U.S. patent number 3,866,741 [Application Number 05/372,236] was granted by the patent office on 1975-02-18 for stacker and method of stacking frozen food patties.
This patent grant is currently assigned to Formax, Inc.. Invention is credited to Thomas J. Carbon, Henry N. Lekan, Louis R. Richards, Josef T. Zeisberger.
United States Patent |
3,866,741 |
Carbon , et al. |
February 18, 1975 |
STACKER AND METHOD OF STACKING FROZEN FOOD PATTIES
Abstract
A stacking method and apparatus for frozen food patties and like
disc-shaped articles; the patties are discharged in free fall and
at predetermined speed over the terminal end of an input conveyor
and are accumulated on a stationary stacking conveyor after
rotation of about 180.degree., being guided into an orderly stack
by a guide positioned outwardly of the terminal end of the input
conveyor. The stack height is monitored, preferably by counting the
patties; when a full stack is collected, the guide is lifted up and
away from the stacking conveyor and the stacking conveyor is
actuated to move the stack away from the stacking position. The
guide is moved back to its original position and the stacking
conveyor is stopped before the next patty falls onto the stacking
conveyor.
Inventors: |
Carbon; Thomas J. (Addison,
IL), Zeisberger; Josef T. (Chicago, IL), Richards; Louis
R. (Mokena, IL), Lekan; Henry N. (Chicago, IL) |
Assignee: |
Formax, Inc. (Mokena,
IL)
|
Family
ID: |
23467281 |
Appl.
No.: |
05/372,236 |
Filed: |
June 21, 1973 |
Current U.S.
Class: |
414/789; 198/402;
414/794.4; 198/434; 414/790.7 |
Current CPC
Class: |
B65G
57/11 (20130101) |
Current International
Class: |
B65G
57/11 (20060101); B65G 57/02 (20060101); B65g
057/00 () |
Field of
Search: |
;198/35 ;271/DIG.7
;93/93C,93DP ;214/6D |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Marbert; James B.
Assistant Examiner: Watts; Douglas D.
Attorney, Agent or Firm: Kinzer, Plyer, Dorn &
McEachran
Claims
1. A stacker for stacking frozen food patties or like disc-shaped
articles, comprising:
a substantially horizontal input conveyor, having a terminal end
located at a stacking station for conveying frozen food patties or
like disc-shaped articles to the stacking station at a
predetermined speed and with predetermined minimum spacing, the
input conveyor discharging the articles, in free fall, over its
terminal end;
a normally stationary stacking conveyor, extending outwardly of the
stacking station from a stacking location at a point directly below
the terminal end of the input conveyor, the vertical distance from
the terminal end of the input conveyor to the stacking conveyor
being sufficient to allow each article to rotate through an angle
of about 180.degree. as it falls toward the stacking conveyor;
a guide, movable between a stack guidance position adjacent the
stacking conveyor and a stack release position displaced upwardly
from the stacking conveyor and outwardly from the stack guidance
position, for guiding the articles to accumulate in an orderly
stack on the portion of the stacking conveyor at the stacking
location;
stacking conveyor actuating means for actuating the stacking
conveyor for a limited time interval, not substantially greater
than the time interval between discharge of successive articles
into the stacking station, to transport an accumulated stack of
articles away from the stacking location;
guide actuating means for actuating the guide from stack guidance
position to release position and back again in timed relation to
operation of the stacking conveyor actuating means, the guide
returning to stack guidance position before more than one article
for the next stack reaches the stacking conveyor;
and means to monitor article accumulation at the stacking location
and to energize both of said actuating means when a desired
accumulation has been
2. A stacker according to claim 1, in which the guide actuating
means comprises a linearly movable actuator member connected to the
guide and extending upwardly from the stacking location at an acute
angle to the vertical, away from the stacking location, so that
movement of the guide to its release position displaces the guide
outwardly of the stacking station and allows actuation of the
stacking conveyor before the guide
3. A stacking conveyor according to claim 2, in which the actuator
member
4. A stacker according to claim 2, in which the guide actuating
means includes upper and lower stop members defining the release
and stack guidance positions of the guide, each stop member
including a bumper of resilient material positioned at one end of
the path of the guide movement
5. A stacker according to claim 1 wherein the monitoring means for
counting articles moving along the input conveyor and for
initiating operation of the guide actuating means is and the
stacking conveyor actuating means
6. A stacker according to claim 5, in which the input conveyor is a
wire mesh conveyor and the monitoring means includes a light source
and a photocell aligned with each other, one above and the other
below the input
7. A stacker according to claim 1, including a horizontally
adjustable mount for the guide and guide actuating means, allowing
