Beverage Drink Filling Machine

DCGF18-18-6 rinsing filling capping machine 冲瓶灌装拧盖机第 1 页共 51页
目录
Catalog
第一部分概述 Part.1 Summary ...................................................................... 3
一、一般安全参考 General safety reference.......................................................... 3
二、中途贮存 Midway Storage................................................................................ 4
三、安全须知 Safety instructions............................................................................. 5
四、概述 Summary.......................................................................................................6
1、产品的用途及适用范围 Products' use and scope of application................ 6
2、设备组成 Equipment Composition.....................................................................7
3、技术特点 Technical characteristics................................................................... 5
4、运行 working........................................................................................................... 6
5、传动 transmission..................................................................................................6
6、安全装置 Safety device......................................................................................... 7
五、主要技术参数 Main technical parameter.........................................................7
第二部分各单机介绍 Part.2 equipment introduction.......................................... 8
一、冲瓶机 washing machine..................................................................................8
1 概述 Summary............................................................................................................8
2 设备组成及结构介绍 Equipment Composition and Structure introduction
........................................................................................................................................... 8
二、灌装机 filling machine.....................................................................................14
1 概述 Summary......................................................................................................... 14
............................................................................................................................................. 14
三、拧盖机 capping machine................................................................................ 24
1 概述 Summary......................................................................................................... 24
.........................................................................................................................................25
四、工作台及传动 working plate and transmission...........................................31
1 输瓶部件 bottle conveyor......................................................................................31
2 驱动装置 Driving device........................................................................................ 32
第三部分设备维护与保养 Part.3 Equipment maintenance........................... 33
一、CIP 清洗 CIP cleanning.....................................................................................33
二、设备维护 Equipment maintenance................................................................ 35

三、安装、调整 Installation and adjustment.......................................................37
四、使用、操作 use and operation ...................................................................... 38
五、故障分析与排除 analysing and removing fault ......................................... 39
六、图、表 sheet........................................................................................................ 43
七、随机技术文件 random technical files............................................................ 43
第一部分概述 Part.1 Summary
一、一般安全参考 General safety reference
在机器首次投入运行前，必须阅读和理解有关安全的重要信息。
Before the machine is put into operation for the first time,
important information about safety must be read and understood.
张家港市今日饮料机械有限公司机器的安全符合专业协会的规定，以及相关的应
用安全法律和当前已知的机器指导规范。只要操作恰当，并在允许
的范围内进行操作，则对操作者与机器的危险就会降到现代技术所
能达到的较低水平。
The machine safety of Zhangjiagang JinRi Beverage Machinery Co., Ltd.
complies with the regulations of the professional association, as well as the
relevant applied safety laws and the current known machine guidance
specifications. As long as it is properly operated and operated within the
allowable range, the risk to operators and machines will be reduced to a lower
level that modern technology can achieve.
Use the 在操作面板和机器上的紧急关机开关只有在操作人员或机器

emergency
处于危险中时才可使用。在一般情况下，不能使用紧急关机开关
shutdown
来关停机器！ The emergency shutdown switch on the operation
switch only in
panel and machine can only be used when the operator or
case of
machine is in danger. In general, the emergency shutdown
emergency!
switch can not be used to shut down the machine!
Please pay
attention to 在正常关机时不能用紧急关机开关！
the use of
No emergency shutdown switch can be used when shutdown is
emergency
normal!
shutdown
switch!
一旦启动，紧急关机开关自动锁死。
Once activated, the emergency shutdown switch is automatically locked
只有在排除了对操作人员和机器的安全威胁后才能重新启动机器！
Restart the machine only after eliminating security threats to operators and
machines
二、中途贮存 Midway Storage
如果需要在中途进行贮存，贮存场地必须满足如下要求，以防止一些对温度
和湿度敏感的部件遭到损坏，或者被腐蚀 If intermediate storage is required, the
storage site must meet the following requirements in order to prevent damage
or corrosion of parts sensitive to temperature and humidity.：
使机器及其部件远离污垢、尘埃及油漆分子。用塑料膜将机器盖好。
Keep machines and their components away from dirt, dust and Egyptian paint
molecules. Cover the machine with plastic film
环境温度须在零下 10 度至零上 50 度之间。
The ambient temperature should be between -10℃ and 50℃。
防止机器内外凝结露水。保证贮存场地有良好的通风。
Prevent condensation of dew inside and outside the machine. Ensure good
ventilation of storage site.
在机器周围地区不能有溶剂、酸液、碱液的挥发蒸气。
There should be no volatile vapor of solvent, acid or alkali in the area around
the machine.
保证机器置放地的水平，机器重量均匀分布在每个螺旋式支脚上。To
ensure the level of the machine placement, the weight of the machine is
evenly distributed on each spiral support foot.
经过较长时间的贮存后（多于 4-5 个月），检查一下 PLC 控制
器中的电池是否完好，所有的程序单元是否仍然存在。如果有
疑问的话，请通知今日公司人员。After a long period of storage (more than
4-5 months), check whether the batteries in the PLC controller are in
good condition, and whether all the program units still exist. If you have
any questions, please inform the staff of today's company.
在出现下列情况时也适用以上做法 The above practices are also

applicable in the following situations：
由于贮存时间太长或是缓冲电池容量不够而导致程序单元的完全或部分丢
失。 Due to long storage time or insufficient buffer battery capacity, the
program unit is completely or partially lost.
三、安全须知 Safety instructions
本机器是按照相应的安全规则建造的。它的结构使其在调整，保养，
维护，修理和排除暂时故障方面可以无危险的运行。在这些种类的工
作期间，机器必须只能用手来转动，或者使用点动开关。
The machine is built according to the corresponding safety rules.
Its structure enables it to operate without danger in terms of
adjustment, maintenance, maintenance, repair and troubleshooting.
During these kinds of work, the machine must be turned only by
hand or by a point switch.
如果开关位于从事这种工作的人所能达到的距离之外，或者如果
有几个人同时在机器上或机器内工作，那么为此目的要专门指派一个
人，此人必须从能观察到工作和能立即使机器停止的位置上来操纵机
器，在工作进行的过程中此人不得离开这个位置。
If the switch is located outside the reach of the person engaged in
such work, or if several persons are working on the machine or in

the machine at the same time, a person must be designated to
operate the machine from a position where the work can be
observed and the machine can stop immediately. This person must
not leave this position during the course of the work.
在任何一次接通前，检查瓶子的通道上要没有工具，清洗用具等。
特别重要的是要认真阅读所有安全规章和安全专职人员的须知。
Before any connection, there should be no tools, cleaning utensils,
etc. on the way to check the bottle.
It is particularly important to carefully read all safety regulations and
instructions for safety professionals.
另外，主要的是要看清下列各点 In addition, the main thing is to see
the following points：
a)不要穿任何宽松的工作服。 Don't wear any loose overalls
b)保护好长头发，使用发网或某些其他形式的工作帽。 Protect long
hair and use a hairnet or some other form of work cap
c)在处理化学物品，热水和蒸汽时，为防止腐蚀灼伤，烫伤和受伤，
要按规章规定穿上防护服（防护眼镜，橡胶围裙，靴子，手套）。
When handling chemicals, hot water and steam, in order to prevent
corrosion, burns, scalds and injuries, wear protective clothing
(protective glasses, rubber aprons, boots, gloves) as required by
the regulations.
d)当灌装机运转正常过程中，不允许突然切断电源。 When the filling
machine is running normally, it is not allowed to suddenly cut off the
power supply.
四、概述 Summary
1.产品的用途及适用范围 Use and scope of application of products
本机是在引进德国技术基础上，结合了本公司多年生产经验后开发的新产
品。该机集冲、灌、封为一体，设计科学合理，造型美观。操作维修方便，自动
化程度高。主要适用于碳酸饮料的冲洗、灌装、封口。
This machine is a new product developed on the basis of

introducing German technology and combining the company's many
years of production experience. The machine integrates punching,
irrigation and sealing. Its design is scientific and reasonable, and its
shape is beautiful. Easy operation and maintenance, high degree of
automation. It is mainly suitable for washing, filling and sealing
carbonated beverages.
2.设备组成 Equipment Composition
机器被分为六个主要部分 6parts：
 冲瓶机 washing head
 灌装机 filling head
 拧盖机 capping head
 工作台及传动 working platform and transmission
 电气、气动部分 Electrical and pneumatic parts
 管道等 pipeline.etc
3 技术特点 technical characteristics
1、整机采用悬挂式卡瓶口输送结构，从而使整线运行更为可靠。从而使整
线输送瓶子更为可靠。不同瓶型只需调整输送带高度及少量的变更件。
因此换瓶型更快捷、省力；
The whole machine adopts the suspended bottle-mouth conveying
structure, which makes the whole line run more reliably. This makes the
whole line of bottles more reliable. Different bottle types only need to
adjust the height of conveyor belt and a small number of changes.
Therefore, bottle change is faster and labor-saving.
2、本机冲洗喷口采用梅花状多孔对瓶底各夹角冲洗充分，冲洗效率高,空瓶
随轨道自动进行 180 度翻转，对瓶内进行冲洗；
The flushing nozzle of this machine uses plum-blossom-like porous to
flush the bottom of the bottle adequately, and has high flushing
efficiency. The empty bottle is automatically turned 180 degrees with
the track, and the inside of the bottle is flushed.

