Packaging device and method for production of ready-to-eat fish premade vegetables

Abstract

The invention belongs to the technical field of food processing, and particularly relates to a packaging device and method for instant fish prefabricated dish production, and the packaging device comprises an initial positioning conveying line, a mold circulation line, a dynamic profiling mold, a 3D scanning unit, a bagging module, a modified atmosphere fresh-keeping module and a sealing module; according to the method, the contour of a fish body of a whole fish is scanned through the 3D scanning unit, the controller imports the collected scanning point cloud data into reverse engineering software to generate a 3D model with biological characteristic parameters, optimal groove shape parameters are automatically matched according to internally stored fish classification data, and the shape of the whole fish is obtained. The groove shape of the dynamic profiling mold is adjusted in real time according to the obtained optimal groove shape parameters, the fish body of the whole fish is more attached to the groove of the dynamic profiling mold, displacement and deformation of the fish body in the packaging process are reduced, on one hand, fins can be prevented from puncturing a packaging bag in the displacement process, and the packaging efficiency is improved. On the other hand, the better fit support can prevent the fish body from deforming, and the attractiveness is improved.

Description

Technical Field

[0001] The present invention belongs to the technical field of food processing, and specifically relates to a packaging device and method for producing instant fish prefabricated dishes. Background Art

[0002] Fish is rich in protein and moisture, and is prone to breeding aerobic spoilage bacteria (such as Pseudomonas, psychrophilic bacteria, etc.). When the CO2 concentration is ≥20%, it can penetrate the bacterial cell membrane, reduce the intracellular pH value, interfere with enzyme activity, and significantly slow down the bacterial reproduction rate. Moreover, after CO2 dissolves in the water on the surface of the fish body, a weak acidic environment of carbonic acid is formed, which further inhibits the metabolism of microorganisms and reduces the generation of spoilage products. As can be seen from the above, although the growth of microorganisms is inhibited by gas replacement (such as CO2≥20%), the residual oxygen is reduced to delay oxidation, and the packaging collapse is prevented.

[0003] However, gas replacement only solves the gas environment problem, and cannot prevent physical damage caused by the displacement of the fish body during the packaging process, such as the fish fins piercing the packaging film; nor can it optimize the contact surface between the fish body and the packaging bag, which leads to wrinkles in the packaging bag, and then leads to air retention, resulting in local oxidation or antibacterial failure. Summary of the Invention

[0004] In order to make up for the deficiencies of the prior art, the present invention provides a packaging device and method for producing instant fish prefabricated dishes. The present invention is mainly used to solve the problems that the existing packaging device cannot prevent physical damage caused by the displacement of the fish body during the packaging process; nor can it optimize the contact surface between the fish body and the packaging bag, which leads to wrinkles in the packaging bag, and then leads to air retention, resulting in local oxidation or antibacterial failure.

[0005] The technical solution adopted by the present invention to solve its technical problems is: the present invention provides a packaging device for producing instant fish prefabricated dishes, including an initial positioning conveyor line, a mold circulation line, a dynamic profiling mold, a 3D scanning unit, a bagging module, a modified atmosphere packaging module, and a sealing module; the initial positioning conveyor line is used to sequentially feed the whole fish to be packaged into the mold circulation line; the mold circulation line is used to drive a group of the dynamic profiling molds to circulate and convey; the 3D scanning unit is arranged above the end of the initial positioning conveyor line; the 3D scanning unit is used to scan the fish body contour of the whole fish; the dynamic profiling mold adjusts its groove shape in real time according to the fish body contour; the bagging module is used to pack the whole fish into a packaging bag; the modified atmosphere packaging module is used to introduce a modified atmosphere gas into the packaging bag; the sealing module is used to seal the packaging bag.

[0006] During operation, the pre-processed whole fish is neatly arranged by the preliminary positioning conveyor line and intermittently conveyed by the preliminary positioning conveyor line to the dynamic profiling mold on the mold circulation line. After preliminary positioning is completed at the end of the preliminary positioning conveyor line, the 3D scanning unit above scans the fish body contour of the whole fish below, and conducts multi-angle scanning on typical fish species such as carp and perch to completely capture features such as the surface curve of the fish body and the distribution of fish fins. The controller imports the scanned point cloud data collected by the 3D scanning unit into reverse engineering software to generate a 3D model with biological characteristic parameters, including fish body curvature, thickness distribution, etc., and then automatically matches the optimal groove shape parameters according to the fish species classification data stored internally. Furthermore, the groove shape of the dynamic profiling mold is adjusted in real time through the obtained optimal groove shape parameters, so that the fish body of the whole fish fits better with the groove of the dynamic profiling mold, thereby reducing the displacement and deformation of the fish body during the packaging process. On the one hand, it can prevent the fish fins from piercing the packaging bag during the displacement process, and on the other hand, the more fitting support can prevent the fish body from deforming and improve the aesthetic degree. Moreover, after the bionic groove ensures the stable positioning of the fish body, the vacuum pumping technology can efficiently complete the gas replacement. If the fish body is offset, the gas adjustment ratio may be unbalanced (such as local insufficient CO2 concentration). Therefore, by fitting the fish body curve to reduce the gap between the packaging bag and the fish body, the gas replacement is more thorough, reducing the air residue and thus preventing local oxidation or antibacterial failure. Subsequently, the controller controls the bagging module, the modified atmosphere preservation module, and the sealing module in sequence to realize loading the whole fish into the packaging bag, introducing the modified atmosphere preservation gas into the packaging bag, and sealing the packaging bag, thereby realizing the packaging of the ready-to-eat fish prefabricated dishes.