adjustment of the horizontal position of the guide, toward and away
from the stacking
8. A stacker according to claim 1, and further comprising a
supplemental stationary guide, positioned at the opposite side of
the stacking location
9. A method of stacking frozen food patties and like disc-shaped
articles, comprising:
conveying a series of disc-shaped articles, in flat, spaced,
longitudinal alignment at a predetermined speed along a given
generally horizontal input path toward a terminal end of the
path;
discharging the articles, successively, in free fall, from the
terminal end of the input path and into a stacking station;
collecting the falling articles in a stack on a normally stationary
conveyor surface at the stacking station, at a point directly below
the terminal end of the input path, the vertical distance from the
terminal end of the input path to the stacking conveyor surface
being sufficient to allow each article to rotate through an angle
of about 180.degree. as it falls;
guiding the articles into an orderly stack by normally maintaining
a guide in a guidance position adjacent the stacking conveyor
surface and spaced outwardly of the terminal end of the input
path;
continuously monitoring the height of the stack of articles
accumulating on the stacking conveyor surface by counting the
articles traversing the input path;
moving the guide upwardly of the stacking conveyor surface and
outwardly of the terminal end of the input path to a stack release
position upon accumulation of a stack of given height;
moving the stacking conveyor surface to transport the stack away
from the stacking location, substantially simultaneously with
movement of the guide toward its release position and in response
to monitoring a predetermined height of articles on the stacking
conveyor;
and restoring the guide to guidance position and stopping movement
of the stacking conveyor before the next article reaches the
stacking conveyor.
10. A method of stacking according to claim 9 in which the path of
movement of the guide is inclined at an acute angle to the
vertical, away from the stacking station, and in which movement of
the stacking conveyor surface is initiated before the guide reaches
its release position.
Description
BACKGROUND OF THE INVENTION
Pre-molded food patties, particularly hamburger patties, have found
increasing popularity for both commercial and household use. A
number of different high-speed high-volume devices have been
developed for the manufacture of these food patties. To obtain the
advantages of centralized production, increasingly larger
percentages of hamburger patties and other food patties are being
marketed in frozen form. In a typical installation, the patties are
molded in a high speed molding machine, conveyed directly into and
through a cryogenic freezing tunnel, and then packaged for
distribution to commercial and retail outlets. The frozen patties
are hard and brittle, as they emerge from the cryogenic freezing
equipment, and must be maintained in frozen condition throughout
any packaging or subsequent processing.
For the most part, hand stacking and packaging has been employed
for frozen hamburgers and other food patties, even in high-volume
production facilities. This often requires a substantial number of
stacker employees, adding considerably to the expense of overall
plant operation, particularly for a plant in which molding and
freezing of the patties is a fully automated operation. Hand
stacking is a rather unpleasant job, since the patties are frozen
and difficult to handle. Any inaccuracy in the stacking operation
may result in an economic loss to the plant operator, either from
customer complaints or from delivery of excess goods to the
customers. Substantial floor space may be required, in a high speed
frozen food patty processing line, in order to afford adequate work
room for the stackers. Any frozen patties that are dropped
represent an economic loss, due to breakage and the loss of
sanitary control.
In many installations, it is highly desirable to afford a complete
in-line operation from the patty molding equipment through the
relatively long cryogenic freezing tunnel and then through the
packaging operation. Any deviation from a direct linear processing
path may materially increase floor space requirements, particularly
in installations in which more than one processing line is
employed.
Several different forms of equipment have previously been proposed
for stacking disc-shaped articles. For example, in the tortilla
stacker shown in Mason patent No. 3,393,645 tortillas slide down a
chute and are projected out along a horizontal extension of the
chute, coming to rest in a stack that accumulates on a set of
movable plates. The plates are retracted when the stack is
complete, allowing the tortillas to fall onto an output conveyor.
In another stacker, shown in Maulini U.S. Pat. No. 3,338,370,
biscuits are discharged at relatively high speed from the bottom of
a hopper, either in pairs or on an individual basis; a relatively
complex multiple hopper arrangement is used to develop stacks
containing a plurality of biscuits.
