Frozen Block Separation With Elevator-Based Precision Cutting
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Solution Overview
Problem
Existing methods for separating frozen blocks, particularly frozen meat products, are inefficient, inaccurate, and unsafe, especially in the context of the pet food industry, where precise portioning is crucial for quality control.
Innovation Solution
A stainless steel apparatus with an elevator, cutting member, and human-machine interface (HMI) that elevates frozen blocks to a precise cutting height, uses a cutting member to slice portions, and moves them into a batch receptacle, allowing for accurate and consistent portioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual separation methods are used for frozen blocks, then operational simplicity is maintained, but manufacturing precision and productivity are insufficient
Solution Approach 1:
The apparatus segments the frozen block into precise portions using a cutting member that divides the block according to predetermined dimensions. The system separates the cutting function from the support function, with the cutting member independently positioned and actuated to achieve precise portioning while maintaining manageable system complexity through functional decomposition
Solution Approach 2:
The system replaces manual mechanical separation with an automated cutting mechanism. The cutting member is actuated by a drive mechanism that provides controlled motion, substituting human operation with automated mechanical systems that deliver consistent precision while reducing operational complexity through standardization
2Productivity
If automated cutting is implemented, then productivity is improved, but device complexity increases
Solution Approach 1:
The apparatus integrates multiple functions into a unified system: the support surface elevates and positions the frozen block, the cutting member performs separation, and the drive mechanism provides actuation. This multi-functional integration improves productivity by automating the entire separation process while managing complexity through functional consolidation rather than separate independent systems
Solution Approach 2:
The cutting member is designed to support the portion it cuts during the separation process, eliminating the need for additional support structures. The portion rests on the cutting member body during cutting and is then transferred to a batch receptacle, creating a self-sufficient cutting system that improves productivity without proportionally increasing complexity
3Manufacturing precision
If precise cutting height control is achieved, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The system incorporates sensors that detect the position of the frozen block and provide feedback to the control system. This feedback mechanism enables the drive mechanism to adjust the cutting member position dynamically, achieving precise cutting height control while managing complexity through automated closed-loop control rather than complex mechanical positioning systems
Solution Approach 2:
The support surface elevates the frozen block to the predetermined cutting height before the cutting operation begins. This preliminary positioning action ensures that when the cutting member actuates, the block is already at the correct height, achieving precision without requiring complex real-time adjustment mechanisms during the cutting process
Data Source
AI summary
A frozen block separation system is disclosed herein. An example system includes a product receptacle having an elevator and an opening configured to receive a frozen product in a stacked block format and elevate the frozen product to a cutting height, a cutting member positioned above the product receptacle, the cutting member configured to move perpendicularly to the frozen product and remove a portion of the frozen product when the frozen product is at the cutting height, and a first plate that is configured to move the portion in a first direction, from the cutting member into a batch enclosure.