Optimization of Robotic Beverage Bottling Lines Based on Mathematical Modeling and Process Efficiency Analysis

Abstract

This study focuses on the development of a mathematical model that incorporates hydraulic, mechanical, and electromechanical processes occurring in beverage bottling and container transport systems. The model aims to identify pump and drive optimal operating modes to minimize total energy losses while maintaining the required production output. Enhancing productivity while simultaneously reducing energy consumption is a top priority in modern robotic bottling lines. Under conditions of uneven loading and improper selection of drive and pump parameters, efficiency losses can reach up to 30 %. Optimizing such systems can significantly lower costs and improve competitiveness for both large-scale producers and mid-sized enterprises in the food industry. In this work, an approach that includes analysis and modeling of energy consumption and losses in system components such as drives, conveyor belts, and frequency converters, was developed. A comprehensive modeling framework combines hydrodynamic equations for evaluating flow rate and pressure in pipelines with regard to tribological losses in conveyor elements. The characteristics of drives and pumps, including the effects of frequency regulation and torque on overall efficiency, were taken into account. Calculations at different speeds and load levels were performed to identify the key factors determining energy consumption. The modeling confirmed the potential for improving energy efficiency and operational stability by means of optimal tuning of main system components, including friction coefficients in moving conveyor elements, thus opening prospects for further development and optimization of similar manufacturing processes. Field experiment data were used to verify the model accuracy, with the results compared against real operating parameters of analogous conveyor lines. Based on the analysis, strategies to optimize component operation and enhance overall efficiency in transportation and bottling processes, are proposed.