Another biscuit stacker is Morton U.S. Pat. No. 3,282,399 in which
biscuits slide off of the end of a plate at high speed and fly
outwardly into engagement with an anvil. From the anvil, the
biscuits fall downwardly to accumulate on an output conveyor. In
the Morton arrangement, the biscuits turn through a limited angle,
less than 90.degree.. Another stacker that utilizes a turning
motion of about 90.degree. is shown in Monaco U.S. Pat. No.
2,519,419, in which the biscuits or like articles slide off of the
end of an upwardly inclined conveyor and down a guide chute to
accumulate in a vertically oriented stack.
An entirely different form of stacker is shown in Joa U.S. Pat.
Nos. 3,324,930 and 3,391,777. In these mechanisms, the flat objects
to be stacked are carried upwardly away from an input conveyor by a
transfer conveyor that deposits the articles on an output conveyor.
The transfer conveyor rotates the articles through an angle of
180.degree., in an operating cycle that maintains the transfer
conveyor in contact with the articles throughout the stacking
operation.
Each of these previously proposed stacking devices presents some
disadvantage and difficulty when applied to the stacking of hard,
brittle, disc-shaped articles such as frozen food patties. Some of
the stackers require the use of relatively high conveyor speeds in
the stacking operation, particularly where the stacked articles are
maintained in the same angular orientation throughout the stacking
operation. This high speed operation presents a substantial
possibility of damage, when the movement of the articles is
interrupted by an anvil or other blocking member. In several
instances, the stacking equipment is relatively complex, unduly
increasing the cost and presenting a maintenance problem in the
rather difficult environment presented by a food processing plant.
Hand stacking, on the other hand, is expensive, potentially
inaccurate, and entails the use of excessive amounts of floor
space.
SUMMARY OF THE INVENTION
It is a principal object of the present invention, therefore, to
provide a new and improved stacker apparatus and stacking method,
applicable to the stacking of frozen food patties and other similar
disc-shaped articles in high-volume production facilities, that
does not require the utilization of high speed conveyors and can be
operated effectively at relatively low conveyor speeds.
A particular feature of the present invention is the provision of a
high-volume stacking method and apparatus, operable with conveyors
functioning at relatively low speeds, in which stacking is effected
through free fall of the stacked articles through a relatively
short distance, entailing a rotation of approximately 180.degree.
and continuous but limited guidance of the articles during the
stacking process.
Another object of the invention is to provide a high speed
operating mechanism for displacing a guide, in a free-fall stacker
for frozen food patties and like disc-shaped articles, that removes
the guide to permit the transport of a completed stack away from
the stacking location and subsequently restores the guide to its
normal guiding position before the first article for the next stack
reaches the stacking location.
Another object of the invention is to provide a new and improved
method and apparatus for monitoring the accumulation of frozen food
patties or like disc-shaped articles in the course of stacking
those articles for packaging at the output of a high volume
production line.
A particular object of the invention is to provide a new and
improved stacker for frozen food patties or like disc-shaped
articles that is simple and economical in construction, requires a
minimum of maintenance, and is adapted to use in a straight-line
production arrangement.
Accordingly, the invention relates to a stacker for stacking frozen
food patties or like disc-shaped articles; the stacker comprises a
substantially horizontal input conveyor, having a terminal end
located at a stacking station, for conveying frozen food patties or
like disc-shaped articles to the stacking station at a
predetermined speed and with predetermined minimum spacing, the
input conveyor discharging the articles in free fall over its
terminal end. A normally stationary stacking conveyor extends
outwardly of the stacking station from a stacking location below
the terminal end of the input conveyor, the vertical distance from
the terminal end of the input conveyor to the stacking conveyor
being sufficient to allow each article to rotate through an angle
of about 180.degree. as it falls toward the stacking conveyor. A
guide, movable between a stack guidanace position adjacent the
stacking conveyor and a stack release position displaced from the
stacking conveyor, is employed to guide the articles to accumulate
in an orderly stack on the portion of the stacking conveyor at the
stacking location. Stacking conveyor actuating means are provided,
actuating the stacking conveyor for a limited time interval, not
substantially greater than the time interval between discharge of
successive patties into the stacking station, to transport an
accumulated stack of patties away from the stacking location.
Further, guide actuating means are provided to actuate the guide
from its stack guidance position to its release position and back
again in timed relation to operation of the stacking conveyor
actuating means, the guide returning to its back guidance position
before more than one patty for the next stack reaches the stacking
conveyor.
