Plunger Stroke Control for Single-Compression Food Filling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing canning systems compress food items multiple times before they are placed in containers, leading to compromised texture and appearance, and reduced ability to absorb liquids, due to excess foodstuff accumulation in the compression chamber.
Innovation Solution
An apparatus with a control system and linear displacement measurement device that precisely controls the plunger's movement to minimize leftover foodstuff in the compression chamber, ensuring only a single compression stroke is used for filling, using a brushless linear actuator and magnetic sensor for accurate positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the plunger is used to transfer foodstuff into the compression chamber, then the foodstuff is compressed to fill the cavities, but the foodstuff is compressed multiple times which compromises its texture and appearance
Solution Approach 1:
The system dynamically adjusts the plunger stroke length based on real-time monitoring of foodstuff accumulation in the compression chamber. The control system varies the compression distance to ensure that foodstuff is compressed only once or minimally, rather than being repeatedly compressed in fixed cycles. This dynamic adjustment resolves the contradiction by maintaining filling efficiency while eliminating excessive compression damage to the foodstuff.
Solution Approach 2:
A monitoring system continuously tracks the amount of foodstuff remaining in the compression chamber after each filling cycle. This feedback information is used by the control system to adjust the plunger stroke length for the next cycle, preventing over-compression. The feedback mechanism ensures that only the necessary amount of foodstuff is compressed, resolving the contradiction between maintaining productivity and avoiding harmful multiple compressions.
2Quantity of substance
If excess foodstuff is loaded into the compression chamber to ensure sufficient material for filling, then filling requirements are met, but leftover foodstuff accumulates and requires multiple compression cycles
Solution Approach 1:
The plunger stroke length is dynamically adjusted based on the actual amount of foodstuff loaded into the compression chamber. When less foodstuff is loaded, the plunger travels a shorter distance, and when more is loaded, it travels farther. This dynamic adjustment ensures that all foodstuff is utilized in a single compression cycle without accumulation, resolving the contradiction between maintaining sufficient quantity and avoiding repeated compression of leftovers.
Solution Approach 2:
The system changes the compression parameter (plunger stroke length) based on the quantity of foodstuff present in the compression chamber. By varying this parameter dynamically, the system ensures that the compression distance matches the actual amount of material, preventing accumulation and multiple compressions while maintaining adequate foodstuff quantity for complete filling.
3Manufacturing precision
If the plunger compresses foodstuff repeatedly to ensure complete filling of cavities, then filling completeness is achieved, but the natural appearance and liquid absorption ability of the foodstuff are compromised
Solution Approach 1:
The plunger stroke length is dynamically optimized to achieve complete filling of cavities in a single or minimal number of compressions. The control system monitors the filling process and adjusts the compression distance to match the cavity requirements exactly, preventing the need for repeated compressions that would damage the foodstuff texture and appearance while ensuring complete filling.
Solution Approach 2:
Instead of applying full compression repeatedly, the system applies a precisely controlled partial compression that is sufficient for complete filling. By calculating the exact stroke length needed based on cavity volume and foodstuff properties, the system achieves complete filling with minimal compression action, preserving the foodstuff's natural characteristics while ensuring filling completeness.
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 ensures that food items are minimally compressed, maintaining their natural texture and appearance, and improving their ability to absorb liquids, by optimizing the amount of foodstuff transferred into cans with each cycle.
Implementation Method 1
a linear displacement measurement device extending along the direction of travel of the plunger; and a sensor mounted to travel with the plunger to produce an output signal corresponding to the location of the plunger
Implementation Method 2
The plunger is powered by a brushless linear actuator wherein the travel of the plunger and/or the force imposed on the plunger by the linear actuator can be monitored and controlled
Data Source
AI summary
An infeed chamber or channel 12 receives fish fillets 17 from a conveyor belt 13 of an infeed system 14. A plunger 16 pushes the fish 17 upwardly from the infeed channel 12 into an upper compression chamber 18 which includes one or more cavities or lobes 20 into which the fish is pushed by the plunger 16 thereby to fill the lobes 20. Pistons 28 are advanced into the lobes to eject the formed fish cakes 24 out of the lobes and into container cans 30. The end position of the plunger 16 is monitored and measured, and the control system utilizes this information to operate the feed system wherein the fish fillets 17 are loaded into the infeed chamber. In this manner, the volume of fish 17 loaded into the infeed chamber can be controlled so that at the end of the plunger stroke, only a minimum amount of fish 17 remains within the compression chamber 18, thereby avoiding the residual fish 17 to be compressed more than twice.