Servo Knockout Assembly Using Direct Servo Drive for Food Forming
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Solution Overview
Problem
Existing food forming machinery relies on complex hydraulic systems and gear drives, which are costly, require frequent maintenance, and have numerous wear components, making them inefficient and difficult to maintain.
Innovation Solution
An electrical servo knockout assembly using a rotary servo motor to drive knockout cups, reducing the number of components and simplifying maintenance by using a coupling mechanism that eliminates the need for overhead cams or hydraulics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If hydraulic systems or complex gear drives are used to provide sufficient force for food forming, then the required force is achieved, but the device complexity and maintenance requirements increase significantly
Solution Approach 1:
The patent replaces complex mechanical systems (hydraulic systems, gear drives, cams) with a direct servo motor-driven knockout cup assembly. The servo motor provides precise control and sufficient knockout force through direct or gearless connection, eliminating the need for intermediate mechanical transmission components and significantly reducing system complexity.
Solution Approach 2:
The patent extracts and removes the complex intermediate mechanical components (hydraulic systems, gear drives, cams, shafts) from the knockout assembly, retaining only the essential servo motor and knockout cup components. This extraction simplifies the overall system while maintaining the required knockout functionality.
2Force
If complex gear drives with multiple components are used, then sufficient knockout force is achieved, but the number of wear components increases leading to frequent maintenance
Solution Approach 1:
The servo motor-driven system replaces mechanical systems with moving mechanical parts that subject to wear (gears, cams, shafts). The servo motor provides the required force through electromagnetic conversion without intermediate mechanical transmission, eliminating wear components and significantly improving reliability and reducing maintenance frequency.
Solution Approach 2:
The patent employs a design where the knockout cup can be easily replaced as a consumable component, while the main servo motor assembly remains durable and maintenance-free. This approach treats the knockout cup as a disposable or easily replaceable part, simplifying the overall maintenance strategy.
3Ease of operation
If overhead cams or hydraulic systems are installed, then knockout functionality is achieved, but component replacement becomes difficult and time-consuming
Solution Approach 1:
The knockout assembly is segmented into modular components: the servo motor, the knockout cup, and the mounting structure. This segmentation allows the knockout cup to be independently removed and replaced without affecting the servo motor or other components, significantly improving ease of repair and maintenance.
Solution Approach 2:
The patent extracts the knockout cup as a separate, independently replaceable component from the integrated mechanical systems of prior art. This extraction eliminates the need to disassemble complex overhead cams or hydraulic systems for component replacement, as the knockout cup can be accessed and replaced directly.
4Productivity
If rapid repetitive cycles are required for food forming, then productivity increases, but the mechanical stress on components increases leading to wear
Solution Approach 1:
The servo motor replaces mechanical transmission systems that would be subject to wear from rapid repetitive cycling. The direct electromagnetic drive of the servo motor has no mechanical wear components, allowing rapid repetitive cycles to be performed without degrading component durability through friction and mechanical stress.
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
The servo motor-based assembly significantly reduces maintenance frequency and cost by minimizing wear components, enabling rapid and repetitive cycles for food forming, and facilitating easy component replacement.
Implementation Method 1
an electrical rotary servo motor
Data Source
AI summary
Systems and methods for a food processing are provided. A food processing knockout assembly includes: a motor; a crank arm connected to the motor and configured to be rotated by the motor, around an axis that passes through the crank arm; a connecting arm connected to the crank arm and configured to move in a vertical direction in response to rotation of the crank arm; a beam connected to the connecting arm and configured to move in the vertical direction in response to movement of the connecting arm in the vertical direction; and at least one knockout shaft connected to the beam, at one end of the at least one knockout shaft, and configured to move in the vertical direction in response to movement of the beam in the vertical direction.