Automatic sorting station for frozen foods

Abstract

The invention relates to a station including one or more loading positions, a feeder for feeding empty boxes to the loading positions, a loading robot with a gripper for picking up and transferring groups of frozen food into the boxes, a scale for automatically weighing the boxes, and a dispenser for automatically depositing individual units of frozen food into the loaded boxes. This conditioning station is controlled to slightly underload the boxes so that at the end of the loading by the loading robot, the individual units of frozen food do not have to be removed from the boxes and so that after deposition by the dispenser, the weight of the loaded boxes is equal to or greater than a predefined set value within a predefined tolerance. This allows the loading to be automated and the weight of the boxes of frozen food to be optimized.

Description

Technical Field

[0001] The present invention can be included in the food field, particularly in the frozen food field. More specifically, the object of the present invention relates to an adjustment station for adjusting frozen hamburgers, particularly frozen hamburgers containing beef, chicken, turkey, pork or vegetable hamburgers.

Background Art

[0002] In the food field, particularly in the meticulous finishing and packaging of previously frozen foods, equipment for the in-line packaging of prepared, deeply frozen hamburgers intended for large-scale distribution to extensive sales points worldwide is known, where the hamburgers are packaged to be sent to the sales points and given the final finishing there.

[0003] The packaging of frozen hamburgers is particularly delicate. The reason is that it is carried out manually on the hamburger processing line itself by specialized workers who manually package a specific number of units in a stack oriented horizontally or vertically in a box.

[0004] This is an operation carried out in a food processing and freezing facility, so the working conditions are extreme. This is because on the one hand, it involves working at low temperatures and on the other hand, continuous handling of deep freezing food which makes the operator more sensitive to extreme cold even though protected against these conditions with various PPE such as gloves and gowns.

[0005] Therefore, in this field, these types of jobs are particularly dangerous and thus should be optimized as follows: on the one hand, overall production is optimized, amortizing human jobs that do not bring added value, and on the other hand, from a purely ergonomic point of view, jobs under dangerous conditions should be eliminated.

Summary of the Invention

Problems to be Solved by the Invention

[0006] The present invention solves the aforementioned problems with an automated sorting station for frozen foods, such as frozen hamburgers, thereby enabling a combination of automated packaging and optimization of the contents of the packaging material (generally a box). [Means for solving the problem]

[0007] The adjustment station includes one or more loading positions from which empty boxes are supplied by a box feeder. It also includes at least one scale for automatically weighing the boxes, preferably one scale at each corresponding loading position, and at least one loading robot equipped with a gripper for picking up groups, such as stacks of frozen food, and transferring them to the boxes at the loading positions in synchronization with the feeder. The adjustment station is controlled to underload the boxes after loading by one or more loading robots, so that the weight of the boxes does not exceed a predetermined lower limit plus a predetermined tolerance, i.e., so that individual units do not need to be removed from the frozen food. Specifically, this configuration aims to ensure that, at the end of loading by the loading robots, the loaded boxes have a weight selected from the following: - Below the lower limit setting, - The lower limit is set only by a value that does not exceed the tolerance, so that there is no need to remove individual units from frozen foods.

[0008] Advantageously, the sorting station further includes at least one dispenser for automatically stacking one or more individual units of frozen food into a loaded box. In this case, the configuration seeks to ensure that, after stacking by the dispenser, the weight of the loaded box is above a predetermined lower limit within a predetermined tolerance range.

[0009] The loading station can operate in both vertical and horizontal stacking modes for various formats of frozen foods, particularly frozen hamburgers, in boxes of different sizes and weights, but exclusively for one format at a time. The frozen foods are loaded automatically, meaning no human intervention is required. The frozen foods are loaded into boxes according to previous specifications, i.e., to reach a predetermined range of number, height, and weight, based on the number of units of the frozen food (e.g., hamburgers), the thickness of the stacked units (i.e., total height), the weight, or a combination of some or all of these.

[0010] It may optionally include a frame intended to introduce a grid pattern into the box once it is placed in the loading position, before it is loaded, in order to facilitate filling. The grid pattern divides the box into cells and thus defines a predetermined loading format. In this way, the loading robot loads the boxes according to a predetermined arrangement according to the configuration of the grid pattern. food Because it can be piled up inside the box, inside the cell, the freezing inside the box food This simplifies the orderly loading process. Similarly, the frame can be configured to clamp liners, typically plastic bags, into the box without them collapsing or falling out.

