Automatic Vehicle Oil Drum Filling Machine for 200L Standard Product Type Filling Machines
I. Working Principles
Bucket Feeding and Positioning:
After the filling machine is started, the conveying device will transport the empty buckets to the filling position. Common conveying methods include roller conveying and chain conveying. When the empty bucket reaches the designated position, the positioning system starts to work. For mechanical positioning, the bucket mouth is accurately stopped at the specified position through structures such as mechanical baffles and positioning plates. For systems using CCD vision - servo positioning, the camera captures the position information of the bucket mouth and transmits the data to the servo motor. The servo motor then precisely drives the filling head to move above the bucket mouth, ensuring accurate alignment.
Filling Process:
After the filling head descends to a certain position inside the bucket mouth, the valve opens and the liquid begins to be filled. If it is a gravity filling, the liquid flows directly into the bucket under the action of gravity; if it is a pressure filling, the liquid is quickly pressed into the bucket by the pressure generated by the pump. The dual-speed feeding system fills at a relatively fast speed in the initial stage of filling. When the liquid level approaches the set value, it switches to slow filling. This can prevent liquid splashing and ensure filling accuracy. For example, when filling liquids with higher viscosity, most of the liquid is quickly filled first, and then the remaining part is slowly added to avoid inaccuracies in liquid level or bubble generation due to the fast flow rate of the liquid.
Cap Sealing Stage:
After the filling is completed, the cap sealing mechanism starts. For press-type cap sealing, the cylinder drives the capping head downward to tightly press the cap onto the bucket mouth. For screw-type cap sealing, the motor drives the capping head to rotate, tightening the cap onto the bucket mouth according to the thread structure.
Bucket Unloading and Conveying:
After the cap sealing is completed, the conveying device starts again, transporting the filled buckets to the next process or storage area. Throughout the entire process, the actions of each part are coordinated and controlled by the control system to ensure the continuity and stability of the filling process.
II. Equipment Composition
Frame Structure:
It is usually constructed from high-strength steel or aluminum alloy materials, having sufficient strength and stability to bear the weight of 200L of liquid and various forces during equipment operation. The frame design is reasonable, facilitating the installation and maintenance of various components, while also ensuring the overall aesthetics of the equipment.
Filling System:
Liquid Storage Tank: It is used for storing the liquid to be filled, generally made of stainless steel material, which has good corrosion resistance and sealing performance. The capacity of the liquid storage tank is determined according to production needs and is equipped with a liquid level sensor. When the liquid level is insufficient, it can timely issue an alarm so that the operator can add liquid. Filling Head: It is a key component for filling liquid, and its number can be determined according to the production capacity and filling method of the equipment. The material of the filling head is usually stainless steel or corrosion-resistant alloy material, and the internal channel is smooth to ensure smooth liquid flow. The filling head is also equipped with a valve to control the on-off of the liquid. Conveying Pipeline: It connects the liquid storage tank and the filling head to ensure stable transportation of liquid from the liquid storage tank to the filling head. The material of the pipeline also needs to consider the nature of the liquid. For corrosive liquids, special corrosion-resistant materials should be used. Positioning System:
Mechanical Positioning Parts: Including various baffles, positioning plates, guide rails, etc. These parts can ensure the accuracy of the bucket mouth at the filling position through precise machining and assembly. Optical Detection Elements: If visual positioning technology is adopted, it will be equipped with high-resolution cameras and image processing software. The camera is installed in a suitable position and can clearly capture the image of the bucket mouth. Then, through image processing algorithms, the position information of the bucket mouth is calculated to provide data support for servo positioning. Servo Motor and Driver: The servo motor is the core component that performs positioning actions. It can accurately rotate a certain angle or move a certain distance according to the instructions of the control system. The driver is used to control the speed, direction, and other parameters of the servo motor to ensure the accuracy and rapidity of positioning. Control System:
Human-Machine Interface (HMI): Generally using touch screens or LCD displays, operators can conveniently set and adjust filling parameters through it, such as filling volume, filling speed, start-stop time, etc. At the same time, the human-machine interface can also display the working status and fault information of the equipment, facilitating operators to monitor and manage the equipment. Controller: Usually using programmable logic controllers (PLC), which is responsible for receiving input signals from the human-machine interface and controlling various execution components according to preset programs and algorithms. PLC has the advantages of high reliability, strong anti-interference ability, and flexible programming, meeting the complex control needs of 200L fully automatic liquid filling machines. Sensors: Including liquid level sensors, position sensors, photoelectric sensors, etc. The liquid level sensor is used to monitor the liquid level height in the liquid storage tank and the liquid level in the bucket; the position sensor is used to detect the position of the bucket and the filling head; the photoelectric sensor is used to detect the shape and size of the bucket mouth and whether there is a bucket, etc. These sensors convert the detected physical quantities into electrical signals and transmit them to the controller, so that the controller can make corresponding decisions.
III. Selection Points
Product Quality:
Material Quality: Ensure that the parts in contact with the material adopt materials that meet hygiene standards and chemical compatibility requirements, such as 304 or 316L stainless steel. For non-contact parts, it is also necessary to ensure that their materials have good durability and corrosion resistance. Processing Accuracy: The processing accuracy of the equipment directly affects the filling accuracy and stability of the equipment. High-quality equipment will control the processing accuracy of key components at a high level, such as the sealing surface of the filling head and the dimension accuracy of the positioning system. Performance Parameters:
Filling Accuracy: Choose filling accuracy according to actual production needs. For some products with high requirements for filling volume, such as high-precision chemicals or expensive liquids, it is necessary to choose equipment with high filling accuracy, generally requiring an error within ±0.2%; for ordinary liquid products, the filling accuracy can be selected at about ±0.5%. Production Capacity: Consider the production capacity needs of the production line and select appropriate filling speed. If the production task quantity is large, it is necessary to choose equipment with higher production capacity, such as equipment that can fill 20 - 30 barrels per hour or even higher. At the same time, it is also necessary to consider the automation degree and operational stability of the equipment to ensure continuous and stable production. Safety:
Electrical Safety: The equipment should comply with relevant electrical safety standards, such as good grounding and reliable insulation. The control system should have functions such as leakage protection and overload protection to prevent safety accidents caused by electrical faults. Mechanical Safety: The mechanical structure design of the equipment should be reasonable to avoid sharp corners and protruding parts that may cause harm to operators. At the same time, it is necessary to be equipped with emergency brake buttons and safety protection doors, which can quickly stop the operation of the equipment in case of emergencies to ensure the personal safety of operators. After-sales Service:
Technical Support: Choose suppliers who can provide timely and professional technical support. Suppliers should have professional technical personnel who can provide services such as equipment installation, commissioning, and operation training for users, and can respond quickly and provide effective solutions when the equipment fails. Warranty Policy: Understand the warranty period, warranty scope, and warranty conditions of the equipment. Generally speaking, high-quality equipment has a longer warranty period, such as one year or two years. Within the warranty scope, the supplier should be able to repair or replace damaged parts for free.
