Servo Driven Ice Cream Sandwich Assembly Machine

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Solution Overview

Problem

Existing ice cream sandwich-making machines face mechanical failures due to complex drivetrain systems with multiple motors, gearboxes, and belts, leading to maintenance challenges, limited adjustability, and reduced production efficiency.

Innovation Solution

The apparatus employs a modular design with servo motors and linear actuators to drive each station, coordinated by a programmable logic controller (PLC), allowing for easier maintenance, adjustability, and increased production rates by simplifying the drivetrain and enabling precise control of each component.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a combination of AC motor and gearbox with multiple belts, chains, and shafts is used to drive components, then the machine can achieve complex motions and timing of components, but the device complexity increases and mechanical failures occur more frequently

Engineering Contradiction:

Improvemotions and timing of componentsVSAvoiddrivetrain system

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent replaces the complex mechanical drivetrain system (AC motor, gearbox, belts, chains, shafts) with a servo motor system that uses electronic control and feedback mechanisms. Each station has its own servo motor with encoder feedback, controlled by a PLC, eliminating the need for mechanical power transmission elements and reducing device complexity while maintaining motion control capability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent divides the drivetrain system into independent servo-driven stations, where each station (wafer feeder, extruder, indexing wheel, conveyor, wrapping station) has its own servo motor. This segmentation allows independent control of each component without requiring a complex interconnected mechanical drivetrain, reducing overall system complexity

Inventive Principle:

Principle #1Segmentation

2Stability of the object's composition

If a complex mechanical drivetrain with multiple components is used, then the machine can provide fixed motions and timing, but maintenance becomes more difficult and downtime increases

Engineering Contradiction:

Improvemotions and timing of componentsVSAvoidmaintenance of drivetrain

Core Design Contradiction:

Stability of the object's compositionVSEase of repair

Solution Approach 1:

The patent replaces the mechanical drivetrain with servo motors that have built-in feedback and control electronics. This substitution eliminates wear-prone mechanical components (belts, chains, gears) and replaces them with electronically controlled systems that require minimal maintenance and can be easily diagnosed and repaired through software updates or component replacement

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The servo motors include built-in feedback mechanisms (encoders) and self-diagnostic capabilities that allow the system to monitor its own operation and detect issues before they lead to failures. The PLC controller can identify problematic components and guide maintenance personnel through repair procedures, reducing downtime

Inventive Principle:

Principle #25Self-service

3Adaptability or versatility

If mechanical components and settings are used for different sandwich sizes, then the machine can be adjusted manually, but substantial downtime is required for reconfiguration

Engineering Contradiction:

Improveproduction of various sandwich sizesVSAvoiddowntime for reconfiguration

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The patent implements dynamic, programmable control through servo motors and PLC that can be reconfigured via software for different sandwich sizes. Instead of manual mechanical adjustments, the system uses digital programming to change motion parameters, speeds, and timing for each station, allowing rapid reconfiguration without physical reassembly or manual adjustment of mechanical components

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes operational parameters (speed, position, timing) through software control of servo motors rather than physical reconfiguration of mechanical components. This allows different sandwich sizes to be produced by modifying control parameters in the PLC program, eliminating downtime associated with manual reassembly and adjustment of mechanical drivetrain components

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11477993B2Servo driven ice cream sandwich assembly and wrapping machine

Publication Date: 2022.10.25 INTERBAKE FOODS LLC

AI summary

An apparatus for the preparation of comestible-containing sandwich products comprises a sandwich product assembly station and corresponding means for the fabrication and assembly of a sandwich product in the vertical direction. The apparatus includes an extruder nozzle, wafer trays and corresponding components for the location of wafers on opposite sides of the extruded product, an indexing wheel for receiving the assembled sandwich product, and sandwich transporting means for moving the sandwich to a wrapping assembly and from there to a discharge end, wherein all of the components of the apparatus are mounted in cantilevered fashion on a vertical support or base member. Each element is powered individually by a servo motor or actuator and controlled by a controller allowing the variability of throughput for each station.