The invention further relates to a method of stacking frozen food
patties and like disc-shaped articles. In the stacking method, a
series of disc-shaped articles are conveyed in flat, spaced,
longitudinal alignment at a predetermined speed along a given
generally horizontal input path toward a terminal end of the path;
the articles are discharged, successively, in free fall, from the
terminal end of the input path and into a stacking station. The
falling articles are collected in a stack on a normally stationary
conveyor surface at the stacking station, below the terminal end of
the input path, the vertical distance from the terminal end of the
input path to the stacking conveyor surface being sufficient to
allow each article to rotate through an angle of about 180.degree.
as it falls. The articles are guided into an orderly stack by
normally maintaining a guide in a guidance position adjacent the
stacking conveyor surface and spaced outwardly of the terminal end
of the input path. The height of the stack of articles accumulating
on the stacking conveyor surface is continuously monitored, and the
guide is moved upwardly of the stacking conveyor surface and
outwardly of the terminal end of the input path to a stack release
position upon accumulation of a stack of given height. The stacking
conveyor surface is moved to transport the stack away from the
stacking location, substantially simultaneously with movement of
the guide toward its release position. The guide is restored to its
guidance position and movement of the stacking conveyor is stopped
before the next article reaches the stacking conveyor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation view of a patty stacker constructed in
accordance with one embodiment of the present invention and capable
of carrying out the stacking method of the invention;
FIG. 2 is a plan view of the stacker of FIG. 1;
FIG. 3 is an end view, taken from the output end, of the stacker of
FIGS. 1 and 2;
FIG. 4 is a partly schematic elevation view of the stacking station
in the stacker of FIGS. 1-3, drawn to an enlarged scale and
employed to explain the stacking operation;
FIG. 5 is a detail view, partly schematic, taken approximately
along line 5--5 in FIG. 4, illustrating the monitoring apparatus
for the stacker;
FIG. 6 is a side elevation view of the stacking station for the
stacker of FIGS. 1-3, drawn to an enlarged scale, with the covers
of a part of the apparatus removed to show details of the operating
mechanism;
FIG. 7 is a detail end elevation view of the stacking mechanism of
FIG. 6, with covers cut away to show the operating mechanism;
and
FIG. 8 is a detail sectional view taken approximately along line
8--8 in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The general construction of a stacker 10 for stacking frozen food
patties or like disc-shaped articles, comprising one embodiment of
the present invention, is shown in FIGS. 1-3. Stacker 10 includes
an input conveyor 11 mounted on a frame 12 and located in alignment
with the output end of production apparatus, such as a cryogenic
freezing tunnel 13, in position to receive frozen food patties
discharged from a conveyor 14 within the production equipment.
The input conveyor 11 is substantially horizontal in alignment,
although some deviation from the horizontal can be permitted as
indicated in FIG. 1. The terminal end 15 of conveyor 11 is located
at a stacking station 20. A stacking conveyor 21, mounted upon a
frame 22, is included in stacker 10. The stacking conveyor 21
extends outwardly of stacking station 20, away from a stacking
location 23 below the terminal end 15 of input conveyor 11. Input
conveyor 11 operates at a predetermined, constant speed and the
stacking location 23 on output conveyor 21 is spaced below the
terminal end 15 of input conveyor 11 by a vertical distance which
is sufficient to allow each patty to rotate through an angle of
180.degree. in free fall, as described in greater detail
hereinafter.
Stacker 10 includes a guide 24 that is normally maintained in a
stack guidance position, as shown in FIGS. 1 and 3, adjacent the
surface of the stacking conveyor 21. Guide 24 is spaced outwardly a
short distance from the terminal end 15 of input conveyor 11. Guide
actuating means, generally identified by reference numeral 25, are
provided for actuating guide 24 from its normal stack guidance
position to a release position. This movement of guide 24 is in a
direction upwardly from stacking conveyor 21 and somewhat outwardly
with respect to the terminal end 15 of input conveyor 11.
Actuating means are also provided for the stacking conveyor 21,
comprising a conveyor drive motor 26. Stacker 10 includes controls
for controlling and synchronizing operation of both the guide
actuating means 25 and the stacking conveyor actuating means 26. A
main control unit 27 is mounted in the lower part of frame 12; a
supplemental control unit 28 is mounted upon an upward extension 29
of frame 12 that also serves as a support for the guide actuating
means 25. Stacker 10 may also include an auxiliary guide 31 located
on the opposite side of the stacking station 20 from the movable
guide 24. Guide 31 is a stationary guide, and may be omitted in
some installations.
