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The Explosion-Proof Liquid Filler is an automated filling machine for liquid specifically designed to safely and accurately fill liquids in hazardous environments where flammable and explosive gases, vapors, dusts or liquids are present. Its core working principle is to eliminate or strictly control any ignition source that may ignite the explosive environment while realizing high-precision filling.
Container Positioning: Empty containers are placed by conveyor belt or manually to the filling station and are positioned and clamped.
Filling head down/container up: The filling head is lowered and inserted into the mouth of the container, or the container is raised over the filling nozzle to form a relatively hermetic connection.
Liquid Transfer: Liquid is transferred from the reservoir to the filling head by pump or by gravity/pressure.
Accurate Metering: This is a critical component and is commonly used in the following ways:
Volumetric: The volume of liquid flowing through the head is accurately controlled using a high-precision flow meter, a servo motor-driven piston cylinder, or a rotary valve.
Mass type: The container to be filled is placed on a precision electronic scale, the weight change is monitored in real time during the filling process, and the filling is stopped when the preset target weight is reached.
Liquid Level: The filling is controlled by detecting the liquid level in the container through sensors.
Filling control: PLC receives signals from the metering device and accurately controls the opening/closing of the valves, the starting and stopping of the pumps or the speed to realize the precise filling volume.
Filling Completion: After reaching the preset quantity, the filling valve closes, the filling head lifts up or the container drops down.
Container Removal: The filled container is removed from the work station and goes to the next process.
1. Core components
Filling device: SS304 stainless steel filling head, part of the model is equipped with a swing-arm mechanism to adapt to different container caliber.
Weighing system: integrated high-precision electronic scales and weighing sensors, real-time feedback through the PLC weight signals, to achieve three-stage filling: high-flow coarse irrigation, low-flow fine irrigation, micro-supplementary irrigation, the error is controlled within ± 0.15%.
Explosion-proof control cabinet: built-in explosion-proof motor, explosion-proof electrical components, shell protection level up to IP67, to ensure the safe operation of the electrical system in explosive environments.
Conveying equipment: integrated explosion-proof conveyor, driven by spark-proof motor, supports automatic conveying and positioning of 25L to 200L containers.
2.Workflow
Empty bottle loading: containers enter the filling area automatically through the conveyor.
Positioning and filling: PLC controls the filling head to descend to the mouth of the container and start three-stage filling.
Capping and output: automatic capping after filling is completed, and the finished product is sent out through the conveyor.
Data Recording: Support batch counting and weight accumulation, data traceability and OEE analysis can be realized through Ethernet/IoT connection.
1. Intrinsically safe design
Electrical system: Intrinsically safe (Ex i) or explosion-proof (Ex d) structure is adopted; key components such as PLC, sensors, motors are ATEX/IECEx certified for Zone 1/21 hazardous areas.
Material selection: Material contact parts are made of 316L stainless steel or polytetrafluoroethylene (PTFE) to avoid static electricity accumulation; sealing system adopts double-layer design to prevent liquid leakage.
Non-sparking design: pneumatic components replace electric parts, filling gun is equipped with static elimination device, and the whole equipment is grounded.
2.Safety Protection Device
Multi-protection: overload protection, power leakage protection, emergency stop button, equipped with combustible gas detection and alarm system.
Sealing and exhausting: The enclosed filling area is equipped with HEPA filter and exhaust port to control the concentration of volatile gases; optional nitrogen purge system to inhibit the risk of oxidation and explosion.
Leakage prevention: Drip cup, spill-proof cover and automatic shut-off function to prevent material leakage and pollution of the environment.
1. PLC control system
Full automation process: Realize full automatic control of empty bottle loading, positioning, filling, capping, and finished product output, reducing manual intervention.
Recipe management: support storing up to 10 kinds of product parameters (such as filling volume, speed, temperature compensation), and quickly switching through touch screen HMI.
Real-time monitoring: display filling progress, fault alarm information, support Ethernet/IoT connection for remote monitoring.
2.Accurate metering technology
Temperature and density compensation: real-time monitoring of material temperature, automatic adjustment of metering parameters to ensure stable accuracy at different temperatures.
High-precision sensor: volume mode accuracy ±0.5%, weight mode accuracy ±0.1%, applicable to low viscosity (such as alcohol) to high viscosity (such as lubricating oil) liquids.
Applicable materials: flammable and explosive liquids such as alcohol, ethanol, solvents, petroleum products, pharmaceutical ingredients, etc.
Application areas: chemical, pharmaceutical, petrochemical, food (alcoholic beverages), agrochemicals and other industries.
High safety: through the intrinsically safe design and multiple protection mechanisms, it can effectively control gas emission and static electricity accumulation during the filling process to ensure safe operation, and completely eliminate the ignition source to ensure the safety of hazardous environment operation.
High precision: three-stage filling and temperature compensation technology, realizing micro-level precision control. Adopting advanced electronic scale measuring system to ensure the accuracy of filling quantity.
High efficiency: automated process and high-speed filling (up to 1200 bottles/hour), greatly improving production efficiency. The high degree of automation enables fast and accurate filling and improves production efficiency.
Easy maintenance: modular design and quick disassembly parts reduce maintenance costs and downtime
Accuracy: advanced electronic scale metering system ensures accurate filling volume.
