U.S. patent application number 11/893130 was filed with the patent office on 2008-03-20 for cooling air system for a patty-forming apparatus.
Invention is credited to Salvatore Lamartino, Glenn Sandberg.
Application Number | 20080066627 11/893130 |
Document ID | / |
Family ID | 34381977 |
Filed Date | 2008-03-20 |
United States Patent
Application |
20080066627 |
Kind Code |
A1 |
Lamartino; Salvatore ; et
al. |
March 20, 2008 |
Cooling air system for a patty-forming apparatus
Abstract
A cooling air system is provided for a patty-forming apparatus
having a machine base that includes an enclosing wall and contains
equipment within the machine base that generates heat, such as
electric motors, electrical and control equipment. The machine base
includes an air inlet opening and an air outlet opening through the
enclosing wall. At least one air fan is arranged to move outside
air from the air inlet opening to the air outlet opening. A first
air damper is arranged to close the air inlet opening. A second air
damper is arranged to close the air outlet opening. The first and
second air dampers are configured to automatically close if power
is interrupted to the apparatus. The dampers each includes a cover
or plate and at least one inlet pneumatic cylinder that elevates
the cover above the inlet or outlet opening when energized,
allowing outside air to pass through the machine base. Springs are
arranged such that when the pneumatic cylinders are de-energized,
the springs urge the covers onto the openings to close up the
machine base.
Inventors: |
Lamartino; Salvatore;
(Orland Park, IL) ; Sandberg; Glenn; (New Lenox,
IL) |
Correspondence
Address: |
THE LAW OFFICE OF RANDALL T. ERICKSON, P.C.
1749 S. NAPERVILLE ROAD
SUITE 202
WHEATON
IL
60187
US
|
Family ID: |
34381977 |
Appl. No.: |
11/893130 |
Filed: |
August 14, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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|
10942627 |
Sep 16, 2004 |
7255554 |
|
|
11893130 |
Aug 14, 2007 |
|
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60503354 |
Sep 16, 2003 |
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60515585 |
Oct 29, 2003 |
|
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60571368 |
May 14, 2004 |
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Current U.S.
Class: |
99/447 |
Current CPC
Class: |
A22C 7/003 20130101;
A23P 30/10 20160801; A22C 7/0038 20130101; A22C 7/0023 20130101;
A22C 7/0084 20130101 |
Class at
Publication: |
099/447 |
International
Class: |
A22C 7/00 20060101
A22C007/00 |
Claims
1. In a patty-forming apparatus having a machine base having an
enclosing wall and containing equipment within said machine base
that generates heat, the improvement comprising: an air inlet
opening and an air outlet opening through said enclosing wall; an
air fan arranged to move outside air from said air inlet opening to
said air outlet opening; a first air damper arranged to close one
of said air inlet opening or said air outlet opening, said first
air damper configured to automatically close if power is
interrupted to said apparatus.
2. The patty forming apparatus according to claim 1, wherein said
first air damper is arranged to close said air inlet opening, and
further comprising a second air damper arranged to close said air
outlet opening, said second air damper configured to automatically
close if power is interrupted to said apparatus.
3. The patty forming apparatus according to claim 2, wherein said
inlet opening is located on a top side of said machine base, and
said first damper comprises a cover and at least one inlet
pneumatic cylinder that elevates said cover above said inlet
opening when energized, allowing outside air to enter said inlet
opening, and at least one inlet spring configured such that when
said inlet pneumatic cylinder is de-energized, said inlet spring
urges said cover onto said inlet opening to close said inlet
opening.
4. The patty forming apparatus according to claim 3, wherein said
outlet opening is located on a bottom of said machine base, and
said second damper comprises a plate over said outlet opening and
an outlet pneumatic cylinder operatively connected to said plate to
elevate said plate above said outlet opening to open said outlet
opening when said outlet pneumatic cylinder is energized, and an
outlet spring arranged to urge said plate onto said outlet opening
to close said outlet opening when said outlet pneumatic cylinder is
de-energized.
5. The patty forming apparatus according to claim 1, wherein said
inlet opening is located on a top side of said machine base, and
said first damper comprises a cover and at least one inlet
pneumatic cylinder that elevates said cover above said inlet
opening when energized, allowing outside air to enter said inlet
opening, and at least one inlet spring configured such that when
said inlet pneumatic cylinder is de-energized, said inlet spring
urges said cover onto said inlet opening to close said inlet
opening.
6. The patty forming apparatus according to claim 1, wherein said
outlet opening is located on a bottom of said machine base, and
said first damper comprises a plate over said outlet opening and an
outlet pneumatic cylinder operatively connected to said plate to
elevate said plate above said outlet opening to open said outlet
opening when said outlet pneumatic cylinder is energized, and an
outlet spring arranged to urge said plate onto said outlet opening
to close said outlet opening when said outlet pneumatic cylinder is
de-energized.
7. The improvement according to claim 1, wherein said air inlet
opening is formed through an upper portion of said enclosing wall
and said air outlet is formed through a lower portion of said
enclosing wall.
8. The improvement according to claim 1, wherein said first damper
comprises a cover that is pneumatically powered to lift away from
said air inlet opening to open said air inlet opening.
9. The improvement according to claim 1, wherein said second damper
comprises a cover that is pneumatically powered to lift away from
said air outlet opening to open said air outlet opening.
10. The improvement according to claim 1, wherein said first air
damper is arranged to close said air inlet opening and further
comprising a second air damper arranged to close said air outlet
opening, said first air damper arranged outside of said enclosing
wall and said second air damper arranged within said enclosing
wall.
Description
[0001] This application claims the benefit of U.S. provisional
application Ser. No. 60/503,354, filed Sep. 16, 2003; U.S.
provisional application Ser. No. 60/515,585, filed Oct. 29, 2003;
and U.S. provisional application Ser. No. 60/571,368, filed May 14,
2004.
BACKGROUND OF THE INVENTION
[0002] Use of pre-processed foods, both in homes and in
restaurants, has created a demand for effective high-capacity
automated food processing equipment. That demand is particularly
evident with respect to hamburgers, molded steaks, fish cakes, and
other molded food patties.
[0003] Food processors utilize high-speed molding machines, such as
FORMAX F-6, F-12, F-19, F-26 or F-400 reciprocating mold plate
forming machines, available from Formax, Inc. of Mokena, Ill.,
U.S.A., for supplying patties to the fast food industry. Prior
known high-speed molding machines are also described for example in
U.S. Pat. Nos. 3,887,964; 4,372,008; 4,356,595; 4,821,376; and
4,996,743 herein incorporated by reference. Patty-forming machines
include an enclosed base that houses heat generating equipment. A
cooling air circulating system is provided to eliminate heat from
inside the machine base.
[0004] Patty-forming machines must be cleaned and sanitized
periodically during operation in a processing plant. During
periodic spray cleaning and sanitizing of patty-forming machines,
care must be taken that spray and wash debris doesn't enter and
contaminate the machine base.
[0005] Although heretofore known FORMAX patty-molding machines have
achieved commercial success and wide industry acceptance, the
present inventors have recognized that needs exist for a
patty-forming machine that is effectively cooled and is more easily
maintained and cleaned, and which avoids contamination during spray
cleaning.
SUMMARY OF THE INVENTION
[0006] The present invention provides an improved cooling air
system for a patty-forming apparatus having a machine base. The
machine base includes an enclosing wall and contains equipment
within the machine base that generates heat, such as electric
motors, electrical and control equipment. The machine base includes
an air inlet opening and an air outlet opening through the
enclosing wall. At least one air fan is arranged to move outside
air from the air inlet opening to the air outlet opening. A first
air damper is arranged to close one of the air inlet opening or the
air outlet opening. The first air damper is configured to
automatically close if power is interrupted to the apparatus.
[0007] According to a further enhancement of the invention, the
first air damper is arranged to close the air inlet opening, and a
second air damper is arranged to close the air outlet opening. The
second air damper is also configured to automatically close if
power is interrupted to the apparatus.
[0008] According to the preferred embodiment, the inlet opening is
located on a top side of the machine base, and the first damper
comprises a cover and at least one inlet pneumatic cylinder that
elevates the cover above the inlet opening when energized, allowing
outside air to enter the inlet opening. An inlet spring can be
arranged such that when the inlet pneumatic cylinder is
de-energized, the inlet spring urges the cover onto the inlet
opening to close the inlet opening.
[0009] According to the preferred embodiment, the outlet opening is
located on a bottom of the machine base, and the second damper
comprises a plate over the outlet opening. An outlet pneumatic
cylinder is operatively connected to the plate to elevate the plate
above the outlet opening to open the outlet opening when the outlet
pneumatic cylinder is energized. An outlet spring can be arranged
to urge the plate onto the outlet opening to close the outlet
opening when the outlet pneumatic cylinder is de-energized.
[0010] According to the preferred embodiment, the first air damper
arranged outside of the enclosing wall and the second air damper is
arranged within the enclosing wall.
[0011] The dampers of the invention can be automatically closed by
the springs and/or by gravity if electric power is lost to the
machine, causing the pneumatic actuators to be de-actuated.
[0012] Thus, when the machine is powered down for cleaning, the
dampers automatically close the air intake and/or outlet openings.
The fan will be powered off. This effectively battens down the
machine base and prevents wash water, spray and contaminants from
entering the machine base. Also, the fact that the machine is
pressurized during operation by the fans can prevent some
contaminants from entering the machine base during operation.
[0013] Numerous other advantages and features of the present
invention will be become readily apparent from the following
detailed description of the invention and the embodiments thereof,
and from the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a perspective view of a patty-forming machine of
the present invention;
[0015] FIG. 1A is an elevational view of the patty-forming machine
of FIG. 1;
[0016] FIG. 2 is a longitudinal sectional view of the patty-forming
machine of FIG. 1, with components and/or panels removed for
clarity;
[0017] FIG. 3 is a sectional view taken generally along line 3-3 of
FIG. 2, with components and/or panels removed for clarity;
[0018] FIG. 4 is a sectional view taken generally along line 4-4 of
FIG. 2, with components and/or panels removed for clarity;
[0019] FIG. 5 is a sectional view taken generally along line 5-5 of
FIG. 2, with components and/or panels removed for clarity;
[0020] FIG. 6 is a sectional view taken generally along line 6-6 of
FIG. 2, with components and/or panels removed for clarity;
[0021] FIG. 7 is a sectional view taken generally along line 7-7 of
FIG. 2, with components and/or panels removed for clarity;
[0022] FIG. 8 is a sectional view taken generally along line 8-8 of
FIG. 2, with components and/or panels removed for clarity;
[0023] FIGS. 9A-9K are enlarged fragmentary sectional views taken
from FIG. 2, showing the machine configuration as the mold plate is
moved along its path of reciprocation;
[0024] FIG. 10A is a fragmentary sectional view taken generally
along line 10A-10A of FIG. 9A, with components and/or panels
removed for clarity;
[0025] FIG. 10B is a fragmentary sectional view taken generally
along line 10B-10B of FIG. 9E, with components and/or panels
removed for clarity;
[0026] FIG. 11A is a fragmentary sectional view taken generally
along line 11A-11A of FIG. 9A, with components and/or panels
removed for clarity;
[0027] FIG. 11B is a fragmentary sectional view taken generally
along line 11B-11B of FIG. 9E, with components and/or panels
removed for clarity;
[0028] FIG. 12 is a fragmentary sectional view taken generally
along line 12-12 of FIG. 9B, with components and/or panels removed
for clarity;
[0029] FIG. 13 is an enlarged fragmentary sectional view taken
generally along line 13-13 of FIG. 2;
[0030] FIG. 13A is a fragmentary sectional view taken from FIG. 13,
with components removed for clarity;
[0031] FIG. 14 is a fragmentary sectional view taken generally
along line 14-14 of FIG. 13;
[0032] FIG. 15 is a schematic block diagram showing a control
system of the patty-forming machine
[0033] FIG. 16 is a fragmentary sectional view taken generally
along line 16-16 of FIG. 2;
[0034] FIG. 16A is a fragmentary sectional view taken generally
along line 16A-16A of FIG. 16;
[0035] FIG. 16B is an enlarged fragmentary sectional view taken
from FIG. 4;
[0036] FIG. 16C is a fragmentary sectional view taken generally
along line 16C-16C of FIG. 16B;
[0037] FIG. 16D is a sectional view taken generally along line
16D-16D of FIG. 16C;
[0038] FIG. 17 is an elevational view of a tube valve of the
present invention;
[0039] FIG. 18 is a sectional view taken generally along line 18-18
of FIG. 17;
[0040] FIG. 19 is a sectional view taken generally along line 19-19
of FIG. 17;
[0041] FIG. 20 is a sectional view taken generally along line 20-20
of FIG. 17;
[0042] FIG. 21 is an elevational view taken generally along line
21-21 of FIG. 20;
[0043] FIG. 22 is an enlarged diagrammatic cross section of the
tube valve of FIG. 17, showing the positions of and rotary expanse
of inlet and outlet ports of the tube valve;
[0044] FIG. 23 is an enlarged fragmentary sectional view taken
generally along line 23-23 of FIG. 5;
[0045] FIG. 24 is an enlarged fragmentary sectional view taken from
FIG. 5;
[0046] FIG. 24A is an elevational view of a bushing taken from FIG.
