Screw Conveyor Biscuit Batch Grouping

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Solution Overview

Problem

Existing methods and apparatuses for grouping discrete laminar articles like biscuits into batches of predetermined count face issues such as miscount due to varying biscuit thickness, breakage, and inefficiencies in handling, leading to non-uniform batches and increased complexity and cost.

Innovation Solution

An apparatus featuring a feed conveyor with synchronized left-hand and right-hand screws, a platform assembly, and a pusher mechanism, controlled by a servo-motor and rotary encoder, which automates the counting and transfer of biscuits into batches, ensuring precise formation and handling without damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If prior-art methods and apparatuses are used for grouping biscuits into batches, then batching operation can be performed, but miscount occurs due to variation in biscuit thickness resulting in non-uniform batch sizes

Engineering Contradiction:

Improvebatch size uniformityVSAvoidbiscuit counting accuracy

Core Design Contradiction:

Manufacturing precisionVSMeasurement precision

Solution Approach 1:

The patent replaces complex mechanical counting mechanisms with a servo-motor controlled system that uses rotary encoders to precisely control the rotation of left-hand and right-hand screws. This electronic control system accurately positions and counts biscuits regardless of thickness variations, eliminating miscounting issues while maintaining uniform batch sizes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the control parameter from mechanical force-based counting to precision rotation control. By using servo-motors to control the rotation angle and speed of the screws, the system can accurately dispense a predetermined number of biscuits into batches, ensuring consistent batch sizes despite variations in individual biscuit thickness.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If existing apparatuses are used for forming and transferring batches, then batching operation can be performed, but breakage or crushing of biscuits occurs due to shearing action during handling

Engineering Contradiction:

Improvebatch formation speedVSAvoidbiscuit breakage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a specially designed pusher mechanism that acts as an intermediary between the screw conveyor and the batch formation area. This pusher gently pushes the counted biscuits forward without applying excessive force, and the platform assembly provides a stable surface that prevents crushing during transfer, thereby maintaining biscuit integrity while enabling efficient batch formation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system uses synchronized rotation of left-hand and right-hand screws that can dynamically adjust their operation. The servo-motor control allows the screws to rotate at controlled speeds and stop precisely when the predetermined batch count is achieved, enabling rapid batch formation while the dynamic control prevents excessive force that could cause breakage.

Inventive Principle:

Principle #15Dynamics

3Object-affected harmful factors

If pressure-less feeders are used to restrain damage to biscuits, then biscuit breakage is reduced, but the apparatus becomes complicated and expensive

Engineering Contradiction:

Improvebiscuit breakageVSAvoidapparatus complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent extracts the essential function of pressure-less handling from complex existing feeders and implements it through a simplified mechanism. The pusher mechanism applies minimal, controlled pressure only when needed to move biscuits, while the majority of the handling process relies on gravity and the natural flow of biscuits along the conveyor, achieving damage reduction without the complexity of full pressure-less feeder systems.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention uses simple, inexpensive components such as basic screw conveyors, a straightforward pusher mechanism, and standard servo-motor/encoder assemblies rather than expensive specialized pressure-less feeder systems. These simpler components achieve the same protective function at lower cost and with reduced complexity.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Data Source

PatentUS8286408B2Method and an apparatus for grouping discrete laminar articles into batches of predetermined count

Publication Date: 2012.10.16 PARLE PRODS PRIVATE

AI summary

An apparatus for grouping discrete laminar articles (hereinafter referred to as articles) into batches of predetermined count includes a feed conveyor, a left-hand screw and a right-hand screw combination (hereinafter referred to as screws), a means for synchronizing and automating starting and stopping rotation of the screws and a platform assembly. The platform assembly is connected to the feed conveyor and includes a hatch and a pusher mechanism. The feed conveyor supports articles disposed thereon. The screws are disposed along edges of and at either side of the feed conveyor and are adapted to rotate to facilitate counting and pushing of the articles. The screws stop rotating and thereby stop further pushing of the articles, when a predetermined count of articles has been pushed. The pusher mechanism receives the predetermined count of articles pushed by screws and moves them to the hatch from where they are dropped into delivery line.