Batch Freezer Safety Blocking Mechanism
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Solution Overview
Problem
Existing batch freezers lack efficient and safe mechanisms for stopping the mixer during the ice cream extraction process, leading to quality issues and safety risks due to the reliance on worn-out braking systems and manual intervention.
Innovation Solution
A batch freezer with a safety blocking-unblocking system that includes a flange with a mechanical interlocking device and a microcontroller for controlled release, utilizing a bimetallic component and electromagnetic impulse to ensure safe and rapid stopping of the mixer, allowing for quick product extraction while maintaining safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the mixer is stopped by removing power from the motor and relying on gear motor braking or blade scraping capacity, then the stopping time is extended, but the product quality deteriorates due to delayed extraction
Solution Approach 1:
The patent extracts the braking function from the gear motor and blade scraping system, introducing a separate electromagnetic brake mechanism. This dedicated braking component provides rapid, controlled stopping independent of the original wear-prone systems, resolving the contradiction between reliable stopping and quick extraction.
Solution Approach 2:
The patent introduces an electromagnetic brake as an intermediary mechanism between the motor and the mixer shaft. This intermediary provides controlled energy dissipation during stopping, enabling rapid deceleration without the delays and quality issues associated with direct motor power removal or blade scraping.
2Productivity
If manual intervention is used to facilitate extraction, then the extraction speed is improved, but safety risks increase for the operator and machine integrity
Solution Approach 1:
The patent implements a safety blocking-unblocking system that automatically controls access to the freezing cylinder. The system self-manages the blocking state during operation and automatically unblocks when safe for extraction, eliminating the need for manual intervention and the associated safety risks while maintaining rapid extraction capability.
Solution Approach 2:
The safety blocking system performs preliminary actions by automatically preparing the system for safe extraction before the operator needs to access the cylinder. The blocking lever and interlocking mechanism proactively manage safety conditions, preventing harmful situations before they can affect operator safety or machine integrity.
3Reliability
If the blocking lever is held in blocking position by a safety magnet, then accidental openings are prevented, but the system complexity increases with additional components
Solution Approach 1:
The patent merges the safety magnet function with the existing blocking lever mechanism. The electromagnetic brake and safety magnet share the same actuation system, combining multiple safety functions into a unified structure. This integration provides reliable safety blocking without proportionally increasing system complexity, as the same control system manages both braking and safety locking.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables fast and safe blocking and opening of the batch freezer, minimizing the time required for mixer stoppage and ensuring high-quality product extraction while enhancing safety by reducing the reliance on worn-out braking systems and preventing accidental openings.
Implementation Method 1
a bimetallic component (62) which, by heating and expanding, blocks the movement of the metal sheet 30
Implementation Method 2
or by means of an impulse electromagnetic impulse which forces the rapid release of the blocking lever 18
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A batch freezer with fast and safe blocking and opening comprising a front wall (11) provided with an access or closure flange (12) for an opening (13) positioned in the front in a freezing cylinder (14), a hopper (15) for the insertion of ingredients for the production of ice cream, positioned above the flange (12) and a gridded door (16) for extracting the finished product beneath the flange (12), the flange (12) being positioned on a closing crosspiece (17) articulated with a pin (20) at a first end to the front wall (11), and at a second end carrying a blocking lever (18), wherein a safety blocking-unblocking group (19), which serves for blocking the access flange (12) to the freezing cylinder (14), is associated with the closing crosspiece (17) near the blocking lever (18), a sensor being provided on the one hand connected to a microcontroller which switches off the motor of the batch freezer and removes the power supply from the blocking-unblocking group (19) so that, after a prefixed time, the flange (12) is released to allow the closure of the opening (13) and on the other hand, the sensor communicates to the microcontroller, the pressing of a stop button (50) with the handle closed, so that the microcontroller, after a settable time, sends a release command to the blocking-unblocking group (19) allowing the flange (12) to be released for closing the opening (13).