[0007] Preferably, the dynamic profiling mold includes a mold base, a deformable silica gel layer, an elastic expansion body, and a first micro air pump; the mold base is connected to the mold circulation line; a receiving cavity is provided on the mold base; the deformable silica gel layer is arranged in the receiving cavity; the elastic expansion bodies are evenly spaced and arranged below the deformable silica gel layer; each elastic expansion body is connected to a first micro air pump.

[0008] By combining the displacement in the obtained optimal groove shape parameters with the inner diameter of the elastic expansion body and the displacement of the first micro air pump, the inflation duration of each first micro air pump can be calculated. Then, the controller controls the first micro air pump to inflate the corresponding elastic expansion body according to the calculated inflation duration of each first micro air pump, thereby controlling the elongation of the elastic expansion body. Then, the elastic expansion body supports the deformable silica gel layer to deform, thereby realizing the adaptive deformation of the deformable silica gel layer in the dynamic profiling mold according to the fish body contour data scanned by the 3D scanning unit. Thus, the fish body of the whole fish fits better with the deformable silica gel layer of the dynamic profiling mold, reducing the displacement and deformation of the fish body during the packaging process. On the one hand, it can prevent the fish fins from piercing the packaging bag during the displacement process, and on the other hand, the more fitting support can prevent the fish body from deforming. The deformable silica gel layer is antibacterial fluororubber and is connected to the mold base by hot melt welding.

[0009] Preferably, the dynamic profiling mold further includes a water content detection module and a zoning control module; the water content detection module detects the water content distribution of the fish body; the zoning control module controls the micro pumps at different pressures according to the water content distribution.

[0010] The water content detection module detects the water content distribution of the fish body through visible light and near-infrared light scanning technology. Then, the zoning control module controls the micro pumps at different pressures according to the water content distribution. Specifically, the inflation pressure of the elastic expansion body is reduced in the high water content area of the fish belly, specifically to 0.1 MPa, and increased to 0.3 MPa at the fish bone part, thereby providing flexible support for the high water content area, preventing the fish body from being squeezed and damaged, and improving the packaging quality of the ready-to-eat fish prefabricated dishes.

[0011] Preferably, a thin film pressure sensor is arranged inside the elastic expansion body; the thin film pressure sensor is used to detect the pressure inside the elastic expansion body.

[0012] By embedding a thin film pressure sensor inside the elastic expansion body, the contact pressure between the fish body and the deformable silica gel layer is monitored in real time. Then, when the threshold is exceeded, the pressure release valve is triggered, ensuring flexible support for the fish body, preventing the fish body from being squeezed and damaged, and improving the packaging quality of the ready-to-eat fish prefabricated dishes.

[0013] Preferably, the dynamic profiling mold further includes a mounting frame and a first telescopic element; one end of the mold base is hinged to one end of the mounting frame, and the hinge point is connected to the dragging chain of the mold circulation line through a first rotating shaft; a kidney-shaped hole is arranged at the other end of the mounting frame; a second rotating shaft passes through the kidney-shaped hole; both ends of the second rotating shaft are connected to the dragging chain of the mold circulation line; the bottom surface of the mold base is connected to the extending end of the first telescopic element through a hinge seat; the cylinder body of the first telescopic element is hinged to the mounting frame.

[0014] The mold base can be turned up around one end through the mounting frame and the first telescopic element. When the dynamic profiling mold moves to the output end of the initial positioning conveyor line along with the drag chain of the mold circulation line, the controller controls the first telescopic element to extend, thereby driving the mold base to turn up upward around the hinge end, so that the mold base forms an inclination angle of 10-15° with the initial positioning conveyor line, making it smoother for the whole fish to enter the groove on the mold base when being conveyed from the initial positioning conveyor line to the mold base. After the whole fish enters the groove on the mold base, the controller then controls the first telescopic element to retract, so as not to affect the subsequent operations. The other end of the mounting frame is set as a kidney-shaped hole to compensate for the shortened distance between the two hinge points when the drag chain enters the arc sections at both ends, thus ensuring that the mold base can be smoothly conveyed in a cycle along with the drag chain.

[0015] Preferably, the bagging module includes a robotic arm, a silica gel gripper, a first pressure sensor, and a second micro air pump; the robotic arm is arranged on one side of the mold circulation line; the silica gel gripper is arranged at the end of the robotic arm; each silica gel gripper is connected to a second micro air pump; and a first pressure sensor is arranged in each silica gel gripper.