Equipment status confirmation
Explosion-proof certification verification: confirm that the equipment shell is marked with a complete explosion-proof certification marking (such as ATEX, IECEx, GB/T 3836), and within the validity period.
Electrical system check: Check whether the explosion-proof control cabinet, motor, sensors and other components are intact, without damage or looseness; confirm that the grounding wire is reliably connected and the grounding resistance is ≤4Ω.
Mechanical components check: Check whether the filling head, conveyor belt, seals, etc., are free from leakage, wear or deformation; confirm that the emergency stop button (E-Stop) functions normally.
Test of explosion-proof devices: Verify that the combustible gas detection alarm, explosion-proof ventilation system, nitrogen purge device, etc. are in normal working condition.
Environmental Safety Assessment
Area Classification Confirmation: Ensure that the equipment is installed in an area that meets explosion-proof standards (e.g., Zone 1/21) and that no unauthorized personnel have access to it.
Gas Concentration Detection: Use a portable combustible gas detector to detect the concentration of flammable gases in the environment and ensure that it is below 25% of the Lower Explosive Limit (LEL).
Ventilation Confirmation: Check that the explosion-proof ventilation system is functioning properly to ensure that the volatile gas concentration is effectively diluted.
Material Preparation
Material Compatibility Verification: Confirm the chemical compatibility of the filling liquid with the contact parts of the equipment (e.g. stainless steel, PTFE) to avoid corrosion or reaction.
Temperature control: If the material needs to be filled at a constant temperature, start the heating/cooling system in advance to ensure that the material temperature is within the permissible range (usually ±2℃).
Personnel Protection Requirements
Personal Protective Equipment (PPE): Operators must wear anti-static coveralls, chemical-resistant gloves, goggles, and explosion-proof shoes; long hair should be tied back to avoid contact with rotating parts.
Training and qualification: Only personnel who have been professionally trained and certified to operate explosion-proof equipment are allowed to operate the equipment; unauthorized personnel are prohibited from approaching the equipment.
Filling Parameter Setting
Explosion-proof Mode Enable: Enable “Explosion-proof Mode” in the control system to limit the running speed of the equipment and avoid static electricity or sparks.
Precise parameter input: set the filling volume, speed, temperature compensation and other parameters according to the characteristics of the material, and confirm the correctness through the touch screen.
Prohibit overfilling: Ensure that the filling volume does not exceed 90% of the rated capacity of the container to avoid the risk of liquid overflow.
Real-time monitoring and intervention
HMI interface monitoring: pay close attention to the filling progress, weight data and fault alarm information displayed by the PLC control system.
Abnormal response:
Leakage treatment: If the filling head is found dripping, immediately press the “emergency stop” button, close the feed valve and clean up the leaking liquid.
Gas exceeds the standard: if the combustible gas detector alarm, immediately start the explosion-proof ventilation system, pause filling, and investigate the source of leakage.
Equipment failure: If electrical failure or mechanical jamming occurs, it is forbidden to disassemble and repair by yourself, and you should contact professionals to deal with it.
Daily Maintenance
Cleaning and Disinfection: After the end of daily filling, use explosion-proof tools to clean up the residual liquid on the surface of filling head, conveyor belt and equipment; if filling food or medicine, it needs to be disinfected according to GMP norms.
Seals check: check the sealing ring of filling head, conveyor belt joints and other wear parts every week, and replace them immediately if they are found to be aging or broken.
Testing of explosion-proof devices: Monthly testing of the response time and sensitivity of the combustible gas detection alarm, emergency stop button, and explosion-proof ventilation system.
Regular overhaul
Electrical system overhaul: Quarterly inspection of insulation and explosion-proof performance of explosion-proof motors, sensors and junction boxes by licensed electricians, and replacement of aging cables.
Mechanical parts lubrication: every six months on the conveyor belt bearings, filling head lifting guide and other moving parts filled with explosion-proof grease to avoid friction heat.
Update of explosion-proof certification: Contact the third-party testing organization to review the explosion-proof performance of the equipment every year and update the explosion-proof certification mark.
Spare parts management
Storage of explosion-proof spare parts: spare explosion-proof motors, sensors, seals, etc. should be stored in a dry, non-corrosive gas environment to avoid moisture or damage.
Disposal of end-of-life equipment: The eliminated explosion-proof filling equipment should be disassembled according to the hazardous waste treatment specifications, and it is prohibited to discard or resell at will.
SIGHTEC in the filling of liquid materials, measurement, data processing, etc., with advanced technology and rich experience, combined with the user’s specific working environment and production process, can be “customized” for the user a complete set of perfect filling and weighing solutions. Equipment can be widely used in petrochemical, fine chemical, food and other industries, especially for flammable and explosive, toxic corrosive, easy to produce foam, easy to oxidize, easy to volatile and other special liquid materials for automated filling, which can significantly reduce the labor intensity of employees, to protect the production safety of personnel; the system can also be integrated with other additional functions according to customer requirements: such as automatic opening / tightening the lid, automatic marking/labeling, communications/printing filling The system can also integrate other additional functions according to customer requirements: such as automatic opening/closing, automatic marking/labeling, communication/printing of filling data, nitrogen filling, system insulation, weight rechecking, automatic palletizing, automatic pallet storage, etc.
