Method for Operating a Filling System and Filling System

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.

Claims

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 the corrected substitute flow or substitute level value is determined using the same method as the substitute flow or substitute level value, or different methods are used.

7. 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.

8. 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 level values during the diagnostic mode; wherein the second control and evaluation unit is designed to transmit a deviation message to the first control and evaluation unit in the event of detection of a deviation of the current flow or fill level value from the flow or fill level value expected on the basis of the valve curve; and wherein the first control and evaluation unit is further designed in such a way that, after receipt of the deviation message, the first control and evaluation unit interrupts the diagnostic mode and switches to normal operation or outputs corrected substitute flow or substitute level values.

9. The filling system according to claim 8, 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 the second control and evaluation unit and the third control and evaluation unit are designed in such a way that, in the diagnostic mode of the first filling point, the second control and evaluation unit compares a currently measured flow rate or fill level value with the flow rate 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 filling level values from the flow or filling level values expected on the basis of the valve curve curves, the second control and evaluation unit and the third control and evaluation unit determine the measure and/or the direction of the deviations and compare them with one another and, in the event of a similar deviation, transmit the measure and/or the direction of the deviation to the first control and evaluation unit; and wherein the first control and evaluation unit is further designed to correct 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 is further designed to output a corrected substitute flow rate or substitute fill level value determined with the corrected valve curve.

10. The filling system according to claim 8, wherein the first control and evaluation unit, the second control and evaluation unit and—if present—the third control and evaluation unit are further designed in such a way that at least one of: 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; 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; 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 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; 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, 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; and 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.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0039] In detail, there are now a plurality of possibilities for designing and further developing the method for operating a filling system according to the invention as well as the filling system according to the invention. For this purpose, reference is made to the description of preferred embodiments in conjunction with the drawings.

[0040] FIG. 1 illustrates a block diagram of a first variation of a method for operating a filling system.

[0041] FIG. 2 illustrates a block diagram of a first preferred further development of method steps of the method shown in FIG. 1.

[0042] FIG. 3 illustrates a block diagram of a second preferred further development of method steps of the method shown in FIG. 1.

[0043] FIG. 4 illustrates a block diagram of a third preferred further development of method steps of the method shown in FIG. 1.

[0044] FIG. 5 illustrates a block diagram of a fourth preferred further development of method steps of the method illustrated in FIG. 1.

[0045] FIG. 6 illustrates a block diagram of a second variation of a method for operating a filling system.

[0046] FIG. 7 illustrates a first design of a filling system.

[0047] FIG. 8 illustrates a second design of a filling system.

DETAILED DESCRIPTION

[0048] FIG. 1 shows a block diagram of a first variation of a method 100 for operating a filling system 1. A filling system 1 designed to carry out the method 100 shown in FIG. 1 is shown in FIG. 7. The filling system 1 comprises a first filling point 2 and a second filling point 3. The first filling point 2 has a first filling valve 4, a first flow or fill level sensor 5 and a first control and evaluation unit 6. The first control and evaluation unit 6 is designed for controlling and monitoring the filling process of the first filling point 2. The second filling point 3 has a second filling valve 7, a second flow or fill level sensor 8 and a second control and evaluation unit 9, wherein the second control and evaluation unit 9 is designed for controlling and monitoring the filling processes of the second filling point 3. The first control and evaluation unit 6 of the first filling point 2 and the second control and evaluation unit 9 of the second filling point 3 are connected to one another via a communication channel 10.

[0049] The method for operating a filling system 1 shown in FIG. 1 is characterized by various method steps. In a first method step 101, the first filling point 2 enters a diagnostic mode during the operating state of the filling system 1. In a second method step 102, the first control and evaluation unit 6 of the first filling point 2 signals the diagnostic start to the second control and evaluation unit 9 of the second filling point 3. The message is transmitted via the communication channel 10. During the diagnostic mode, the first control and evaluation unit 6 outputs substitute flow or substitute fill level values (method step 103). In a further method step 104, the second control and evaluation unit 9 transmits a deviation message to the first control and evaluation unit 6 in the event of detection of a deviation of the current flow or fill level value from the flow or fill level value to be expected on the basis of the valve curve stored in the second control and evaluation unit 9. After receiving 105 the deviation message, the first control and evaluation unit 6 terminates the diagnostic mode in a method step 106 and switches to normal operation. In an alternative variation, the control and evaluation unit 6 outputs corrected substitute flow or substitute level values to the first filling point 2 after receiving 105 the deviation message (method step 107).

[0050] The method shown is particularly suitable for carrying out a diagnostic mode of at least one filling point during ongoing filling operation of the filling system. During the diagnostic mode, a filling operation is also carried out at the filling point in diagnostic mode. In addition to the possibility of integrating the diagnostic mode into the filling operation, the method shown also has the advantage that filling at the filling points can be made much more precise, firstly because the filling point in diagnostic mode outputs substitute values for the flow rate or fill level, which are used to check/control the filling, and secondly because any errors which occur can be detected directly in diagnostic mode and thus rectified in a timely manner.