[0011] The automation of loading ensures accuracy, speed, and adherence to quantity and weight specifications, without manual intervention such as removing individual units of frozen food from loaded boxes due to weight overages.

[0012] The aforementioned advantages and features will be better understood in light of the following detailed description of embodiments, which, in addition to other advantages and features, refer to the following figures, which are to be read non-exclusively as descriptive. [Brief explanation of the drawing]

[0013] [Figure 1]Shows a schematic top perspective view of the adjustment station of the present invention. [Figure 2] Shows a detailed view of the structure of the support and the sub-stack. [Figure 3] Shows one detail of the gripper. [Figure 4] Shows details of the frame and the grid pattern.

Explanation of Reference Numerals

[0014] 1 Frozen food / Frozen hamburger 2 Box 3 Group / Stack 4 Conveyor belt 5 Grouping device / Stacker 6 Support for stacked hamburgers 7 Empty box feeder 8 Loading position 9 Loading robot 10 Gripper 11 Sub-stack 12 Separating means 13 Claw 14 Side hatch 15 Lower hatch 16 Actuator 17 Frame 18 Grid pattern 19 Plastic liner / Bag 20 Dispenser 21 Tank 22 Upper plate 23 Lower plate 24 Upper through-hole 25 Pressing plate 26 Cell 27 Frame 28 Internal tubular part 29 First driving device 30 Connecting rod 31 Closure 32 Second driving device 33 Laser 34 Meter [Modes for carrying out the invention]

[0015] Frozen hamburger (1) without losing generality food A detailed description of a preferred exemplary embodiment of the automatic adjustment station of (1) according to a first aspect of the present invention is provided below with the help of the above Figures 1-4.

[0016] In the example presented below, the preparation station of the present invention is installed in a frozen hamburger (1) manufacturing facility, and the hamburgers (1) are preferably first formed and then frozen, so that they arrive at the preparation station in a frozen state and are packaged in boxes (2) according to predetermined weight conditions. For this purpose, the preparation station includes the following two substations: - Packaging substation where a group (3) of frozen hamburgers is automatically loaded into a box (2): - A finishing substation where the weight of a box (2) loaded with frozen hamburgers (1) is automatically checked, and the weight is adjusted as necessary by incorporating one or more individual frozen hamburgers (1).

[0017] In the manufacturing facility, hamburgers (1) are prepared and then frozen. The frozen hamburgers (1) go through a visual verification system (not shown) that checks for pre-specified format requirements, such as shape, orthogonal dimensions, and thickness, and sorts the frozen hamburgers (1) into acceptable and unacceptable hamburgers based on pre-set criteria. Visual verification can be performed after the hamburgers (1) are frozen, as described above, but it is also preferable to perform it before freezing. In general, it is important to perform visual verification both before and after freezing for different reasons. Visual verification after freezing is particularly important because the hamburgers (1) may break and deform during freezing, which could cause problems in the operation of the station.

[0018] The frozen and, if necessary, verified hamburgers (1) are transported along a conveyor belt (4) and arrive at the packaging station in an orderly and neatly arranged state.

[0019] The packaging substation includes a grouping device (5), such as a stacker (5), which receives frozen hamburgers (1) via, for example, a conveyor belt (4), and forms one or more groups (3), such as stacks (3), which are supported on respective inclined supports (6). The number of groups (3), and in particular the number of stacks (3), may depend on the dimensions of the hamburgers (1). In the figure, as an example, the grouping device (5) shown forms five stacks (3).

[0020] The packaging substation further comprises at least one feeder (7) for supplying empty boxes (2) to one or more loading positions (8) of the packaging substation. The feeder (7) may, without loss of generality, be of a type that supplies already formed boxes (2) or of a type that supplies corrugated cardboard sheets to form boxes (2).

[0021] Similarly, the packaging substation includes at least one loading robot (9) equipped with a gripper (10) for synchronously taking sub-stacks (11) of hamburgers (1) from the stack (3) and transferring them to boxes (1) in conjunction with the feeder (7). As an example, in the illustrated embodiment, there are two loading robots (9) positioned on either side of a single feeder (7) and two loading positions (8) to allow simultaneous operation of the two loading robots (9). Without loss of generality, the present invention is applicable to both a single loading robot (9) and to more than two loading robots (9), for example, three loading robots (9).

