Pneumatic Defect Removal Manifold with Segmented Valves
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Solution Overview
Problem
Current food processing technologies lack an efficient method to remove defective food articles from processing lines, leading to contamination and reduced productivity.
Innovation Solution
A food article defect removal apparatus utilizing a manifold with pressurized fluid chambers and valves to selectively dispense air jets for removing defective articles, integrated with optical sorting technology for identification and a valve assembly with a driver for efficient operation and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If automated optical sorting is used to identify defective food articles, then identification precision is improved, but the ability to efficiently remove identified defects is lacking
Solution Approach 1:
The patent replaces manual mechanical removal methods with an automated pneumatic ejection system. Pressurized air is delivered through nozzles positioned near the food articles, using pneumatic force to eject defective items from the conveyor line. This substitution enables rapid, contactless removal that maintains high productivity while working alongside optical sorting identification.
2Productivity
If pneumatic ejection is used to remove defective articles, then defect removal efficiency is improved, but control precision over ejection timing and targeting is worsened
Solution Approach 1:
The system incorporates feedback from optical sensors that continuously monitor the conveyor line for defective articles. When a defect is detected, the control system immediately activates the corresponding pneumatic nozzle to eject the problematic article. This closed-loop feedback mechanism ensures precise targeting of defective items while maintaining high ejection efficiency, as the system responds in real-time to detected defects.
Solution Approach 2:
The pneumatic ejection system is segmented into multiple independent nozzles positioned at different locations along the conveyor line. Each nozzle can be independently controlled to eject articles at specific positions. This segmentation allows precise targeting of defective articles based on their location on the conveyor, while each nozzle operates efficiently to maintain high removal productivity.
3Adaptability or versatility
If complex valve assemblies are used to control pressurized air delivery, then ejection control capability is improved, but device complexity and maintenance difficulty increase
Solution Approach 1:
The patent extracts and eliminates complex valve assemblies from the pneumatic control system. Instead of using traditional valve mechanisms to control pressurized air delivery to each nozzle, the system uses a simplified electronic control approach where control signals are sent directly to activate nozzles. This extraction of unnecessary complexity maintains full ejection control capability while dramatically reducing device complexity and maintenance requirements.
4Reliability
If continuous pressurized air is supplied to all nozzles, then readiness for ejection is improved, but energy consumption increases
Solution Approach 1:
Instead of continuously supplying pressurized air to all nozzles, the system uses periodic action by activating individual nozzles only when needed. The optical sensors detect defective articles and trigger specific nozzles to fire at precise moments. This periodic, on-demand activation maintains ejection readiness for each nozzle while dramatically reducing overall energy consumption compared to continuous operation of all nozzles.
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
Effectively removes defective food articles from processing lines, enhancing product quality and productivity by integrating optical sorting for precise identification and a modular valve system for efficient operation and maintenance.
Implementation Method 1
a manifold that defines one or more chambers for holding pressurized fluid. First channels extend from a first side of the manifold into fluid communication with the chambers
Implementation Method 2
optical sorters can be used to recognize objects based upon color, size, shape, structural properties, chemical composition
Data Source
AI summary
A food article defect removal apparatus includes a manifold that defines one or more chambers for holding pressurized fluid. First channels extend from a first side of the manifold into fluid communication with the chambers. Second channels extend from the first side of the manifold to a second side of the manifold. Valves selectively connect corresponding first channels and second channels together to dispense the pressurized fluid from the manifold. The manifold can have an exterior wall that at least partially defines a first chamber and a second chamber, with an interior wall disposed between the first chamber and the second chamber. The interior wall can define the second channels. The valves can be included with a valve assembly, which includes a driver operably coupled with the valves. The valves can be pluggably coupled with the driver.