[0016] When the fish body of the whole fish is placed in the dynamic profiling mold in a fitting manner, the robotic arm can control the silica gel gripper to accurately grasp the fish body and can accurately control the grasping position on the fish body. Then the controller controls the pressure of the second micro air pump corresponding to different grasping positions. The pressure values in the fish head area and the fish belly area need to be appropriately reduced to prevent damage to the fish belly area due to excessive clamping force, thus affecting the packaging quality of the ready-to-eat fish prefabricated dishes. Moreover, the first pressure sensor arranged in the silica gel gripper can monitor the pressure value in real time. When the pressure value exceeds the threshold, the pressure is released, so that the pressure value is within the set range, ensuring that the fish body will not be damaged by clamping, and thus improving the packaging quality of the ready-to-eat fish prefabricated dishes. A biomechanical model can also be introduced to dynamically adjust the clamping force of the silica gel gripper according to the fish body thickness. Specifically, for carp, apply 0.25 MPa at a body thickness ratio of 0.35, and for bass, apply 0.18 MPa at a body thickness ratio of 0.28.

[0017] Preferably, the modified atmosphere packaging module includes an air extraction unit, a gas mixer, and an air supplement unit; the air extraction unit evacuates the packaging bag through a pulse vacuum pump with double-stage air extraction; the gas mixer mixes the gases in real time through a high-precision mass flow controller; and the air supplement unit is used to supplement the gases mixed by the gas mixer into the packaging bag.

[0018] The air extraction unit uses a pulse vacuum pump in combination with a two-stage air extraction method to evacuate the air to -0.09 MPa for the first time and -0.095 MPa for the second time. As a result, the residual oxygen can be reduced to less than 0.5%, enabling more thorough gas replacement, reducing air residue, and preventing local oxidation or antibacterial failure. The gas mixer uses a high-precision mass flow controller to mix gases in real time, specifically achieving real-time mixing of CO2 (40 - 60%), O2 (≤3%), and N2 (balance). It can also optimize the gas ratio according to different fish species: Salmon: CO2 50% + O2 2% + N2 48% Sea bass: CO2 40% + O2 3% + N2 57% Through the above-mentioned modified atmosphere packaging preservation treatment, a gas replacement rate greater than 98% and a residual oxygen content less than 0.5% can be achieved. This can minimize air residue to the greatest extent, prevent local oxidation or antibacterial failure, and improve the packaging quality of ready-to-eat fish prefabricated dishes.

[0019] Preferably, the modified atmosphere packaging preservation module and the sealing module are jointly controlled by a PLC controller.

[0020] By using a PLC controller to jointly control the gas replacement of the modified atmosphere packaging preservation module and the heat sealing action of the sealing module, millisecond-level synchronization can be achieved, which can greatly avoid gas leakage. The specific steps of the sequential linkage of the two are as follows: The air extraction unit evacuates the air for the first time (0.5 seconds) → the gas injection unit injects gas (1 second) → the sealing module performs the first heat sealing (1.5 seconds) → the air extraction unit evacuates the air for the second time (0.2 seconds) → the gas injection unit replenishes gas for the second time (0.3 seconds) → the sealing module performs the final sealing (0.7 seconds), and the entire process ≤ 4.2 seconds; by using a PLC controller to jointly control the two to achieve millisecond-level synchronization and combined with this process step, gas leakage can be greatly avoided, enabling more thorough gas replacement, minimizing air residue to the greatest extent, preventing local oxidation or antibacterial failure, and improving the packaging quality of ready-to-eat fish prefabricated dishes.

[0021] Preferably, the sealing module includes clamping plates, a second telescopic element, a displacement compensation unit, and an industrial camera; the clamping plates are made by wrapping nickel-based alloy heating sheets with high-temperature resistant silica gel; the second telescopic element is used to drive the clamping plates to move up and down; the displacement compensation unit is used to drive the clamping plates and the second telescopic element to move horizontally; the industrial camera is used to capture the position information of the packaging bag during sealing.

[0022] The controller drives the clamping plate to move downward by controlling the second telescopic element, and then heat-seals the packaging bag after contacting and pressing the lower packaging bag; specifically, the heat-sealing temperature is adjustable from 150 to 220 °C, and the pressure is 0.2 to 0.5 MPa; when the position of the packaging bag relative to the clamping plate during sealing captured by the industrial camera exceeds the preset value, the controller controls the displacement compensation unit to drive the clamping plate to move, so that the sealing width of the packaging bag is 8 - 15 mm (adjustable), thus ensuring the accuracy of sealing and improving the packaging quality of instant fish prefabricated dishes. The above preset value is obtained by conversion according to the condition that the sealing width of the packaging bag needs to be 8 - 15 mm. During the sealing process, the pressure of the clamping plate can also be monitored in real time, and the elongation of the second telescopic element is dynamically adjusted through the PID algorithm to avoid embrittlement of the seal caused by overpressure.

[0023] A packaging method for the production of instant fish prefabricated dishes, comprising the following steps: S1: Obtain fish body biometric data through the 3D scanning unit; S2: The controller imports the fish body biometric data collected by the 3D scanning unit into reverse engineering software to generate a 3D model with biometric parameters, and then automatically matches the optimal groove shape parameters according to the fish species classification data stored internally; S3: Adjust the groove shape of the dynamic profiling mold in real time according to the optimal groove shape parameters obtained in S2; S4: Load the whole fish into the packaging bag through the bagging module, and place the packaging bag in the groove of the dynamic profiling mold; S5: Coordinate and control the gas conditioning preservation module and the sealing module to work synchronously through the PLC controller. The specific steps of the coordinated control are as follows: The air extraction unit evacuates the air once → the air supply unit injects gas → the sealing module heat-seals once → the air extraction unit evacuates the air twice → the air supply unit supplies air twice → the sealing module finally seals; S6: Freeze the sealed packaging bag through the -30 °C quick-freezing tunnel of the low-temperature shaping module to form an ice crystal protection layer on the surface of the fish body, and the shaping time is less than 8 minutes; S7: Real-time monitor the sealing integrity through the near-infrared spectrometer, and automatically reject and alarm when air leakage is found.

