Pickling machine with detection device

Solution Overview

Problem

Existing pickling machines fail to reliably detect damaged or broken needles during the injection process, leading to potential health risks for consumers and significant financial losses due to undetected needle pieces being left in pickled products.

Innovation Solution

A pickling machine equipped with a detection device featuring sensors that measure the movement of needles relative to the sensor, allowing for immediate detection of blocked, damaged, or broken needles, with each needle associated with a sensor to ensure quick identification and automatic stop of the machine when defects are detected, reducing downtime and rejects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional detection devices are used to examine pickled product after injection, then needle breakage can be detected in some cases, but small broken-off needle pieces or pieces near bones are not detected, leading to health risks for consumers

Engineering Contradiction:

Improvedetection reliabilityVSAvoidhealth risk from undetected needle pieces

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces conventional mechanical/optical detection devices with a sensor-based detection system that measures the position and movement of needles during the injection process. This substitution enables detection of needle breakage at the source rather than relying on post-injection examination, significantly improving detection reliability and eliminating the harmful effect of undetected needle pieces in food products.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The detection device performs preliminary detection of needle integrity during the injection process itself, before the pickled product leaves the processing area. By detecting needle breakage immediately when it occurs and stopping the machine, the system prevents contaminated products from being distributed, thereby eliminating the health risk associated with delayed detection.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If detection devices examine pickled product after injection, then needle breaks can be identified, but there is a time interval delay causing considerable batches of products to be removed or recalled

Engineering Contradiction:

Improveneedle defect detectionVSAvoidtime interval between breaking and detection

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The sensor-based detection system performs preliminary detection of needle integrity during the injection process itself, before the pickled product leaves the processing area. By detecting needle breakage immediately when it occurs and stopping the machine, the system prevents contaminated products from being distributed, thereby eliminating the health risk associated with delayed detection.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The detection device provides real-time feedback about needle integrity during the injection process. When a needle breakage is detected, the system immediately provides feedback to stop the machine, creating a closed-loop control system that eliminates time delays and prevents further production of contaminated products.

Inventive Principle:

Principle #23Feedback

3Reliability

If conventional detection methods are used, then needle breaks are detected with delay, but immediate detection of impending needle damage such as cracks or deformations cannot be achieved

Engineering Contradiction:

Improveneedle damage detectionVSAvoidresponse time for needle replacement

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The detection device provides real-time feedback about needle integrity during the injection process. When a needle breakage is detected, the system immediately provides feedback to stop the machine, creating a closed-loop control system that eliminates time delays and prevents further production of contaminated products.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The sensor-based detection system performs preliminary detection of needle integrity during the injection process itself, before the pickled product leaves the processing area. By detecting needle breakage immediately when it occurs and stopping the machine, the system prevents contaminated products from being distributed, thereby eliminating the health risk associated with delayed detection.

Inventive Principle:

Principle #10Preliminary action

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 solution ensures reliable detection of even small needle pieces, preventing contaminated products from reaching consumers and minimizing financial losses by immediately stopping the machine upon detecting damage, thus reducing the risk of product recalls and maintaining product quality.

Implementation Method 1

the at least one sensor is arranged in a hold-down plate of the pickling machine that serves to hold down the pickled product when the needles are being pulled out

Methodology Applied

Scientific EffectInductive sensing: Electromagnetic Induction

Implementation Method 2

using inductive, capacitive, or optical sensors arranged in the hold-down plate

Methodology Applied

Scientific EffectCapacitive sensing: Capacitance

Implementation Method 3

using inductive, capacitive, or optical sensors arranged in the hold-down plate

Methodology Applied

Scientific EffectOptical sensing: Light

Data Source

PatentUS10602750B2Pickling machine with detection device

Publication Date: 2020.03.31 GUNTHER MASCHENBAU

AI summary

The invention relates to a pickling machine comprising a detection device for detecting if a needle is blocked, damaged and/or broken.