Variable Speed Extrusion Cutter Head for Accurate Portion Placement
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Solution Overview
Problem
Existing extrusion portioning machines struggle with inconsistent cutting and placement of semi-viscous food products due to fixed cutting speed profiles, leading to inaccurate portioning and increased production costs, especially when dealing with varying materials like cookie dough with inclusions.
Innovation Solution
A programmable cutting head with variable speed profiles controlled by a servo motor and PLC, allowing for adjustable cutting velocities throughout the cutting cycle, synchronized with other machine functions to enhance accuracy and consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed cutting speed profile is used in existing extrusion portioning machines, then the machine structure is simple, but the cutting and placement accuracy of semi-viscous food products becomes inconsistent
Solution Approach 1:
The patent applies dynamics by transitioning from a fixed cutting speed profile to a variable cutting speed profile that changes throughout the cutting cycle. The cutting head accelerates and decelerates at specific phases to optimize portion separation and placement accuracy, making the system adaptive rather than static.
Solution Approach 2:
The patent changes the speed parameter dynamically during the cutting cycle. By adjusting the cutting speed at different phases (acceleration during initial cut, deceleration during placement), the system achieves consistent portioning accuracy while managing the complexity through controlled parameter variation.
2Productivity
If the cutting speed is increased to improve productivity, then more portions can be produced per unit time, but the energy impact on cut portions increases causing inconsistent placement
Solution Approach 1:
The patent implements periodic action by applying high cutting speed only during specific phases of the cutting cycle when productivity is critical, then reducing speed during phases where precision is needed. This periodic variation in speed allows the system to achieve high overall productivity while minimizing energy impact on portion placement during critical phases.
Solution Approach 2:
The dynamic speed profile allows the cutting head to operate at high speeds during the main cutting phase to maximize productivity, then smoothly decelerate during the placement phase to reduce energy impact on portions, achieving both high productivity and consistent placement.
3Adaptability or versatility
If the machine is adapted to handle different materials with varying viscosities and inclusions, then material versatility improves, but hardware changes are required increasing complexity
Solution Approach 1:
The patent achieves material versatility through parameter changes in the cutting speed profile rather than hardware modifications. By adjusting speed parameters digitally for different materials (viscosities, inclusions, temperatures), the system adapts to various food products without physical hardware changes, reducing complexity while improving versatility.
Solution Approach 2:
The variable speed control system serves multiple functions: it optimizes cutting for different material types, controls placement accuracy, and manages energy impact. This universal control mechanism replaces the need for material-specific hardware configurations, making the machine versatile across different food products.
4Manufacturing precision
If extensive hardware changes are made to optimize cutting for specific materials, then cutting precision for that material improves, but production downtime increases during material changes
Solution Approach 1:
The patent replaces mechanical hardware changes with digital control changes. Instead of physically reconfiguring the machine for different materials, the system uses programmable speed profiles that can be changed instantly through software, eliminating production downtime associated with hardware reconfiguration while maintaining cutting precision.
Solution Approach 2:
The universal variable speed control system can handle multiple material types without hardware changes. By storing and switching between pre-programmed speed profiles for different materials, the machine maintains optimal cutting precision across various products while minimizing changeover time to nearly zero.
Data Source
AI summary
The invention is directed to a foodstuff extrusion portioning device and more specifically a cutter head assembly on such an extruder having a servo motor, a cutter shuttle coupled to a cutting element, a controller and being programmed via a product variable to provide a velocity profile. The cutter in the velocity profile has a first velocity and it reduces speed to a second velocity and goes more slowly through the last portion of the foodstuff. The at least two velocities being fully programmable and the controller can provide for instantaneous and additional programmed velocities throughout the cutting profile. The cutter further providing tilt control so it can drop the portion at the moment the portion detaches from the extruded foodstuff stream. It cuts and/or breaks off portions in a far more uniform and controllable manner to more accurately portion and better place the cut portions. This also provides the portion with minimal residual energy pushing it forward as it drops through the effect of gravity and the cutter can be used so as to further direct and push the portion downward so as to optimally place it.