SUSPENDED AUTOMATED TRAY SHAKER WITH MULTIPLE MOTION MODES.

Abstract

An automated vibratory tray conveyor has a central longitudinal axis and a central lateral axis; the automated vibratory tray conveyor includes a vibratory assembly that is configured to induce a plurality of motion modes in the baking tray; the vibratory tray assembly includes a carriage assembly, a clamping assembly supported by the carriage assembly, and a drive assembly; the carriage assembly resides below the conveyor belt of the automated vibratory tray conveyor; the drive assembly further includes a drive post connected to the carriage assembly, a first drive assembly that includes a first drive linkage connected to the drive post, and a second drive assembly that includes a second drive linkage connected to the drive post.

Description

This application claims the benefit of U.S. Provisional Patent Application Serial No. 62 / 820,351 entitled Underhung Pan Shaker With Multiple Modes of Movement, filed on March 19, 2019, the disclosure of which is incorporated herein by reference. FIELD OF INVENTION The present invention relates in general to equipment used in the baking industry and more particularly, but not by way of limitation, to equipment configured to vibrate trays filled with dough. BACKGROUND OF THE INVENTION For many years, commercial bakeries have used assembly line production to prepare and bake products. In many cases, baked goods are prepared by placing trays on a conveyor system, loading dough into the trays, and moving the trays and dough through the preparation, baking, and packaging processes. Commercial baking trays often include multiple rows of molds used to hold the dough. Because the dough is deposited into these molds using automated equipment, there is a possibility that some pieces of dough may fall partially or completely outside their designated mold within the tray. Vibratory tray conveyors are used to center the dough within each mold, ensuring uniform product distribution. Historically, these conveyors have utilized a magnetic base that temporarily adheres to the bottom of the tray, lifts the tray off the conveyor system, and performs an orbital motion to vibrate it. This orbital motion ensures consistent dough placement within the tray molds. Once the orbital motion is complete, the magnetic base returns the tray to the conveyor system, releasing it. Although generally effective, prior art vibratory tray conveyors may be unsuitable for certain applications. In particular, prior art vibratory tray conveyors are configured to produce a single motion. ML / t / ZUZ I / UOUOZÓ orbital. Depending on the arrangement and configuration of the molds on the tray, orbital motion can be ineffective in centering the dough within the molds. Consequently, conventional vibratory tray conveyors may not be well-suited for performing vibration operations on a variety of baking trays. Furthermore, as baking trays have increased in size, the magnetic base used to capture and vibrate the tray may be insufficient. It is to this and other shortcomings in the prior art that preferred methods are directed. BRIEF DESCRIPTION OF THE INVENTION In one aspect, the present invention includes an automated vibratory tray conveyor having a central longitudinal axis, a central lateral axis, and a conveyor belt configured to move a bakery tray through the automated vibratory tray conveyor along the central longitudinal axis. The automated vibratory tray conveyor includes a vibratory assembly configured to induce a plurality of motion modes in the bakery tray. In another aspect, the present invention includes an automated vibratory tray conveyor having a central longitudinal axis, a central lateral axis, and a conveyor belt configured to move a bakery tray along the central longitudinal axis. The automated vibratory tray conveyor includes a vibratory assembly comprising a carriage assembly, a clamping assembly supported by the carriage assembly, and a drive assembly. The carriage assembly and the drive assembly are located below the conveyor belt. The drive assembly further includes a drive post connected to the carriage assembly, a first drive assembly comprising a first drive linkage connected to the drive post, and a second drive assembly comprising a second drive linkage connected to the drive post. In another aspect, the present invention includes an automated vibratory tray conveyor having a length extending in a longitudinal direction and a width extending in a lateral direction. The automated vibratory tray conveyor includes a stationary frame assembly and a vibratory assembly. The vibratory assembly includes a trolley assembly and a drive assembly supported by the frame assembly and configured to move the trolley assembly. The drive assembly has a