[0022] Preferably, the packaging substation has detection means (not shown) for determining the number of hamburgers (1) stacked in each stack (3) and the thickness, i.e., the total height, of each stack (3). When the number of hamburgers (1) and the height of the stack (3) satisfy predetermined stacking requirements, for example, when the stack (3) reaches a predetermined number of hamburgers (1) or a predetermined maximum height, the separation means (12) separates the hamburgers (1) forming a substack (11) from the stack (3) and separates them from the remaining hamburgers (1) of the stack (3). The separation means (12) may include claws (13) mounted on a support (6) which move the substack (11) upward and separate them from the stack (3) which is continuously formed as hamburgers (1) are supplied.

[0023] At this point, the gripper (10) of the loading robot (9) grasps the sub-stack (11) and introduces it into the box (2). Preferably, the gripper (10) has a side hatch (14) that closes and encloses the sub-stack (11). If the hamburgers (1) are stacked horizontally in the box (2), the side hatch (14) opens to drop the hamburgers (1) from the sub-stack (11) into the box (2). If stacked vertically, the gripper (10) has a bottom hatch (15) that opens to drop the hamburgers (1). Typically, any type of box (2) is intended to be filled horizontally only or vertically only, but it is preferable that the loading robot (9) is configured for both horizontal and vertical loading, for example, by including both the side hatch (14) and the bottom hatch (15). The gripper (10) can be suitably configured according to the specific shape of the hamburgers (1). For example, it can be configured to capture not only oval-shaped hamburgers (1) but also round hamburgers (1).

[0024] The figure shows a preferred example of the operation of the gripper (10) described below. Each gripper (10) has an outer tubular frame (27) and two inner tubular sections (28) concentric with the frame (27) and movable by a first drive unit (29), such as by a connecting rod (30), which in turn opens a side hatch (14), allowing the gripper (10) to approach and capture the substack (11), and then closes the side hatch (14) to hold the frozen hamburger (1) without damage. This configuration also serves to unload the substack (11) in the case of horizontal filling, as described above. The gripper (10) is simply placed horizontally on the box (2) and the side hatch (14) is opened. In the case of vertical filling, the gripper (10) may also include a closure (31) for opening and closing a lower hatch (15) by a second drive unit (32). When the gripper (10) is loaded, it moves toward the box (2) and is positioned vertically within the box (2) as needed, in the corresponding position. At this point, the second drive unit (32) drives the closure (31) to open the lower hatch (15) and drop the sub-stack (11). The interior of the tubular section (28) is designed and dimensioned so that the hamburger (1) falls perfectly vertically, avoiding friction against the walls and absorbing tolerance differences in the hamburger (1), which are matched, if necessary, to the tolerances of the grid pattern (18) to avoid jamming when loading into the box (2).

[0025] In the example shown in the figure, as the substack (11) grows as the frozen hamburgers (1) accumulate on the support (6), a laser (33) emitted from a meter (34) measures the stopping position of the substack (11), thereby, when it reaches a predetermined position, a separation means (12), and if necessary a claw (13), driven by a signal sent from the meter (34) to a drive unit (16), pushes the claw (13) toward the substack (11), separating the substack (11) into two parts, thereby allowing the gripper (10) of the loading robot (9) to perform the collection operation of the substack (11) from its position on the support (6) and perform the remaining loading operation, as described above.

[0026] The loading robot (9) stacks substacks (11) of hamburgers (1) into boxes (2) according to preset parameters relating to the number of hamburgers (1) to be loaded and the weight of the boxes (2) to be loaded. For example, both the number of hamburgers (1) and the weight of the loaded boxes (2) may be within a preset range. In this regard, the packaging substation may further include a packaging scale (not shown) for measuring the weight of the boxes (2) as they are filled.

