Rotary molding system
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Solution Overview
Problem
Existing rotary molding systems for food patty formation face challenges in efficiently and cost-effectively molding food products due to the high expense and maintenance requirements of the fill plate, as well as wear and tear issues with the wear plate, which affect the system's operational efficiency and productivity.
Innovation Solution
The rotary molding system incorporates a fill plate with strategically aligned holes, a cylindrical drum with mold cavities, and a platen with roller supports, along with a stripper plate that moves reciprocally to manage food product flow and air release, while the wear plate is designed for easy replacement to mitigate wear and maintenance costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a traditional fill plate with multiple holes is used for food product deposition, then food product can be efficiently distributed to mold cavities, but the fill plate becomes expensive and requires frequent maintenance
Solution Approach 1:
The patent replaces the expensive, maintenance-intensive fill plate with a disposable wear plate that has a simple hole pattern. The wear plate can be easily replaced when worn, eliminating the need for costly repairs or replacement of the entire fill plate assembly. This disposable approach maintains productivity while reducing manufacturing costs and maintenance requirements.
Solution Approach 2:
The patent separates the fill plate functionality into two distinct components: a permanent fill plate with a specific hole pattern and a replaceable wear plate with matching holes. This segmentation allows the wear plate to be independently replaced when degraded, protecting the investment in the main fill plate structure and reducing overall maintenance costs.
2Reliability
If a wear plate is used to protect the fill plate, then component longevity is improved, but the wear plate itself is subject to wear and requires replacement
Solution Approach 1:
The wear plate is designed as a low-cost, disposable component that protects the expensive fill plate. When the wear plate becomes worn, it is simply replaced rather than repaired, minimizing downtime and maintenance complexity. The simplicity of the wear plate design makes it inexpensive to manufacture and quick to install.
Solution Approach 2:
The wear plate replicates the hole pattern and basic structure of the fill plate, allowing it to perform the same food product deposition function temporarily. This copying approach enables the wear plate to protect the original fill plate while maintaining system functionality throughout the wear plate's service life.
3Manufacturing precision
If the stripper plate moves reciprocally to manage food product flow, then molding precision is improved, but the system complexity increases
Solution Approach 1:
The stripper plate is designed to move reciprocally between two positions: a first position where it allows food product to pass through to the mold cavities, and a second position where it blocks food product flow. This dynamic positioning enables precise control over food product deposition timing and location, improving molding precision while using a simple mechanical movement mechanism.
Data Source
AI summary
A rotary molding system for use in a patty forming machine and configured to mold food products and a fill plate for use within the rotary molding system are provided. A replaceable wear plate is provided which seats between a reciprocating stripper plate and a fill plate. Each plate has holes through which food product passes. A drum having mold cavities receives the food product from the fill plate.