[0024] The beneficial effects of the present invention are as follows: 1. The 3D scanning unit above in the present invention scans the fish body contour of the whole fish below, scans typical fish species such as carp and bass from multiple angles, and completely captures features such as the surface curve of the fish body and the fin distribution; subsequently, the controller imports the scanned point cloud data collected by the 3D scanning unit into reverse engineering software to generate a 3D model with biological characteristic parameters, including fish body curvature, thickness distribution, etc., and then automatically matches the optimal groove shape parameters according to the fish species classification data stored internally. Furthermore, the groove shape of the dynamic profiling mold is adjusted in real time through the obtained optimal groove shape parameters, so that the fish body of the whole fish fits better with the groove of the dynamic profiling mold, thereby reducing the displacement and deformation of the fish body during the packaging process. On the one hand, it can prevent the fish fins from piercing the packaging bag during the displacement process, and on the other hand, the more fitting support can prevent the fish body from deforming and improve the aesthetics; moreover, after the bionic groove ensures the stable positioning of the fish body, the vacuum technology can efficiently complete the gas replacement. If the fish body shifts, the gas modulation ratio may be unbalanced. Therefore, by fitting the fish body curve to reduce the gap between the packaging bag and the fish body, the gas replacement is more thorough, reducing air residue and thus preventing local oxidation or antibacterial failure.

[0025] 2. In the present invention, by combining the displacement amount in the obtained optimal groove shape parameters with the inner diameter of the elastic expansion body and the displacement of the first micro air pump, the inflation duration of each first micro air pump can be calculated. Then, the controller controls the first micro air pump to inflate the corresponding elastic expansion body according to the calculated inflation duration of each first micro air pump, thereby controlling the elongation amount of the elastic expansion body. Furthermore, the elastic expansion body supports the deformable silica gel layer to deform, so as to realize the adaptive cooperation and deformation of the deformable silica gel layer in the dynamic profiling mold according to the fish body contour data scanned by the 3D scanning unit, so that the fish body of the whole fish fits better with the deformable silica gel layer of the dynamic profiling mold, thereby reducing the displacement and deformation of the fish body during the packaging process. On the one hand, it can prevent the fish fins from piercing the packaging bag during the displacement process, and on the other hand, the more fitting support can prevent the fish body from deforming.

[0026] 3. When the fish body of the whole fish is placed fittingly in the dynamic profiling mold, the robotic arm can control the silica gel gripper to accurately grasp the fish body and can accurately control the grasping position on the fish body. Then, the controller controls the pressure of the second micro air pump corresponding to different grasping positions. The pressure values in the head clamping area and the fish belly area need to be appropriately reduced to prevent damage to the fish belly area due to excessive clamping force, which will affect the packaging quality of the ready-to-eat fish prefabricated dishes; moreover, through the first pressure sensor arranged in the silica gel gripper, the pressure value can be monitored in real time. If the pressure value exceeds the threshold, the pressure is released, so that the pressure value is within the set range, thereby ensuring that the fish body will not be damaged by clamping, and improving the packaging quality of the ready-to-eat fish prefabricated dishes.

[0027] 4. The present invention realizes millisecond-level synchronization by using a PLC controller to coordinately control the gas replacement of the controlled atmosphere fresh-keeping module and the heat-sealing action of the sealing module, thereby being able to greatly avoid gas leakage, making the gas replacement more thorough, and being able to minimize air residue to prevent local oxidation or antibacterial failure, thereby improving the packaging quality of ready-to-eat fish prepared dishes. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The present invention will be further described below in conjunction with the accompanying drawings.

[0029] Figure 1 is a schematic diagram of the overall structure of the packaging device of the present invention; Figure 2 is Figure 1 a partial enlarged view of part A in Figure 3 is the front view of the packaging device of the present invention; Figure 4 is the top view of the packaging device of the present invention; Figure 5 is a schematic diagram of the structure of the initial positioning conveyor line in the present invention; Figure 6 is a schematic diagram of the structure of the bagging module in the present invention; Figure 7 is a connection diagram of the sealing module in the present invention; Figure 8 is a schematic diagram of the structure of the dynamic profiling mold in the first perspective in the present invention; Figure 9 is a schematic diagram of the structure of the dynamic profiling mold in the second perspective in the present invention; Figure 10 is a schematic diagram of the internal structure of the dynamic profiling mold in the present invention; In the figure: initial positioning conveyor line 1, mold circulation line 2, dynamic profiling mold 3, mold base 31, deformable silica gel layer 32, elastic expansion body 33, first micro air pump 34, mounting frame 35, first telescopic element 36, 3D scanning unit 4, bagging module 5, robotic arm 51, silica gel gripper 52, second micro air pump 53, sealing module 7, clamping plate 71, second telescopic element 72, displacement compensation unit 73, low-temperature shaping module 8. DETAILED DESCRIPTION OF THE INVENTION

[0030] In order to make the technical means, creative features, achieved purposes and effects of the present invention easy to understand, the present invention will be further described below in conjunction with specific embodiments.