Stacker 10 further includes means for monitoring the stacking
operation; this monitoring means comprises a light source 32
mounted above the input conveyor 11 on a bracket 33 affixed to a
frame member 35, as generally illustranted in FIGS. 1-3 and shown
in greater detail in FIGS. 4 and 5. A photocell 34 is positioned
below conveyor 11 and is aligned with light source 32 (FIGS. 4 and
5). For this particular monitoring arrangement, a wire mesh belt is
utilized for input conveyor 11 so that the passage of a patty 36
through the light beam 37 between source 32 and photocell 34 can be
detected in the output from the photocell, enabling a part of the
control system 27, 28 to obtain an accurate account of the patties
as they are passed through the stacker.
In the method of the present invention, as carried out by patty
stacker 10, a series of frozen hamburger patties or other similar
disc-shaped articles 36 is conveyed along input conveyor 11 in
flat, spaced, longitudinal alignment as shown in FIG. 2. Patties 36
are maintained in orderly rows on conveyor 11, as shown in FIG. 2,
but the spacing between adjacent rows need not be constant. Input
conveyor 11 is operated at a relatively constant speed and the path
of the patties along the input conveyor is approximately
horizontal. The input path along conveyor 11 terminates at the
terminal end 15 of the conveyor, from which the patties are
discharged in free fall into stacking station 20.
As each row of patties falls from input conveyor 11, the patties
are collected in stacks on the surface of stacking conveyor 21 at
the stacking location 23 below the terminal end 15 of the input
path. As noted above, the vertical distance from the terminal end
15 of the input path to the surface of the stacking conveyor 21 is
chosen to allow each patty 36 to rotate through an angle of
approximately 180.degree. as it falls toward the stacking conveyor
(see FIG. 4). The bottom patty in each stack rotates through an
angle somewhat greater than 180.degree. and is re-aligned
horizontally as it comes to rest on stacking conveyor 21. The top
patty in each stack rotates through an angle somewhat less than
180.degree. because its fall is interrupted before full rotation is
achieved. The average rotation for all patties, however, is
approximately 180.degree..
As the stack of patties accumulate in stacking station 20, the
stacks are maintained in orderly alignment by the movable guide 24,
which is held steady in the stack guidance position shown in FIGS.
1 and 3. Thus, any patty that tends to fall too far outwardly away
from the terminal end 15 of the input path is constrained from
moving beyond the desired stack alignment by guide 24. The
stationary guide 31 may be utilized to prevent excessive movement
of the falling patties in the opposite direction from that
controlled by the movable guide 24, particularly by patties
deflected by guide 24. In many instances, however, there is no
tendency toward excessive movement of the patties in this latter
direction, so that the stationary guide 31 may be eliminated.
As the stacks of patties accumulate in stacking station 20, the
number of patties is counted by the monitoring means comprising
light source 32 and photocell 34. When a stack of desired height,
such as the stack 41, has accumulated (FIG. 4), guide 24 is moved
rapidly upwardly from the stacking conveyor surface and outwardly
from the terminal end 15 of the input path, as indicated by the
arrow A in FIG. 4. In this manner, guide 24 is shifted to a stack
release position as indicated by the phantom outline 24A. At
approximately the same time, the actuating means for the stacking
conveyor 21 is activated, moving the upper surface of the stacking
conveyor 21 in the direction of the arrow B to transport the stack
away from the stacking location 23 to the position shown for stack
41.
As soon as the stack of patties has been moved out of the stacking
location 23 to a position clear of the stacking guide 24, the guide
is moved back downwardly and inwardly of the stacking station to
its original guidance position, moving in the direction of the
arrow A' in FIG. 4. At about the same time, the movement of the
stacking conveyor 21 is interrupted and the stacking conveyor is
subsequently held stationary for the accumulation of another stack
of patties in stacking station 20. The complete cycle of operation
of stacking guide 24 and stacking conveyor 21 should be
accomplished before the next patty reaches the upper surface of the
stacking conveyor 21, or at least very shortly thereafter, so that
the first patty for the next stack will be properly positioned in
the stacking location 23.
