Corn Coating Apparatus with Rotating Grip and Tracking Drying Rack
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Solution Overview
Problem
Current methods for coating ears of corn are inefficient, requiring extensive handling and lack automation for high throughput, and fail to provide even application of magnetically active coatings, which are high-viscosity liquids, and do not allow for tracking and indexing of coated ears during drying.
Innovation Solution
A ventilated enclosure with a motor assembly and coating applicator that securely grips and rotates the ear of corn for even coating, integrated with a drying rack system for tracking and indexing coated ears.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual coating techniques are used, then coating application is simple, but productivity is low and extensive handling is required
Solution Approach 1:
The ear of corn is mounted on a rotating grip that automatically rotates during coating, allowing the coating applicator to apply coating evenly without extensive manual handling. The system serves itself by using the rotation mechanism to achieve uniform coating application.
Solution Approach 2:
Manual coating operations are replaced with an automated coating applicator system that uses controlled rotation mechanics to apply coating uniformly. The motor-driven rotation replaces manual manipulation, enabling higher throughput while maintaining coating quality.
2Reliability
If magnetically active coatings are applied, then kernel orientation and handling are improved, but coating application becomes problematic due to high viscosity
Solution Approach 1:
The coating applicator is moveable and can be positioned dynamically during the rotation process. The system adapts the coating application timing and position based on the rotation speed and coating viscosity, ensuring proper application of magnetically active materials without excessive handling.
Solution Approach 2:
The rotation speed of the grip can be adjusted to control the coating application process. By changing rotational parameters, the system manages the high viscosity of magnetically active coatings, allowing them to be applied evenly without excessive handling or pooling.
3Manufacturing precision
If coated ears are handled extensively during coating, then coating application is thorough, but handling time increases and throughput decreases
Solution Approach 1:
The ear of corn rotates continuously during the coating process, allowing the coating applicator to maintain continuous contact and application. This continuous rotation ensures uniform coating without requiring pauses for manual handling or adjustment, reducing overall handling time.
Solution Approach 2:
The ear of corn is pre-mounted on the rotating grip before coating begins. This preliminary positioning allows the coating process to proceed continuously without interruptions for handling or adjustment, improving both coating uniformity and reducing handling time.
4Productivity
If multiple ears are dried simultaneously, then productivity increases, but tracking and indexing becomes difficult
Solution Approach 1:
The drying rack is segmented into multiple positions or compartments, each capable of holding and tracking individual ears of corn. This segmentation allows simultaneous drying of multiple ears while maintaining the ability to track and index each ear through its specific position or identifier.
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
Enables efficient, high-throughput coating of ears of corn with minimal handling, ensuring even application of magnetically active coatings and allows for tracking and indexing during the drying process, enhancing operational efficiency and handling of coated ears.
Implementation Method 1
Automatic orientation by magnetic attenuation is shown and described in U.S. application Ser. No. 11/939,380 filed Nov. 13, 2007 and Ser. No. 11/939,402 filed Nov. 13, 2007
Implementation Method 2
applying a magnetically active coating to the crown of corn kernels on an ear of corn
Data Source
AI summary
Apparatuses and methods for applying a coating to an ear of corn are disclosed. An enclosure having a user accessible workspace and a motor to turn an ear of corn therein to apply a coating to the ear of corn rotated by the motor is also disclosed. The method includes providing an enclosure with a user accessible workspace for housing a motor assembly having a motor with a grip, releasably securing the ear of corn to the grip, rotating the ear of corn with the motor, and spraying the coating on the ear of corn with the coating applicator associated with the workspace. Each ear of corn has an identifier to track and index the ear corn during coating and drying.