3、灌装阀采用国外先进技术，具有灌装速度快，液位控制精度高的特点；
使得灌装快捷、液位准确。该机具有无瓶不灌装的特点；
The filling valve adopts advanced technology from abroad, which has
the characteristics of fast filling speed and high accuracy of liquid level
control, and makes filling fast and accurate. The machine has the
characteristics of no bottle and no filling.
4、本机采用磁力扭矩盖头，实现抓盖、拧盖功能，拧盖力矩无级可调，恒
力矩的拧旋盖，且不伤盖，封口严密可靠；
The machine adopts magnetic torque cap to realize capping and
screwing function. The capping moment can be adjusted steplessly and
the constant torque cap can be screwed tightly and reliably without
damaging the cap.
5、回转式理盖器采用气力理盖，具有不损坏盖表面，料斗内缺盖发讯号，
控制上盖机自动补盖等功能；
The rotary cover cutter adopts pneumatic cover, which has the
functions of not damaging the surface of the cover, signaling the
missing cover in the hopper, and controlling the automatic cover filling
of the cover cutter.
6、整机采用先进的人机界面操作，PLC 控制，变频无级调速等自动控制技
术，具有无瓶不开阀不加盖，缺瓶等待，盖滑槽内缺盖停机等功能；
The whole machine adopts advanced man-machine interface operation,
PLC control, variable frequency stepless speed control and other
automatic control technologies. It has the functions of no bottle, no
valve capping, no bottle waiting, no cap stopping in the cover chute,
etc.
7、与水接触的零部件均采用 304 不锈钢材料，主要电器、气动元件均采用
进口元件；
All parts in contact with water are made of 304 stainless steel. Imported
components are used for main electrical and pneumatic components.
4 运行 Process
灌装的产品、清洗剂、压缩空气都通过各自的进料管和物料分配管入口送
到灌装设备上。
The filling products, cleaning agents and compressed air are delivered
to the filling equipment through their respective feeding pipes and material
distribution pipes.
空瓶由输送链经工作台上的进瓶星轮送至冲瓶机，瓶翻转 180°─冲瓶─沥
干─翻转 180°瓶口朝上，瓶再由出瓶星轮、过渡星轮及灌装机进瓶星轮送至灌装
机，回转过程中，在进出瓶凸轮和瓶升降装置的作用下，与灌装阀压合，灌装过
程开始，瓶中灌入饮料。如果没有瓶，则相应的阀门保持关闭状态。
Empty bottles are sent to the bottle-punching machine by the conveyor
chain through the bottle-feeding star wheel on the worktable. The bottle is
turned 180 degrees-bottle-punching-draining-turning 180 degrees upward. The
bottle is then sent to the filling machine by the bottle-feeding star wheel,
transition star wheel and filling machine. During the rotation process, under the
action of the bottle-feeding cam and bottle-lifting device, the bottle is pressed
with the filling valve. The filling process begins and the bottle is filled with
beverages. If there is no bottle, the corresponding valve remains closed
灌装完毕后，瓶提升装置下降。通过灌装机出瓶星轮传送到拧盖机进行拧盖。
拧盖后的饮料瓶由出瓶星轮传输到出瓶输送带。
After filling, the lifting device of the bottle drops. The bottle outlet star
wheel of the filling machine is transmitted to the capping machine for capping.
The capped beverage bottle is transferred from the outlet star wheel to the
outlet conveyor belt.
5 传动 Transmission
主传动采用蜗轮减速器、三角带和变频电机传动。
The main drive is driven by worm gear reducer, triangular belt and variable
frequency motor.
6 安全装置 Safety device
操作人员应该熟悉所有的安全装置及其使用方法，以避免人身伤害和机
器损坏。 Operators should be familiar with all safety devices and their
use methods to avoid personal injury and machine damage.
在机器操作台上设有一个急停开关。 There is an emergency stop switch

on the machine operating table.
五、主要技术参数 Main technical parameters
冲瓶机头数： 18
Washing heads amount: 18
灌装阀头数： 18
Filling heads amount: 18
拧盖机头数： 6
Capping heads amount: 6
额定产量（ 500ml 瓶）： 4000P/ｈ
Output(500ml bottle): 4000P/ｈ
适用瓶型：PET、PVC 型：瓶高 150～ 300mm
瓶径 Φ50～ Φ110mm
Bottle type: height: 150～ 300mm
Diameter: Φ50～ Φ110mm
灌装温度： 0-4℃
Filling temperature: 0-4℃
冲瓶水消耗量： 1.1m 3 /h
Washing water consumption: 1.1m 3 /h
工作电压 AC 380V
Working voltage: 380V
控制电压 DC 24V
Controlling voltage 24V
动力： 3.73KW
Power:3.73KW
其中：主电机 main motor ： 3KW 理盖电机 caps
arranging motor： 0.18KW
喷冲泵 washing pump： 0.55KW
设备外形尺寸 2380X1900X2550（长 ×宽 ×高）
Size: 2380X1900X2550(length*width*height)
设备重量 (约 ) 3000Kg
Weight: 3000kg
第二部分各单机介绍 single part introduction
一冲瓶机 washing machine
1 概述 summary
本机为高速回转式冲瓶机,主要用于啤酒、饮料、矿泉水等产品的冲洗瓶之
用。设备主要结构、与冲洗介质接触部分和外部防护罩均为不锈钢材料。
This machine is a high-speed rotary bottle-punching machine. It is mainly
used for washing bottles of beer, beverage, mineral water and other products.
The main structure of the equipment, the contact part with the flushing medium
and the external protective cover are all stainless steel materials.
2 设备组成及结构介绍 equipment construction
冲瓶机主要由升降装置（1）、主传动装置（2）、固定架（3）、夹钳装置（4）、
分配器（5）、防转横梁（6）、限位装置（7）、翻转凸轮（8）等组成。
Bottle punching machine is mainly composed of lifting device (1), main
transmission device (2), fixture (3), clamp device (4), distributor (5),
anti-rotation beam (6), limit device (7), overturning cam (8), etc.
2.2 主传动装置（图一） main transmission (picture 1)
主传动装置是冲瓶机的关键部件之一，其上安装有夹钳、介质分配器等部件。
当图中的回转齿轮（1）旋转时，带动回转台（2）及其上安装的其它零部件同时
旋转。
The main transmission device is one of the key parts of the bottle punching
machine, which is equipped with clamps, dielectric distributors and other
components. When the rotary gear (1) in the figure rotates, the rotary table (2)
and other parts installed on it rotate simultaneously.
2.4 夹钳装置（图二） clip machine (picture 2)
瓶夹是冲瓶机中重要的部件，图中导杆随翻转凸轮运动，带动瓶夹主体绕转
轴转动，使瓶夹翻转 180o，完成对瓶的冲洗和沥干等重要过程。当瓶子运行到
进瓶拔轮与冲瓶机回转中心的连线上时，瓶颈卡入夹钳的左右夹爪中，夹钳夹住
瓶子一起转动，并在冲瓶机出瓶位置松开夹爪放出瓶子。
Bottle clamp is an important part of bottle punching machine. The guide
rod moves with the overturning cam, which drives the main body of the bottle
clamp to rotate around the rotating axis, so that the bottle clamp can be turned
180 o, and the important process of washing and draining the bottle is
completed. When the bottle is running on the line between the pulley and the
revolving center of the bottle puncher, the bottleneck is clamped in the left and
right claws of the clamp. The clamp holds the bottle and rotates together, and
releases the bottle at the outlet position of the bottle puncher.
图中导向手、定位杆均为易损件，在使用过程中应该及时更换。
The guide hand and positioning rod in the drawing are all vulnerable parts,
which should be replaced in time in the course of use.
图二 picture 2
2.5 分配器（图三） dispenser (picture 3)
介质分配器是将冲洗用的介质由用户管道接至设备。并分配到分配盘上的每
一个直通终端快插管接头而分配到喷嘴，本部件用材为不锈钢和专用材料，均符
合食品卫生要求。
The medium distributor connects the medium used for flushing from the user
pipeline to the equipment. And distributed to each through terminal fast
intubation joint on the distribution plate and to the nozzle. The components are
made of stainless steel and special materials, which meet the requirements of
food hygiene.
图三 picture 3
2.7 翻转凸轮（图四） Flip cam (picture 4)
翻转凸轮是通过夹钳将待冲洗的瓶从进瓶星轮处翻转上升送至冲瓶位置进
行冲洗沥干，然后将瓶下翻转送至出瓶星轮输出，完成瓶的冲洗的重要装置。
The overturning cam is an important device to flush the bottle by turning
the bottle up from the starwheel in the bottle to the position of the
bottle-flushing for flushing and draining, and then turning the bottle down to the
output of the starwheel out of the bottle.
当上翻转时，瓶口由朝上转至朝下；
When the bottle is turned upside down, the mouth of the bottle turns upside
down.
当下翻转时，瓶口由朝下转至朝上。
When the bottle is turned upside down, the mouth of the bottle turns upside
down.
轨道结构在出厂前均已调整好，请不要随意调整。
The track structure has been adjusted before leaving the factory. Please
do not adjust it at will.
图四 picture 4
二灌装机 filling part
1 概述（图五） Summary
灌装机主要由旋转台座(1)、主液管(2)、灌装缸(3)、灌装缸支撑(4)、升降凸轮(5)、上
分配器（6）、灌装缸配管（7）控制环装置（8）、开阀装置（9）、闭阀装置（10）、排气装
置（11）、吹气装置（12）
、灌装阀（13）、操作阀杆（14）、对中导向（15）等组成。具有
灌装速度快、系统稳定、结构简单、容易操作、安全可靠等特点。
The filling machine is mainly composed of rotary table (1), main liquid
pipe (2), filling cylinder (3), filling cylinder support (4), lifting cam (5), upper
distributor (6), filling cylinder piping (7) control ring device (8), valve opening
device (9), valve closing device (10), exhaust device (11), air blowing device
(12), filling valve (13), operating valve stem (14), and centering guide (15). It
has the characteristics of fast filling speed, stable system, simple structure,
easy operation, safety and reliability.
2 设备组成及结构简介 equipment structure
2.1 回转台（图六） Turntable (picture 6)
回转台为灌装机与工作台及传动系统连接的关键部件。通过灌装回转齿轮(1)
的传动，带动回转座(2)的转动，通过灌装缸支撑(3)与灌装缸（4）连接，以实现
灌装机的转动。回转座(2)为灌装机的主承载体。
Turntable is the key component connecting filling machine with worktable

