Extrusion Cutter Head Variable Speed Profile for Uniform Portioning
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Solution Overview
Problem
Existing extrusion portioning machines struggle with achieving uniform and repeatable portioning of semi-solid materials like cookie dough due to varying viscosities, inclusions, and material properties, leading to inconsistent cutting and placement, which results in production inefficiencies and increased costs due to the need for specialized equipment for each product.
Innovation Solution
A programmable cutter head with a variable speed profile controlled by a servo motor, allowing for adjustments in velocity throughout the cutting cycle, synchronized with other machine components like feed rollers and conveyor speed, to optimize cutting and placement accuracy and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed-speed cutter head is used, then the device complexity is reduced, but the manufacturing precision of portioning deteriorates due to inability to accommodate varying material viscosities and properties
Solution Approach 1:
The cutter head speed is changed from fixed to variable, allowing dynamic adjustment of cutting velocity to match different material properties. The servo motor enables real-time speed modification during the cutting cycle, transforming a static system into a dynamic one that adapts to varying dough viscosities and inclusion contents.
Solution Approach 2:
The cutting speed parameter is made variable rather than constant. By programmatically adjusting the cutter head speed parameter according to the specific material being processed, the system achieves optimal cutting conditions for different dough types, inclusions, and viscosities without requiring physical hardware changes.
2Adaptability or versatility
If specialized equipment is used for each product, then the manufacturing precision is maintained, but the adaptability of the cutting head deteriorates
Solution Approach 1:
The cutter head system is designed to perform multiple functions by accommodating different material types through programmable speed profiles. A single cutter head can process various dough viscosities, inclusion contents, and product specifications by loading appropriate speed profiles, eliminating the need for dedicated equipment for each product type.
Solution Approach 2:
The system dynamically adapts to different products by changing operational parameters (speed profiles) rather than requiring physical reconfiguration. This dynamic programmability enables one cutter head to serve multiple product lines while maintaining cutting consistency through optimized speed settings for each material type.
3Productivity
If the cutter head speed is increased to boost productivity, then the productivity improves, but the manufacturing precision deteriorates due to inconsistent portion separation
Solution Approach 1:
The cutting cycle employs periodic variation in speed rather than maintaining a constant high speed. The servo motor accelerates and decelerates the cutter head at specific phases of the cutting cycle, creating a rhythmic speed pattern that ensures clean separation at critical moments while maintaining high overall productivity through rapid positioning and return strokes.
Solution Approach 2:
The cutter head speed is dynamically adjusted during the cutting cycle rather than remaining static. The system accelerates to high speeds for rapid positioning and material traversal, then decelerates at precise moments to ensure clean portion separation and accurate placement, optimizing both productivity and precision through time-varying speed control.
Data Source
AI summary
The invention is directed to a foodstuff extrusion portioning device and more specifically a cutter head assembly on such an extruder having a servo motor, a cutter shuttle coupled to a cutting element, a controller and being programmed via a product variable to provide a velocity profile. The cutter in the velocity profile has a first velocity and it reduces speed to a second velocity and goes more slowly through the last portion of the foodstuff. The at least two velocities being fully programmable and the controller can provide for instantaneous and additional programmed velocities throughout the cutting profile. The cutter further providing tilt control so it can drop the portion at the moment the portion detaches from the extruded foodstuff stream. It cuts and/or breaks off portions in a far more uniform and controllable manner to more accurately portion and better place the cut portions. This also provides the portion with minimal residual energy pushing it forward as it drops through the effect of gravity and the cutter can be used so as to further direct and push the portion downward so as to optimally place it.