drive post, a first drive assembly, and a second drive assembly. The first drive assembly includes a first drive linkage extending to the drive post in a predominantly longitudinal direction. The second drive assembly includes a second drive linkage extending ML / t / ZUZ I / UOUOZÓ up to the actuator post in a direction that is predominantly lateral. In another aspect, the present invention includes a method for inducing a selected orbital motion in a bakery tray using an automated vibratory tray conveyor. The method includes the steps of providing a carriage assembly configured for lateral and longitudinal motion within the automated vibratory tray conveyor, providing a clamping assembly carried by the carriage assembly, and providing a drive assembly having a first drive assembly and a second drive assembly. The first drive assembly and the second drive assembly each have a motor that rotates a motor shaft, an eccentric cam connected to the motor shaft, and a linkage connected to the eccentric cam and a common drive post.The method also includes the steps of closing the clamping mechanism on the baking tray, placing the motor shaft of the first actuator assembly in an initial rotation position, and placing the motor shaft of the second actuator assembly in an initial rotation position. The method then includes the step of rotating the motor shaft of the first actuator assembly according to a first rotation profile and rotating the motor shaft of the second actuator assembly according to a second rotation profile. BRIEF DESCRIPTION OF THE FIGURES FIG. 1 is a perspective view of a vibrating tray conveyor constructed according to a currently preferred embodiment. FIG. 2 is a front view of the vibratory tray conveyor. FIG. 3 is a view from behind the vibratory tray conveyor. FIG. 4 is a top view of the vibratory tray conveyor. FIG. 5 is a bottom view of the vibratory tray conveyor. FIG. 6 is a top view of the vibratory tray conveyor showing the top of the vibratory assembly. FIG. 7 is a perspective view of the vibrating assembly. FIG. 8 is a side view of the vibrating assembly. FIG. 9 is a front view of the clamping assembly of the vibratory mount. FIG. 10 is a top view of the drive assembly. FIG. 11 is a bottom view of the drive assembly. FIG. 12 is a perspective view of the drive assembly. ML / t / ZUZ I / UOUOZÓ DETAILED DESCRIPTION OF THE INVENTION Referring first to Figures 1 to 5, several views of a vibratory tray conveyor 100 constructed according to currently preferred embodiments are shown. The vibratory tray conveyor 100 is well-suited for use in a commercial bakery employing automated assembly line production processes. The vibratory tray conveyor 100 is typically configured to perform a vibration operation on a series of trays 200 (Figures 2 to 4) that are fed to the vibratory tray conveyor 100 on an assembly line (not shown). Each of the trays 200 includes a series of tray molds 202 that are sized and shaped to hold the dough of a specific baked product (e.g., hamburger buns, sandwich bread, etc.).The vibration operation helps to center the dough within each of the 202 tray molds to encourage the production of substantially uniform baked goods. The vibratory tray conveyor 100 includes several main assemblies, including a frame assembly 102, a conveyor assembly 104, a control assembly 106, and a vibratory assembly 108. The frame assembly 102 includes a series of legs 110, structural cross members 112, and mass guards 114 that support and protect the other components within the vibratory tray conveyor 100. In particular, the vibratory assembly 108 is in a suspended configuration, with the vibratory assembly 108 located below the conveyor assembly 104. The mass guards 114 prevent mass and other materials from falling onto the vibratory assembly 108 from below the tray 200 and the conveyor assembly 104. The frame assembly 102 also includes a pair of frame rails 116 and motor mounts 118 that support the components within the vibratory assembly 108. The conveyor assembly 104 includes a conveyor belt 120 and a conveyor belt motor 122 that carries the tray 200 through the vibratory tray conveyor 100. As used in this disclosure, the term longitudinal refers to an axis followed by the tray 200 as it passes through the vibratory tray conveyor 100. The term lateral refers to an axis that is transverse to the longitudinal axis. The lateral axis extends across the width of the vibratory tray conveyor 100. Control assembly 106 includes operator controls, power supplies, alarm systems, and control systems (not separately designated). Control assembly 106 receives input from various sensors located within the vibratory tray conveyor 100 and controls the operation of the vibratory assembly 108 and the conveyor assembly 104. In certain