23;
[0047] FIG. 25 is a view taken generally of along line 25-25 of
FIG. 24;
[0048] FIG. 25A is a sectional view taken generally of along line
25A-25A of FIG. 25;
[0049] FIG. 26 is an enlarged, sectional view taken generally along
line 26-26 of FIG. 2;
[0050] FIG. 27 is an enlarged, sectional view taken generally along
line 27-27 of FIG. 2;
[0051] FIG. 28 is a diagrammatic view of the frame system of the
invention;
[0052] FIG. 29 is an enlarged, fragmentary sectional view taken
from the left side of FIG. 2;
[0053] FIG. 30 is an enlarged, fragmentary sectional view taken
from a front portion of FIG. 2, with components and/or panels
removed for clarity;
[0054] FIG. 31 is sectional view taken generally along line 31-31
of FIG. 30;
[0055] FIG. 32 is sectional view taken generally along line 32-32
of FIG. 31 in a first stage of operation;
[0056] FIG. 33 is sectional view similar to FIG. 31 in a second
stage of operation;
[0057] FIG. 34 is a diagrammatic view of a lube oil system of the
invention;
[0058] FIG. 35 is an enlarged fragmentary sectional view taken from
the right side of FIG. 6;
[0059] FIGS. 36-38 are alternate mold plate and fill slot
arrangements for the patty-forming machine;
[0060] FIG. 39 is a sectional view of an alternate embodiment of
the valve arrangement shown in FIG. 12, taken generally along line
39-39 from FIG. 9A;
[0061] FIG. 40 is a sectional view taken generally along line 40-40
of FIG. 39;
[0062] FIG. 41 is a sectional view taken generally along line 41-41
of FIG. 39;
[0063] FIG. 42 is a diagram of the frame system of the
patty-forming machine;
[0064] FIG. 43 is an enlarged view of a portion of the frame system
taken from FIG. 42;
[0065] FIG. 44 is an exploded perspective view of a hopper and some
attached components of the patty-forming machine;
[0066] FIG. 45 is an enlarged fragmentary sectional view taken
generally along line 45-45 of FIG. 5.
[0067] FIG. 46 is an enlarged, fragmentary sectional view taken
generally along line 46-46 of FIG. 2 and showing a further aspect
of the invention;
[0068] FIG. 47 is a sectional view taken generally along line 47-47
of FIG. 46;
[0069] FIG. 48 is a plan view of an alternate embodiment tube valve
of the invention in a first rotary position;
[0070] FIG. 49 is a plan view of an alternate embodiment tube valve
of the invention in a second rotary position;
[0071] FIG. 50 is a plan view of the alternate embodiment tube
valve of FIG. 49 in a third rotary position;
[0072] FIG. 51 is a plan view of the alternate embodiment tube
valve of FIG. 49 in a fourth rotary position;
[0073] FIG. 52 is a sectional view taken generally along line 52-52
of FIG. 46;
[0074] FIG. 53 is a sectional view taken generally along line 53-53
of FIG. 6;
[0075] FIG. 59 is a position versus time diagram for a mold plate
according to the invention;
[0076] FIG. 54A is a fragmentary sectional view taken generally
along line 54A-54A of FIG. 13A showing the knockout apparatus in a
rear position, with some panels and/or components removed for
clarity;
[0077] FIG. 54B is a sectional view similar to FIG. 36A showing the
knockout apparatus in a forward position;
[0078] FIG. 55 is an exploded perspective view of a portion of FIG.
2;
[0079] FIG. 56 is an exploded perspective view of a portion of the
frame structure of the apparatus;
[0080] FIG. 57 is an exploded perspective view of a rear portion of
the frame structure of the apparatus;
[0081] FIG. 58 is an exploded perspective view of a front portion
of the frame structure of the apparatus;
[0082] FIG. 60 is a diagram of a first mold plate waveform;
[0083] FIG. 61 is a diagram of a second mold plate waveform;
[0084] FIG. 62 is a diagram of a third mold plate waveform; and
[0085] FIG. 63 is a diagram of a fourth mold plate waveform.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0086] While this invention is susceptible of embodiment in many
different forms, there are shown in the drawings, and will be
described herein in detail, specific embodiments thereof with the
understanding that the present disclosure is to be considered as an
exemplification of the principles of the invention and is not
intended to limit the invention to the specific embodiments
illustrated.
General Description Of The Apparatus
[0087] The high-speed food patty molding machine 20 illustrated in
the figures comprises an exemplary embodiment of the invention.
This application incorporates by reference U.S. provisional
application Ser. No. 60/571,368, filed May 14, 2004; U.S.
Application Ser. No. 60/503,354, filed Sep. 16, 2003 and U.S.
Provisional Application Ser. No. 60/515,585, filed Oct. 29,
2003.
[0088] The molding machine 20 includes a machine base 21,
preferably mounted upon a plurality of feet 22, rollers or wheels.
The machine base 21 supports the operating mechanism for machine 20
and can contain hydraulic actuating systems, electrical actuating
systems, and most of the machine controls. The base can be clad in
3/16 inch stainless steel panels or skin. The machine 20 includes a
supply 24 for supplying moldable food material, such as ground
beef, fish, or the like, to the processing mechanisms of the
machine.
[0089] A control panel 19, such as a touch screen control panel, is
arranged on a forward end of the apparatus 20 and communicates with
a machine controller 23, shown in FIG. 24.
[0090] As generally illustrated in FIGS. 2-6, supply means 24
comprises a large food material storage hopper 25 that opens into
the intake of a food pump system 26. The food pump system 26
includes at least two food pumps 61, 62, described in detail
hereinafter, that continuously, or intermittently under a
pre-selected control scheme, pump food material, under pressure,
into a valve manifold 27 flow-connected to a cyclically operated
molding mechanism 28.
[0091] In the operation of machine 20, a supply of ground beef or
other moldable food material is deposited into hopper 25 from
overhead. An automated refill device (not shown) can be used to
refill the hopper when the supply of food product therein is
depleted. The floor of hopper 25 at least partially closed by a
conveyor belt 31 of a conveyor 30. The belt 31 includes a top
surface 31a for moving the food material longitudinally of the
hopper 25 to a hopper forward end 25a.
[0092] The food material is moved by supply means 24 into the
intake of plunger pumps 61, 62 of pumping system 26. The pumps 61,
62 of system 26 operate in overlapping alteration to each other;
and at any given time when machine 20 is in operation, at least one
of the pumps is forcing food material under pressure into the
intake of manifold 27.
[0093] The manifold 27 comprises a path for feeding the food
material, still under relatively high pressure, into the molding
mechanism 28. Molding mechanism 28 operates on a cyclic basis,
first sliding a multi-cavity mold plate 32 into a receiving
position over manifold 27 (FIG. 9A) and then away from the manifold
to a discharge position (FIG. 9F) aligned with a series of knock
out cups 33. When the mold plate 32 is at its discharge position,
knock out cups plungers or cups 33 are driven downwardly as
indicated by 33A in FIG. 2, discharging hamburgers or other molded
patties from machine 20. The molded patties are deposited onto a
conveyor 29 (FIG. 1A), to be transported away from the apparatus
20.
Food Supply System
[0094] The food supply means 24 and associated hopper 25 are
illustrated in FIGS. 2-6. As seen, the conveyor belt 31 spans
completely across the bottom of hopper 25, around an end of idler
roller or pulley 35 and drive roller or pulley 36, the lower
portion of the belt being engaged by a tensioning roller 37. In
some cases the tensioning roller 37 may not be necessary, and can
be eliminated. A drum motor (not visible) is provided within the
drive roller 36 for rotating the drive roller.
[0095] The belt 31 can include a longitudinal V-shaped rib on an
inside surface thereof that fits within a V-shaped cross sectional
notch provided on the rollers 35, 36 to maintain a lateral
centering of the belt during operation.
[0096] The forward end 25a of hopper 25 communicates with a
vertical pump 38 having an outlet 39 at least partly open into a
pump intake manifold chamber 41. A vertically oriented frame 42
extends above hopper 25 adjacent the right-hand side of the outlet
39. A motor housing 40 is mounted on top of the frame 42. A support
plate 43 is affixed to the upper portion of frame 42 extending over
the outlet 39 in hopper 25. The frame comprises four vertical tie
rods 44a surrounded by spacers 44b (FIG. 5).
[0097] As shown in FIG. 5, the vertical pump 38 comprises two feed
screw motors 45, 46 that drive feed screws 51, 52. The two
electrical feed screw motors 45, 46 are mounted upon the support
plate 43, within the motor housing 40. Motor 45 drives the feed
screw 51 that extends partly through opening 39 in alignment with a
pump plunger 66 of the pump 61. Motor 46 drives the feed screw 52
located at the opposite side of hopper 25 from feed screw 51, and
aligned with another pump plunger 68 of the pump 62.
[0098] A level sensing mechanism 53 is located at the outlet end of
hopper 25. The mechanism is shown in detail in FIG. 45. The
mechanism 53 comprises an elongated sensing element 54. As the
moldable food material is moved forwardly in the hopper 25, it may
accumulate to a level in which it engages and moves the sensing
element 54 to a pre-selected degree. When this occurs, a signal is
generated to stop the drive for the roller 36 of conveyor 31. In
this manner the accumulation of food material at the forward end
25a of hopper 25 is maintained at an advantageous level.
[0099] The element 54 includes a food engaging leg 54a, and a
bent-off leg 54b. The bent off leg 54b includes a welded-on axle
54c that is journaled for pivoting on each end by bushings held by
two lugs 54d. An air cylinder 55 is arranged on the support plate
43. The air cylinder 55 exerts a pre-selected force on the upper
leg 54b to oppose rotation of the entire element 54 caused by
pressure from food product in the hopper. The cylinder 55 is
remotely adjustable to change the force to compensate for variable
food material density or to change the level desired at the feed
screws 51, 52.
[0100] A proximity sensor assembly 56 is arranged next to the
cylinder 55 on the support plate 43. A bracket 56a guides a moving
shaft 56b. A proximity sensor 56c is mounted to the bracket 56a.
The shaft 56b includes a metal target 56d that is sensed by the
proximity sensor 56c. The shaft 56b extends through a bushing 43
held on the support plate 43. A lower end of the shaft 56b makes
contact with a head of an adjustment screw 54e threaded into the
bent off leg 54b. A spring 56e surrounds an upper portion of the
shaft 56b and abuts a horizontal portion 56f of the bracket 56a.
The spring thus urges the shaft into contact with the adjustment
screw 54e. The bent off leg 54b includes an up turned end 54f that
contacts the motor housing when the element 54 is rotated
counterclockwise (FIG. 45) to a maximum amount by the cylinder 55
corresponding to low or no level of food product to the right of
the portion 54a as seen in FIG. 45, or to left of the portion 54a
as seen in FIG. 2.
[0101] FIG. 45 shows the element 54 rotated to a maximum extent
clockwise subject to a high level of food product in the forward
end 25a of the hopper 25. The proximity target 56d has passed the
sensor 56c to trigger a signal to the machine control 23 to turn
off the conveyor 30.
