer sensors and fewer variants.

[0112] It is possible to use the sensor device 20 for PET bottles and for glass bottles, cans or other types of container, as a result of which sensor variants are reduced.

[0113] Even filling products with low conductivities can be easily measured, in contrast to using electric rod probes.

[0114] The use of flow meters, for example costly Coriolis mass flow meters, is unnecessary.

[0115] The necessary communication between the evaluation device 30, the filling member controller 40 and/or a master plant controller can be substantially reduced with decentral controller concepts. The requirement for the permitted transmission delay is also reduced since, for example, the starting signal for the bottling operation no longer has to be transmitted.

[0116] If applicable, all of the individual features which are illustrated in the exemplary embodiments can be combined with one another and/or replaced without departing from the scope of the invention.