applications, control assembly 106 is configured to receive input from upstream components within the bakery. For example, control assembly 106 can MA / t / ZUZ I / uoyozó be configured to proactively adapt the operation of the vibratory assembly 108 and the conveyor assembly 104 in anticipation of a change in the size, speed, or configuration of the trays 200 approaching the vibratory tray conveyor 100. Returning to Figures 6 to 9, several views of the vibratory tray conveyor 100 and the vibratory assembly 108 are shown. The vibratory assembly 108 includes a trolley assembly 124, a clamping assembly 126, and a drive assembly 128. The trolley assembly 124 includes a side rail 130 that travels on a low-friction bearing connection to the frame rails 116. The trolley assembly 124 further includes a center support 132 that travels on the side rail 130. The side rail 130 allows the trolley assembly 124 to move longitudinally back and forth along the frame rails 116 while simultaneously allowing the center support 132 to move laterally back and forth on the side rail 130. The clamping assembly 126 is supported by the center support 132. The clamping assembly 126 includes a double-acting pneumatic cylinder 134, a clamping rail 136, a drive belt 138, clamps 140a, 140b, outer pulleys 142, and inner pulleys 144. In the currently preferred embodiment, clamps 140a, 140b are offset on the clamp rail 136. Each clamp 140a, 140b is fixed to the drive belt 138. The inner pulleys 144 and outer pulleys 142 are spaced and configured to guide the drive belt 138 across the width of the vibrating assembly 108 such that opposite sides of the drive belt 138 are positioned in a linear relationship through the center of the center support 132. Each clamp 140a, 140b is that way centered above the central support 132 and attached to the drive belt 138 on opposite sides of the outer pulleys 142. The first clamp 140a is also attached to the pneumatic cylinder 134, and the first clamp 140a moves back and forth on the clamp rail 136 in response to the bidirectional actuation of the pneumatic cylinder 134. As the first clamp 140a moves, it pulls the drive belt 138. The drive belt 138 causes the second clamp 140b to move on the clamp rail 136 in the opposite direction from the first clamp 140a. In this way, the two clamps 140a and 140b come together or separate in unison in response to the controlled and automated actuation of the pneumatic cylinder 134. Encoders on the outer pulleys 142 provide the control assembly 106 with real-time information about the position of the drive belt 138 and the clamps 140a and 140b, as best illustrated in the figures. 1 and 4, clamps 140a, 140b extend upwards through slots in the mass protectors 114.The slots in the mass protectors 114 are long and wide enough to allow lateral, longitudinal and compound (e.g., orbital) movements of the clamps 140a, 140b. ML / t / ZUZ I / uoaozó During operation, clamps 140a and 140b quickly close to secure the 200 tray. Once the vibration operation is complete, clamps 140a and 140b separate to release the 200 tray. The clamping assembly 126 offers a significant advantage over prior art magnetic clamping systems. It can be used for heavier 200 trays and trays not made of ferromagnetic materials. The clamping assembly 126 can also be automatically and in real time adapted for use with 200 trays of various shapes, sizes, and orientations. These features allow the 100 tray vibratory conveyor to be used for a variety of trays and bakery products without extensive and time-consuming reconfiguration. Returning to FIGS. 10 to 12, several views of the drive assembly 128 are shown therein. The drive assembly 128 generally includes a first actuator assembly 146a, a second actuator assembly 146b, and an actuator post 148 connected to the central support 132. The first actuator assembly 146a and the second actuator assembly 146b each include an electric motor 152 that drives a rotating shaft 154, which in turn drives an eccentric cam 156. The first actuator assembly 146a and the second actuator assembly 146b each include a linkage 158 that is connected to the corresponding eccentric cam 156 at one end and to the actuator post 148 at the other end. At each end, the linkage 158 includes a bearing 162 that allows the eccentric cam 156 and the actuating post 148 to rotate within the linkage 158. The rotation of each eccentric cam 156 thus induces a reciprocating linear-orbital motion in the corresponding linkage 158.This linear-orbital movement is transmitted through the linkages 158 to the actuating post 148. Because the first drive assembly 146a and the second drive assembly 146b are positioned in an off-center relationship, the drive post 148 is moved in different directions by the two linkages 158a and 