[0031] Such as Figures 1 to 5As shown in the figure, a packaging device for instant fish prepared dishes includes a preliminary positioning conveyor line 1, a mold circulating line 2, a dynamic profiling mold 3, a 3D scanning unit 4, a bagging module 5, a modified atmosphere preservation module, and a sealing module 7. The preliminary positioning conveyor line 1 is used to sequentially feed whole fish to be packaged into the mold circulating line 2. The mold circulating line 2 is used to drive a group of the dynamic profiling molds 3 to circulate and convey. The 3D scanning unit 4 is arranged above the end of the preliminary positioning conveyor line 1. The 3D scanning unit 4 is used to scan the fish body contour of the whole fish. The dynamic profiling mold 3 adjusts the groove shape of itself in real time according to the fish body contour. The bagging module 5 is used to pack the whole fish into a packaging bag. The modified atmosphere preservation module is used to introduce modified atmosphere gas into the packaging bag. The sealing module 7 is used to seal the packaging bag.

[0032] During operation, the whole fish that has been pre-treated is neatly arranged by the preliminary positioning conveyor line 1 and intermittently conveyed by the preliminary positioning conveyor line 1 to the dynamic profiling mold 3 on the mold circulating line 2. After preliminary positioning is completed at the end of the preliminary positioning conveyor line 1, the 3D scanning unit 4 above scans the fish body contour of the whole fish below, and conducts multi-angle scanning on typical fish species such as carp and perch to completely capture features such as the surface curve of the fish body and the distribution of fish fins. The controller imports the scanned point cloud data collected by the 3D scanning unit 4 into reverse engineering software to generate a 3D model with biological characteristic parameters, including fish body curvature, thickness distribution, etc., and then automatically matches the optimal groove shape parameters according to the fish species classification data stored internally, and further adjusts the groove shape of the dynamic profiling mold 3 in real time through the obtained optimal groove shape parameters, so that the fish body of the whole fish fits better with the groove of the dynamic profiling mold 3, thereby reducing the displacement and deformation of the fish body during the packaging process. On the one hand, it can prevent the fish fins from piercing the packaging bag during the displacement process, and on the other hand, the more fitting support can prevent the fish body from deforming and improve the aesthetics. Moreover, by fitting the fish body curve, the gap between the packaging bag and the fish body is reduced, making the gas replacement more thorough, reducing air residue, and thus preventing local oxidation or antibacterial failure. Subsequently, the controller realizes packing the whole fish into the packaging bag, introducing modified atmosphere preservation gas into the packaging bag, and sealing the packaging bag by sequentially controlling the bagging module 5, the modified atmosphere preservation module, and the sealing module 7, thereby realizing the packaging of instant fish prepared dishes.

[0033] As Figures 8 to 10 shown in the figure, the dynamic profiling mold 3 includes a mold base 31, a deformable silicone layer 32, an elastic expansion body 33, and a first micro air pump 34. The mold base 31 is connected to the mold circulating line 2. A receiving cavity is provided on the mold base 31. The deformable silicone layer 32 is arranged in the receiving cavity. The elastic expansion bodies 33 are evenly spaced and arranged below the deformable silicone layer 32. Each elastic expansion body 33 is connected to a first micro air pump 34.

[0034] By combining the displacement in the obtained optimal groove shape parameters with the inner diameter of the elastic expansion body 33 and the displacement of the first micro air pump 34, the inflation duration of each first micro air pump 34 can be calculated. Then, the controller controls the first micro air pump 34 to inflate the corresponding elastic expansion body 33 according to the calculated inflation duration of each first micro air pump 34, thereby controlling the elongation of the elastic expansion body 33. Then, the elastic expansion body 33 supports the deformable silica gel layer 32 to deform, thereby realizing the adaptive cooperation and deformation of the deformable silica gel layer 32 in the dynamic profiling mold 3 according to the fish body contour data scanned by the 3D scanning unit 4. As a result, the fish body of the whole fish fits better with the deformable silica gel layer 32 of the dynamic profiling mold 3, reducing the displacement and deformation of the fish body during the packaging process. On the one hand, it can prevent the fish fins from piercing the packaging bag during the displacement process, and on the other hand, the more fitting support can prevent the fish body from deforming. The deformable silica gel layer 32 is antibacterial fluororubber and is connected to the mold base 31 by hot melt welding.

[0035] The dynamic profiling mold 3 further includes a water content detection module and a zoning control module; the water content detection module detects the water content distribution of the fish body; the zoning control module controls the micro pumps at different pressures according to the water content distribution.

[0036] The water content detection module detects the water content distribution of the fish body through visible light and near-infrared light scanning technology. Then, the zoning control module controls the micro pumps at different pressures according to the water content distribution. Specifically, the inflation pressure of the elastic expansion body 33 is reduced in the high water content area of the fish belly, specifically to 0.1 MPa, and increased to 0.3 MPa at the fish bone part, thereby providing flexible support for the high water content area, preventing the fish body from being squeezed and damaged, and improving the packaging quality of the ready-to-eat fish prefabricated dishes.

