Servo Plate Forming Machine for High-Speed Meat Integrity
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Solution Overview
Problem
Existing food product molding machines face challenges in high-speed production, product integrity, leakage, and maintenance complexity, particularly in forming hamburger patties and other food products, leading to inefficiencies and product waste.
Innovation Solution
A servo-driven plate forming machine with a one-piece hopper, servo-proportional hydraulics, and closed-loop controls, featuring fewer moving parts, improved leakage control, and enhanced maintenance access, which uses spiral screws to trap meat and maintain whole muscle integrity, and includes configurable breathing slots for precise cavity filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional feed pumps are used to force meat through to the plunger and pump box, then high-speed production is achieved, but product integrity deteriorates due to damage to cellular structure
Solution Approach 1:
The patent removes the feed pump component from the system entirely. Instead of using a pump to force meat through, the design uses gravity-fed hoppers and spiral augers to transport meat to the molding cavity, eliminating the mechanical damage caused by pump forcing while maintaining production speed
Solution Approach 2:
The patent introduces spiral augers as an intermediary mechanism between the hopper and molding cavity. These augers gently convey meat using rotational motion rather than forced pumping, preserving cellular structure while enabling controlled feeding at high speeds
2Adaptability or versatility
If multiple piece hoppers are used in existing designs, then assembly flexibility is improved, but leakage increases and cleanliness deteriorates
Solution Approach 1:
The patent merges multiple separate hopper pieces into a single monolithic hopper structure. This eliminates the joints and seals between pieces that cause leakage, while the internal geometry can still be configured for different assembly arrangements. The unified structure also improves cleanliness by removing crevices where food particles can accumulate
Solution Approach 2:
The single hopper design incorporates universal features that allow it to serve multiple functions and configurations. The hopper can be oriented and connected in various arrangements while maintaining its leak-free structure, providing assembly flexibility without requiring multiple specialized pieces with sealing interfaces
3Power
If conventional hydraulic systems are used, then power delivery is achieved, but device complexity increases due to numerous moving wear components
Solution Approach 1:
The patent replaces conventional hydraulic systems with a direct mechanical drive system using servo motors and gearboxes. This substitution eliminates hydraulic pumps, valves, hoses, and associated sealing components, reducing the number of moving parts and wear points while maintaining precise power delivery and control
Solution Approach 2:
The patent combines multiple drive functions into integrated mechanical units. The servo-driven system merges positioning, speed control, and power delivery into a single coordinated mechanism, eliminating the need for separate hydraulic control systems and reducing overall device complexity
4Reliability
If traditional molding machines operate at lower speeds, then product quality is maintained, but productivity is reduced
Solution Approach 1:
The patent implements continuous feeding and molding operations without interruption. The gravity-fed hoppers provide constant material supply, while the servo-driven system maintains continuous cycling at high speeds. This continuous action enables faster production while quality control systems ensure consistent product standards throughout the process
Solution Approach 2:
The patent uses dynamically controllable servo motors that can adjust speed and force in real-time. This dynamic control allows the system to operate at high speeds while maintaining optimal pressing force and timing for product quality. The system can adapt its motion profile for each cycle to preserve whole muscle integrity even at 120 strokes per minute
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 machine achieves up to 33% higher throughput, 120 strokes per minute, reduced product damage, and improved cleanliness, with 70% fewer moving parts, ensuring consistent product quality and reduced waste.
Implementation Method 1
a single hydraulic pump combined with proportional hydraulic valves with closed and open loop controls
Implementation Method 2
a user can control pressure of meat in the pump box and mold plate and get closed loop feedback of pressure
Implementation Method 3
the present invention traps meat between flutes of spiral screws and the sides of a cylindrical chamber, then push the meat into the plunger chamber
Implementation Method 4
a servo-driven plate forming machine designed to operate at (120) 10′′ strokes per minute normal operation
Implementation Method 5
pneumatically activated seal to stop leaks between mold cover, receiver and pump box
Data Source
AI summary
A servo-driven plate forming machine comprising: a mold plate that operates at (120) 10″ strokes per minute; a single hydraulic pump combined with proportional hydraulic valves with closed and open loop controls; individually controlled feed screws to control whole muscle integrity and retain particle definition; and a one piece hopper that assists in providing a substantially leak proof feed.