and transmission system. The rotation of the rotary seat (2) is driven by the
transmission of the filling rotary gear (1), and the filling cylinder support (3) is
connected with the filling cylinder (4) to realize the rotation of the filling
machine. Rotary seat (2) is the main bearing body of filling machine
2.2 灌装缸（图七） filling cylinder (picture 7)

灌装缸（1）和缸盖（2）均为微碳不锈钢制作，符合有关卫生要求。灌装缸
与缸盖之间装有密封圈（3），且为易损件，可用直径 5.3 食用密封条制作。由于
是环形件，两端切出斜口紧密结合（密封条应较槽周长略长一些）。灌装缸为环
形缸，故耐压性好。灌装缸及缸盖上装有压力表（4）、安全阀（5）、液位探针（6）、
视镜（7）。
The filling cylinder (1) and cylinder head (2) are made of micro-carbon
stainless steel, which meets the hygienic requirements. There is a sealing ring
(3) between the filling cylinder and the cylinder head, and it is a vulnerable part.
It can be made of edible sealing strip with a diameter of 5.3. Because it is a
circular part, the two ends of the cut-out bevel are tightly combined (the sealing
strip should be slightly longer than the groove circumference). The filling
cylinder is an annular cylinder, so it has good pressure resistance. The filling
cylinder and cylinder head are equipped with pressure gauge (4), safety valve
(5), liquid level probe (6), and viewing mirror (7).
2.4 升降凸轮与拉下凸轮（图九）Lifting Cam and Pull-down Cam(picture 9)

由于采用了瓶子升降，而灌装阀不升降，所以整机运转性能特别可靠。升降
凸轮（1）通过支撑杆（2）安装在工作台面上。而对中导向瓶口定位板（3）在
升降凸轮（1）、拉下凸轮（4）和滚轮（5）、的作用下，作升降回转运动，从而
对中导向作升降回转运动。
Because of the use of bottle lifting, and filling valve does not rise and fall, so
the operation performance of the machine is particularly reliable. The lifting
cam (1) is installed on the working table surface through a support rod (2). On
the other hand, under the action of lifting cam (1), pulling cam (4) and roller (5),
the center guide bottle orifice positioning plate (3) makes a lifting and rotating
motion, thereby making a lifting and rotating motion for the center guide.
2.5 上分配器（图十） up distributor(picture 10)

上分配器（即气体分配器）distributor (distribute air)
·结构 structure
气体分配器主要包括以下零部件 main parts：
1 传感器 sensor
2 分配器内部零部件 Internal parts of distributor
3 分配器外壳 shell
4 支架 support
上分配器安装在下分配器上，所有固定管道都从上面进入，所有排出管道都
呈辐射状排列通向灌装缸。
The upper distributor is mounted on the lower distributor. All fixed pipes enter
from the upper distributor and all discharge pipes radiate to the filling cylinder.
·功能 function
为了将两个相互隔开的压力管道从固定部份通向灌装缸，需要用这个气体分
配器。 This gas distributor is needed to move two separated pressure pipes
from the fixed part to the filling cylinder.
固定部份是分配器内部零部件（2），而外壳（3）和支架（5）则随灌装缸一
起旋转。
The fixed part is the internal part (2) of the distributor, while the shell (3)
and the bracket (5) rotate with the filling cylinder.
从外部进来的固定管道连接在分配器内部零部件（2）上。旋转管道则连接
在外壳（3）上。气体的通道从园螺纹接头，经过分配器内部.
Fixed pipes coming in from the outside are connected to the internal parts
(2) of the distributor. The rotating pipe is connected to the outer shell (3). The
gas passage passes through the distributor from the circular threaded joint.
每个压力室都用将其与相邻压力室或轴承座隔开的两个密封件来保护。
在两个密封件之间有一个与大气相通的卸压孔。万一密封件损坏时，这就消除了
压力室之间短路连接的危险。
Each pressure chamber is protected by two seals separated from the adjacent
pressure chamber or bearing seat. Between the two seals there is a pressure relief hole
connected with the atmosphere. This eliminates the danger of short-circuit connections
between pressure chambers in case of damage to seals.
2.6 开阀装置（图十一） Opening Valve device

该装置由气缸、电磁换向阀及信号控测元件等组成。当有瓶时，测瓶用接近
开关得信号，同时，测工位接近开关也得信号，使电磁换向阀动作，开阀气缸活
塞推出，使灌装阀打开充气灌装；当无瓶时，电磁换向阀失电，气缸活塞缩回，
使灌装阀不打开，避免缸内气体逸出。
The device consists of a cylinder, an electromagnetic reversing valve and a
signal control and measurement element. When there is a bottle, the proximity
switch is used to get the signal. At the same time, the proximity switch is also
used to make the electromagnetic reversing valve move and the cylinder
piston is pushed out to make the filling valve open and inflate. When there is
no bottle, the electromagnetic reversing valve loses power and the cylinder
piston retracts, so that the filling valve does not open and the gas escapes
from the cylinder.
图十一 picture 11
2.7 闭阀装置与排气装置（图十二、图十三）Closing Valve Device and Exhaust
Device (picture 12 ,picture 13)
闭阀装置是在灌装后，强制将操纵阀杆定位至关闭位置，使注气阀及液体阀
同时关闭，然后由排气凸轮推动排气杆，把瓶中的气体放出，防止瓶离开阀时起
泡。排气凸轮调到能将排气阀杆均匀地推进约 3mm 的位置即可。
After filling, the valve closing device forces the control valve stem to be
positioned at the closing position so that both the injection valve and the liquid
valve are closed at the same time, and then the exhaust rod is driven by the
exhaust cam to release the gas in the bottle to prevent bubbling when the
bottle leaves the valve. The exhaust cam can be adjusted to the position where
the exhaust valve stem can be propelled about 3mm evenly.
图十二、闭阀装置 picture 12 Closing Valve Device
图十三、排气装置 picture 13 exhaust device
2.8 吹气装置（图十四） blower part (picture 14)

