Robotic Ingredient Processing System for Flexible Food Manufacturing
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Solution Overview
Problem
Traditional food manufacturing processes are labor-intensive, inflexible, and costly due to the need for extensive equipment and fixed layouts, leading to inefficiencies in ingredient processing and handling, particularly in large-scale production where inconsistent cooking profiles and cumbersome equipment handling become significant challenges.
Innovation Solution
A flexible processing system featuring moveable receptacles and processing devices, managed by a robotic transfer system that allows for various combinations and configurations, reducing the need for extensive piping and human intervention, and enabling scalable and automated food production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If large receptacles are used to increase throughput at the cooking/mixing phase, then productivity increases, but manufacturing precision deteriorates due to inconsistent cooking profiles across the receptacle
Solution Approach 1:
The system divides the cooking process into multiple smaller receptacles (e.g., four 500L receptacles instead of one 2000L receptacle) that can be processed in parallel. Each receptacle maintains consistent cooking profiles independently, while the overall system achieves high throughput through simultaneous processing of multiple segments.
2Reliability
If traditional fixed layouts with extensive piping are used, then reliability is improved through stable infrastructure, but device complexity increases due to the network of pipes, valves and pumps
Solution Approach 1:
The system removes the complex piping network, valves, and pumps from the traditional fixed layout. Receptacles are positioned on mobile platforms that can be moved directly to processing equipment, eliminating the need for extensive fixed infrastructure while maintaining reliable material transfer capabilities.
Solution Approach 2:
The system transitions from a static fixed layout to a dynamic configuration where receptacles on mobile platforms can be repositioned as needed. This allows the same infrastructure to adapt to different production requirements without requiring complex piping reconfiguration.
3Ease of operation
If manual ingredient loading is used, then ease of operation is improved through direct human control, but productivity deteriorates as loading takes 2-3 times the duration of the cooking phase
Solution Approach 1:
The system employs automated robotic arms and conveyors that perform ingredient loading without human intervention. The robotic systems automatically transfer ingredients from storage containers to receptacles, reducing loading time to a fraction of the cooking phase duration while maintaining operational control.
4Ease of operation
If platforms are built adjacent to receptacles for manual operation, then ease of operation is improved through worker access, but device complexity increases due to the requirement for extensive platforms
Solution Approach 1:
The system removes the need for fixed platforms by using mobile platforms with receptacles that can be moved to processing positions. Workers or robotic systems access the receptacles during loading/unloading phases, but no permanent platform infrastructure is required, significantly reducing device complexity.
Data Source
Figure 1
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Figure 4a~5
AI summary
An ingredient processing system, including: at least one moveable receptacle (5) including a lifting bracket (17); at least one moveable processing device (7); and a transfer system including at least one robotic arm (9) and a control system for controlling operation of the robotic arm (9); wherein: the robotic arm (9) includes an engagement tool (19), which is operable to selectively engage and release the lifting brackets (17), the robotic arm (9) is arranged to lift and move at least one receptacle (5) via the lifting bracket (17); the robotic arm (9) is arranged to move a least one processing device (7) from a storage location (35) to at least one receptacle (5); the processing device (7) is operable to process ingredients located within the receptacle (5); and the robotic arm (9) is arranged to remove the processing device (7) from the receptacle (9).