Maglev Carrier Handling for Accurate Food Part Batching
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Solution Overview
Problem
Conventional food processing systems introduce errors in assembling and processing food parts due to variations in object characteristics, such as size and weight, leading to inefficiencies and inaccuracies in packaging and further processing.
Innovation Solution
A food processing system utilizing planar motors to create a magnetic levitation conveyor system that supports independently movable carriers, which assess and align food parts based on characteristics like weight and type, optimizing their assembly and movement to meet desired processing criteria.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional processing techniques are used to assemble and process food parts, then the system can handle various food items, but errors are introduced into the processing system due to variations in object characteristics
Solution Approach 1:
The patent replaces conventional mechanical conveyor systems with a magnetic field-based planar motor system. The planar motors use magnetic fields to levitate and position carriers, eliminating mechanical contact that causes errors. This substitution of mechanical systems with electromagnetic fields directly addresses the reliability and precision problems described in the contradiction.
Solution Approach 2:
The system creates a digital representation of each food part's characteristics (weight, size, shape) and uses this information to plan and control the assembly process. By working with digital copies of object characteristics rather than physically manipulating varied objects directly, the system achieves consistent precision regardless of object variations.
2Productivity
If food parts are manually assembled and grouped, then flexibility in handling different food types is maintained, but efficiency and consistency in meeting batch weight criteria are reduced
Solution Approach 1:
The system continuously measures the weight and characteristics of food parts as they are added to carriers, comparing these measurements against target batch specifications. This real-time feedback allows the system to make precise adjustments to achieve accurate batch weights, significantly improving both productivity and measurement precision compared to manual assembly.
Solution Approach 2:
The system pre-plans the assembly sequence and carrier assignments based on predicted batch requirements before actual assembly begins. By performing preliminary calculations and arrangements, the system optimizes the assembly process to efficiently meet batch weight criteria while maintaining high productivity.
3Ease of operation
If conventional conveyors are used to move food parts, then the system structure is simple, but the ability to independently manipulate and orient carriers for precise processing is limited
Solution Approach 1:
The conveyor system is divided into multiple independent planar motor modules, each capable of independently controlling its assigned carrier. This segmentation allows precise manipulation of individual carriers while maintaining a relatively simple overall system architecture, as each module is a standardized unit that can be independently controlled.
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 enhances processing accuracy by minimizing batch weight deviations and improving efficiency through precise carrier manipulation and orientation, ensuring optimal packaging and further processing of food items.
Implementation Method 1
a plurality of planar motors forming a conveyor system, with the planar motors producing magnetic fields that levitate a plurality of independently movable carriers
Data Source
AI summary
A system and method for object processing using magnetic levitation includes moving carriers with drive magnets across an array of planar motors. Food items on the carriers are moved through processing steps. The system determines the weight of multiple food items and coordinates and arranges for the batching of food items totaling a desired weight from an assembly of available food items and presents the selected food items to an operator for further processing. The system moves the carriers to engage the food items with processing equipment, such as for attaching to poultry shackles, or for cutting by a filet machine.