Calibration apparatuses and methods for food processing machines
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Solution Overview
Problem
Conventional food processing machines require extended downtime for calibration, leading to decreased efficiency and output, as technicians need to manually calibrate the machines, which disrupts continuous operation and increases the need for calibration materials.
Innovation Solution
A calibration system and method that uses a conveyor, scanning system, and cutting device, where a calibration object is scanned and tracked to align the cutting device accurately, allowing for real-time calibration without stopping the machine, using a controller to store and apply calibration values based on digital images of the workpiece and calibration object, enabling precise cutting while the machine operates continuously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual calibration is performed by technicians, then cutting device alignment accuracy is improved, but machine downtime increases and productivity decreases
Solution Approach 1:
The calibration system enables the food processing machine to perform self-calibration automatically without requiring external technicians. The controller executes calibration routines using the calibration object and scanning system, allowing the machine to calibrate itself while maintaining operation, thus eliminating downtime associated with manual calibration while achieving precise alignment
Solution Approach 2:
The system performs calibration actions preliminarily by using a calibration object with known dimensions and features before actual food processing begins. The calibration routine establishes reference measurements and alignment parameters in advance, ensuring cutting device accuracy is pre-established without interrupting production schedules
2Manufacturing precision
If manual calibration is performed, then cutting device alignment is achieved, but calibration time increases and efficiency decreases
Solution Approach 1:
The system replaces manual mechanical calibration procedures with an automated optical measurement system. The scanning system captures images of the calibration object, and the controller automatically processes these images to determine alignment parameters, eliminating the time-consuming manual measurement and adjustment process while maintaining high precision
Solution Approach 2:
The system uses a digital copy or representation of the calibration object through scanning and image processing. Instead of physical manual measurement, the controller creates a digital model of the calibration object's position and dimensions, enabling rapid computational analysis and alignment determination without physical intervention
3Productivity
If continuous operation is maintained, then productivity is improved, but calibration accuracy may deteriorate due to machine drift
Solution Approach 1:
The system implements continuous feedback through the scanning system that monitors the calibration object's position and the cutting device's alignment in real-time during operation. The controller receives ongoing measurements and adjusts alignment parameters dynamically, compensating for machine drift while maintaining continuous production without interrupting operation
Data Source
AI summary
A calibration system for a food processing machine has a conveyor for conveying a workpiece, scanning system for scanning the workpiece and creating a digital image of the workpiece, and a cutting device downstream from the scanning system for cutting the workpiece. A calibration object is conveyed through the food processing machine by the conveyor and scanned. A controller, with a memory, is in communication with the cutting device and the conveyor such that the controller can track position of the cutting device as the cutting device is moved into alignment with the calibration object and store calibration values on the memory corresponding to the movement of the cutting device into alignment with the calibration object. The controller is configured to calibrate movement of the cutting device relative to the workpiece based on the digital image of the workpiece and the calibration values to thereafter accurately cut the workpiece.