158b. As best seen in the top views of Figures 6 to 7 and 10, the first drive assembly 146a is positioned substantially along the central longitudinal axis of the vibratory tray conveyor 100 and is configured with respect to the drive post 148 to induce a primarily longitudinal motion. The second drive assembly 146b is positioned substantially along the central lateral axis of the vibratory tray conveyor 100 and is configured with respect to the drive post 148 to induce a primarily lateral motion.The actuator post 148 transfers the combined and compound motion of the first actuator assembly 146a and the second actuator assembly 146b to the central support 132 of the vibratory assembly 108, which in turn moves the clamping assembly 126 and the tray 200. The rotary encoders 160 are used to detect the position and rotational speed of each motor 152a, 152b. In response to the input information from the encoders ML / I / uoaozó rotary 158 and the operating profile selected by the operator or automatically by the control assembly 106, the control assembly 106 energizes each motor 152a, 152b in accordance with an independent motor control signal. By independently controlling the relative starting positions and rotation speeds of each motor 152a, 152b, the drive assembly 128 can induce an infinite number of motion profiles in the clamping assembly 126. For example, in a first mode of operation, the first actuator assembly 146a is controlled to induce a mode of motion in which the clamping assembly 126 moves reciprocatingly in a substantially linear path along the longitudinal axis of the vibratory tray conveyor 100. Due to the geometry of the eccentric cam 156a and linkage 158, rotation of only the motor 152a of the first actuator assembly 146a would induce some lateral motion in the actuator post 148. To cancel this lateral motion, the second actuator assembly 146b is positioned and rotated slightly forward and backward to compensate for the unwanted lateral motion produced by the first actuator assembly 146a. In a second mode of operation, the second actuator assembly 146b is used to induce a mode of motion in which the clamping assembly 126 moves reciprocatingly in a substantially linear path along the lateral axis of the vibratory tray conveyor 100. To cancel any unwanted longitudinal movement in the tray 200, the first actuator assembly 146a is positioned and rotated slightly forward and backward to compensate for the unwanted longitudinal movement produced by the second actuator assembly 146b. In a third mode of operation, the first actuator assembly 146a and the second actuator assembly 146b cooperate to produce an orbital motion in the clamping assembly 126. By coordinating the starting position and speed of each motor 152a, 152b, the shape of the orbital motion can be made predominantly longitudinal, predominantly lateral, or circular by precisely controlling the starting position and matching the rotational speed of the motors 152a, 152b. Complex motion profiles can be created by adjusting motors 152a and 152b to different rotational speeds or by varying the rotational speeds of motors 152a and 152b during a vibration operation. Furthermore, the drive assembly 128 can be configured to switch between motion profiles within a single vibration operation. For example, it may be desirable to first vibrate tray 200 along a longitudinal axis before vibrating it laterally. An additional benefit of the novel drive assembly 128 is the ability to quickly land tray 200 within the center of the conveyor assembly 104. Based on feedback from the rotary encoders 160, the control system can stop motors 152a and 152b in a position that correctly positions the tray. ML / t / ZUZ I / UOUOZÓ 200 in the center of the 120 conveyor belt. Thus, as described herein, the vibratory tray conveyor 100 overcomes several deficiencies in the prior art and provides a mechanism that can be easily and automatically adapted to perform a customized vibratory motion 5 on trays of different shapes, sizes, and configurations. It should be understood that, although numerous features and advantages of various embodiments of the present invention have been set forth in the foregoing description, along with details of the structure and functions of various embodiments of the invention, this disclosure is merely illustrative, and changes may be made to the details, particularly regarding the structure and arrangement of parts within the principles of the present invention, to the full extent indicated by the broad general meaning of the terms expressed herein and within the appended claims.Those skilled in the art will appreciate that the lessons of the present invention can be applied to other systems without departing from the scope and spirit of the present invention.