[0051] FIGS. 2 to 5 show individual sections of the method shown in FIG. 1 in different variations. Only the method steps between method steps 102 and 103 are shown. All other method steps shown in FIG. 1 are nevertheless carried out before or after the method steps shown in FIGS. 2 to 5.

[0052] FIG. 2 shows a block diagram of a first, preferred further development of method steps of the method 100 shown in FIG. 1. After signaling the diagnostic start 102 of the first filling point 2 to the second filling point 3, in a method step 108 the first control and evaluation unit 6 of the first filling point 2 determines the substitute flow or substitute fill level values on the basis of the current valve position of the first filling valve 4 and the valve curve stored in the first control and evaluation unit 6. Subsequently, in a method step 103, the substitute values are output by the first control and evaluation unit 6.

[0053] An alternative variation for determining the substitute flow or substitute fill level values is shown in FIG. 3. This differs from the design shown in FIG. 2 in that in a method step 108′ the second control and evaluation unit 9 transmits current flow or fill level values to the first control and evaluation unit 6 and the first control and evaluation unit 6 outputs these current flow or fill level values to the second control and evaluation unit 9 as substitute flow or substitute fill level values.

[0054] The variation shown in FIG. 4 differs from the previously shown variations in that in a method step 108″ the first control and evaluation unit 6 determines the substitute flow or substitute fill level values in such a way that flow or fill level values previously stored in the control and evaluation unit 6 are stored from at least one past filling cycle and these are output as substitute flow or substitute fill level values.

[0055] The variation shown in FIG. 5 is characterized in that in a method step 108′″ the second control and evaluation unit 9 transmits flow or fill level values stored in it from a past filling cycle to the first control and evaluation unit 6 of the first filling point 2 and the first control and evaluation unit 6 outputs these values as substitute flow or substitute fill level values.

[0056] FIG. 6 shows a block diagram of a second method 100′ for operating a filling system 1. A corresponding filling system 1, which is particularly suitable for carrying out this method, is shown in FIG. 8. The filling system 1 has a third filling point 11. The third filling point 11 has a third filling valve 12, a third flow or fill level sensor 13 and a third control and evaluation unit 14. The third control and evaluation unit 14 is designed for controlling and monitoring the filling processes of the third filling point 11. The third control and evaluation unit 14 of the third filling point 11 is connected via a communication channel 10′ to the second control and evaluation unit 9 of the second filling point 3 and to the first control and evaluation unit 6 of the first filling point 2.

[0057] The method 100′ shown in FIG. 6 is characterized by the following method steps: In a first method step 101, the first filling point enters a diagnostic mode. In a method step 102′, the first filling point 2 signals the diagnostic start to the third filling point 11 via the communication channel 10, 10′. In a method step 103, the first filling point 2 outputs substitute flow or substitute fill level values while the diagnostic mode is in progress. With the substitute flow or substitute fill level values, filling operation is also maintained at the first filling point. In a method step 104′, the third control and evaluation unit 14 of the third filling point 11 detects a deviation of a flow or fill level value expected on the basis of the valve curve stored in the third control and evaluation unit from the flow or fill level value actually determined and reports a deviation message to the first control and evaluation unit 6 of the first filling point 2. During the method steps described so far, filling processes are also performed at the second filling point 3. In a method step 109, the second control and evaluation unit 9 and the third control and evaluation unit 14 compare the measure and direction of the deviations of the current flow or fill level values from the flow or fill level values to be expected on the basis of the valve curves stored in the respective control and evaluation units 9, 14 and, in the event of a similar deviation of the measure and/or direction of this deviation, transmit this deviation to the first control and evaluation unit 6. In a method step 110, the first control and evaluation unit 6 performs a correction of the valve curve of the first filling valve 4 stored in the first control and evaluation unit 6. In particular, this correction is performed on the basis of the value transmitted by at least one of the other control and evaluation units 9, 14 for the measure and/or direction of the deviation. In a method step 107, the corrected substitute flow or substitute fill level values determined by means of the corrected valve curve are then output by the first control and evaluation unit 6.

[0058] If the first control and evaluation unit 6 detects an error state in diagnostic mode, which is shown by method step 111 in FIG. 6, the first control and evaluation unit 6 makes a request about a diagnostic result of a similar diagnosis to the second control and evaluation unit 9 of the second filling point 3 and/or to the third control and evaluation unit 14 of the third filling point 11. The second control and evaluation unit 9 and/or the third control and evaluation unit 14 transmit or send the requested diagnostic result to the first control and evaluation unit 6 of the first filling point 2. In a method step 112, a comparison of the diagnostic results is performed. In the event of an identical diagnostic result, a method step 113 concludes that the filling system has a process filler and issues the same. In the event of a different diagnostic result, a method step 114 concludes that there is a filling point error at the first filling point 2, and this is output. The method shown in FIG. 6 is therefore also particularly suitable for distinguishing a process error from a fill level error.