[0102] When machine 20 is in operation, the feed screw motor 45 is
energized whenever plunger 66 is withdrawn to the position shown in
FIG. 2, so that feed screw 51 supplies meat from hopper 25
downwardly through outlet 39 into one side of the intake 41 of the
food pumping system 26. Similarly, motor 46 actuates the feed
screws 52 to feed meat to the other side of intake 41 whenever
plunger 68 of the pump 62 is withdrawn. In each instance, the feed
screw motors 45, 46 are timed to shut off shortly after the plunger
is fully retracted, avoiding excessive agitation of the meat. As
the supply of food material in the outlet 39 is depleted, the
conveyor belt 31 continuously moves food forwardly in the hopper
and into position to be engaged by the feed screws 51, 52. If the
level of meat at the outlet 39 becomes excessive, conveyor 30 is
stopped, as described above, until the supply at the hopper outlet
is again depleted.
[0103] The wall of the outlet 39 immediately below conveyor drive
rollers 36 comprises a belt wiper plate 57 that continuously
engages the surface of the conveyor belt 31 to prevent leakage of
the food material 38 from the hopper at this point.
Food Pump System
[0104] The food pump system 26 of molding machine 20 is best
illustrated in FIGS. 2 and 6. Pump system 26 comprises the two
reciprocating food pumps 61, 62 mounted within the machine base 21.
The first food pump 61 includes a hydraulic cylinder 64. The piston
(not shown) in cylinder 64 is connected to an elongated piston rod
67; the outer end of the elongated piston rod 67 is connected to
the large plunger 66. The plunger 66 is aligned with a first pump
cavity 69 formed by a pump cavity enclosure or pump housing 71. The
forward wall 74 of pump cavity 69 has a relatively narrow slot 73
that communicates with the valve manifold 27 as described more
fully hereinafter.
[0105] Preferably, the pump housing 71 and the valve manifold 27
are cast or otherwise formed as a one piece stainless steel
part.
[0106] The second food pump 62 is essentially similar in
construction to pump 61 and comprises a hydraulic cylinder 84.
Cylinder 84 has an elongated piston rod 87 connected to the large
plunger 68 that is aligned with a second pump cavity 89 formed in
housing 71. The forward wall 94 of pump cavity 89 includes a narrow
elongated slot 93 communicating with manifold 27.
[0107] Advantageously, the plungers 66, 68 and the pump cavities
69, 89 have corresponding round cross sections for ease of
manufacturing and cleaning.
[0108] An elongated proximity meter 75 is affixed to the first pump
plunger 66 and extends parallel to piston rod 67 into alignment
with a pair of proximity sensors 76 and 77. A similar proximity
meter 95 is fixed to and projects from plunger 68, parallel to
piston rod 87, in alignment with a pair of proximity sensors 96,
97. Proximity sensors 76, 77 and 96, 97 comprise a part of the
control of the two pumps 61, 62, shown in FIG. 15.
[0109] The meters 75, 95 and sensors 76, 77, 96, 97 monitor the
plunger positions in small, precise increments, such as every 0.25
inches. The meters include teeth or other targets that are sensed
by the sensors and counted by machine electronics, such as in the
controller 23, or in intervening electronics and communicated to
the controller 23.
[0110] Two further proximity sensors 78, 98 responsive to targets
on an inside facing surfaces of the meters 75, 95 respectively, are
provided which communicate to the controller 23, or to intervening
electronics that communicate with the controller 23, the home
position of the respective plunger which corresponds to a front end
of each plunger being just inside, and sealed by a front ring seal
99 (FIG. 2) to the pump housing 71. The home position of each
plunger is used by the controller to calibrate or set the machine
position control of the plungers 66, 86.
[0111] In operation, the first pump 61 pumps the moldable food
material into manifold 27 and the second pump 62 receives a supply
of the moldable food material for a subsequent pumping operation.
Pump 61 begins its pumping stroke, and compresses food product in
pump cavity 69, forcing the moldable food material through slot 73
into manifold 27. As operation of molding machine 20 continues,
pump 61 advances plunger 66 to compensate for the removal of food
material through manifold 27. The pump can maintain a constant
pressure on the food material in the cavity 69 during the molding
cycle, or preferably can provide a pre-selected pressure profile
over the molding cycle such as described in U.S. Pat. No.
4,356,595, incorporated herein by reference, or as utilized in
currently available FORMAX machines. The pressure applied through
pump 61 is sensed by a pressure sensing switch 78 connected to a
port of the cylinder 64.
[0112] As plunger 66 advances, the corresponding movement of
proximity meter 75 signals the sensor 76, indicating that plunger
66 is near the end of its permitted range of travel. When this
occurs, pump 62 is actuated to advance plunger 68 through pump
cavity 89, compressing the food material in the second pump cavity
in preparation for feeding the food material from the cavity into
manifold 27. The pressure applied through pump 62 is sensed by a
pressure sensing switch 79 connected to one port of cylinder
84.
[0113] When the food in the second pump cavity 89 is under adequate
pressure, the input to manifold 27 is modified so that subsequent
feeding of food product to the manifold is effected from the second
pump cavity 89 with continuing advancement of plunger 68 of the
second pump 62. After the manifold intake has been changed over,
pump 61 is actuated to withdraw plunger 66 from cavity 69.
[0114] Thereafter, when plunger 68 is near the end of its pressure
stroke into pump cavity 89, proximity sensor 96, signals the need
to transfer pumping operations to pump 61. The changeover process
described immediately above is reversed; pump 61 begins its
compression stroke, manifold 27 is changed over for intake from
pump 61, and pump 62 subsequently retracts plunger 68 back to the
supply position to allow a refill of pump cavity 89. This
overlapping alternating operation of the two pumps 61, 62 continues
as long as molding machine 20 is in operation.
[0115] The valve manifold 27, shown in FIGS. 2 and 6, holds a
manifold valve cylinder or tube valve 101 fit into an opening 102
in housing 71 immediately beyond the pump cavity walls 74 and
94.
[0116] According to one embodiment, valve cylinder 101 includes two
longitudinally displaced intake slots 107 and 108 alignable with
the outlet slots 73 and 93, respectively, in the pump cavity walls
74 and 94. Slots 107 and 108 are angularly displaced from each
other to preclude simultaneous communication between the manifold
and both pump cavities 69 and 89. Cylinder 101 also includes an
elongated outlet slot 109. The valve cylinder outlet slot 109 is
generally aligned with a slot 111 (see FIG. 9A) in housing 71 that
constitutes a feed passage for molding mechanism 28.
[0117] One end wall of valve cylinder 101 includes an externally
projecting base end 103 that is connected to a drive linkage 104,
which in turn is connected to the end of the piston rod 105 of a
hydraulic actuator cylinder 106 (FIG. 2). Proximity sensors 106a,
106b communicate the rotary position of the valve cylinder to the
machine controller 23.
[0118] When the pump 61 is supplying food material under pressure
to molding mechanism 28, actuator cylinder 106 has retracted piston
rod 105 to the inner limit of its travel, angularly orienting the
manifold valve cylinder 101. With cylinder 101 in this position,
its intake slot 107 is aligned with the outlet slot 73 from pump
cavity 69 so that food material is forced under pressure from
cavity 69 through the interior of valve cylinder 101 and out of the
valve cylinder outlet slot 109 through slot 111 to the molding
mechanism 28. On the other hand, the second intake slot 108 of
valve cylinder 101 is displaced from the outlet slot 93 for the
second pump cavity 89. Consequently, the food material forced into
the interior of valve cylinder 101 from pump cavity 69 cannot flow
back into the other pump cavity 89.
Tube Valve System
[0119] FIG. 17 illustrates the tube valve 101 separate from the
apparatus 20. The tube valve includes the base end 103 and a distal
end 404. The distal end 404 is inserted first into the opening 102
of the housing 71 during installation. The base end 103 includes an
end flange 406 having two tapped holes 408 for connection to the
drive link 104 by fasteners 409a and spacers 409b as shown in FIG.
24. The base end 103 further includes a groove 410 for a ring seal
411, such as an O-ring or a D-ring, and a smooth annular surface
412 that is journaled within a base end bearing or bushing 413
shown in FIGS. 12 and 13A.
[0120] The distal end 404 includes a reduced diameter guide portion
416 that positions a smooth annular surface 420 into a distal end
bearing or bushing 421 as shown in FIG. 24. A ring seal 422, such
as an O-ring or D-ring, is positioned within an inside groove 423
of the opening 182. A smooth annular surface 424 of the distal end
404 engages and seals against the ring seal 422 (FIG. 23).
[0121] As illustrated in FIG. 24A, both bushings 413, 421 include a
crown-shaped profile having openings 425 spaced around a
circumferential surface that abuts the manifold 27 when installed.
Each bushing 413, 421 include openings 426 for fasteners to fasten
the bushings 413, 421 to the manifold 27, and an inside
circumferential grease groove 427 in communication with a grease
fitting 428.
[0122] As illustrated in FIG. 25, the linkage 104 includes a lever
bar 429 that is fastened to the base end 103 by the fasteners 409a,
and spacers 409b. The rod 105 includes an extension 105a that has a
square cross section. The extension has a rectangular notch 105b
that is open towards a back side of the lever bar 429.
[0123] A follower block 430 is rotatably connected to the back side
of the lever bar 429 by a threaded shank 431 of a knob 432. In this
regard, the follower block 430 includes a block portion 433a and a
cylinder portion 433b having a threaded bore 434 to engage the
shank 431. The lever bar 429 includes a cylindrical bore 436 that
receives the cylinder portion 433b. The cylinder portion 433b is
free to rotate in the bore 436.
[0124] The block portion 433a is free to vertically slide within
the notch 105b. Three positions of the block portion 433a are shown
in FIG. 14: 433a, 433ab, 433aa. Two positions of the lever bar 429
are shown: 429 and 429aa.
[0125] FIG. 18 illustrates the relative size and orientation of the
inlet port 108 with respect to the valve 101.
[0126] FIG. 19 illustrates the relative size and orientation of the
inlet port 107 with respect to the valve 101.
[0127] FIGS. 20 and 21 illustrate the relative size and orientation
of the outlet port 109 with respect to valve 101.
[0128] FIG. 22 illustrates the respective rotary positions of the
inlet ports 107, 108 and the outlet port 109 around the
circumference of the tube valve 101. The ports 107, 108, 109 have
angular expanses of 107A, 108A, and 109A respectively. Preferably,
for a 4.4 inch diameter tube valve, given the reference angle 0
degrees shown in FIG. 22, the angular position and expanse 107A is
approximately between 205 degrees and 267 degrees, the angular
position and expanse 108A is approximately between 134 degrees and
197 degrees, and the angular position and expanse 109A is
approximately between 0 degrees and 137 degrees. The sidewalls of
the ports are not all cut radially, in such cases the angles are
taken at the furthest radial point on the sidewall that defines the
port.
[0129] FIGS. 46-52 illustrate a second embodiment tube valve 1601
and manifold 527. FIG. 46 is taken generally along oblique line
46-46 of FIG. 47. FIG. 46 illustrates the valve manifold 527 and
the pump chambers 69, 89 of the pump housing 71 from above, taken
from an angle. The mold plate and breather plate are removed in
this figure so that the inside cavities of the valve manifold 527
and pump chambers 69, 89 are visible. Similar to the previously
described embodiment, it is preferred that the pump housing 71 and
the manifold 527 are formed as a unitary part.
[0130] The manifold 527 includes three oblong inlet openings 111a,
111b and 111c. The openings 111a, 111b and 111c are substantially
equal in open area. The openings 111a, 111b, 111c receive food
material from the alternate embodiment tube valve 1601 shown in
FIGS. 48-51.
[0131] FIG. 46 illustrates the pump chambers 69, 89 empty, i.e.,
there are no plungers 66, 68 shown. On a top surface 650 of the
pump housing 71 and/or manifold 527 there are three grooves or
indentations 1652, 1654, 1656 that communicate with bores or holes
1652a, 1654a, 1656a, respectively.