[0037] A thin film pressure sensor is arranged inside the elastic expansion body 33; the thin film pressure sensor is used to detect the pressure inside the elastic expansion body 33.

[0038] By embedding a thin film pressure sensor inside the elastic expansion body 33, the contact pressure between the fish body and the deformable silica gel layer 32 is monitored in real time. Then, when the threshold is exceeded, the pressure release valve is triggered, ensuring flexible support for the fish body, preventing the fish body from being squeezed and damaged, and improving the packaging quality of the ready-to-eat fish prefabricated dishes.

[0039] As Figures 8 to 10As shown, the dynamic profiling die 3 further includes a mounting bracket 35 and a first telescopic element 36; one end of the die base 31 is hinged to one end of the mounting bracket 35, and the hinge point is connected to the drag chain of the die circulation line 2 through a first rotating shaft; a kidney-shaped hole is provided at the other end of the mounting bracket 35; a second rotating shaft passes through the kidney-shaped hole; both ends of the second rotating shaft are connected to the drag chain of the die circulation line 2; the bottom surface of the die base 31 is connected to the extending end of the first telescopic element 36 through a hinge seat; the cylinder body of the first telescopic element 36 is hinged to the mounting bracket 35.

[0040] The die base 31 can be turned up around one end through the mounting bracket 35 and the first telescopic element 36. Then, when the dynamic profiling die 3 moves to the output end of the preliminary positioning conveyor line 1 along with the drag chain of the die circulation line 2, the controller controls the first telescopic element 36 to extend, thereby driving the die base 31 to turn up upward around the hinged end, so that the die base 31 forms an inclination angle of 10 - 15° with the preliminary positioning conveyor line 1, and thus when the whole fish is conveyed from the preliminary positioning conveyor line 1 onto the die base 31, it can enter the groove on the die base 31 more smoothly; after the whole fish enters the groove on the die base 31, the controller then controls the first telescopic element 36 to retract, so as not to affect the subsequent operations. The other end of the mounting bracket 35 is provided with a kidney-shaped hole to make up for the shortened distance between the two hinge points when the drag chain enters the arc sections at both ends, thereby ensuring that the die base 31 can be smoothly conveyed in a cycle along with the drag chain.

[0041] As Figure 6 As shown, the bagging module 5 includes a robotic arm 51, a silicone gripper 52, a first pressure sensor, and a second micro air pump 53; the robotic arm 51 is arranged on one side of the die circulation line 2; the silicone gripper 52 is arranged at the end of the robotic arm 51; each silicone gripper 52 is connected to a second micro air pump 53; a first pressure sensor is arranged in each silicone gripper 52.

[0042] When the whole fish body is placed in the dynamic profiling mold 3 in a fitting manner, the robotic arm 51 can control the silicone gripper 52 to accurately grasp the fish body and can accurately control the grasping position on the fish body. Then, the controller controls the pressure of the second micro air pump 53 corresponding to different grasping positions. Furthermore, the pressure values in the head clamping area and the belly clamping area need to be appropriately reduced to prevent damage to the belly area due to excessive clamping force, which in turn affects the packaging quality of the ready-to-eat fish prefabricated dishes. Moreover, the first pressure sensor set inside the silicone gripper 52 can monitor the pressure value in real time. When the pressure value exceeds the threshold, the pressure is released, so that the pressure value is within the set range, ensuring that the fish body will not be damaged by clamping, thereby improving the packaging quality of the ready-to-eat fish prefabricated dishes. A biomechanical model can also be introduced to dynamically adjust the clamping force of the silicone gripper 52 according to the fish body thickness. Specifically, for carp, apply 0.25 MPa at a body thickness ratio of 0.35, and for perch, apply 0.18 MPa at a body thickness ratio of 0.28.

[0043] The modified atmosphere packaging module includes an air extraction unit, a gas mixer, and an air supply unit. The air extraction unit evacuates the packaging bag through a pulse vacuum pump in cooperation with double-stage air extraction. The gas mixer mixes the gases in real time through a high-precision mass flow controller. The air supply unit is used to supplement the gases mixed by the gas mixer into the packaging bag.

[0044] The air extraction unit adopts the method of using a pulse vacuum pump in cooperation with double-stage air extraction. It evacuates to -0.09 MPa for the first time and -0.095 MPa for the second time, so as to achieve a residual oxygen content of less than 0.5%, making the gas replacement more thorough, reducing air residue, and preventing local oxidation or antibacterial failure. The gas mixer mixes the gases in real time through a high-precision mass flow controller, specifically realizing the real-time mixing of CO2 (40 - 60%), O2 (≤3%), and N2 (balance). The gas ratio can also be optimized for different fish species: Salmon: CO2 50% + O2 2% + N2 48% Perch: CO2 40% + O2 3% + N2 57% Through the above modified atmosphere packaging treatment, a gas replacement rate greater than 98% and a residual oxygen content less than 0.5% can be achieved, which can minimize air residue, prevent local oxidation or antibacterial failure, and improve the packaging quality of the ready-to-eat fish prefabricated dishes.