[0027] Optionally, the packaging substation further includes a frame (17) intended to introduce a grid pattern (18) having cells (26) defining a predetermined loading format into the box (2) once at the loading position (8) before loading, in order to partition the box (2) and facilitate its filling. In this way, the orderly loading of hamburgers (1) into the box (2) is simplified, since a loading robot (9) can instead deposit sub-stacks (11) into each compartment created by the grid pattern (18). The frame (17) can optionally be configured to clamp liners (19), typically plastic bags (19), inside the box (2) without them collapsing or falling inside the box (2), where, for example, the frame may include a pressing plate (25) for clamping the liners (19). The presence of the frame (17) and the grid pattern (18) accomplishes two tasks. Firstly, the grid pattern (18), along with its cells (26), is configured according to the loading format of the selected box (2), and in particular according to how the products will be loaded into the box (2). Similarly, the cells (26) serve as guides for the frozen hamburgers (1) to enter, i.e., fall into, the box (2) in their correct places during the loading operation. In addition, once loaded, they also hold the frozen hamburgers (1) in the correct position, preventing the sub-stack (11) from collapsing and interfering with subsequent loading operations of the frozen hamburgers (1) into empty cells (26) waiting to be loaded. Secondly, the frame (17) holds the grid pattern (18) in the correct position and allows it to rise and fall according to the cycles during the loading operation, in addition to clamping the bags (19) inside the box (2) by the upper edge of the box (2). This clamp is important to prevent the bag (19) from collapsing inside the box (2) when the bag (19) is not fully positioned inside the box (2) or when there is a gap between the inside of the box (2) and the bag (19), as often happens when the plastic bag (19) is placed in the receiving area.

[0028] In part, the finishing substation includes a finishing scale (not shown) for measuring the weight of boxes (2) loaded into the finishing station, and a distributor (20) configured to introduce a precise number of frozen hamburgers (1) into the loaded boxes (2) after loading by the loading robot (9). The substation is programmed to slightly underload the boxes (2), that is, the number of hamburgers (1) taken in by the loading robot (9) in each operation and / or the length of the substack (11) is programmed such that the weight of the boxes (2) at the end of loading does not exceed a certain setpoint to the extent that individual frozen hamburgers (1) need to be removed. .child This makes it possible that, once the box (2) is weighed by the finishing scale, there is no need to remove the frozen hamburgers (1) from the loaded box (by hand), and only the individual hamburgers (1) (i.e., the exact number required) can be added by the dispenser (20) as needed.

[0029] Preferably, the packaging scale is the same as the finishing scale. In particular, based on weight discrepancies, the station determines how many hamburgers (1) should be included by the dispenser (20).

[0030] The diagram shows how a box (2) loaded at the packaging station is moved to the position of the dispenser (20). Alternatively, although not shown, the dispenser (20) could be positioned to introduce the hamburger patties (1) into the loaded box (2) at the loading position (8) without needing to move the loaded box (2).

[0031] Although a single distributor (20) is shown in the figure, in other embodiments, there may be multiple distributors (20) that work in conjunction with the loading robot (9).

[0032] Preferably, the distributor (20) is configured to be loaded by a loading robot (9). For example, the distributor (20) includes a tank (21), for example, a vertical tank (21), which is loaded vertically by, for example, a loading robot (9). As an example, as shown in the figure, the distributor (20) comprises two overlapping plates (22, 23), for example, two circular plates (22, 23), i.e., an upper plate (22) having a plurality of upper through holes (24) for accommodating frozen hamburgers (1) coming from the tank (21), and a lower plate (23) having at least one lower through hole (not shown) for dropping the frozen hamburgers (1) into a box (2) to be loaded. The upper plate (22) is rotatable relative to the lower plate (23) along a vertical axis coaxial with the two plates (22, 23) so as to face the lower through hole, and preferably also rotatable relative to the tank (21) so as to receive the hamburger (1) from the tank (21) into the upper through hole (24).

[0033] Furthermore, optionally, the distributor (20) incorporates a timer (not shown) that determines the residence time of the frozen hamburgers (1) in the tank (21). This is important for hygienic reasons. The hamburgers (1) must remain in the tank (21) for a predetermined maximum time, for example, 30 minutes, after which they must be discarded. The timer is associated with an alarm device (not shown), which displays the residence time and / or emits an alarm message indicating that the predetermined maximum time is approaching or has been exceeded.