[0132] As shown in FIG. 47, the first plunger 66 is in a position
to begin a filling cycle of food material 660. A front face 1662 of
the plunger 66 includes a beveled region 1664 around beveled
approximately 180.degree., around a top edge of the plunger 66,
constituting the upper portion of the circumference of the plunger
66. This bevel is approximately 15.degree. and acts to hold the
plunger 66 down given the pressure of the food material within the
pump chamber.
[0133] The center groove 1654 on the top surface 1650 is shown
dashed in FIG. 47. The center groove 1654 extends from the bore
1654a to an open area 1654b that is open to the hopper 25. The
other grooves 1652, 1656 and bores 1652a, 1656a are similarly
configured as that shown in FIG. 47 for groove 1654 and bore 1654a.
These grooves 1652, 1656 have open areas 1652b, 1656b to the hopper
25.
[0134] FIG. 48-51 show the alternate tube valve 1601 in detail. The
alternate tube valve 1601 is as described previously as the tube
valve 101 except as herein distinguished. When the inlet port 107
is in registry with the pump chamber 69 there are three outlet
ports 109a, 109b, 109c that are in registry with the openings 111a,
111b, 111c, to pass food material 660 to the molding mechanism
28.
[0135] As can be seen in FIG. 48, the outlet port 109a that is
closest to the inlet port 107 has a smallest, most restrictive
opening, the center outlet port 109b has a slightly greater
opening, and the far outlet port 109c has the greatest opening.
This progressive tube valve outlet opening arrangement, with the
smallest outlet opening closest to the feeding inlet to the tube
valve, assists in equalizing the food product pressure across the
width of the manifold 27 and molding mechanism 28. A more even food
product pressure allows for a more consistent density of molded
products across a width of the mold plate.
[0136] As seen in FIG. 49, the tube valve is rotated so that the
second inlet port 108 is in registry with the second pump cavity
89. The tube valve 1601 provides progressive openings 119a, 119b,
119c that are smallest near the inlet port 108 and largest at the
opposite end of the tube valve 1601, in mirror image reversal of
the openings 109a, 109b, 109c shown in FIG. 48. When the inlet port
108 is in registry with the pump chamber 89, the three outlet ports
119a, 119b, 119c are open to the openings 111a, 111b, 111c to pass
food material 1660 to the molding mechanism 28. This progressive
tube valve outlet opening arrangement, with the smallest outlet
opening closest to the feeding inlet to the tube valve, assists in
equalizing the food product pressure across the width of the
manifold 27 and molding mechanism 28. A more even food product
pressure allows for a more consistent density of molded products
across a width of the mold plate.
[0137] It is also within the scope of the invention that the center
ports 109b, 119b and 111b and 119b be eliminated and that just two
outlet ports 109a, 109c and 119a, 119c and corresponding two inlet
ports 111a, 111c be used. As described, the outlet ports 109c, 119c
would be larger than the outlet ports 109a, 119a.
[0138] FIG. 50 illustrates the tube valve rotated so the inlet port
107 and two substantially rectangular surface depressions 1710,
1712 can be seen. The depressions 1710, 1712 have a constant radial
depth (preferably about 3/16'' deep) from the cylindrical surface
of the tube valve 1601. The center surface depression 1710 is
slightly longer than the end surface depression 1712. When the
first plunger 66 is in operation, pushing food product through the
inlet port 107, the surface depressions 1710, 1712 are in flow
communication with the bores 1652a, 1654a, and the grooves 1652,
1654.
[0139] FIG. 51 illustrates the tube valve rotated so the inlet port
108 and two substantially rectangular surface depressions 1810,
1812 can be seen. The depressions 1810, 1812 have a constant radial
depth (preferably about 3/16'' deep) from the cylindrical surface
of the tube valve 1601. The center surface depression 1810 is
slightly longer than the end surface depression 1812. When the
second plunger 68 is operating, pushing food product through the
inlet port 108, the surface depressions 1810, 1812 are in flow
communication with the bores 1654a, 1656a, and the grooves 1654,
1656.
[0140] FIG. 52 shows the configuration of the tube valve 1601 when
the inlet port 107 is used. Rectangular recesses 1710, 1712,
communicate with the bores 1652a, 1654a and the grooves 1652, 1654
to vent air to the hopper.
[0141] When reloading the pump box with product, the following
occurs. For example, when reloading the pump cavity 89 for plunger
68, the plunger 68 retracts and the feed screws rotate. The
combination of the vacuum created by the plunger 68 withdrawing
from the pumping chamber, and the turning screws, forces food
product in front of the plunger 68. The plunger is then advanced
into the chamber 89 to initially compress the food product before
filling begins. As the plunger 68 advances to the pump chamber 89,
there will be air inter-mixed with food product. This air must be
removed before the plunger 68 starts its mold plate cavity-filling
cycle.
[0142] The plunger 68 advances to compress the reloaded product,
while the plunger 66 continues to feed food product through the
full open port 107 in the tube valve 601. The tube valve 601 is
blocking the plunger 68 from feeding the food product into the
manifold 527; however the grooves 1710, 1712 communicate with bores
1652a, 1654a in the pump box or manifold 527. Grooves 1652, 1654 on
the manifold and pump housing top surface 1650 allow air (but not
product) from the pump chamber 89 to escape back to the hopper,
during initial compression of the food product within the pump
chamber 89 against the tube valve 1601.
[0143] The process alternates with the tube valve rotational shift
of about 70 degrees, to change the active plunger 66, 68.
[0144] As a further feature of the invention, a plurality of
breather holes 1902 are provided at each longitudinal end of the
tube valve, through the tube valve wall. The breather holes 1902
are in communication with an inside of the tube valve and to an
outside circumferential groove 1906a, 1906b respectively that is in
communication with the depressions 1712, 1812 respectively. Thus,
air trapped at either end within the tube valve can be expressed
back to the collection area, the hopper, via the breather holes
1902, the grooves 1906a, 1906b and the depressions 1712, 1812.
Molding Mechanism
[0145] As best illustrated in FIG. 9A, the upper surface of the
housing 71 that encloses the pump cavities 69 and 89 and the
manifold 27 carries a support plate or wear plate 121 and a fill
plate 121a that forms a flat, smooth mold plate support surface.
The mold support plate 121 and the fill plate 121a may be
fabricated as two plates as shown, or a single plate bolted to or
otherwise fixedly mounted upon housing 71. The fill plate 121a
includes apertures or slots that form the upper portion of the
manifold outlet passage 111. In the apparatus illustrated, a multi
fill orifice type fill plate 121a is utilized. A simple slotted
fill plate is also encompassed by the invention.
[0146] Mold plate 32 is supported upon plates 121, 121a. Mold plate
32 includes a plurality of individual mold cavities 126 extending
across the width of the mold plate and alignable with the manifold
outlet passageway 111. Although a single row of cavities is shown,
it is also encompassed by the invention to provide plural rows of
cavities, stacked in aligned columns or in staggered columns. A
cover plate 122 is disposed immediately above mold plate 32,
closing off the top of each of the mold cavities 126. A mold cover
casting or housing 123 is mounted upon cover plate 122. The spacing
between cover plate 122 and support plate 121 is maintained equal
to the thickness of mold plate 32 by support spacers 124 mounted
upon support plate 121. Cover plate 122 rests upon spacers 124 when
the molding mechanism is assembled for operation. Cover plate 122
and mold cover 123 are held in place by six mounting bolts, or nuts
tightened on studs, 125.
[0147] As best illustrated in FIGS. 3, 6, and 53 mold plate 32 is
connected to drive rods 128 that extend alongside housing 71 and
are connected at one end to a transverse bar 129. The other end of
each drive rod 128 is pivotally connected to a connecting link 131
via a coupling plate 131a and a pivot connection 131c, shown in
FIG. 29. The pivot connection 131c can include a bearing (not
visible in the figures) surrounding a pin 131d within an apertured
end 131e of the connecting link 131. The pin 131d includes a cap,
or carries a threaded nut, on each opposite end to secure the crank
arm to the coupling plate 131a.
[0148] Each drive rod 128 is carried within a guide tube 132 that
is fixed between a wall 134 and a front bearing housing 133. The
connecting links 131 are each pivotally connected to a crank arm
142 via a pin 141 that is journalled by a bearing 141a that is fit
within an end portion of the connecting link 131. The pin crank arm
142 is fixed to, and rotates with, a circular guard plate 135. The
pin 141 has a cap, or carries a threaded nut, on each opposite end
that axially fixes the connecting link 131 to the crank arm 142 and
the circular guard plate 135.
[0149] The connecting link 131 also includes a threaded portion
131b to finely adjust the connecting link length.
[0150] The crank arms 142 are each driven by a right angle gear box
136 via a "T" gear box 137 having one input that is driven by a
precise position controlled motor 138 and two outputs to the
gearboxes 136. The "T" gear box 137 and the right angle gear boxes
136 are configured such that the crank arms 142 rotate in opposite
directions at the same rotary speed.
[0151] The precise position controlled motor can be a 6-7.5 HP
totally enclosed fan cooled servo motor. The servo motor is
provided with two modules: a power amplifier that drives the servo
motor, and a servo controller that communicates precise position
information to the machine controller 23.
[0152] The controller 23 and the servo motor 138 are preferably
configured such that the servo motor rotates in an opposite rotary
direction every cycle, i.e., clockwise during one cycle,
counterclockwise the next cycle, clockwise the next cycle, etc.
[0153] A bearing housing 143 is supported on each gearbox 136 and
includes a rotary bearing 143a therein to journal an output shaft
136a of the gear box 136. The output shaft 136a is fixed to the
crank arm 142 by a clamp arrangement formed by legs of the crank
arm 142 that surround the output shaft and have fasteners that draw
the legs together to clamp the output shaft between the legs (not
shown), and a longitudinal key (not shown) fit into a keyway 136b
on the output shaft and a corresponding keyway in the crank arm 142
(not shown).
[0154] A tie bar 139 is connected between the rods 128 to ensure a
parallel reciprocation of the rods 128. As the crank arms 142
rotate in opposite rotational directions, the outward centrifugal
force caused by the rotation of the crank arms 142 and the
eccentric weight of the attached links 131 cancels, and separation
force is taken up by tension in the tie bar 139.
[0155] One circular guard plate 135 is fastened on top of each
crank arm 142. The pin 141 can act as a shear pin. If the mold
plate should strike a hard obstruction, the shear pin can shear by
force of the crank arm 142. The guard plate 135 prevents an end of
the link 131 from dropping into the path of the crank arm 142.
[0156] The drive mechanism of the mold plate is easily reconfigured
to change stroke length of different mold plates. For example, 6,
7, 8, 9, 10 or 11 inch stroke lengths are practically achievable
with the apparatus by changing parts, such as the parts 131, 135,
142.
[0157] FIG. 53 illustrates a proximity sensor 144 in communication
with the machine control. A target 144a is clamped onto an
extension 136d of the rotating shaft 136a. The proximity sensor 144
communicates to the controller 23 that the crank arm 142 is at a
particular rotary position corresponding to the mold plate 32 being
at a preselected position. Preferably, the proximity sensor 144 can
be arranged to signal to the controller that the crank arm 142 is
in the most forward position, corresponding to the mold plate 32
being in the knockout position. The signal confirms to the
controller that the knockout cups 33 can be safely lowered to
discharge patties, without interfering with the mold plate 32.
[0158] During a molding operation, the molding mechanism 28 is
assembled as shown in FIGS. 2 and 9A, with cover plate 122 tightly
clamped onto spacers 124.
[0159] In each cycle of operation, knockout cups 33 are first
withdrawn to the elevated position as shown in FIG. 9F. The drive
for mold plate 32 then slides the mold plate from the full extended
position to the mold filling position illustrated in FIGS. 2 and
9A, with the mold cavities 126 aligned with passageway 111.
[0160] During most of each cycle of operation of mold plate 32, the
knockout mechanism remains in the elevated position, shown in FIG.
9A, with knockout cups 33 clear of mold plate 32. When mold plate
32 reaches its extended discharge position as shown in FIG. 9F the
knockout cups 33 are driven downward to discharge the patties from
the mold cavities.
[0161] The discharged patties may be picked up by the conveyor 29
or may be accumulated in a stacker. If desired, the discharged
patties may be interleaved with paper, by an appropriate paper
interleaving device. Such a device is disclosed in U.S. Pat. No.
