References and projects

Automatic test station for filling valves

My master craftsman project from 2025 – built by myself, from mechanical design to CE documentation.

Starting point

Each filling valve of a can filling line fills up to 700 cans per hour. Until now they could only be tested individually during the annual shutdown.

Solution

A mobile test station simulates the filling process with purge gas, pressurisation, filling and relief. It tests every valve for leaks, opening behaviour and flow, with an automatic test sequence and report.

Technology

Siemens S7-1500 with ET200SP, MTP1000 HMI panel, TIA Portal V18 with FBD and GRAPH, IO-Link pressure sensors, magnetic-inductive flowmeter, proportional pressure regulator, Pilz safety relay with emergency stop and automatic pressure relief. Control panel to an EPLAN drawing, stainless steel frame and buffer tank designed and welded by myself.

Documentation

Workshop drawings, circuit diagrams, program documentation, parts list, risk assessment, instructions for use and EU declaration of conformity.

Result

The station detects defective valves before installation and tests repaired valves before they go back into stock. Master craftsman examination passed with distinction.