From the foregoing description, it will be apparent that stacker 10
affords an efficient and effective apparatus for stacking patties
36, on an essentially automatic basis, eliminating hand stacking
completely. The spacing between adjacent rows of the patties 36 can
vary to a substantial extent, as may occur with some interruption
or minor delay in operation of the production equipment that feeds
the patty stacker. Such an interruption or delay will not result in
the preparation of stacks of non-uniform height, since the stack
height is effectively controlled by the monitoring means comprising
light source 32 and photocell 34.
Stacker 10 serves as an in line extension of the production
equipment, such as the freezing tunnel 13, and requires a minimal
amount of floor space. The input conveyor 11 can be operated at
quite moderate speeds, even for a high volume production line, so
that the frozen patties are not damaged or dropped when they fall
from the input conveyor terminal end 15 to the stacking location 23
on the stacking conveyor 21. Consequently, breakage and loss of
sanitary control are inherently minimized. This relatively low
speed operation is made possible by permitting the patties to
rotate through an angle of approximately 180.degree. in the course
of the stacking operation, as described above and as specifically
illustrated in FIG. 4, in contrast with the high speed operations
frequently required in stackers that maintain the patties in their
initial orientation.
A preferred construction for the stacking station 20, and
particularly the actuating means 25 for movable guide 24, is shown
in FIGS. 6-8. As illustrated therein, the guide actuating means 25
is affixed to an adjustable L-shaped bracket 46 that is mounted
upon a support 45; support 45 is affixed to the upper frame 29 of
the stacker by a plurality of bolts or other suitable mounting
devices 47. A series of bolts 48 mounted in slots 49 constitute the
mounting connection between bracket 46 and support 45, allowing
horizontal adjustment of the position bracket 46 parallel to the
path of movement of patties through the stacker.
A channel-shaped support member 51 is mounted on the front leg 53
of bracket 46 by suitable means such as a plurality of mounting
bolts 52. The base 54 of an electrically-energized linear actuator
55, such as a linear motor or solenoid is centrally mounted within
the channel-shaped support 51, as shown in each of FIGS. 6-8. In
the illustrated construction, the base 54 of the linear actuator 55
is bolted to the channel-shaped support 51, but other mounting
arrangements can be utilized if desired. Support 51 is disposed at
an acute angle to the vertical to provide for movement of guide 24
both upwardly and away from stacking location 23, as described
hereinafter. A sheet metal cover 56 is provided for the linear
actuator 55 and other components of the operating mechanism for
guide 24; the upper end of the sheet metal cover 56 extends well
above the linear actuator but is open at the front to allow access
to a manual operating handle 57 mounted on the actuator rod 58 of
linear motor 55. A removable plate 59 covers an access opening 61
in the lower portion of the sheet metal housing 56.
A bracket 62 is mounted in the support channel 51 a short distance
below the lower end of the linear actuator 55 and a similar bracket
63 is mounted in channel 51 adjacent the lower end of the channel.
The brackets 62 and 63 can be welded to or otherwise suitably
mounted within channel 51. Two guide rods 64 and 65 extend between
and are supported by the bracket 62 and 63, in spaced parallel
relation to actuator rod 58. A bumper 66 is mounted upon the lower
surface of the bracket 62 and a second similar bumper 67 is mounted
on the upper surface of the bracket 63. The two bumpers 66 and 67
are formed of rubber or other relatively soft resilient
material.
The lower end of the actuator rod 58 of linear motor 55 carries a
two-piece clamp 68 and a gate mounting bracket 69. Bracket 69 is
affixed to rod 58 and extends downwardly; a gate plate 71 is
mounted on the lower end of the bracket. Clamp 68 is affixed to
bracket 69; bracket 69 includes lateral extensions that embrace the
two guide rods 64 and 65. Guide 24 comprises a blade insert that is
affixed to the lower end of blade 71.
A retaining device 73 is mounted upon the support channel 51 a
short distance below bracket 62. The retaining device 73 comprises
an axially movable retainer rod 74 that extends through the base
portion of the channel in alignment with the actuator rod 58. Rod
74 is normally maintained in a retracted position, out of the path
of movement of the actuator rod 58 and clamp 68, as shown in FIG.
6. A handle 76 on rod 74 may be employed to move the rod axially to
a position in which it can engage clamp 68 and maintain the clamp
and actuator rod 58 in an elevated position adjacent the upper
bumper 66. A spring-biased plunger 77 normally retains rod 74 in
its retracted position, but a forward thrust upon handle 76 moves
rod 74 to its retaining position 74A when required.