当灌装部件位于出瓶与进瓶星轮之间时，充气阀打开，然后在预设的时间之
后关闭。这样，酒缸中的 CO2 气体把回气管中残留的物料吹出来，防止下次灌

装时应回气管中流有残液而影响灌装精度。
图十四 picture 14
2.9 灌装阀（图十五、图一六） filling valve
1、灌装阀结构 valve structure
该机所有高速灌装阀的结构如图所示，它由注气阀、液体阀和排气阀三部分
组成。
The structure of all high-speed filling valves of the machine is shown in the
figure. It consists of three parts: air injection valve, liquid valve and exhaust
valve.
2、灌装过程 filling process
1)瓶子由提升装置抬起，在压缩弹簧作用下，瓶口通过瓶口密封垫（17）实现与
灌装阀的严密密封。
The bottle is lifted by a lifting device. Under the action of a compression spring,
the bottle mouth is tightly sealed with the filling valve through the bottle mouth
sealing pad (17).
2)瓶子经“无瓶-不灌装”机构测定后，由操作阀杆将拨叉转到注气位置使注气阀在
逆压情况下打开，灌装缸内的压缩空气或 CO2 气先通过充气阀杆（4）开口，再
通过阀杆的内孔和气管的通气口流入瓶内
After the bottle is determined by the "no-bottle-no-filling" mechanism, the
dialing fork is transferred to the air injection position by the operating valve
stem to open the air injection valve under counter-pressure. The compressed
air or CO2 in the filling cylinder first opens through the air-filled valve stem (4),
and then flows into the bottle through the inner hole of the valve stem and the
air outlet of the trachea.
3）当瓶内的压力等于灌装缸的压力时，阀杆（2）在弹簧的作用下打开，灌装缸
内液体通过弹簧套上的圆孔流入阀座（5），再经装在回气管上的分流伞均匀地沿
着瓶子的内壁灌入瓶内，当液体流入瓶内时，瓶内的空气通过气孔再经阀杆和注
气阀，逐步地流回灌装缸内
When the pressure in the bottle equals the pressure in the filling cylinder, the
valve stem (2) opens under the action of the spring, the liquid in the filling
cylinder flows into the valve seat (5) through the round hole on the spring
sleeve, and then is evenly poured into the bottle along the inner wall of the
bottle through the shunt umbrella installed on the return pipe. When the liquid
flows into the bottle, the air in the bottle flows back into the filling cylinder step
by step through the valve stem and the injection valve.
4）液体继续流动，直到液位达到回气管下口为止，这时截断空气的回路，使液
体停止流动，更换不同的回气管就可调整液位。
The liquid continues to flow until the liquid level reaches the lower outlet of the
return pipe. At this time, the air circuit is cut off so that the liquid stops flowing
and the liquid level can be adjusted by replacing different return pipes.
5）阀关闭器逐渐转动操纵阀杆，强制地关闭注气阀，再关上液体阀。排气阀的
阀杆（8）由排气凸轮推动，把瓶内上部剩余的压缩空气逐渐放泄到大气中，以
确保瓶子从对中杯（16）上取下时不会有起泡现象。
The valve closer gradually rotates the control stem, forcibly closes the air
injection valve, and then closes the liquid valve. The valve stem (8) of the
exhaust valve is driven by the exhaust cam, which gradually releases the
remaining compressed air in the upper part of the bottle into the atmosphere to
ensure that the bottle will not foam when it is removed from the middle cup
(16).
图十六、灌装阀结构 picture 16 valve structure
图一七
2.10 操作阀杆（图十七）operating valve lever (picture 17)
操作阀杆是用来开关回气管的专门机构。操作阀杆的转动是否灵活直接影响
到灌装的质量。其结构如下
The operating valve stem is a special mechanism for switching the return
pipe. Whether the rotation of the operating valve stem is flexible or not directly
affects the filling quality. Its structure is as follows：
图十七 picture 17
2.11 对中导向（图十八）sensor guide

对中导向是是将瓶从过渡拨轮提升到灌装位置的专门机构。滚轮（7）在升
降凸轮及拉下凸轮的作用下作上下回转运动，瓶口定位板（2）卡住瓶口沿凸轮
曲线将瓶子提升到阀密封垫，灌装就可以开始了。瓶口定位板（2）属于变更件，
不同的瓶型要更换不同的定位板。滚轮（7）是含油尼龙制品。
Centralization is a specialized organization that lifts bottles from the
transition wheel to the filling position. The roller (7) rotates up and down under
the action of the lifting cam and the pulling cam. The bottle orifice positioning
plate (2) clamps the bottle orifice and raises the bottle to the valve seal along
the cam curve. The filling can begin. The bottle orifice positioning plate (2)
belongs to a changeable part. Different bottle shapes need to be replaced with
different positioning plates. The roller (7) is an oily nylon product.
注意事项：滚轮及衬套为易损件，要定期检查，如发现有损坏现象请及时更
换。
Attention: Rollers and bushings are vulnerable parts. They should be
inspected regularly. If damage is found, please replace them in time.
三拧盖机 capping part
1 概述 Summary
拧盖机由主电机经减速箱传动给齿轮，通过灌装机出瓶星轮传递到拧
盖机齿轮，通过拧盖机主轴将动力传给拧盖头，同时带动回转机架上的销
轴转动从而带动取盖盘的转动。
The capping machine is driven by the main motor through the
reducer to the gear, and is transferred to the gear of the capping machine
by the star wheel of the filling machine. The power is transmitted to the
capping head by the main shaft of the capping machine, and the pin axis
on the rotary frame is rotated to drive the rotation of the capping plate.
拧盖头的上下运动是通过拧盖凸轮来实现，拧盖凸轮是固定
不转的，盖经过料斗里的一个搅拌器送入滑道再经取盖盘送
入拧盖头的拧盖齿圈。
The top and bottom movement of the screw cap is realized
by screwing the cap cam. The screw cap cam is fixed and
does not rotate. The cap passes through an agitator in the
hopper and is fed into the slideway, and then into the screw
cap ring of the screw cap by taking the cap disc.
本机取盖采用摆线齿轮传动，抓盖过程采用二次下抓，确保
抓盖准确可靠。拧盖头为磁力过载保护，确保拧盖力矩恒定。
Cycloidal gear drive is used for capping, and secondary
down-grabbing is used in capping process to ensure the
accuracy and reliability of capping. The screwing head is
magnetic overload protection to ensure that the screwing
moment is constant.
拧盖机由料斗(1)、滑道(2)、取盖装置(3)、拧盖上部(4)、拧盖头(5)、拧盖下
部(6)、升降部分(7)及防转立柱(8)等组成。（图十九）
The capping machine is composed of hopper (1), slideway (2), capping
device (3), capping upper part (4), capping head (5), capping lower part (6),
lifting part (7) and anti-rotation column (8).
2 设备组成及结构介绍 Equipment Composition and structure introduction
2.1 料斗及滑道部件 Hopper and slide way components
·概述 Summary
料斗及滑道是使包装盖有序排列并输送至取盖装置的部分，本机料斗为回
转加风力控制使包装盖有序排列，料斗及滑道为全不锈钢加工而成，完全符合食
品卫生要求。
The hopper and slide way are the parts that make the packing caps
arranged in an orderly manner and conveyed to the capping device. The
hopper of this machine is made of all stainless steel and the packing caps are
arranged in an orderly manner by means of rotary and wind control. The
hopper and slide way are fully in line with the requirements of food hygiene.
·工作原理 Working principle
装于拧盖机上部的料斗通过减速机（1）带动回转盘（2）转动，使盖
2
在离心力的作用下从出盖口离开料斗，在出口处有一正反盖分离装置（3），当
反盖经过时，盖自动落入返回管道中，通过风力自动把反盖吹回料斗，只有正盖
才能顺利进入滑道内。料斗内的盖的量通过接近开关（4）自动检测来控制输盖
机，以保证下盖达到最佳效果。\
The hopper installed on the upper part of the screwdriver drives the rotary
disc (2) to rotate through the reducer (1), so that the cover leaves the hopper
from the outlet under the action of centrifugal force. At the outlet, there is a
positive and negative cover separation device (3). When the reverse cover
passes through, the cover falls into the return pipe automatically, and the
reverse cover is blown back to the hopper automatically by wind force. Only
the positive cover can enter the slide way smoothly. The amount of cover in
hopper is controlled by automatic detection of proximity switch (4) to ensure
the best effect of lower cover.
当正盖进入滑道（5）后即可顺利进入取盖盘。为防意外，在滑道上同
时配置了一个防反盖的拨轮（6），确保进入取盖盘的盖正确。在滑道上还
配置了一对光电开关，当检测到无盖时，就必须停主机。
When the front cover enters the slide way (5), it can enter the
capping plate smoothly. In order to prevent accidents, a dial wheel (6)