3,952,478, or U.S. Ser. No. 60/540,022, filed on Jan. 27, 2004,
both incorporated herein by reference. In fact, machine 20 may be
used with a wide variety of secondary equipment, including steak
folders, bird rollers, and other such equipment.
[0162] By using a servo motor to drive the mold plate, the mold
plate motion can be precisely controlled. The motion can have a
fully programmable dwell, fill time, and advance and retract
speeds.
[0163] FIG. 59 illustrates one motion profile P1 for the movement
of the mold plate 32 that is precisely controlled by the servomotor
138 and controller 23. The mold plate position (any point on the
mold plate) is shown as a function of time between the most
retracted position, the fill position, and the forward most
extended position, the knockout position. The profile P1 of FIG. 59
shows a rather sharp turn around at the fill position, with little
or no mold plate stopping, or dwell period. At the knockout
position, there is a dwell period to allow the knockout cups to
descend into the mold plate cavities to displace the formed patties
from the cavities.
[0164] On the same graph a knockout cup movement profile P2 is
depicted, wherein the knockout cups are lowered and raised during a
segment of time t1 that is within the dwell period of the mold
plate stopped in the knockout position.
[0165] FIGS. 60-63 illustrate one cycle of different mold plate
motion profiles that can be programmed by the controller 23 and the
drive for the servomotor 138. The profile P3 in FIG. 60 is
appropriate for a mold plate stroke speed of 100 cycles/minute and
a knockout dwell period of 0.088 seconds. The profile P3 shows
little or no filling dwell period; adequate filling can occur
during retraction and/or advancement of the mold plate before and
after the fill position. The profile would be for a food product
material that is soft, easily flowable, and possibly warm.
[0166] FIG. 61 illustrates a profile P4 that is appropriate for a
mold plate stroke speed of 100 cycles/minute and a cold, stiff or
viscous product that requires a dwell period at the fill position
to adequately fill the cavities.
[0167] FIG. 62 illustrates a profile P5 appropriate for easily
flowable food product and a mold plate stroke speed of 120
cycles/minute.
[0168] FIG. 63 illustrates a profile P6 appropriate for viscous
product that requires a dwell period at the fill position to
adequately fill the cavities, and a mold plate stroke speed of 120
cycles/minute.
[0169] All of the profiles P3-P6 are for a 9 inch mold plate stroke
length and allow for a 0.088 second knockout period. The different
motion profiles for mold plate movements illustrated in FIG. 31-34
can be selected by an operator via the input screen 19 and the
controller 23.
Lubricating Oil System
[0170] FIG. 34 illustrates a mold drive rod lubricating system 1000
incorporated into the apparatus 20. The lubrication system 1000
includes front bearings 1002 and rear bearings 1002 for each drive
rod 128. The location of the bearings is shown in FIG. 6.
[0171] A pump 1008 takes suction from reservoir 1010 holding
lubricating oil 1012. A motor 1016 being either an electric,
hydraulic, pneumatic or other type motor, drives the pump. The pump
circulates lubricating oil through tubing and/or passages through
the machine base area to the bearings 1002, 1004 and returns the
lubricating oil through a filter 1022 to the reservoir. The pump,
motor, reservoir and filter are all located within the machine base
21.
[0172] FIG. 35 illustrates a front bearing 1002. The other front
bearing and the rear bearings 1004 are configured in substantially
identical manner. The front bearing 1002 includes a housing 1032
having an internal bore 1036 for holding a sleeve bearing element
1038. The sleeve bearing element 1038 has an inside surface sized
to guide the drive rod 128 and has a helical groove 1042 facing and
surrounding the drive rod 128. An oil inlet port 1050 communicates
lubricating oil into an open end of the helical groove. Lubricating
oil proceeds through the helical groove to an opposite end of the
bearing element 1038 to a first outlet groove 1052 in communication
with a second outlet groove 1054 through a longitudinal channel
(not shown). The second outlet groove 1054 is in communication with
an outlet port 1056. The inlet port 1050 is in fluid communication
with the pump 1008 and the outlet port 1056 is in fluid
communication with the oil return lines to the filter 1022. A front
seal 1060 and a rear seal 1062 retain oil within the housing
1032.
Knock Out System
[0173] Molding mechanism 28 further comprises a knockout apparatus
140 shown in FIGS. 2, 9A, 13-14, and 54A-54B. The knockout
apparatus comprises the knockout cups 33, which are fixed to a
carrier bar 145. Knockout cups 33 are coordinated in number and
size to the mold cavities 126 in mold plate 32. One knockout cup 33
aligned with each mold cavity 126. The mold cavity size is somewhat
greater than the size of an individual knockout cup.
[0174] The knockout apparatus 140 is configured to drive the
carrier bar 145 in timed vertical reciprocation.
[0175] FIGS. 13-14, and 54A-54B illustrate the knockout apparatus
140 in more detail. The carrier bar 145 is fastened to knockout
support brackets 146a, 146b. The knockout support brackets 146a,
146b are mounted to two knockout rods 147. Each knockout rod 147
penetrates through a sidewall of a housing 148 and is connected to
a knockout beam 149.
[0176] The knockout beam 149 is pivotally mounted to a crank rod
151 that is pivotally connected to a fastener pin 156 that is
eccentrically connected to a crank hub 155 that is driven by a
motor 157.
[0177] The motor 157 is preferably a precise position controlled
motor, such as a servo motor. An exemplary servomotor for this
application is a 3000 RPM, 2.6 kW servo motor provided with a
brake. The servo motor is provided with two modules: a power
amplifier that drives the servo motor, and a servo controller that
communicates precise position information to the machine controller
23.
[0178] The controller 23 and the motor 157 are preferably
configured such that the motor rotates in an opposite direction
every cycle, i.e., clockwise during one cycle, counterclockwise the
next cycle, clockwise the next cycle, etc.
[0179] A heating element 160 surrounds, and is slightly elevated
from the knockout carrier bar 145. A reflector 161 is mounted above
the heating element 160. The heating element heats the knock out
cups to a pre-selected temperature, which assists in preventing
food product from sticking to the knock out cups.
[0180] In FIGS. 13-14 the crank hub 155 is rotated into a position
wherein the crank rod 151 is vertically oriented and the knockout
beam 149 is lifted to its maximum elevation. The knockout rods are
fastened to the knockout beam 149 by fasteners 152. The knockout
support brackets 146a, 146b are in turn fastened to the knockout
rods 147 by fasteners 153. Each knockout cup 33 is fastened to the
knockout carrier bar by a pair of fasteners 154a and spacers 154b.
An air flap or air check valve 33a can be provided within each cup
to assist in dispensing of a meat patty from the cup 33.
[0181] As shown in FIG. 14, the motor 157 is supported by a bracket
170 from a frame member 172 that is mounted to the mold cover
casting 123. The bracket 170 includes one or more slotted holes,
elongated in the longitudinal direction (not shown). One or more
fasteners 173 penetrate each slotted hole and adjustably fix the
motor 157 to the frame member. The motor 157 includes an output
shaft 176 that is keyed to a base end of the crank hub 155. The
fastener pin 156 retains a roller bearing 178 thereon to provide a
low friction rotary connection between an annular base end 151a of
the crank rod 151 and the pin 156.
[0182] The crank rod 151 has an apertured end portion 179 on an
upper distal end 151b opposite the base end 151a. The apertured end
portion 179 is held by a fastener pin assembly 180 through its
aperture to a yoke 182. The yoke 182 is fastened to the knockout
beam 149 using fasteners. The crank rod 151 is length adjustable.
The fastener pin assembly 180 can include a roller or sleeve
bearing (not shown) in like fashion as that used with the fastener
pin 156 to provide a reduced friction pivot connection.
[0183] The housing 148 is a substantially sealed housing that
provides an oil bath. Preferably, the housing walls and floor is
formed as a cast aluminum part. The crank hub 155, the pin 156,
roller bearing 178, the apertured end portion 179, the fastener pin
180 and the yoke 182 are all contained within the oil bath having
an oil level 183. The limits of the oil bath are defined by a
housing 184 having a front wall 185, a rear wall 186, side walls
187, 188, a top wall 189 and a sleeve 190. The sleeve 190 is a
square tube that surrounds a substantial portion of the crank rod
151 and is sealed around its perimeter to the top wall 189 by a
seal element 196a. The sleeve 190 is connected to the beam 149 and
penetrates below the top wall 189. As the yoke 182 reciprocates
vertically, the beam 149 and the sleeve 190 reciprocate vertically,
the sleeve 190 maintaining a sealed integrity of the oil bath.
[0184] The crank rod 151 includes side dished areas 151a that act
to scoop and propel oil upward during rotation of the hub 155 to
lubricate the pin 180 and surrounding areas.
[0185] The knockout rods 147 are guided to reciprocate through the
side walls 187, 188, particularly, through upper and lower bearings
191a, 191b. The rods 147 are sealed to the top wall by seals 192.
The bearings 191a can include an internal groove 193 that is in
flow-communication with a lubricant supply through port 194.
[0186] A lubricant system 194a is provided to provide lubricant to
the bearings 191a, 191b. The system 194a includes a lubricant
reservoir 194b that is filled with lubricant, such as oil, and
connected to plant air 194c via an electronically controlled valve
194d. The machine controller 23 periodically, according to a preset
routine, actuates the valve 194d to propel some lubricant into the
bearings 191a. Lubricant can run down the knockout rod 147 into a
dished top 191c of the lower bearings 191b to allow oil to
penetrate between the knockout rods 147 and the lower bearings
191b.
[0187] An outer cover 195 is fastened and sealed around the side
walls 187, 188 and front and rear walls 185, 186 by fasteners,
spacers 196 and a seal 197. Any lubricating oil that passes through
the seal can be returned to the oil bath via dished out drain areas
and drain ports through the top wall.
[0188] The front wall 185 includes an oil level sight glass 185a, a
fill port 185b (shown dashed in FIG. 13), a drain port 185c (FIG.
14); and an access hole closed by a screw 185d (FIG. 14).
[0189] The crank hub 155 is journaled for rotation by two roller
bearings 198, 199. The roller bearings 198, 199 are supported by a
collar assembly 200 bolted to the rear wall 186 and to the motor
157.
[0190] The housing 148 is fastened to a support plate 201 by
fasteners 201a. The support plate 201 is fastened to circular
adapter plates 201b by fasteners 201c. The circular adapter plates
201b are removably fit into circular holes 201d in the casting 123.
The circular adapter plates 201b include a bottom flange 201e which
abuts the casting 123. The circular adapter plates 201b surround
the bearings 191b and associated bearing assembly 191c.
[0191] As shown in FIG. 13A, the left bracket 146a is fixedly
connected to the left knockout rod 147 using the fastener 153 while
the right bracket 146b is connected for a sliding connection. In
this regard the right fastener 153 passes through an inverted T-nut
153a that passes through the bracket 146b and fits into a back up
washer 153b that abuts the top side of the bracket 146b. The
bracket 146b includes an oversized opening in the lateral direction
that allows the bracket 146b to shift laterally with respect to the
T-nut and knockout rod 147. This arrangement allows the bar 145 to
expand and contract laterally with respect to the knockout rods
147. When the knockout cups 33 are heated by the heating element
160, the carrier bar 145 can become heated as well. Preferably, the
carrier bar 145 is composed of aluminum which can expand to a
significant degree. The sliding connection of the bracket 146b
accommodates this thermal expansion.
[0192] The knockout assembly is changeable to extend further
forwardly to minimize knockout cup cantilever and stress in
supporting members. This is accomplished by loosening the bracket
170 from the frame member 172 and sliding the motor 157 and the
connected parts forward or rearward and replacing the circular
adapter plates that guide the knockout rods 147.
[0193] As demonstrated in FIGS. 54A and 54B, to change the
longitudinal position of the knockout cups 33, the support plate
201 is shifted longitudinally. Replacement circular adapter plates
201bb are fit into the casting 123 from below. The replacement
circular adapter plates 201 bb include different hole patterns for
the knockout rods 147, forwardly or rearwardly shifted, to
accommodate the new position of the support plate 201.