[0045] The modified atmosphere packaging module and the sealing module 7 are jointly controlled by a PLC controller.

[0046] By using a PLC controller to jointly control the gas replacement of the modified atmosphere packaging module and the heat sealing action of the sealing module 7 to achieve millisecond-level synchronization, gas leakage can be greatly avoided. The specific steps of the sequential linkage between the two are as follows: The air extraction unit evacuates the air for the first time (0.5 seconds) → the gas injection unit injects gas (1 second) → the sealing module 7 seals thermally for the first time (1.5 seconds) → the air extraction unit evacuates the air for the second time (0.2 seconds) → the gas injection unit replenishes gas for the second time (0.3 seconds) → the sealing module 7 seals finally (0.7 seconds), and the whole process ≤ 4.2 seconds; by using a PLC controller to cooperate and control the two to achieve millisecond-level synchronization, and then cooperating with this technological step, gas leakage can be avoided to a great extent, thereby making the gas replacement more thorough, and then being able to minimize the air residue to prevent local oxidation or antibacterial failure, and then improving the packaging quality of the ready-to-eat fish prefabricated dishes.

[0047] As Figure 7 shown, the sealing module 7 includes clamping plates 71, second telescopic elements 72, displacement compensation units 73 and industrial cameras; the clamping plates 71 are made by wrapping nickel-based alloy heating sheets with high-temperature resistant silica gel; the second telescopic elements 72 are used to drive the clamping plates 71 to move up and down; the displacement compensation units 73 are used to drive the clamping plates 71 and the second telescopic elements 72 to move horizontally; the industrial cameras are used to shoot the position information of the packaging bag during sealing.

[0048] The controller drives the clamping plates 71 to move downward by controlling the second telescopic elements 72, and then thermally seals the packaging bag after contacting and pressing the packaging bag below; specifically, the thermal sealing temperature is adjustable from 150 to 220 °C, and the pressure is 0.2 - 0.5 MPa; when the position of the packaging bag during sealing photographed by the industrial camera relative to the position of the clamping plates 71 exceeds the preset value, the controller controls the displacement compensation unit 73 to drive the clamping plates 71 to move, so that the sealing width of the packaging bag is 8 - 15 mm (adjustable), thus ensuring the accuracy of sealing and then improving the packaging quality of the ready-to-eat fish prefabricated dishes. The above preset value is obtained by conversion according to the condition that the sealing width of the packaging bag needs to be 8 - 15 mm. During the sealing process, the pressure of the clamping plates 71 can also be monitored in real time, and the elongation of the second telescopic elements 72 is dynamically adjusted through the PID algorithm to avoid embrittlement of the seal caused by overpressure.

[0049] As Figures 1 to 5 shown, a packaging method for producing ready-to-eat fish prefabricated dishes includes the following steps: S1: Obtain the fish body biological characteristic data through the 3D scanning unit 4; S2: The controller imports the fish body biological characteristic data collected by the 3D scanning unit 4 into reverse engineering software to generate a 3D model with biological characteristic parameters, and then automatically matches the optimal groove shape parameters according to the fish species classification data stored internally; S3: Adjust the groove shape of the dynamic profiling mold 3 in real time according to the optimal groove shape parameters obtained in S2; S4: The whole fish is loaded into a packaging bag by the bagging module 5, and the packaging bag is placed in the groove of the dynamic profiling mold 3; S5: The controlled atmosphere fresh-keeping module and the sealing module 7 are synchronously controlled by the PLC controller. The specific steps of the cooperative control are as follows: The air extraction unit evacuates the air once → the air supplement unit injects gas → the sealing module 7 heat-seals once → the air extraction unit evacuates the air twice → the air supplement unit supplements air twice → the sealing module 7 performs the final sealing; S6: The sealed packaging bag is frozen by the -30°C quick-freezing tunnel of the low-temperature shaping module 8 to form an ice crystal protection layer on the surface of the fish body, and the shaping time is less than 8 minutes; S7: The integrity of the seal is monitored in real time by a near-infrared spectrometer, and any leakage is automatically removed and an alarm is given.

[0050] The embodiments of the present invention have been described above in conjunction with the accompanying drawings. However, the present invention is not limited to the above specific embodiments. The above specific embodiments are merely illustrative and not restrictive. Under the inspiration of the present invention, those of ordinary skill in the art can also make many forms without departing from the spirit and scope protected by the claims of the present invention. These all fall within the protection scope of the present invention.

Claims

1. A packaging device for producing ready-to-eat fish dishes, characterized in that: The invention comprises an initial positioning conveyor line (1), a mold circulation line (2), a dynamic profiling mold (3), a 3D scanning unit (4), a bagging module (5), a gas-controlled fresh-keeping module and a sealing module (7); the initial positioning conveyor line (1) is used to sequentially feed the whole fish to be packaged into the mold circulation line (2); the mold circulation line (2) is used to drive a group of the dynamic profiling molds (3) to circulate and convey; the 3D scanning unit (4) is arranged above the end of the initial positioning conveyor line (1); the 3D scanning unit (4) is used to scan the body contour of the whole fish; the dynamic profiling mold (3) adjusts its own groove shape in real time according to the body contour of the fish; the bagging module (5) is used to pack the whole fish into a packaging bag; the gas-controlled fresh-keeping module is used to introduce gas-controlled gas into the packaging bag; and the sealing module (7) is used to seal the packaging bag.