with anti-back cover is arranged on the slide way at the same time to
ensure that the cover of the capping plate is entered correctly. An
optoelectronic switch is also installed on the slide way. When no cover is
detected, the main engine must be stopped.
为了有效剔除无防盗圈的坏盖及清理料斗里的余盖，在料斗出口正对面有一
活动出口（7）可满足此功能。
In order to effectively remove the bad cover without anti-theft ring and
clean the remaining cover in hopper, there is a movable outlet (7) directly
opposite the hopper outlet to satisfy this function.
·调整 adjustment
料斗转向 Hopper steering
调整料斗电机的接线，保证料斗按逆时针方向旋转（从料斗口向下方
向看）。
Adjust the wiring of the hopper motor to ensure that the hopper
rotates counterclockwise (from the hopper mouth down)
反盖检测装置 Reverse Cover Detection Device
反盖检测应保证拨轮与反盖接触 3～5mm，不宜过少，应保证检测可
靠，也不宜过多，以保证下盖迅速。
Reverse cover detection should ensure that the dial wheel contacts
with the reverse cover for 3-5 mm, not too little, should ensure that the
detection is reliable and not too much, in order to ensure that the lower
cover is fast.
吹气装置 Blower
吹气方向应对向容盖器的入口，气源压力以保证下盖迅速为宜。
The direction of blowing should be directed towards the entrance of
the cap holder, and the pressure of the air source should be used to
ensure that the lower cap is fast.
2.3 拧盖机主轴部分 principal axis of capping part
拧盖下部为拧盖机与工作台及传动系统连接的关键部件。齿轮（7）与传动
系统相连，带动拧盖机公转。轴承座（5）与工作台相连，支撑拧盖机主体。主
轴（3）与拧盖机上部相连，带动拧盖机上部公转。
The lower part of the screw cap is the key component connecting the
screw cap machine with the worktable and transmission system. The gear (7)
is connected with the transmission system to drive the rotation of the
screwdriver. The bearing seat (5) is connected with the worktable to support
the main body of the screwdriver. The spindle (3) is connected with the upper
part of the screwdriver to drive the rotation of the upper part of the screwdriver.
拧盖上部是拧盖机自转、公转的回转体，其自转实现拧盖，公转实现瓶与
盖的输送。
The upper part of the screwing cap is the rotating body of the screwing cap
machine, whose rotation realizes screwing cap, and the rotation realizes the
transportation of bottles and caps.
凸轮（3）与顶板（2）固定，因此，凸轮是静止不动的，当回转机架（10）
旋转时，装在滑套（4）上的滚子沿凸轮工作曲面滚动，使滑套作上下运动，以
实现拧盖头的上下运动。其自转是通过回转机架（10）带动过齿轮（23）转动，
过齿轮的转动是通过内齿圈（7）的啮合实现自转，并带动滑套（4）自转。滑套
（4）的上下滑动是通过凸轮（3）曲线强制实现的，滑套（4）的定向自转与凸
轮曲线强制下压实现拧盖。
The cam (3) is fixed with the top plate (2), so the cam is stationary. When
the rotary frame (10) rotates, the roller mounted on the slide sleeve (4) rolls
along the working surface of the cam, making the slide sleeve move up and
down to realize the up and down motion of the screw cap head. Its rotation is
driven by the rotary frame (10) through the gear (23) rotation, through the gear
rotation through the engagement of the inner ring (7) to achieve rotation, and
drive the sliding sleeve (4) rotation. The upward and downward sliding of slide
sleeve (4) is realized by force of cam (3) curve. The directional rotation of slide
sleeve (4) and the forced downward pressure of cam curve are used to screw
the cap.
2.5 滑套装置（图二十）Sliding sleeve device (picture 20)

工作原理 Working principle
拧盖柱塞由动力带动作旋转运动，当拧盖机旋转一转时，每一个拧盖柱塞
将上、下往复运动一次。凸轮控制拧盖柱塞的上、下运动，凸轮安装在拧盖机上
部的不动部分。
The screw cap plunger is driven by power to rotate. When the screw cap
machine rotates, each screw cap plunger will move up and down once. The
cam controls the upper and lower movement of the capping plunger, and the
cam is installed in the fixed part of the upper part of the capping machine.
当瓶子从灌装机上传送过来以后，拧盖头已从取盖盘上取得了一个瓶
盖。拧盖柱塞在凸轮导轨的作用下向下降，而后籍助推力环进行拧盖操作。
When the bottle is transferred from the filling machine, a cap has
been obtained from the capping plate by screwing the cap head. The
screw-cap plunger drops down under the action of the cam guide rail,
while the screw-cap operation is carried out by the rear boost ring.
2.6 拧盖头（图二十一） capping heads
拧盖头上壳体（3）靠螺纹拧紧在滑套口，当滑套作公转、自转、上、下
运动时，拧盖头也作相应的同步运动，拧盖头一方面随主机旋转，另一方
面通过齿轮的带动又作自转。在拧盖头内装有二组相邻磁性相反的磁柱体
（13），通过磁性体的相吸力，以保证相应拧盖力矩。当拧盖力矩超过规定
值时，以两组磁体间的相对滑动，实现拧盖齿圈（17）的自转停止。拧盖
头力矩的调整是通过二组磁场（14）间距离的调整实现的。松开螺钉（31）、
螺母（32），顺时针转动调整环（10），拧盖力矩增大，反之，则拧盖力矩
减小。顶杆（1）起无瓶有盖保护作用，使误入拧盖头的瓶盖顶出。拧盖齿
圈（17）起拧盖作用。拧盖齿圈（17）是根据瓶盖的具体尺寸而设计的。
对于不同的瓶盖，需更换对应的拧盖齿圈（17）。
The upper shell of the screwing head (3) is tightened at the slip sleeve
opening by threads. When the slip sleeve rotates, rotates, moves up and
down, the screwing head also moves synchronously. On the one hand,
the screwing head rotates with the main engine, on the other hand, it
rotates with the drive of the gear. Two groups of adjacent magnetic
cylinders (13) with opposite magnetism are installed in the screw cap
head, and the corresponding screw capping moment is guaranteed by the
phase attraction of the magnets. When the screwing moment exceeds the
prescribed value, the rotation stop of the screwing ring (17) is realized by
relative sliding between two groups of magnets. The adjustment of the
torque of the screw cap is realized by adjusting the distance between two
sets of magnetic fields (14). Loosen the screw (31) and nut (32), turn the
adjusting ring (10) clockwise, and increase the screwing moment. On the
contrary, the screwing moment decreases. The ejector rod (1) has the
protective effect of a cap without a bottle, so that the cap mistakenly
inserted into the screwing cap head is ejected. The screwing ring (17)
acts as a screwing cover. The screw cap ring (17) is designed according
to the specific size of the bottle cap. For different bottle caps, the
corresponding screw cap ring (17) should be replaced.
四工作台及传动 working platform and conveyor
工作台的主要部件有：表面的不锈钢罩板和框架结构工作台。
Main part: stainless steel cover plate and frame structure working
platform
其中包括 including：
（１）输瓶部件及进瓶导板 Bottle feeding parts and guide plate
（２）出瓶星轮 Bottle Star wheel
（３）输瓶带 conveyor belt
（４）齿轮副传动系统 Gear pair conveying system
1 输瓶部件 Bottle conveying parts
a) 输瓶部件的组成 formation
冲瓶灌装拧盖机输瓶部件由：冲瓶机进瓶星轮、冲瓶机出瓶星轮、
中间星轮、灌装机进瓶星轮、灌装机输送星轮、拧盖星轮、出瓶星轮、
出瓶带部件组成。
The bottle-feeding parts of bottle-punching filling and capping
machine are composed of: bottle-feeding star wheel of
bottle-punching machine, bottle-punching machine, bottle-releasing
star wheel, intermediate star wheel, bottle-feeding star wheel of
filling machine, bottle-filling machine, bottle-feeding star wheel,
capping star wheel, bottle-releasing star wheel and bottle-releasing
belt components.
b) 瓶子路线 Bottle Route
来自输送带的瓶子被传递给进给星轮。星轮把瓶子送入冲瓶机清
洗后经过渡星轮过渡到灌装机提升装置上，在此处，瓶子随提升装置上
升将灌装阀打开，而后瓶子随提升装置回转进行灌装。
The bottle from the conveyor belt is passed to the feeding star
wheel. Star wheel feeds bottles into the bottle-punching machine for
cleaning and then transits to the lifting device of the filling machine
through the ferry. Here, the bottle opens the filling valve with the
lifting device rising, and then the bottle is filled with the lifting device
rotating.
在灌装过程完成后，提升装置通过拉下凸轮慢慢拉下，而后，瓶
子通过导瓶板传送给拧盖机进行拧盖。
After the filling process is completed, the lifting device is slowly
pulled down by pulling down the cam, and then the bottle is
transferred to the capping machine through the guide plate for
capping.
当拧盖过程完成之后，出瓶星轮将拧盖完毕了的瓶转送到出瓶输送
带上。
When the capping process is completed, the capped bottle is
transferred to the conveyor belt by the star wheel.

c) 功能 function
(1) 星轮部件 star wheel part
星轮是保证瓶子进入冲瓶机到拧盖完成后输出过程的执行元件，星
轮的安装及同步调整直接关系到冲瓶、灌状、拧盖的稳定性。
Star wheel is an actuator to ensure the output of bottle from the
bottle-punching machine to the screwing cap. Installation and
synchronous adjustment of star wheel are directly related to the
stability of bottle-punching, filling and screwing caps.
d)安装及调整 Installation and adjustment
所有星轮是用螺钉固定在星轮座上的，星轮位置由定位销保证。安
装导瓶板时必须注意与星轮间的间隙，一般控制在瓶直径 D+(1 ～
1.5)mm 左右。每对星轮及导瓶板安装时保证处于同一水平面上。
All the star wheels are fixed on the constellation with screws,
and the position of the star wheels is guaranteed by the positioning
pin. When installing the guide plate, attention must be paid to the
clearance between the guide plate and the star wheel. Generally, the
diameter of the guide plate should be controlled about D+ (1-1.5) mm.
Installation of each pair of star wheel and guide bottle plate ensures
that they are on the same horizontal plane.
.2 驱动装置 drive part
本机有一台主电机带动减速机，由减速机齿轮带动拧盖机齿轮，再
依次传向各个齿轮。从而实现冲洗、灌装、拧盖各个过程。
This machine has a main motor to drive the reducer, the reducer
gear to drive the screwdriver gear, and then to each gear in turn.
Thus, each process of flushing, filling and screwing can be realized.
第三部分设备维护与保养
Part3 equipment maintenance
一 CIP 清洗系统 CIP cleaning system