During the accumulation of a stack of patties at stacking station
20, as described above in connection with FIGS. 1-5, the operating
mechanism 25 for guide 24 remains de-energized and guide 24 is held
in the position shown in FIG. 6. When the last patty of the stack
has been discharged over the terminal end 15 of input conveyor 11,
and has fallen onto the stack, linear actuator 55 is energized
through an electrical circuit controlled by the monitoring device
comprising photocell 34 (FIGS. 4 and 5). Energization of linear
actuator 55 pulls actuator rod 58 upwardly very rapidly. The upward
movement of actuator rod 58 elevates gate mounting bracket 69
moving the clamp 68 along a guided path determined by the guide
rods 64 and 65, which are parallel to the actuator rod. In this
manner, because guide 24 is suspended from bracket 69, the guide is
rapidly moved from its normal stack guidance position adjacent the
upper surface of stacking conveyor 21 to its stack release position
24A (FIG. 4). The upward movement of actuator rod 58, bracket 69,
clamp 68, and guide 24 is interrupted by engagement of clamp 68
with the resilient bumper 66, which serves as a stop for the
mechanism and also functions as a shock absorber.
When the accumulated stack of patties has been moved clear of the
stacking location 23 by a brief actuation of conveyor 21, as
described above, linear actuator 55 is energized for movement of
rod 58 in the reverse or downward direction. As a consequence clamp
68 and guide 24 are driven downwardly at high speed until clamp 68
engages the lower bumper 67. Bumper 67, like bumper 66, serves both
as a stop and as a shock absorber for clamp 68 and the other
components that are supported upon actuator rod 58.
In some circumstances, it may be necessary or desirable to operate
a production line in which stacker 10 is incorporated without
attempting to stack the articles produced by the line. For example,
this may occur if the production line is changed over to the
production of articles of some configuration not susceptible to
stacking (e.g. meatballs). Under these circumstances, handle 57 is
utilized to pull actuator rod 58 upwardly through linear motor
until clamp 68 engages bumper 66. In addition, the retainer device
73 is actuated, by means of handle 76, to insert retainer rod 74
inwardly to its position 74A, where it engages clamp 68 to hold the
clamp, actuator rod 58, and guide 24 in the elevated stack release
position. This arrangement also makes it possible to continue
utilization of the production line in the event of a failure or
malfunction of linear motor 55 or of any of the control equipment
for the linear motor.
The guide actuating means 25, in the form illustrated in FIGS. 6-8,
affords efficient and highly effective operation for the stacking
station 20 of stacker 10. Linear motor 55 allows for rapid movement
of guide 24 upwardly from its normal guidance position to its
release position and back from the release position to the guidance
position. The high speed movement is essential to complete the
cyclic movement of guide 24 during a very short period determined
by the time interval between the discharge of two consecutive
patties over the terminal end 15 of the input conveyor path. The
stop arrangement incorporated in the actuating mechanism 25,
comprising bumpers 66 and 67, effectively allows for the requisite
rapid operation without damage to the actuating mechanism. The
linear motor operating mechanism is substantially more reliable and
effective than virtually any arrangement utilizing a conventional
rotary motor. A double-acting hydraulic or pneumatic piston could
be employed, but the electrical linear actuator is preferable from
the standpoint of low inertia, high acceleration, and relatively
low noise level. The angled movement of guide 24, horizontally away
from stacking location 23 as well as upwardly from conveyor 21,
makes it possible to start the stacking conveyor before the guide
completes its movement to release position, shortening the
stack-completed operating cycle without having the stack bump
against guide 24.
In many plants, particularly those producing hamburger patties, a
single production line may be employed to produce patties of
several different sizes. A changeover in patty size is readily
accomplished, in stacker 10, by adjusting the position of bracket
46 on support 45, thereby re-positioning guide 24 for the new patty
dimension. The mount for actuating means 25 may be calibrated for
various standard sizes, with a scale 81 on bracket 46.
For changes in thickness, the controls actuated by monitor
photocell 34 can readily be adjusted to trigger actuation of
conveyor 21 and guide 24 for a patty count commensurate with the
desired stack height. Some adjustment of the positions of light
source 32 and photocell 34 may be necessary to accommodate changes
in the number of patties in each row; on the other hand, it is
usually possible to position the monitor to function for any of the
standard row arrangements of the production line, since the monitor
can operate as long as the light beam 37 is interrupted by some
part of a patty in each row.
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