Needle Cleaning via Reverse Flow Pneumatics
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Solution Overview
Problem
The existing methods for cleaning needles used for injecting fluids into meat products, such as brine, are time-consuming and unproductive, requiring needles to be detached and soaked in cleaning solutions for extended periods.
Innovation Solution
A method and machine that uses a series of steps involving pressurized cleaning solutions, gases, and washing liquids to clean needles within an airtight vessel, ensuring thorough cleaning and efficient reuse by forcing solutions through the needles' outlet ports and inlet openings, with a machine design that includes support bases, ducts, and valves for controlled fluid passage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If needles are detached and soaked in cleaning solution for extended periods, then cleaning thoroughness is improved, but productivity and cleaning speed deteriorate
Solution Approach 1:
The patent uses pressurized gas (pneumatic) to force cleaning solution through the needles in reverse flow direction, and subsequently uses pressurized gas to blow dry the needles. This pneumatic-hydraulic combination enables rapid yet thorough cleaning and drying within seconds, eliminating the need for extended soaking periods while maintaining cleaning effectiveness.
Solution Approach 2:
The patent reverses the normal flow direction by forcing cleaning solution to enter through outlet ports and exit through inlet openings. This reverse flow approach allows cleaning solution to effectively reach and flush out contaminants from the inner duct and outlet ports, achieving thorough cleaning in a short time without extended soaking.
2Productivity
If needles remain attached to injection head during cleaning, then operational continuity is improved, but cleaning effectiveness deteriorates
Solution Approach 1:
The patent divides the cleaning process into distinct functional zones within a single integrated device: a container for holding cleaning solution, a support base for positioning needles, and separate pathways for cleaning solution flow and gas flow. This segmentation allows effective cleaning to be achieved while needles remain attached, maintaining operational continuity.
Solution Approach 2:
The use of pressurized fluid flow and pressurized gas circulation enables effective cleaning action to be delivered to all needle surfaces and internal passages while needles remain in place, eliminating the need to detach them for cleaning effectiveness.
3Ease of operation
If cleaning process is simplified, then operational ease is improved, but cleaning thoroughness deteriorates
Solution Approach 1:
The patent employs automatic circulation systems where a pump draws cleaning solution from the container, pressurizes it, and forces it through the needles. The system then automatically draws the used solution back and recirculates it. Pressurized gas automatically blows dry the needles. This self-service automation maintains cleaning thoroughness while simplifying operator intervention to minimal monitoring.
Solution Approach 2:
The integrated use of hydraulic (pressurized liquid) and pneumatic (pressurized gas) systems within a single device provides both thorough cleaning and drying functions through automated fluid circulation, achieving comprehensive cleaning without complex manual procedures.
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
This approach significantly reduces cleaning time and increases productivity by ensuring thorough cleaning of needles, allowing for quicker reuse and improved operational efficiency in meat processing.
Implementation Method 1
feeding a pressurized cleaning solution, such as caustic soda, into said container so as to force said cleaning solution to penetrate through the outlet ports, pass through the inner duct and then exit through the upper inlet opening
Implementation Method 2
feeding a pressurized gas, such as air, into said container so as to force said gas to penetrate through the outlet ports, pass through the inner duct and then exit through the upper inlet opening, and from there outwards, in order to eject any cleaning solution that might remain inside the needles
Implementation Method 3
feeding a pressurized washing liquid, such as water, into said container so as to force said cleaning solution to penetrate through the outlet ports, pass through the inner duct and then exit through the upper inlet opening, and from there outwards, so that the washing liquid washes the inner duct and the holes of the needles
Data Source
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AI summary
The method consists of forcing a cleaning solution, such as caustic soda, through an inner passage of the needles (40), then injecting pressurized air into said needles, and afterwards flushing pressurized water through the inside of the needles. The machine comprises upper and lower compartments (2, 3) separated by a tray (6), and a tank (4) for the cleaning solution. The tray (6) supports the needles to be cleaned, such that a lower portion thereof is inside a number of containers (17) from which said needles (40) receive said cleaning solution driven by a pump (29), the pressurized air (23) and the washing water (25), through ducts (19, 21, 23, 25, 27) provided with valves (20, 24, 26, 28) in communication with the containers (17). The tray (6) collects the fluids coming out of the upper holes of the needles (40).