食品生产线上清洗过程的目的是使最终成品必须达到规定的质量
标准。
The purpose of the cleaning process on the food production line
is to make the final product meet the required quality standards.
清洗的基本原则和目的 Basic principle and cleaning purpose
水在高速下循环流过饮料要经过的所有部件（如灌装缸、装置和管
路等），于是就达到机械清洗的效果。为了进一步改善这种清洗效果，
可以使清洁度的程度增加到无菌的状态。
Water circulates through all the components (such as filling
cylinders, devices and pipes) of the beverage at high speed, thus
achieving the effect of mechanical cleaning. In order to further
improve the cleaning effect, the degree of cleanliness can be
increased to a sterile state.
每一种清洗过程可以区分为两类 Each cleaning process can be
divided into two categories：
a）机械清洗，此时，污垢粒子被弄松并被清除。
Mechanical cleaning, in which the dirt particles are loosened
and removed
b）籍助于热水或蒸汽的灭菌清洗。
Sterilization and cleaning of hot water or steam
为保证这种清洗工艺的成功，要有正确的条件
In order to ensure the success of this cleaning process,
correct conditions are needed.：
——温度 temperature
——机械方法 Mechanical method
——化学物质的浓度 Concentration of chemical substances
——反应时间 reaction time
原位清洗方法能使有关的清洗剂多次使用，在清洗时，浓度或温
度的损失由再次增加浓度或用再加热来加以补偿。同样的溶液如何经常
使用，必须视情况而定，一种溶剂可用 2 至 3 次。
The in-situ cleaning method can make the cleaning agent used
many times. When cleaning, the loss of concentration or temperature
is compensated by increasing concentration again or by reheating.
How often the same solution is used depends on the situation. A
solvent can be used two to three times.
* 功能顺序 Functional order
灌装机装有循环冲洗系统，灌装缸通过主液管来冲洗，而灌装缸
中的清洗剂通过一个 CIP 系统返回到储备缸，于是结束流程。
The filling machine is equipped with a circulating flushing system.
The filling cylinder is flushed through the main liquid pipe. The
cleaning agent in the filling cylinder is returned to the reserve
cylinder through a CIP system, and the process is terminated.
在生产的终了，残留在灌装机中的主液体，为了避免其渗入环路
中，应通过溢流阀来将它排放掉。
At the end of production, the main liquid remaining in the filling
machine should be discharged through the relief valve in order to
avoid its infiltration into the loop.
为了避免不必要的水以及化学药剂的损失，应确保在各个清洗过
程中要有个短暂的 “搅拌周期 ”，为此，在此清洗过程结束后，要尽可能
彻底将灌装机排干净。
In order to avoid the loss of unnecessary water and chemicals, it
is necessary to ensure that there is a short "mixing cycle" in each
cleaning process. Therefore, after the cleaning process, the filling
machine should be exhausted as thoroughly as possible.
位于灌装缸外侧的灌装阀零件也要进行定期的冲洗和清洗。
The filling valve parts located outside the filling cylinder should
also be washed and cleaned regularly.
在现代生产线上运行的大多数灌装机，为了每天或每周清洗的目
的，均装有清洗杯 (机器旋转清洗时必须把灌装机中间星轮导瓶板拆
除 )，这就保证了灌装阀外部零件和回气管的可靠清洗。
Most filling machines running on modern production lines are
equipped with cleaning cups for daily or weekly cleaning purposes

(when the machine rotates to clean, the guide plate of the star wheel
in the middle of the filling machine must be removed), which ensures
the reliable cleaning of the external parts of the filling valve and the
return pipe.
* 清洗剂的使用极限 Limits of use of lotions
清洗剂浓度接触时间温度
Lotion concentration contact time temperature
1.使用 NaOH 基的碱性液清洗 < 2% 30 分 80℃

Cleaning with NaOH-based alkaline solution < 2% 30minutes
80℃
2.用 NaOH 基的消毒液 +Na 次氯酸盐
（ PH 值 =12）混合清洗 < 2% 30 分 70℃
NaOH-based disinfectant + Nahypochlorite < 2%
30minutes 70℃
3.用 H 3 PO 4 基或 HNO 3 基（磷酸和硝酸）
的酸性清洗剂 < 1% 20 分 30℃
Use H3PO4 or HNO3 groups (phosphoric acid and nitric acid) < 1%
20minutes 30℃
4. Na 次氯酸盐基（ PH 值 =9）消毒液
活性氯不超过 200ppm（百万分之一） 20 分 20℃
Nahypochlorite group (PH=9) disinfectant
Active chlorine does not exceed 200 ppm (one millionth) 20 minutes
20℃
5.过脂酸基（ PES）消毒剂
工业用水的氯含量不超过 300 ppm< 0.1% 16 小时 20℃
Perfatty acid group (PES) disinfectant
The chlorine content of industrial water does not exceed 300 ppm
< 0.1% 16hours 20℃
6. Jodophor 基消毒剂
工业用水的氯离子含量不超过 300 ppm 16 小时 20℃
Jodophor-based disinfectant
The chloride ion content of industrial water does not exceed 300 ppm
16hours 20℃
活性碘 50ppm
7. 用热水消毒 45 分 95℃
Hot water 45min 95℃
8.用 0.5 巴蒸汽消毒（每一灌装位置在压力为 0.5 巴，温度为 +110°，
蒸汽消耗量为 2.5Kg) 45 分 110℃
Steam disinfection with 0.5 bar (at pressure of 0.5 bar at each filling
position, temperature of + 110 degree, steam consumption of 2.5 Kg)
45min 110℃
* 事后清洗 cleaning afterwards
在每一次外部清洗之后，或用清洗剂溢流，在现场清洗后用工业用
水对灌装机的内外表面进行事后冲洗是绝对必要的，要确保事后冲
洗过程的持续时间，使以后不可能用常规的分析方法检测出所用清
洗剂的各种化学特性。如果不这样，则由于酸和碱中所含水的蒸发
而造成浓度增加，导致灌装机所用材料的损坏，特别是塑料件的损
坏。
It is absolutely necessary to wash the inner and outer surface of
filling machine with industrial water after each external cleaning
or with the overflow of cleaning agent. It is necessary to ensure
the duration of the washing process after each external cleaning,
so that it is impossible to detect the chemical characteristics of
the cleaning agent used by conventional analysis methods in the
future. If not, the evaporation of water in acid and alkali will
increase the concentration, which will lead to the damage of
filling machine materials, especially plastic parts.
切勿使用磨蚀或强碱性的清洗剂、刮刀或其它锐利工具、苯、含铅
石油、丙酮或四氯化碳等用于清洗。
Do not use abrasive or alkaline cleaners, scrapers or other sharp

tools, benzene, lead-containing petroleum, acetone or carbon
tetrachloride for cleaning.
推荐在室温下用的清洗剂 Cleaner recommended for use at room
temperature：
异丙基醇 Isopropyl alcohol
氟利昂 TF Freon TF
乙醇 ethanol
甲醇 methanol
松节油代用品 Turpentine substitute
庚烷 Heptane
石油醚（沸点 6.5℃） Petroleum ether (boiling point 6.5 C)
丁醇 butanol
丁氧基乙醇 Butoxyethanol
二设备维护 equipment maintenance
* 灌装机的维护说明 Maintenance instructions
1 每日维护 daily maintenance
1.1 在灌装的终了，用水喷扫整个机器，并去掉所有赃物，将零件擦干
或者用压缩空气吹干。
当清洗工作时，要大致地检查机器的磨损和裂纹征兆。
At the end of filling, spray the whole machine with water, remove all
stolen goods, dry the parts or blow them with compressed air.
When cleaning, the wear and crack symptoms of the machine should
be roughly checked.
1.2 必须检查灌装阀及排气管，并重新调整。
Filling valves and exhaust pipes must be inspected and readjusted
1.3 检查油脂泵中的油脂供应，如果需要，应予补充。
Check grease supply in grease pump, if necessary, should be
supplemented
1.4 给灌装机冲洗并消毒。
Rinse and disinfect the filling machine

