Corn Dog Apparatus with Spring-Loaded Plungers for Coating Consistency

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Solution Overview

Problem

Existing corn dog production methods lack efficiency and consistency in coating and frying, leading to suboptimal flavor and production output.

Innovation Solution

An apparatus with a frame-mounted loading, dipping, frying, and unloading station, utilizing a stick bar with spring-loaded plungers to secure sticks, allowing for automated processing and adjustable force to maintain stick position during coating and frying, enhancing the production efficiency and flavor consistency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual corn dog preparation methods are used, then flexibility and simplicity are maintained, but production efficiency and output are low

Engineering Contradiction:

Improveproduction efficiencyVSAvoidapparatus complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The apparatus is divided into distinct functional stations (loading, dipping, frying, unloading) that process multiple sticks simultaneously. Each station handles a specific task, allowing parallel processing of multiple corn dogs through the production line, thereby increasing overall productivity without requiring an overly complex monolithic system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The stick bar with multiple apertures serves as a universal carrier that can hold and transport multiple sticks through all processing stations. The spring-loaded plungers provide a universal securing mechanism that works for each stick position, reducing the need for individual complex holding mechanisms for each stick.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If automated processing is implemented, then production output increases, but manufacturing precision and coating consistency become challenging

Engineering Contradiction:

Improveproduction outputVSAvoidcoating consistency

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The spring-loaded plungers are pre-adjusted to apply optimal securing force to each stick before the coating process begins. This preliminary action ensures that all sticks are held with consistent force throughout the dipping process, preventing variations in coating quality while maintaining high production output through automated processing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The apparatus allows adjustment of the spring plunger force parameters to optimize the holding pressure on each stick. By carefully controlling this parameter, the system maintains consistent coating application across all sticks while operating at high automated speeds, resolving the trade-off between productivity and precision.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If spring-loaded plungers are used to secure sticks, then stick position stability is improved, but device complexity increases

Engineering Contradiction:

Improvestick position stabilityVSAvoidstick bar mechanism complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The spring-loaded plungers are designed to automatically engage and secure each stick as it is inserted into the aperture. The spring mechanism self-regulates to apply appropriate holding force without requiring external control systems or complex actuation mechanisms, thereby improving stick position stability while minimizing the increase in device complexity.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The spring plungers are simple, inexpensive components that can be easily replaced if needed. Their simplicity reduces the overall complexity of the stick bar mechanism while providing reliable stick positioning. The straightforward design allows for easy maintenance and replacement without complicating the overall system.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 apparatus significantly increases the efficiency and output of corn dog production while ensuring consistent flavor by automating the coating and frying processes, allowing for adjustable force to securely hold sticks, resulting in improved product quality.

Implementation Method 1

The stick bar has a spring loaded plunger extending into the aperture to engage the first end of the stick to secure the stick, and the food article thereon, during coating and frying of the food article

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11910800B2Apparatus for preparing and cooking coated food articles impaled upon a stick

Publication Date: 2024.02.27 AUTOMATED FOOD SYST

AI summary

An apparatus is disclosed for preparing a food article (300) such as a corn dog. The apparatus includes a frame (10) mounting a loading station (50), a dipping station (162), a frying station (190) and an unloading station (220). The loading station (50) inserts one end (306) of a stick (302) into the food article (300) and the other end (304) into an aperture (40) in a stick bar (38). The stick (302) and food article (300) are held in the aperture (40) by a spring loaded plunger (310) extending into the aperture (40). The spring loaded plunger (310) holds the stick (302) and food article (300) on the stick bar (38) while the food article (300) is dipped in batter at the dipping station (162) and fried at the frying station (190). The cooked food article (300) and stick (302) are removed from the stick bar (38) at the unloading station (220) for shipment to the customer.