[0194] A proximity sensor 202 is bolted to the outer cover 195, and
a target 203 is provided on the crank beam 149 to be sensed by the
proximity sensor 202. The proximity sensor 202 communicates to the
controller 23 that the knockout cups are raised and the mold plate
can be retracted without interfering with the knockout cups.
[0195] The movement of the knock out cups is fully programmable for
different motion profiles, including dwell, accelerations and
extend and retract speeds. Such motion profiles may be useful
depending on the properties of the food product to be discharged
from the mold plate cavities. Because both the mold plate and the
knock out cups can be driven by programmably controlled servo
motors, they can be flexibly sequenced without being restricted in
motion by a common mechanical system.
Auxiliary Pump System for Air and Fines from the Breather
System
[0196] FIGS. 9A through 12 and 36-41 illustrate another aspect of
the invention. According to this aspect, the mold plate 32 includes
two ends, a forward end 202 and a rearward end 204. The cavities
126 are located at a central position between the ends 202, 204.
Elongated connection recesses 208 are located at a rearward
position, near the rearward end 204. Relief recesses 209 are
located between the connection recesses 208 and the cavities 126.
In FIG. 9A the mold plate 32 is in a fill position, fully retracted
toward the rear. The cover plate or breather plate 122 includes
breather holes 216 that are in air communication with the cavities
126 while the mold plate is in the fill position.
[0197] The holes 216 are in communication with a top side air
channel in the form of a dished region 220 of the cover plate 122.
The dished region 220 includes branch regions 222 that extend
forwardly. The branch regions 222 are in air communication with an
antilip channel 230 open on a bottom side of the cover plate 122,
through narrow apertures 234.
[0198] On a rearward portion of the dished region 220 are recesses
237 that are in communication with through holes 238 that extend
through the thickness of the cover plate 122. In the mold plate
position of FIG. 9A, the through holes 238 are open into the
elongated connection recesses 208.
[0199] On a rearward portion of the cover plate 122 is a bottom
side recess 242 that is in communication with an overhead valve
passage 246 that can be closed by action of a valve 250,
particularly by action of a valve element 252 of the valve 250. The
valve element 252 is in the open position as shown in FIG. 9A. The
valve element is movable within a valve chamber 258 formed into a
bottom side of the mold cover 123.
[0200] The valve chamber 258 extends laterally and is flow
connected to two through bores 264, 266 that each extend through
the cover plate 122, the spacer 124, the top plate 121, and an
insert plate 270 fit on a recess 272 of the pump housing 71. The
recess 272 is open into the pump inlet 39.
[0201] In the position shown in FIG. 9A, the cavities are filled
through a plurality of fill apertures or slots 121b through fill
plate 121a (see FIG. 38 as an example of fill apertures) fastened
to the pump housing 71. The mold plate 32 is beginning its forward
travel, driven by the drive rods 128 via the link 129. The valve
element 252 is up; the valve 250 is open.
[0202] As illustrated in FIG. 9B, when the connection recess 208 is
no longer in communication with the bottom side recess 242, the
moving end 204 of the plate 32 creates a suction chamber 280S
formed between the spacer 124, the end 204, the breather plate 122
and the top plate 121. The element 252 is drawn down by the suction
to close the valve passage 246.
[0203] In the position of the mold plate shown in FIG. 9C, the
cavities 126 have moved into a position to be relieved in pressure
by the antilip slot 230, any expansion of the patties is cut as the
patties pass under the antilip bar 231. Further suction is drawn in
the chamber 280 by movement of the end 204.
[0204] As shown in FIG. 9D, maximum suction is developed at this
point in the chamber 280S by movement of the end 204.
[0205] As shown in FIG. 9E, the end 204 has passed under the
through hole 238. The suction chamber 280 draws air and meat fines
from the chambers and recesses 230, 234, 222, 220, 237, 238 into
the suction chamber 280S.
[0206] FIG. 9F illustrates the mold plate 32 in its discharge
position. The relief recesses 209 open the antilip channel 230 to
outside air. Outside air flushes through the series of recesses and
other passages identified as 209, 230, 234, 222, 220, 237, and 238
and into the suction chamber 280S under influence of a vacuum
present in the suction chamber 280S. The pressure in the suction
chamber 280S and the connected chambers and passages 238, 237, 220,
222, 234, 230 is increased to atmospheric pressure. The valve
element 252 is then elevated and the valve 250 is then open.
[0207] FIG. 9G illustrates the patty has been discharged by
downward movement of the cup 33, which subsequently has been
elevated. The patty has been deposited onto the conveyor. The mold
plate 32 begins a rearward movement. The suction chamber 280 now
becomes a compression or pump chamber 280P. Any air or meat fines
drawn into the suction chamber 280S can now be transported by
positive pressure or pumping action of the pump chamber 280P
through the open valve 250 and into the pump inlet 39 as now
described.
[0208] FIG. 9H illustrates that for a brief time during the return
stroke of the mold plate, the mold plate moved a small amount to
the left of the position shown in FIG. 9H, the moving end 204 will
pump air rearward through the pump chamber 280P and forward through
the passages 238, 237, 220, 222, 234, 230, 126 to atmosphere.
However the latter forward path is more restrictive than the
rearward path so little flows in this direction. Most air and fines
are pumped through the chamber 280P, through the recess 242,
through the valve passage 246, through the recess 258, through the
bores 264 and 266, through the recess 272 and into the pump inlet
39.
[0209] FIG. 9I illustrates that the end 204 has passed the passage
238 and thus all of the air and fines in the pump chamber 280P must
pass rearward toward the pump inlet 39.
[0210] FIG. 9J illustrates the cavities 126 become open to the fill
slots 121b of the fill plate 121a wherein the cavities begin to
fill with meat under pressure. The pump chamber is continuously
reduced in volume as the end 204 proceeds rearward. The valve 250
is still open.
[0211] FIG. 9K illustrates a late stage of movement of the mold
plate 32. The cavities 126 are continuing to be filled. The meat,
under pressure forces air and meat fines through the apertures 216
into the chambers 220, 222, 237, 238, 208. The valve 250 remains
open wherein the mold plate reaches the position of FIG. 9A, the
air and meat fines can exit the chambers 220, 222, 237, 238, 208 by
virtue of the recess 208 being in air flow communication with the
recess 242 and the passages 246, 258, 264, 266, 272 and 39.
[0212] Although a single row of cavities is shown in the mold plate
32 in FIGS. 10A-11B, 14 and 15, it is encompassed by the invention
to provide multiple rows of cavities, in straight or staggered
columns, such as described in U.S. Pat. Nos. 6,454,559; 6,517,340;
4,872,241; 6,572,360; and/or 3,747,160; or international patent
publications WO 01/41575 and/or WO 02/102166, all herein
incorporated by reference.
[0213] FIGS. 36-38 illustrate alternate mold plates 1232, 1234,
1236 having similar mold plate features as described above, but
having two rows of cavities 1238 in staggered columns. In FIGS. 36
and 37 the cavities are filled by individual fill slots 1242 below
the mold plates 1232, 1234. In FIG. 38, the cavities 1238 are
filled by a plurality of fill apertures 1250 in registry with the
cavities 1238. The apertures 1252 that are not in registry with the
cavities are shown but are not drilled through the plate 1236.
[0214] Furthermore, the apparatus 20 can also have, in conjunction
with the mold plate and fill plate arrangements, a stripper or seal
off mechanism such as described in U.S. Pat. Nos. 4,821,376;
4,697,308; and/or 4,372,008, all herein incorporated by reference,
or as available on current FORMAX F-26 machines.
[0215] FIGS. 39-41 illustrates an alternate valve arrangement than
described with regard to FIG. 12. The porting of the valve elements
252 remains the same. The mechanism for opening and closing the
valve elements 252 is modified. The sectional view is broken along
its vertical centerline CL to show two valves 1290 with elements
252 lowered, and closed, to the left of the centerline CL, and two
valves 1290 with elements 252 raised, and opened, shown to the
right of the centerline CL. It should be understood however that in
operation all four valve elements raise-and-lower together to open
and close the valves.
[0216] The valves 1290 are mounted on a support bar 1300. The
valves 1290 are mounted to the bar by a threaded adjustment
mechanism 1304. The adjustment mechanism includes a handle 1306
locked onto a threaded shaft 1308 that is threaded into a valve
stem assembly 1310 such that when the threaded shaft 1308 is turned
by the handle 1306, the threaded shaft selectively raises or lowers
the valve element 252 by precise amounts to set valve clearance and
to ensure that the valves seat at the same time given their common
movement. The valve stem assembly includes a ring seal 1311 to seal
against a stationary sleeve 1312 of the valve 1290.
[0217] The support bar 1300 is supported on two rods 1320, 1322. A
crossbar 1326 spans between the rods 1320, 1322 and is fastened
thereto. A bracket 1330 is supported on a machine wall 1336. A pair
of pneumatic cylinders 1342, 1344 are fixed to the bracket 1330 and
have actuation rods or piston rods 1348, 1350 fixed to the crossbar
1326. When the rods 1348, 1350 extend together from the cylinders
1342, 1344, the crossbar 1326 raises the rods 1320, 1322, which
raises the support bar 1300, which raises the valve stems 1310 and
the valve elements 252. This opens the valves 1290.
[0218] Contracting the rods 1348, 1350 into the cylinders 1342,
1344 has the opposite effect, lowering the valve elements 252 and
closing the valves 1290.
[0219] The pneumatic cylinders 1342, 1344 are signal-connected via
pneumatic tubing and electronics to the machine controller that can
precisely control the raising and lowering of the valve element to
be synchronized with the mold plate movements. The valve element
can be positively raised and lowers according to a precisely
controlled timing sequence rather than being controlled by vacuum
or positive pressure in the suction chamber or pump chamber.
[0220] FIG. 15 illustrates in schematic form, the control system of
the present invention. The machine controller 23 can be programmed
to control the servo motor drives 138, 157 and the pneumatic
cylinders 1342, 1344, via the interface 1345, to be properly
sequenced to coordinate the movements of the knockout cups and the
valves 1290 with the movement and position of the mold plate 32.
The controller can be pre-programmed, or programmed through the
control panel 19, to control the mold plate accelerations,
decelerations, advance and retract speeds, and dwell durations.
These mold plate movement parameters can be selected depending on
the particular product being molded, the characteristics of the
food material, the selected production output rate of the machine,
or other factors. The controller can control the advance and
retract speeds, the accelerations and decelerations, and the dwell
durations of the knock out cups 33 as well. These knock out cup
movement parameters can be selected depending on the particular
product being molded, the characteristics of the food material, the
selected production output rate of the machine, or other factors.
The controller can have pre-programmed routines for a selectable
product and output rate that are selectable via the control panel
19 that sets and coordinates the mold plate 32 movements, the knock
out cup 33 movements and the valve 1290 movements.
[0221] The controller also controls the operation of the hydraulic
cylinders 64, 84 to control the food pumps 61, 62.
Machine Frame System
[0222] The preferred embodiment apparatus 20 of the present
invention utilizes an exemplary frame 500 as illustrated in FIGS.
2, 3, 5-8 and 26-28, 42-43, and 56-58.
[0223] The frame 500 includes a thick base plate 21a. The base
plate 21a comprises a stainless steel plate, 1/2 inch thick. Two
rear anchors 506a, 506b and two forward anchors 508a, 508b are
fastened to the base plate 21a with fasteners 507a and keys 507b,
in a rectangular pattern. The base plate 21a and the anchors have
recesses or keyways to receive the keys 507b.
[0224] Two rear struts 510a, 510b extend obliquely forward in
parallel from the rear anchors 506a, 506b and are fastened thereto
using fasteners and shims. Two forward struts 510a, 510b extend
obliquely rearward in parallel from the front anchors 508a, 508b
and are fastened thereto using fasteners and shims.
[0225] As illustrated in FIGS. 2, 26, 28, and 56 each rear strut
510a, 510b comprises a rectangular tube column 510c having a plate
flange 510d, 510e welded to each end thereof. The tube columns
preferably have 3 inch by 2 inch by 1/4 inch thick cross sections.
