Control Board and System for Filling Machines

Control Board and System for Filling Machines

Control Board and System for Filling Machines

Customer Request 📝

Our client previously used a filling machine with a large, complex control cabinet and an error-prone, inaccurate control system. Although the machine was designed for simple filling tasks, it caused several issues:

  • Tangled wiring increased assembly and maintenance time
  • Complicated operation
  • Reduced production efficiency

The client wanted a compact, simplified “plug & play” control solution. The goal was to shorten production and assembly times, save costs, and improve user-friendliness.

Our Solution 💡

Our team thoroughly analyzed the existing system and developed an integrated hardware and software solution. The new system was designed to be user-friendly, reliable, and modular.

Solution Components:

  • Hardware Design: Compact control board with simplified connections
  • Embedded Software: Precise filling control algorithms
  • Sensor and Motor Integration: Optical sensors, on/off valves
  • HMI Interface: Clear and easy-to-understand touchscreen display

With the new system, the filling machine can handle smaller batches more quickly. Operator intervention is reduced, downtime minimized, and overall machine reliability increased.

Technical Details ⚙️

Hardware and Board Design

  • Compact, modular control board eliminates wiring clutter
  • MCU-based control module with inputs for optical sensors, valve actuators, and analog/digital I/Os
  • Modular terminal connections simplify assembly and maintenance
  • Robust design for industrial environments (dust, humidity, vibration, and temperature resistant)

Valve Control

  • Integrated control of filling valves and motors
  • Precise adjustment of valve open/close times and motor speed
  • Software algorithms automatically adapt to different batch sizes

Sensor Integration

  • Optical sensors detect product and start/stop filling
  • Sensor data filtered to prevent false triggers
  • All sensor data integrated in real time into the control logic

Communication

  • Real-time data transfer between HMI and control board
  • Bidirectional transmission of error codes, status, and filled volumes

HMI Interface

  • User-friendly touchscreen for easy batch adjustments
  • Displays fill quantity, fill time, error logs, and statistics
  • Clean, aesthetic design for intuitive operation

Embedded Software

  • C-based embedded control algorithms
  • Milliliter-accurate filling control
  • Real-time management of fill time, sensor data, and motor control
  • Automatic stop and warning mechanisms in case of errors

Results

Thanks to design and software optimization, the new control system significantly exceeded the client’s expectations. Key benefits include:

Reliability and Continuous Operation

The system operates stably and reliably even under demanding production conditions, with virtually no downtime. Automated processes greatly reduce the need for operator intervention, enhancing safety and reducing personnel workload.

Precise Filling Control

Milliliter-accurate control ensures consistent, precise filling, preventing material waste and maintaining consistent product quality. The software automatically adjusts parameters for different product types or batch sizes.

Easy Operation

The intuitive HMI interface provides clear oversight of all filling processes. Operators can monitor fill volumes, cycle times, and system status in real time. Alerts and error messages are displayed immediately, enabling quick and targeted maintenance, reducing downtime and improving overall production efficiency.

Compact, Modular Design

The control board and new control cabinet layout are compact and modular, significantly reducing space requirements. Tangled wiring, which previously complicated assembly and maintenance, is eliminated. The modular design allows rapid installation, simple maintenance, and easy integration into other machines or production lines.

Operational Efficiency

Optimized software and simplified control speed up all processes, increasing production throughput while reducing errors. This results in higher productivity and a more stable production flow.

Cost Savings

Fewer components, compact design, and simplified assembly reduce material and labor costs. Minimal training is needed due to the intuitive interface, saving additional costs and easing staff onboarding.

Future-Proof Flexibility

The system can be easily adapted to different batch sizes or product types without additional hardware or software investment. This flexibility enables the client to respond quickly to future production changes, maximizing the long-term value of the investment.

Data Privacy 🔒

This project is presented without company or product names for confidentiality reasons. All illustrations are for demonstration purposes only.

🔗 Get in touch with us :
Phone/WhatsApp: +41 76 212 8248
✉️ E-Mail: info@revantechnology.com

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