Claims

1. An automated vibratory tray conveyor having a central longitudinal axis and a central lateral axis, the automated vibratory tray conveyor comprising: a conveyor assembly, wherein the conveyor assembly includes a conveyor belt configured to transport a bakery tray through the automated vibratory tray conveyor in a direction substantially parallel to the central longitudinal axis; and a vibratory assembly, wherein the vibratory assembly is configured to induce a plurality of motion modes in the bakery tray.

2. The automated vibratory tray conveyor according to claim 1, further characterized in that the plurality of motion modes is selected from the group consisting of linear reciprocation along the longitudinal axis, linear reciprocation along the central lateral axis, and orbital motion.

3. The automated vibratory tray conveyor according to claim 1, further characterized in that the vibratory assembly is configured to lift the bakery tray from the conveyor assembly before inducing one of the plurality of motion modes in the bakery tray.

4. The automated vibratory tray conveyor according to claim 1, further characterized in that the vibratory assembly is configured to sequentially induce a first mode of movement in the bakery tray and then a second mode of movement in the bakery tray.

5. The automated vibratory tray conveyor according to claim 1, further characterized in that the vibratory assembly is configured to induce a plurality of motion modes in the bakery tray and wherein at least one of the plurality of motion modes is a composite motion that includes both linear and orbital motions.

6. The automated vibratory tray conveyor according to claim 1, further characterized in that the vibratory tray conveyor assembly comprises: a carriage assembly located below the conveyor belt; a clamping assembly supported by the carriage assembly; and a drive assembly located below the conveyor belt.

7. The automated vibratory tray conveyor according to claim 6, further characterized in that the drive assembly additionally comprises: a drive post connected to the carriage assembly; a first drive assembly including a first drive linkage connected to the drive post; and a second drive assembly including a second drive linkage connected to the drive post.

8. The automated vibratory tray conveyor according to claim 7, further characterized in that the first drive linkage and the second drive linkage are not linearly aligned.

9. The automated vibratory tray conveyor according to claim 7, further characterized in that the first drive linkage is substantially aligned with the central longitudinal axis, and wherein the second drive linkage is substantially aligned with the central lateral axis.

10. The automated vibratory tray conveyor according to claim 7, further characterized in that the first drive assembly further comprises a motor having a rotating shaft and an eccentric cam connected to the rotating shaft and the first drive linkage, and wherein the second drive assembly further comprises a motor having a rotating shaft and an eccentric cam connected to the rotating shaft and the second drive linkage.

11. The automated vibratory tray conveyor according to claim 7, further characterized in that it additionally comprises a frame assembly including a pair of separate frame rails extending in a direction that is substantially parallel to the central longitudinal axis.

12. The automated vibratory tray conveyor according to claim 11, further characterized in that the carriage assembly further comprises: a side rail extending in a direction that is substantially parallel to the central side axis, wherein the side rail moves in the frame rails; and a central support that moves in the side rail.

13. The automated vibratory tray conveyor according to claim 7, further characterized in that the clamping assembly comprises: a clamping rail connected to the central support; and a pair of clamps that move on the clamping rail, wherein the pair of clamps are configured to releasably grip the bakery tray.

14. The automated vibratory tray conveyor according to claim 13, further characterized in that the clamping assembly further comprises: a pneumatic cylinder, wherein the pneumatic cylinder is connected to a first of the pair of clamps; and a drive belt connected to the second of the pair of clamps, wherein the movement of the first of the pair of clamps by the pneumatic cylinder causes the second of the pair of clamps to move in a direction opposite to the first of the pair of clamps.

15. The automated vibratory tray conveyor according to claim 14, further characterized in that it additionally comprises one or more mass guards above the vibratory assembly, wherein the one or more mass guards include a plurality of clamp slots and wherein the first and second pair of clamps each extend upwards through a corresponding one of the plurality of clamp slots.

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