The bottom plate flange 510d is fastened to the respective anchor
506a, 506b using fasteners and shims. Each anchor includes a
central stud threaded into the anchor and abutting the respective
base plate and used for positioning and spacing the bottom flange
510d so that the shims may be installed before the strut is
fastened to the anchor. The top plate flange 510e is fastened to a
vertical backing plate 516 using fasteners 507a and a key 507b fit
into keyways in the flange 510e and the backing plate 516.
[0226] As illustrated in FIGS. 2, 5 and 56, each of forward struts
512a, 512b comprises a rectangular tube column 512c having a plate
flange 512d welded to each bottom end thereof and a block flange
512e welded to each top end thereof. The tube columns preferably
have 3 inch by 2 inch by 1/4 inch thick cross sections. Each bottom
plate flange 512d is fastened to a respective anchor 508a, 508b.
The top block flanges 512e, 512e are fastened to a respective
connection block 520a, 520b, by a tie rod 522a, 522b that is
threaded into the respective block flange 512e. The connection
blocks 520a, 520b are fastened to the manifold 27.
[0227] The tie rods 522a, 522b are surrounded by respective
surrounding sleeves or spacers 524a, 524b located between
respective connection block 520a, 520b and the vertical backing
plate 516. The tie rod 522a, 522b are tensioned by nuts 525a, 525b
via tie backing blocks 526a, 526b. The spacers 524a, 524b are
compressed between the connection blocks 520a, 520b and the backing
plate 516 when the nuts 525a, 525b are tightened.
[0228] The tie rods 522a, 522b are preferably 1/4 inch in diameter
and the spacers are 23/4 inch in outside diameter.
[0229] The connection blocks 520a, 520b are supported by internal
columns 530a, 530b that are fastened to the base plate 21a (FIGS. 2
and 13) and the block flanges 512e. The internal columns 530a, 530b
are preferably square tubes having a 2 inch by 2 inch by 1/4 inch
thick cross section. The vertical backing plate 516 is supported by
a wall 532 provided within the machine base 21. The plate 516 is
fastened to the wall 532.
[0230] A pair of columns 531a, 531b supports the manifold 27 at a
front of the machine (FIGS. 2, 8, and 58). The columns are formed
by tie rods 531c surrounded by tubular spacers 531d. The tie rods
531c are fastened to the anchors 508a, 508b using nuts 531e. The
upper end of the tie rod can be threaded into the manifold 27. The
tubular spacer is compressed between the manifold 27 and the
respective anchor 508a, 508b when the nuts 531e are tightened.
[0231] As shown in FIGS. 3 and 6, three more tie rods, with
associated spacers or sleeves are used. Two top level tie rods
532a, 532b, surrounded by spacers or sleeves 536a, 536b, and
located laterally outside the pump cavities 69, 89 are threaded
into threaded bores in the pump housing 71. The tie rods 532a, 532b
are tensioned with nuts 537a, 537b on a rear side of backing plate
516, via the backing blocks 526a, 526b. A central tie rod 540
surrounded by a spacer or sleeve 542 and located laterally between
the pump cavities 69, 89 is threaded into a threaded bore in the
pump housing 71 and is tensioned by a nut 543 and washer pressed
directly against the backing plate 516.
[0232] The tie rods, when tensioned, compress the spacers or
sleeves 525a, 525b, 536a, 536b and 542 tightly between the backing
plate 516 and the pump housing 71 and the connection blocks 520a,
520b which are fastened to, or formed as part of the manifold
housing 71.
[0233] The tie rods 532a, 532b, 540 have a diameter of 11/4 inch
and the spacers 536a, 536b and 542 have a 23/4 inch outside
diameter.
[0234] The hydraulic cylinders 64, 84 have front flanges 64a, 84a
bolted to the backing plate 516 via two reinforcing washer plates
548a, 548b. Thus, when one of the hydraulic cylinders 64, 84 drives
the respective piston 66, 68 into the pump cavity 69, 89 to
pressurize the food product therein, a reaction force is created
that tends to separate the backing plate 516 from the pump housing
71. The five tie rods oppose this reaction force by tension in the
tie rods. Because the tie rods take up this reaction force, instead
of the machine frame, the associated stress within the machine
frame is reduced, or eliminated.
[0235] As shown in FIGS. 3 and 6, the T gear box 137 is supported
from a pedestal 568 on a support plate 570. The right angle
gearboxes 136 are also supported from pedestals 569 fastened to the
plate 570 (FIG. 29). The support plate 570 is fastened to a bottom
of two vertically oriented, parallel, longitudinally arranged
plates 571, 572. The plates 571, 572 are supported at a rear by
being fastened to a crossbeam 574 that is supported by sidewalls of
the machine base 21.
[0236] The longitudinally arranged plates 571, 572 are laterally
braced by a cross brace 577. The plates 571, 572 extend to the
backing plate 516 and are fastened thereto by being fastened to the
backing blocks 526a, 526b respectively by fasteners 573, locating
pins 573a, and keys 573b fit into corresponding keyways in the
blocks 526a, 526b and the plates 571, 572 (FIG. 57).
[0237] According to the preferred embodiment, the backing plate 516
has a thickness of 11/4 inches. The plates 571, 572 can have
thicknesses of 3/4 inches and heights of 131/4 inches. The support
plate 570 can have a thickness of 11/4 inches.
[0238] For additional rigidity, the bearing housings 143 that are
located above each right angle gear box 136, are connected by
pre-stressed tie rods 580a, 580b to the backing plate 516. The tie
rods 580a, 580b are threaded into tapped holes in the backing plate
516 and secured to each respective housing 143 by a nut 581. A
vertical, rectangular opening 143d is provided through each bearing
housing 143 to access the nuts 581 (FIG. 29). Each nut 581 is
threaded onto an end of one rod 580a, 580b and tightened against
the respective bearing housing 143. The tie rods 580a, 580b are
surrounded by respective tubes 582a, 582b. The tubes 582a, 582b are
compressed between a respective housing 143 and the backing plate
516 when the nuts 581 are tightened onto the tie rods 580a, 580b.
The tie rods 580a, 580b, and the tubes 582a, 582b fix the bearing
housings 143 with respect to the backing plate 516. The tie rod
580b and tube 582b are not shown in FIG. 29 but are identically
configured and attached in parallel fashion as the tie rod 580a,
582a. The tie rods have a diameter of 3/4 inches.
[0239] As shown in FIG. 28, reciprocating forces from the mold
plate and drive system originate substantially in the horizontal
plane of movement of the mold plate. These reciprocating forces are
resisted by forces transmitted through the plates 570, 571, 572 and
the tie rod/tube combinations 580a, 582a and 580b, 582b to the
vertical backing plate 516. The horizontal component of some of the
reciprocation forces is transferred through the vertical backing
plate through the rear struts 510a, 510b and into the base plate
21a.
[0240] The horizontal component of some of the reciprocation forces
is transferred through the tie rod/tube combinations 532a, 536a;
532b, 536b; 540, 542; 522a, 524a; and 522b, 524b to the pump
housing 71 and the blocks 520a, 520b. These forces are transferred
through the blocks 520a, 520b through the forward struts 512a, 512b
and into the base plate 21a.
[0241] According to one aspect of the invention, the individual
struts 510a, 510b, 512a, 512b are removable given the fact that
they are fastened in place using fasteners and can be removed from
the machine base 21 and replaced. This is particularly advantageous
during assembly and replacement of other components, wherein the
struts can be removed for access to other components within the
machine base 21.
[0242] All of the internal structural members' can be composed of
structural steel, except the base plate 21a is preferably composed
of stainless steel and the pump housing 71 and manifold 27 are
preferably composed of stainless steel. FIG. 58 illustrates the
pump housing 71 and the valve manifold 27 as a single cast
stainless steel part. By forming these parts as a unitary part,
significant assembly time is reduced, and the machine part count is
reduced.
Hopper System
[0243] The hopper 25 can be constructed as a unitary, one piece
part (FIG. 13), comprised of a 0.09 inch thick welded and polished
stainless steel part. A one piece hopper is advantageous to reduce
leakage.
[0244] As shown in FIG. 3, the hopper 25 is supported at a rear by
a hinge shaft 602 via a rear bracket 604 that is fastened to a rear
wall 25d of the hopper 25. The bracket 604 is fixed to the hinge
shaft 602 to rotate therewith. The fixing can be by a press fit
engagement, a keyed arrangement between the bracket and the shaft,
or by the bracket being fastened to the shaft with fasteners, or by
another known non-rotation fixation method.
[0245] As shown in FIGS. 4, 5, 16, 27 and 29, the hinge shaft 602
is supported from the machine base 21 and journaled for rotation by
a rear support 606 (FIGS. 4 and 16) and by a front support 608
(FIG. 5). The rear support 606 includes a roller bearing 612 that
surrounds the hinge shaft 602 and provides for a reduced-friction
rotation of the hinge shaft. The front support 608 comprises a
sleeve bearing that provides for a reduced-friction rotation of the
hinge shaft.
[0246] As shown in FIGS. 5 and 44, the hopper 25 and feed screw
frame 42 are fixed to the shaft 602 by a bracket 610 that includes
two bosses 610a each with a bore 610b. The bracket 610 is fixed to
rotate with the shaft 602 by use of a non-circular, hexagonal
opening 611a in the bracket 610 (See FIG. 13) that fits tightly
over a correspondingly shaped end protrusion 611b (FIG. 4) of the
shaft 602. The bracket is then tightly clamped to the shaft by a
bolt 609 and a washer 609b (FIGS. 4 and 5), the bolt 609 engaged
into a threaded bore in the protrusion 611b. The bracket 610 is
fixed to the frame 42 by the bosses 610a being fit within a gap
along the spacers 44b of the front two spacers 44b and the
associated tie rods 44a being inserted through the bosses 610a and
spacers 44b and then tightened. The tie rods 44a are tightened via
threaded inserts 613a to a horizontal plate 613 that forms part of
the hopper assembly. Also shown in FIG. 44, the base plate 613
includes four slots 613b, arranged symmetrically, two on each side
of the hopper. Four studs 613c (one shown) are threaded into
threaded holes in the pump housing 71, and fit within the slots
613b when the hopper is pivoted down to its operational position.
Four nuts 613d secure the base plate 613 and the hopper 25 to the
pump housing 71. At a rear of the apparatus, as shown in FIGS. 16
and 29 a crank lever 614 is provided that is keyed by a key 614a to
the shaft 602.
[0247] A large threaded lock nut or lock collar 615 is threaded
tightly onto a threaded end of the shaft and locked with a set
screw 615a. The crank lever 614 is pivotally connected at a distal
end to an actuator, such as a hydraulic cylinder 616. The cylinder
616 is pivotally connected at an opposite end thereof to an anchor
lug 618 fixed to the base plate 21a. The cylinder is
signal-connected via a hydraulic/electronic interface to the
machine controller. Expansion of the cylinder 616 causes the crank
lever 614 to be turned counterclockwise (FIG. 16) by about 85
degrees to the position shown as 614aa. The shaft 602 is thus
turned about 85 degrees, as is the hopper 25 to the position marked
25aa.
[0248] By rotating the hopper 25 to the position shown as 25aa, the
conveyor belt 31 is exposed for cleaning or removal. The plate 613,
being a part of the hopper assembly, pivots with the hopper 25, as
does the frame 42.
[0249] As a further aspect of the embodiment, as shown in FIGS. 2
and 4, the conveyor 30 includes a frame 619 having a hinge-side
sidewall 620, an opposite-side sidewall 621, a plurality of lateral
tie rods 622, a plurality of longitudinal ribs 623 supported on the
tie rods 622, and two lateral tie rod beams 624, 625. The lateral
tie rods 622 and the tie rod beams 624, 625 each have surrounding
sleeves or spacers between the sidewalls 620, 621 and are fixed at
opposite ends by nuts or the like to the sidewalls 620, 621. The
conveyor frame 619 is simply supported on the machine base along
the opposite-side sidewall 621.
