Filling System Speed Control for Food Product Consistency
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Solution Overview
Problem
Existing filling and portioning systems for food products face challenges in maintaining optimal rotational speed ratios for feeder/mixing arms and counterholding devices, leading to overloading, inconsistent processing, and incomplete filling due to changing product consistency and filling levels, which affects product quality and efficiency.
Innovation Solution
A filling and portioning system with an electronic control device for automated rotational speed control of feeder/mixing arms and counterholding devices, adjusting speeds based on real-time machine and product parameters such as filling level, vacuum, pressure, and weight, to ensure continuous adaptation to changing production conditions and prevent mechanical overloading or incomplete filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the feeder/mixing arm rotates at high speed to maintain sufficient filling of conveyor chambers when the hopper is empty, then the filling reliability of the conveyor mechanism is improved, but the food product may be mechanically overloaded and damaged
Solution Approach 1:
The patent applies dynamics by making the rotational speed of the feeder/mixing arm variable rather than constant. The control device dynamically adjusts the rotational speed based on real-time detection of filling level in the hopper. When the hopper is nearly empty, the speed increases to ensure complete filling of conveyor chambers; when the hopper is full, the speed decreases to prevent mechanical overloading of the food product.
Solution Approach 2:
The patent implements feedback control through a detection device that continuously monitors the filling level of the hopper and feeds this information to the control device. The control device uses this feedback to automatically adjust the rotational speed of the feeder/mixing arm, creating a closed-loop control system that adapts to changing conditions and resolves the contradiction between filling reliability and mechanical overloading.
2Reliability
If the feeder/mixing arm rotates faster to compensate for low filling levels, then the vacuum continuity in the conveyor mechanism is maintained, but product ejection occurs at high filling levels
Solution Approach 1:
The system dynamically adjusts the rotational speed of the feeder/mixing arm based on the detected filling level. At low filling levels, the increased speed ensures continuous vacuum supply to the conveyor mechanism by preventing air leaks. At high filling levels, the reduced speed prevents excessive mechanical action that would cause product ejection, thus resolving the contradiction between maintaining vacuum continuity and preventing product ejection.
Solution Approach 2:
The detection device provides continuous feedback on the filling level to the control device, which automatically adjusts the rotational speed to prevent both vacuum interruption and product ejection. This feedback mechanism ensures that the system responds appropriately to changing filling conditions, maintaining vacuum continuity when needed and preventing mechanical overaction when the hopper is full.
3Ease of operation
If a fixed rotational speed ratio is used between feeder/mixing arm and conveyor mechanism, then the system operation is simplified, but the system cannot adapt to changing product consistency during processing
Solution Approach 1:
The patent transforms the fixed rotational speed ratio into a dynamic, variable ratio. The control device independently adjusts the rotational speed of the feeder/mixing arm based on detected product consistency and filling level, rather than maintaining a fixed ratio. This allows the system to adapt to changing product conditions during processing while keeping the conveyor mechanism operating at its optimal fixed speed.
Solution Approach 2:
The patent segments the control of rotational speeds, allowing independent control of the feeder/mixing arm from the conveyor mechanism. The control device can adjust the feeder/mixing arm speed based on product consistency detection without affecting the conveyor mechanism speed, enabling adaptive response to changing conditions while maintaining simple operation of the overall system.
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 system ensures consistent product quality and reliable filling and portioning by dynamically adjusting rotational speeds, preventing overloading and incomplete filling, and maintaining optimal processing conditions for various food products, even as their consistency changes during processing.
Implementation Method 1
a vacuum-assisted conveyor mechanism with which the food product is supplied to an attachment device for portioning
Data Source
AI summary
A filling and portioning system for food products and a method for rotational speed control of a feeder and/or mixing arm and/or counterholding device present thereon for conveying the food product in a filling hopper are described. According thereto, the feeder/mixing arm in the filling hopper can be rotated about itself by way of a motor for conveying the food product and is driven independently of a downstream conveyor mechanism. The counterholding device is also arranged in the filling hopper and can optionally be rotated about itself by way of a motor for conveying the food product and is driven independently of a downstream conveyor mechanism. The rotational speed of at least one of the motors is controlled in an automated manner in dependence of at least one machine or product parameter measured during operation of the filling and portioning system.