2 每周维护 weekly maintenance
2.1 检查齿轮装置的油脂，如果必要，手动润滑。
Check grease in gear unit and lubricate manually if necessary
2.2 每周两次润滑进瓶螺杆部件。
Lubricate the screw parts into the bottle twice a week
2.3 检查灌装元件的转换。
Check the conversion of filling elements
2.4 空气过滤器，检查过滤薄膜或过滤器滤筒，如果需要，更换之。
Air filter, check filter film or filter cartridge, replace if necessary
2.5 检查油水分离器。
Check oil-water separator
2.6 按润滑表进行润滑。
Lubrication by Lubrication Meter
3 每月维护
Monthly maintenance
3.1 清洗油垢。
Cleaning grease scale
3.2 对各润滑点进行润滑
Lubricate all lubricating points
4 每季维护
Quarterly maintenance
4.1 检查减速箱：按制造商说明书换油
Check gearbox: change oil according to manufacturer's instructions
4.2 及时进行润滑维护
Timely lubrication maintenance
5 每半年的维护 half-year maintenance
5.1 检查小齿轮轴承
Check pinion bearings
5.2 检查管接头是否漏油，如果需要则旋紧之或更换油封
Check whether the pipe joint is leaking, tighten or replace the oil seal
if necessary
5.3 检查瓶子导向元件，并拆开检查其损坏或磨损，如果必须，更换之
Check bottle guide components and remove them to check for
damage or wear. If necessary, replace them.
5.4 检查所有润滑点的漏油和正常功能
Check oil leakage and normal function of all lubrication points
5.5 按各润滑点进行润滑
Lubrication according to each lubrication point
* 拧盖机的维护说明 maintenance introduction of capping machine
1.1 每日维护按 1.1.1—1.1.4 的准则
Daily maintenance according to 1.1.1-1.1.4 criteria
1.1.1 在生产终了，用水冲洗机器并清除脏物，擦干光亮部份或用压缩
空气吹干。当清洗时，要大致检查机器的磨损或裂纹症兆。
At the end of production, rinse the machine with water and remove
dirt, dry the bright parts or blow dry with compressed air. When
cleaning, roughly check the wear or crack symptoms of the machine
1.1.2 彻底清洗料斗、转动机构、和瓶盖滑道。
Thoroughly clean hopper, rotating mechanism, and cap slideway
1.1.3 对拧盖头上部零件进行清洗和消毒。
Cleaning and disinfection of upper parts of screw cap head
1.1.4 各润滑点进行润滑
Lubrication at each lubrication point
1.2 每周维护按 1.2.1—1.2.3 的准则
Weekly maintenance according to 1.2.1-1.2.3 criteria
1.2.1 如果需要，检查齿轮箱油位，并加满。
If necessary, check the oil level of the gearbox and fill it up
1.2.2 按润滑卡润滑
Lubrication by Lubrication Card
1.3 每月维护按 1.3.1—1.3.4 的准则
Monthly maintenance according to 1.3.1-1.3.4 criteria
1.3.1 检查拧盖头的导向柱塞和压力滚轮
Check the guide plunger and pressure roller of the screw cap
1.3.2 检查瓶盖的拧盖尺寸，如果需要，调整之
Check the screw cap size of the bottle cap and adjust it if necessary
1.3.3 检查下盖过渡转盘的调节
Check the adjustment of the lower cover transition turntable
1.3.4 各润滑点进行润滑 +
Lubrication at each lubrication point
2． 4 六个月的维护 maintenance of six months
1.4.1 每日维护按 1.1.1—1.1.4 的准则
Daily maintenance according to 1.1.1-1.1.4 criteria
1.4.2 每周维护按 1.2.1—1.2.2 的准则
Weekly maintenance according to 1.2.1-1.2.2 criteria
1.4.3 每月维护按 1.3.1—1.3.4 的准则
Monthly maintenance according to 1.3.1-1.3.4 criteria
1.4.4 检查料斗回转盘的轴承部件
Inspection of Bearing Components of Hopper Rotary Disk
1.4.5 拆下拧盖头并进行彻底清洗
Remove the screw cap and thoroughly clean it
三安装、调整 install and adjustment

1 设备基础，安装条件及安装的技术要求
Equipment Foundation, Installation Conditions and Technical Requirements for
Installation
地面平整，单位平方厘米承重大于 10Kg；厂房高度不低于 3.3 米（配自动
上盖机）。
Ground is flat, unit square centimeter bearing weight of 10 Kg; plant height
not less than 3.3 meters (with automatic capping machine)
2 安装程序，方法及注意事项 install progress solution and points for attention
2．1 由于设备较重无需地脚螺栓将机器固定在地面上，设备应安装在能承载的
基础上。整机调整地脚水平。调整工作高度与整条线高度相同，检查调整的连接
部分的连接件是否坚固，运动零部件是否运动自如。
Because the equipment is heavy and does not need foot bolts to fix the
machine on the ground, the equipment should be installed on the basis of
carrying capacity. The whole machine adjusts the foot level. Adjust the height
of the work with the same height of the whole line, check whether the
connecting parts of the adjustment part are strong, and whether the moving
parts are moving freely.
2．2 与输瓶带连接好，并调整好相对位置和高度。
Connect well with the bottle belt and adjust the relative position and height.
2．3 连接好设备和外部管道。Connect equipment and external piping
A 主液管 Main liquid pipe
B 压缩空气管 Compressed air pipe
C 冲瓶机进水管 Bottle washing machine intake pipe
D 冲瓶机回水管 Bottle washing machine outtake pipe
E 其它管路 other pipelines
2．4 电气连接 Electrical connection
机器内部电器控制出厂时已调好。只要连接外部电源即可。
The internal electrical control of the machine has been adjusted when it
leaves the factory. Just connect the external power supply.
3 调整 adjustment
设备在试车前的调整非常重要，应对本机认真调整，并作好试车前的准备
工作，调整时用的瓶和盖与正常生产时用的相同。
The adjustment of equipment before commissioning is very important.
The machine should be adjusted carefully and the preparation work before
commissioning should be done well. The bottles and caps used in the
adjustment are the same as those used in normal production.
A 本机高度与输瓶带一致，输瓶带的速度与本机回转线速度一致。
The height of the machine is the same as that of the bottle conveying belt,
and the speed of the bottle conveying belt is the same as that of the rotary line
of the machine.
B 调整好冲瓶机的工作高度。以瓶颈能被冲瓶机瓶夹夹住，且瓶夹最大外
圆处与进瓶星轮不干涉，且能在冲瓶机瓶夹上下活动。检查或调整定位装置是否
正确，瓶夹的位置是否正确。
Adjust the working height of the bottle washing machine. The bottleneck
can be clamped by the bottle clip of the bottle washing machine, and the
maximum outer circle of the bottle clip does not interfere with the entry star
wheel, and can move up and down the bottle clip of the bottle washing
machine. Check or adjust the positioning device correctly and the position of
the bottle clamp correctly.
C 调整好灌装机的工作高度。使灌装机瓶口定位板与进出星轮高度一致，
瓶子进出通畅，液位控制正确。
Adjust the working height of filling machine. Make the positioning plate of
the bottle mouth of the filling machine consistent with the height of the stellar
wheel in and out, make the bottle in and out unobstructed, and control the
liquid level correctly.
D 调整好拧盖机的工作高度。以瓶颈能被拧盖机内定位块卡住，调整好拧
盖力矩 1.6～2.2N.M（或按用户要求）。
Adjust the working height of the capping machine. The bottleneck can be
clamped by the positioning block in the capping machine, and the capping
machine moment can be adjusted from 1.6 to 2.2N.M (or according to the
user's requirements).
E 调整好料斗的出盖量，调整料斗电机的转速使料斗的出盖量为实际生产
量的 1.2 倍。
Adjust the amount of hopper cover and adjust the speed of hopper motor
to make the amount of hopper cover 1.2 times the actual production.
4 安装，调整后的验收项目、方法和判断 Installation, adjusted acceptance items,
methods and judgments
A 进出瓶及导向通畅平稳，无卡阻现象。
Entry and exit bottles and guide smooth and smooth, no obstruction
phenomenon
B 冲瓶机进出平稳，瓶夹夹持可靠，翻转灵活。冲瓶机进回水管无泄漏。
Bottle washing machine has smooth entry and exit, reliable clamping and
flexible turnover. No leakage of inlet and return pipes of bottle washing
machine
C 灌装阀的流量大于 130ml/s，灌装液位到瓶口距离在 50mm 以内可调。
The flow rate of filling valve is more than 130 ml/s, and the distance
between filling liquid level and bottle mouth is adjustable within 50 mm.
D 拧盖机拧盖力矩恒定。拧盖机进气管无泄漏。
The capping moment of the capping machine is constant. No leakage of

intake pipe of screwdriver
E 料斗的出盖量为实际生产量的 1.2 倍。
The capping capacity of hopper is 1.2 times of actual production.
F 瓶盖外表面无划伤。
No scratch on the outer surface of bottle cap
5 试运行前的准备，试运行启动，试运行
Preparations before commissioning, start-up and commissioning
在生产条件具备的情况下 Under the condition of production conditions all
provided：
A 检查电气性能和各项动作是否符合设计要求；
Check whether the electrical performance and various actions meet the
design requirements
B 检查设备与外部连接管路，水、气及其它管路是否正确，有无泄漏；
Check whether the equipment is correctly connected to the external
pipeline, water, gas and other pipelines, and whether there is leakage or not.
C 检查所需试车的瓶型是否有足够的瓶数量；
Check whether there are enough bottles for the test run.
D 检查各部分变更件是否与瓶型相符；
Check whether the parts are in conformity with the bottle type
E 检查料斗中盖型是否相符，数量是否足够；
Check whether the cap type in hopper is consistent and the quantity is
enough.
F 试车前设备内外部的情况（注意保护电气元件）；
Internal and external conditions of equipment before commissioning
(attention should be paid to protecting electrical components)
G 试车（可以用城市生活自来水冲洗）。
Test run (washable with city running water)
试车完毕后，按设备清洗要求进行清洗。
After test run, cleaning according to equipment cleaning requirements
四使用，操作 operation
1 使用前的准备，检查 check and preparation
2 保养时注意事项 attentions while maintenance