[0250] Two intermediate fixtures 636, 638 (FIGS. 4, 16B-16D) are
welded or otherwise fixed to the wall 620 of the conveyor and
surround the shaft 602. The intermediate fixtures 636, 638 are
rotatable with respect to the shaft 602 about the axis of the shaft
602. The fixtures 636, 638 have cross pins 640, 642 respectively.
The fixtures are in two pieces that are assembled around the shaft
using fasteners 643. Two lift pins 644, 646 with enlarged heads
extend from the shaft adjacent opposite sides of each fixture 636,
638. The pins are press fit and fixed into bores in the shaft 602
by fasteners 648. During rotation of the shaft 602 by about 85
degrees for the hopper 25 to assume the position indicated as 25aa
in FIG. 10, the pins 644, 646 sweep a first portion of the 85
degrees freely until contact is made with the pins 640, 642. The
pins 644, 646 sweep the last portion of the 85 degrees, lifting the
pins 640, 642 and rotating the conveyor upward about 13 degrees.
This raises the conveyor from its support on the opposite-side 621
of the frame 619. At this position, the conveyor can be cleaned or
repaired as required. The surface area beneath the conveyor belt
can be cleaned as well. The conveyor belt 31 can be removed and/or
cleaned.
[0251] Although the 85 degree hopper tilt and 13 degree conveyor
tilt are advantageous, it is anticipated that other angular tilts
such as 45 degrees-90 degrees for the hopper and 10 degrees-30
degrees for the conveyor may be advantageous as well. The location
and size or shape of the pins 644, 646 can be adjusted to select
the hopper and conveyor tilt amounts.
[0252] The hopper 25 and conveyor 30 are pivoted by the actuator
616 via the machine controller, particularly by instructions give
to the controller via the control panel 19.
[0253] The hopper tilt system is configured such that apparatus can
be easily factory converted from a right side operating apparatus
to a left side operating apparatus, that is, the hopper assembly is
factory reversible across the longitudinal centerline of the
apparatus. For example the crank lever 614 comprises a lever arm
614b that is welded to a collar 614c that is secured to the shaft
602. In the factory, the lever arm 614b can easily be switched for
a right side operation by flipping over the lever arm and welding
the lever arm the collar. The remaining shaft supports and brackets
can be reused for mounting the system on the opposite side of the
machine. Parts needing to be designed and manufactured can be
reduced, given the bidirectional feature of the design.
Cooling Air System
[0254] The present invention also provides an improved cooling air
system. The cooling air system includes two axial fans 702, 704
shown in FIGS. 16 and 29 that draw air in on a top side and
discharge air downward into the machine base 21. The fans 702, 704
are mounted on elevated baffle plate 706 within a fan chamber 708.
The baffle plate 706 provides openings beneath the fans 702, 704,
for axial airflow into the machine base 21. The fan chamber
includes a rectangular surrounding side wall 710 having a seal 712
around its upper lip.
[0255] A cover 716 is provided over top side wall 710. The cover
716 is movable up-and-down. In FIG. 29, the cover 716 is shown in
broken fashion to illustrate the movement of the cover 716. It is
understood however that the cover 716 is one part and is either
raised her lowered as one part. The elevated position of the cover
716 is indicated as 716a shown on the right side half of the cover
716 and the lowered position is indicated as 716b shown on the left
side half of the cover.
[0256] Plural pneumatic cylinders 722, eight according to the
preferred embodiment, are fastened at base ends to the baffle plate
706. The pneumatic cylinders include extendable rods 726 that are
fastened to the cover 716. The cylinders 722 are configured such
that when energized with pressurized air the cylinders extend rods
726 to elevate the cover 716 to the position indicated as 716a,
held above the seal 712. Outside air can be admitted under the
cover and up and over the seal 712 to the inlet of the fans 702,
704 as indicated by the arrows "A." The cylinders 722 overcome the
compression force of springs 730 within the cylinders 722 to
elevate the cover 716 as shown in position 716a. If the cylinders
722 are de-energized, such as by loss of electrical power to the
apparatus 20, the springs 730 urge the cover 716 downward onto the
seal 712, as shown in position 716b, to close the inlet.
[0257] During operation, the cylinders 722 are energized, and the
cover 716 is elevated as shown in position 716a. The fans 702, 704
force air through the machine base 21.
[0258] Air passes through the machine and exits the machine base 21
at a front of the machine base 21. As shown in FIGS. 7 and 8, two
air exit dampers 740, 742 are provided having shut off plates 744,
746. The shut off plates 744, 746 are positioned over air openings
750, 752 through the base plate 502. The plates 744, 746 are
carried by rods 754, 756 via self aligning couplings 754a, 756a and
are raised and lowered by cylinders 758, 760. The cylinders are
supported by a bracket 764 from the machine base 21 or other
stationary structure.
[0259] Within the cylinders 758, 760 are springs (not shown) that
are configured to urge the plates 744, 746 downward from the
elevated, open position indicated as 744a, 746a to the lowered,
closed position indicated as 744b, 746b. During operation,
cylinders 758, 750 are energized and pneumatic pressure elevates
the plates 744, 746 to the position 744a, 746a, overcoming the
urging of the springs within the cylinders 758, 760.
[0260] If power is interrupted to the apparatus 20, the plates 744,
746 are lowered by the springs within the cylinders 758, 760 to
close the air exit dampers 740, 742.
[0261] When the apparatus 20 is washed and sanitized, power is
normally shut off. Because power is interrupted, the cover 716 is
automatically closed and the air exit dampers 740, 742 are
automatically closed. Thus, spray, wash water and debris are
prevented from entering the machine base 21.
[0262] The hopper tilt system, the control panel 23, and the
cooling air system are configured such that apparatus can be easily
factory converted from a right side operating apparatus to a left
side operating apparatus, that is, factory reversible across the
longitudinal centerline of the apparatus.
Hydraulic System
[0263] The apparatus incorporates a hydraulic system such as
described in U.S. Pat. No. 3,887,964 or Re 30,096, herein
incorporated by reference, or as currently used on FORMAX F-26
machines. In such systems a lower pressure, higher volume hydraulic
pump and a higher pressure, lower volume hydraulic pump are used.
The lower pressure pump is useful for moving the hydraulic piston
and the associated plunger a large distance such as from a
retracted position to a position wherein the food product is
initially compressed within the cylinder by the plunger. The higher
pressure pump is useful to move the plunger an incremental distance
each mold plate reciprocation cycle, to deliver food product under
pressure into the mold cavities.
[0264] One improvement in the present invention is the fact that
the lower pressure pump 1410 and the higher pressure hydraulic pump
1414 are both driven by a common electric motor 1416, in series on
the motor output shaft, wherein the pumps 1410, 1414 are located in
the hydraulic fluid reservoir 1418, submerged below a hydraulic
fluid fill line 1417. By being submerged, the pumps run quieter,
cooler and more efficiently.
[0265] The motor 1416 is preferably a 15 HP totally enclosed, fan
cooled motor. As shown in FIGS. 29 and 55, the motor 1416 is
supported on a platform 1416a that is supported in cantilever
fashion from the reservoir 1416. The motor includes a rotary output
shaft 1416b.
[0266] The reservoir 1418 is preferably a stainless steel tank. A
bottom 1419 of the reservoir is advantageously visible for
inspection and cleaning and sanitizing. The reservoir 1418 can be
elevated from the base 21a on isolation mounts.
[0267] As shown in FIG. 2, the pumps 1410 and 1414 have pump shafts
1424a, 1424b connected by a coupling 1424c, shown dashed. As shown
in FIGS. 29 and 55, the pump shaft 1424a is coupled to the motor
output shaft 1416b by a mechanical coupling 1426. A motor mount
1430 surrounds the coupling 1426 as it is sealed to a wall 1418a of
the reservoir 1418 by a ring seal 1430a clamped between a backing
ring 1430b that is fastened through the wall 1418a to the motor
mount 1430. The lower pressure pump 1410 is bolted to the backing
ring in sealed fashion.
Mold Cover Lift System
[0268] During mold plate change or to clean the apparatus, it is
necessary to lift the mold housing or mold cover 123 from above the
mold plate 32. The bolts 125 are removed as a first step for
lifting of the housing 123.
[0269] A mold housing lift mechanism 800 is mounted inside the
machine base 21 and extends upward to the housing 123. The lift
mechanism includes two jacks 802, 804 shown in FIGS. 8 and 27. The
jacks are operatively connected to right angle drives 808, 810,
which are operatively connected to a T type right angle drive 814,
via drive shafts 818, 820 and respective couplings 823, 824, 826,
828, 830. The right angle drive 814 is driven into rotation by a
hydraulic motor 836.
[0270] The jack 802 is described below with the understanding that
the jack 804 is identically configured and functions identically,
in tandem, as the jack 802.
[0271] As shown in FIGS. 8, 27 and 30-33, the drive 808 turns a
threaded rod or jackscrew 842 that drives a nut drive assembly 844
vertically. The jack screw 872 is journaled for rotation at a top
end by a guide 845. The jack screw 842 and guide 845 can include a
bearing therebetween for smooth journaled rotation of the
jackscrew. The drive assembly 844 is operatively connected to a
lift column 850 via a bracket 851 which is vertically driven with
the drive nut assembly. The columns 850 of the jacks 802, 804, are
fixed to the housing 123 by bolts 856, 858. The columns 850 are
hollow and can also serve as wire and tube conduits.
[0272] As shown in FIGS. 30-31, the bracket 851 is clamped onto a
bottom of column 850. The bracket 851 rests on a drive nut 870 that
is driven by the drive rod 842. A limit plate 862 is fastened to
the drive nut 870 by spacers 867 and fasteners 866. A collar 874 is
fastened to the bottom of the drive nut 870 with fasteners 875.
[0273] The drive nut 870 has inside threads engaged to the outside
threads of the drive rod 842. A secondary nut 882 is threaded onto
the jackscrews 842 beneath the drive nut 870.
[0274] Proximity target, magnetic plate 892 is fastened to a
mounting plate 894 which is fastened to the bracket 851 by
fasteners 900. A proximity sensor 908 is mounted within the machine
base 21 along the vertical path of the magnetic plate 892 and set
at a maximum acceptable. The magnetic plate 892 sets an acceptable
vertical range for a mold cover operating elevation. If the mold
cover is elevated beyond this range, the sensor 908 will be below
the magnetic plate 892 and will so signal the machine controller
which will prevent operation of the machine.
[0275] A further proximity target 904 is fastened to a lateral side
of the bracket 851. Proximity sensor 910 is mounted at an elevated
position within the machine base along the vertical path of the
target 904 and signals a pre-determined raised maximum height of
the mold cover casting for a mold plate change out procedure. The
proximity sensor 910 signals the machine controller to stop the
motor 836 at that point.
[0276] The collar 874 has internal protruding pins 878, surrounding
the jackscrew 842 and a secondary nut 882. The secondary nut
includes notches 886 for receiving the pins 878. During normal
lifting operation, the pins will be engaged to, or will engage, the
secondary nut 882 as shown in FIG. 14. The secondary nut 882 ceases
to rotate freely with the jackscrew 842 and thereafter travels with
the assembly 844 up and down on the jackscrew 842. The secondary
nut 882 provides backup support for the drive nut 870 in the
unlikely event that the drive nut fails to support the bracket
851.
[0277] As shown in FIG. 32, before engagement with the pins of the
drive nut assembly 844, the secondary nut 882 is free to rotate
with the jackscrew 842 between the nut 870 and the pins 878. Once
the pins 878 are relatively elevated with respect to the nut 882 to
engage the notches 886 the secondary nut moves vertically with the
assembly 844. If the drive nut 870 fails during lifting, the
secondary nut 882 is in a position to support the drive nut
assembly and bracket 851, but will not function to lift the nut
assembly 844. If the jackscrew is turned, the secondary nut 882
will rise to the point until it disengages from the pins 878 and
then turn substantially freely with the rotating jackscrew 842.
[0278] FIG. 33 illustrates the assembly with the mold cover lowered
and the nut 870 lowered a further amount with the plate 862
contacting, or adjacent to, the bracket 851. Thus, the nut assembly
844 can completely disengage from the bracket 851.
[0279] From the foregoing, it will be observed that numerous
variations and modifications may be effected without departing from
the spirit and scope of the invention. It is to be understood that
no limitation with respect to the specific apparatus illustrated
herein is intended or should be inferred.
* * * * *