Automated Ice Cream Stick Insertion Device with Sensor Feedback
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Solution Overview
Problem
Existing stick insertion devices for ice cream products lack sensors for monitoring stick insertion, cannot vary stroke length, and require manual adjustment, leading to waste due to products being made outside of tolerances and lack of automation.
Innovation Solution
A stick insertion device equipped with sensors to measure stick position, angle, and depth, connected to a control unit and servo mechanism, allowing for automated adjustment of stroke length and insertion parameters to maintain tolerance within desired insertion depth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual adjustment is used to vary stroke length and insertion angle, then the device can be operated with simple mechanical components, but production efficiency decreases and requires operator presence during production
Solution Approach 1:
The system performs self-adjustment through automated feedback control. Sensors monitor stick insertion parameters and the control unit automatically adjusts stroke length and timing without operator intervention, enabling the system to service itself and maintain optimal performance continuously
Solution Approach 2:
Manual mechanical adjustment is replaced with an automated control system comprising sensors, a control unit, and a servo mechanism. This substitution eliminates the need for operators to manually adjust settings while maintaining precise control over insertion parameters
2Device complexity
If no sensors are used for monitoring stick insertion, then the device structure remains simple, but waste is generated due to products being made outside of tolerances
Solution Approach 1:
Sensors continuously monitor stick insertion parameters including position, angle, and depth. This feedback is transmitted to the control unit which compares measurements against tolerance specifications and automatically adjusts the servo mechanism to correct any deviations, ensuring products remain within tolerances and preventing waste
Solution Approach 2:
Manual inspection and adjustment processes are replaced with automated sensor-based monitoring and control. The sensor system detects insertion parameters and the control unit automatically compensates for variations, eliminating the need for manual intervention while preventing defective products
3Device complexity
If stroke length cannot be varied, then the mechanical structure remains simple, but insertion depth precision decreases and products are made outside of tolerances
Solution Approach 1:
The stroke length is made dynamically adjustable through the servo mechanism controlled by the control unit. The system can vary stroke length in real-time based on feedback from sensors, allowing precise control of insertion depth for different product specifications while maintaining a relatively simple base mechanical structure
Solution Approach 2:
The control unit dynamically changes the stroke length parameter based on sensor feedback and product requirements. By adjusting this key parameter, the system achieves precise insertion depth control without requiring complex mechanical adjustment mechanisms, maintaining simplicity while improving precision
4Device complexity
If manual adjustment by operator is required, then the device can use simple control mechanisms, but the operation requires specialized knowledge and experience
Solution Approach 1:
The control system performs self-adjustment based on sensor feedback without requiring operator expertise. The automated control unit interprets sensor data and makes necessary adjustments to stroke length and timing, eliminating the need for operators to possess specialized knowledge while maintaining simple control mechanisms
Data Source
AI summary
A method for inserting a stick into an ice cream product with a stick pusher, the stick pusher including an actuator for linear and reciprocating movement, a control unit controlling the actuator, a sensor for measuring at least one of: the stick's position in relation to the ice cream product's height, horizontal position in relation to the product's end point, and angle in relation to the product's end point, where the control unit is connected to the sensor, the method including, at a start time, pushing a stick into an ice cream product to a stick position by accelerating the stick pusher in a first direction from a starting position, deaccelerating the stick pusher to a speed equal to zero and moving the stick pusher to the starting position, where the control unit controls the stick pusher's start time based on measurements from the at least one sensor.