2. The packaging device for producing ready-to-eat fish prepared dishes according to claim 1, characterized in that: The dynamic profiling mold (3) comprises a mold base (31), a deformable silicone layer (32), an elastic expansion body (33) and a first micro air pump (34); the mold base (31) is connected to the mold circulation line (2); a receiving cavity is arranged on the mold base (31); the deformable silicone layer (32) is arranged in the receiving cavity; the elastic expansion bodies (33) are evenly spaced below the deformable silicone layer (32); and each of the elastic expansion bodies (33) is connected to one of the first micro air pumps (34).

3. The packaging device for producing ready-to-eat fish prepared dishes according to claim 2, characterized in that: The dynamic profiling mold (3) further comprises a water content detection module and a partition control module; the water content detection module detects the water content distribution of the fish body; the partition control module divides the micro pump into different pressures for control according to the water content distribution.

4. The packaging device for producing ready-to-eat fish prepared dishes according to claim 2, characterized in that: A thin film pressure sensor is arranged inside the elastic expansion body (33); the thin film pressure sensor is used to detect the pressure inside the elastic expansion body (33).

5. The packaging device for producing ready-to-eat fish prepared dishes according to claim 2, characterized in that: The dynamic profiling mold (3) also includes a mounting frame (35) and a first telescopic element (36); one end of the mold base (31) is hinged to one end of the mounting frame (35), and the hinge point is connected to the drag chain of the mold circulation line (2) through a first rotating shaft; a waist-shaped hole is provided at the other end of the mounting frame (35); a second rotating shaft passes through the waist-shaped hole; both ends of the second rotating shaft are connected to the drag chain of the mold circulation line (2); the bottom surface of the mold base (31) is connected to the protruding end of the first telescopic element (36) through a hinge seat; the cylinder body of the first telescopic element (36) is hinged on the mounting frame (35).

6. The packaging device for producing ready-to-eat fish prepared dishes according to claim 1, characterized in that: The bagging module (5) comprises a mechanical arm (51), a silicone gripper (52), a first pressure sensor and a second micro air pump (53); the mechanical arm (51) is arranged on one side of the mold circulation line (2); the silicone gripper (52) is arranged at the end of the mechanical arm (51); each of the silicone grippers (52) is connected to one of the second micro air pumps (53); and each of the silicone grippers (52) is arranged in one of the first pressure sensors.

7. The packaging device for producing ready-to-eat fish prepared dishes according to claim 1, characterized in that: The controlled atmosphere preservation module includes an exhaust unit, a gas mixer and an air replenishing unit; the exhaust unit exhausts air from the packaging bag through a pulse vacuum pump in combination with a two-stage exhaust; the gas mixer mixes the gas in real time through a high-precision mass flow controller; the air replenishing unit is used to replenish the gas mixed by the gas mixer into the packaging bag.

8. The packaging device for producing ready-to-eat fish prepared dishes according to claim 7, characterized in that: The atmosphere-controlled fresh-keeping module and the sealing module (7) are cooperatively controlled by a PLC controller.

9. The packaging device for producing ready-to-eat fish prepared dishes according to claim 1, characterized in that: The sealing module (7) comprises a clamping plate (71), a second telescopic element (72), a displacement compensation unit (73) and an industrial camera; the clamping plate (71) is made by wrapping a nickel-based alloy heating plate with high-temperature resistant silicone; the second telescopic element (72) is used to drive the clamping plate (71) to move up and down; the displacement compensation unit (73) is used to drive the clamping plate (71) and the second telescopic element (72) to move horizontally; and the industrial camera is used to capture position information of the packaging bag when it is sealed.

10. A packaging method for producing ready-to-eat fish dishes, applicable to any one of claims 1 to 9, characterized in that: The steps include: S1: Obtaining fish body biometric data through a 3D scanning unit (4); S2: The controller imports the fish body biometric data collected by the 3D scanning unit (4) into the reverse engineering software to generate a 3D model with biometric parameters, and then automatically matches the optimal groove morphology parameters according to the fish species classification data stored internally; S3: adjusting the groove shape of the dynamic profiling die (3) in real time according to the optimal groove shape parameters obtained in S2; S4: The whole fish is put into a packaging bag through the bagging module (5), and the packaging bag is placed in the groove of the dynamic profiling mold (3); S5: The PLC controller is used to coordinately control the atmosphere conditioning and fresh-keeping module and the sealing module (7) to work synchronously. The steps of the coordinated control are as follows: The exhaust unit performs a vacuum pumping operation → the air supply unit performs gas injection → the sealing module (7) performs a heat seal operation → the exhaust unit performs a vacuum pumping operation → the air supply unit performs a gas injection operation → the sealing module (7) performs a final seal operation; S6: freezing the sealed packaging bag through a -30°C quick freezing tunnel of a low-temperature shaping module (8) to form an ice crystal protective layer on the surface of the fish body, with the shaping time being less than 8 minutes; S7: The seal integrity is monitored in real time by near infrared spectrometer, and leaks are automatically removed and an alarm is issued.

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