A 清洗时不宜将水进入齿轮，轴承，各密封件，工作台内部。油漆表面的残
留液应擦洗干净。
When cleaning, water should not enter gear, bearing, seals and worktable.
Residual liquid on paint surface should be scrubbed clean
B 在对零部件进行维修保养时，尽量不要破坏零件外表面，密封件和非金属
件。
In the maintenance of spare parts, try not to destroy the outer surface of
the parts, seals and non-metallic parts.
C 需事先填装润滑脂的地方，在保养过程中均应补充足够润滑脂。
Where grease needs to be filled in advance, adequate grease should be
added during maintenance.
D 配套件（如电机，减速机）的保养应按厂家提供的说明书保养，如有必要，
可请专业厂家协助进行维修保养。
Maintenance of accessories (e.g. motor, reducer) shall be in accordance
with the manufacturer's instructions. If necessary, professional manufacturers
may be invited to assist in maintenance.
3 设备电气的说明（参见电气使用说明书）
Instructions for electrical equipment (see Electrical Instructions)
五故障分析与排除 Fault analysis and troubleshooting

fault analysis Solve solution

Check whether the motor is out of phase or
Insufficient voltage or improper electrical
wrong in operation ；
The machine operation ；
Manual startup of hopper motor to cover the
can't turn. Slide cap missing;
slide way ；
bottle stoppage in bottle outlet；
Cleaning of bottle with blockage ；
Quality of bottles ； Check the quality of bottles ；

Bottles cannot
Star wheel Extrusion Blockage ； Adjusting Star Wheel Extrusion Blockage ；
be properly input
Adjusting the Height of Star wheel Plate and
or shake Star wheel Plate and Transition Plate Height ； Transition Plate ；
Installation improper, reinstallation or parts
The nozzle is crooked ； manufacturing errors, replacement parts ；
The spray is umbrella-shaped, or the water Check whether the intake pressure meets the
Irregular column cannot reach the bottom of the bottle. ； requirement or if there is foreign matter in the
washing There are debris on the wear resistant disc in the nozzle or in the pipeline, and remove it. ；
distributor, which causes water leakage. Reinstallation adjustment ；
Failure of Electric or Gas Control System ； Find out the cause of the malfunction and
remove it ；
something in filling valve ；
something in filling valve ；
Removal of foreign body in slide sleeve of
Irregular filling Backflow of filling valve is not smooth ；
filling valve ；
Non-standard size and shape of bottle mouth ；
Remove substandard bottles ；
Drop leakage of Insufficient main spring pressure of filling valve ； Replacement of main spring of filling valve ；
filling valve Damage of O-ring ； Replacement of O-ring
Damage of shunt umbrella
Replacement of shunt umbrella
Incorrect filling Leakage between bottle and filling valve
Change qualified bottles
level There are foreign objects in comb ring of filling
Clean up debris
valve
The position of the capping plate and the capping
head is skewed. Bottle neck guard loosened on
capping machine Adjust capping plate
The misalignment between the capping head and Tighten the bottleneck guard ring
Not tightly
the locating ring of the bottleneck of the clamp is Adjust the position of bottleneck retainer
screwed
not good. Increasing Torque
Insufficient Torque of capping Head Replacement of suitable screw cap ring
Too loose fit clearance between capping ring and
cap
Bottle incoming
and outgoing of Inside and out of bottle star wheel is not Synchronization of adjusting the star wheel of
filling machine synchronized with filling machine ； the bottle in and out with the filling machine ；
are not smooth
六图、表 Sheet
A 气动原理图 Pneumatic schematic diagram

B 电气原理图 Electrical schematic diagram
七随机技术文件 Random Technical Documents
A 使用说明书 An instruction manual
B 合格证明书 Certificate of Conformity
C 装箱单 Packing list
D 随机备件清单 Random spare parts list
合格证
（ZJ—7.5—06） NO：
产品型号：
产品名称：
出厂编号：
本产品经检验合格，准予出厂。
检验员：
质检部长：
日期：年月日
装箱单
（ZJ—7.5—01） NO：
包装箱号：箱体尺寸：
净重：毛重：
一、主机及辅机
序号代号名称规格数量备注
1
2
3
4
二、随机备件
见使用说明书
三、随机技术文件
1
2 `
3
4
5
四、随机工具清单
1
2
3
4
5
6
7

Beverage Drink Filling Machine

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DCGF18-18-6 rinsing filling capping machine 冲瓶灌装拧盖机 第 1 页 共 51页

二、设备维护 Equipment maintenance................................................................ 35

第一部分 概 述 Part.1 Summary

一、一般安全参考 General safety reference

Use the 在操作面板和机器上的紧急关机开关只有在操作人员或机器

Once activated, the emergency shutdown switch is automatically locked

二、中途贮存 Midway Storage

环境温度须在零下 10 度至零上 50 度之间。

The ambient temperature should be between -10℃ and 50℃。

在 出 现 下 列 情 况 时 也 适 用 以 上 做 法 The above practices are also

三、安 全 须 知 Safety instructions

such work, or if several persons are working on the machine or in

1.产品的用途及适用范围 Use and scope of application of products

This machine is a new product developed on the basis of

2.设备组成 Equipment Composition

3 技术特点 technical characteristics

the track, and the inside of the bottle is flushed.

6 安全装置 Safety device

在机器操作台上设有一个急停开关。 There is an emergency stop switch

五、主要技术参数 Main technical parameters

第二部分 各单机介绍 single part introduction

一 冲瓶机 washing machine

2 设备组成及结构介绍 equipment construction

2.2 主传动装置（图一） main transmission (picture 1)

2.4 夹钳装置（图二） clip machine (picture 2)

2.5 分配器（图三） dispenser (picture 3)

2.7 翻转凸轮（图四） Flip cam (picture 4)

do not adjust it at will.

二 灌装机 filling part

Turntable is the key component connecting filling machine with worktable

2.2 灌装缸（图七） filling cylinder (picture 7)

2.4 升降凸轮与拉下凸轮（图九）Lifting Cam and Pull-down Cam(picture 9)

2.5 上分配器（图十） up distributor(picture 10)

2.6 开阀装置（图十一） Opening Valve device

图十二、闭阀装置 picture 12 Closing Valve Device

图十三、排气装置 picture 13 exhaust device

2.8 吹气装置（图十四） blower part (picture 14)

后关闭。这样，酒缸中的 CO2 气体把回气管中残留的物料吹出来，防止下次灌

逆压情况下打开，灌装缸内的压缩空气或 CO2 气先通过充气阀杆（4）开口，再

After the bottle is determined by the "no-bottle-no-filling" mechanism, the

air outlet of the trachea.

by step through the valve stem and the injection valve.

图十六、灌装阀结构 picture 16 valve structure

2.11 对中导向（图十八）sensor guide

三 拧盖机 capping part

2 设备组成及结构介绍 Equipment Composition and structure introduction

2.1 料斗及滑道部件 Hopper and slide way components

capping plate smoothly. In order to prevent accidents, a dial wheel (6)

2.3 拧盖机主轴部分 principal axis of capping part

2.5 滑套装置（图二十）Sliding sleeve device (picture 20)

2.6 拧盖头（图二十一） capping heads

四 工作台及传动 working platform and conveyor

1 输瓶部件 Bottle conveying parts

transferred to the conveyor belt by the star wheel.

.2 驱动装置 drive part

一 CIP 清洗系统 CIP cleaning system

清洗的基本原则和目的 Basic principle and cleaning purpose

equipped with cleaning cups for daily or weekly cleaning purposes

1.使 用 NaOH 基 的 碱 性 液 清 洗 < 2% 30 分 80℃

Do not use abrasive or alkaline cleaners, scrapers or other sharp

二 设备维护 equipment maintenance

Rinse and disinfect the filling machine

DCGF18-18-6 rinsing filling capping machine 冲瓶灌装拧盖机第 1 页共 51页

第一部分概述 Part.1 Summary

在出现下列情况时也适用以上做法 The above practices are also

三、安全须知 Safety instructions

第二部分各单机介绍 single part introduction

一冲瓶机 washing machine

二灌装机 filling part

三拧盖机 capping part

四工作台及传动 working platform and conveyor

1.使用 NaOH 基的碱性液清洗 < 2% 30 分 80℃

二设备维护 equipment maintenance

三安装、调整 install and adjustment

五故障分析与排除 Fault analysis and troubleshooting