Claims

1. A preparation station for frozen food (1), wherein the preparation station is One or more loading positions (8) and At least one feeder (7) for supplying empty boxes (2) to the loading position (8), A loading robot (9) equipped with a gripper (10) for picking up the group (3) of the frozen food (1) and transferring it to the box (2) at the loading position (8) in synchronization with the feeder (7), A scale configured to automatically weigh the box (2), The loading robot (9) loads the units of the frozen food (1), and at least one distributor (20) is configured to automatically stack one or more individual units of the frozen food (1) into the loaded box (2), wherein the distributor (20) The loading robot (9) loads the units of the frozen food (1) into at least one vertical tank (21), Two overlapping plates (22, 23), An upper plate (22) having a plurality of upper through holes (24) for accommodating units of frozen food (1) coming from the tank (21), A lower plate (23) having at least one lower through-hole for dropping the frozen food unit (1) into the box (2), Plates (22, 23) including, A distributor (20) including, Includes, The adjustment station, upon completion of loading by the loading robot (9), ensures that the loaded boxes (2) are in the correct position. Weight below a predetermined lower limit, In order to avoid the need to remove individual units of the frozen food (1), the weight exceeding the lower limit setting value by a value that does not exceed a predetermined tolerance, It is controlled to load into the box (2) to have a weight selected from the following: The adjustment station is further controlled so that, after stacking by the distributor (20), the weight of the loaded boxes (2) is equal to or greater than the predetermined lower limit setting value within the predetermined tolerance. An adjustment station characterized by the following features.

2. The adjustment station according to claim 1, characterized in that the upper plate (23) is rotatable relative to the lower plate (23) along a vertical axis coaxial with the two plates (22, 23) such that the unit of the frozen food (1) faces the lower through hole.

3. The adjustment station according to claim 2, characterized in that the upper plate (22) is further rotatable relative to the tank (21) in order to receive the frozen food (1) units from the tank (21) into the upper through-hole (24).

4. The adjustment station according to any one of claims 1 to 3, further comprising a grouping device (5) that receives the frozen food (1) units and forms one or more groups (3) of the received frozen food (1) units to be transferred to the box (2) by the loading robot (9).

5. The adjustment station according to claim 4, characterized in that the grouping device (5) includes each support (6) that supports the group (3).

6. The adjustment station according to claim 5, characterized in that the support (6) is inclined.

7. The adjustment station according to any one of claims 1 to 6, further comprising detection means for determining the number of individual units of frozen food (1) grouped into each group (3) and the total thickness of each group (3).

8. The adjustment station according to claim 4, further comprising a separation means (12) for isolating the frozen food (1) from each group (3), wherein the frozen food (1) forms subgroups (11), and the separation means (12) separates the frozen food (1) of the subgroups (11) from the remaining frozen food (1) of the group (3).

9. The adjustment station according to claim 8, wherein the grouping device (5) includes a support (6) for each of the groups (3), and the separation means (12) includes a claw (13) installed on the support (6) which moves the subgroup (11) upward and separates the subgroup (11) from the group (3).

10. The adjustment station according to claim 8 or 9, further comprising a meter (34) that emits a laser (33) for detecting the stopping position of the subgroup (11), wherein the station is configured such that the separation means (12) is activated when the meter (34) detects that the stopping position has reached a predetermined position.

11. The adjustment station according to any one of claims 8 to 10, characterized in that the gripper (10) includes a side hatch (14) that surrounds and closes the subgroup (11) of the frozen food (1).

12. The adjustment station according to claim 11, characterized in that the side hatch (14) is controlled to open in order to horizontally stack the subgroup (11) inside the box (2).

13. The adjustment station according to claim 11 or 12, characterized in that the gripper includes an outer tubular frame (27) and two inner tubular portions (28) that are concentric with the frame (27) and movable by a first drive unit (29) to open and close the side hatch (14).

14. The adjustment station according to any one of claims 11 to 13, further comprising a lower hatch (15) that opens to allow the subgroup (11) to drop vertically into the box (2).

15. The adjustment station according to claim 14, wherein the gripper (10) further includes a closure (31) for opening and closing the lower hatch (15) by a second drive device (32).

16. The adjustment station according to any one of claims 1 to 15, further comprising a frame (17) intended to introduce a grid pattern (18) defining a predetermined loading format into the box (2) once it is placed in the loading position (8) in order to partition the box (2) during loading.

17. The adjustment station according to claim 16, characterized in that the frame (17) is configured to clamp the bag (19) inside the box (2).

18. The preparation station according to any one of claims 1 to 17, characterized in that the frozen food (1) includes a frozen hamburger (1).

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