Variable Speed Extrusion Cutter Head for Uniform Portioning Accuracy
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Solution Overview
Problem
Existing extrusion portioning machines struggle with achieving uniform and repeatable portioning of semi-solid materials like cookie dough due to varying viscosities, inclusions, and material properties, leading to inconsistent cutting and placement, which results in production inefficiencies and increased costs due to the need for specialized equipment for each product.
Innovation Solution
A programmable cutter head with a variable speed profile controlled by a servo motor, allowing for customizable velocity adjustments throughout the cutting cycle, synchronized with other machine components like feed rollers and conveyor speed, to optimize cutting and placement accuracy and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a fixed speed cutting head is used, then the device complexity is reduced, but the manufacturing precision and placement accuracy deteriorate due to inability to accommodate varying material viscosities and properties
Solution Approach 1:
The cutting head incorporates a variable speed drive system that allows the cutting speed to be dynamically adjusted based on material properties. The motor speed can be changed during operation to optimize cutting performance for different viscosities and material compositions, resolving the contradiction between simple fixed structure and precise variable performance.
Solution Approach 2:
The system enables change of the cutting speed parameter to adapt to different material conditions. By adjusting the rotational speed of the cutting head according to material viscosity and properties, the system achieves consistent portioning accuracy across diverse materials without requiring completely different cutting heads.
2Manufacturing precision
If specialized cutting heads are used for each product line, then the manufacturing precision is improved, but the device complexity and loss of time increase due to frequent changeovers
Solution Approach 1:
The cutting head is designed with multi-functionality to handle multiple product lines and material types. By incorporating variable speed control and adjustable parameters, a single cutting head can be optimized for different materials through parameter adjustment rather than physical replacement, eliminating frequent changeovers while maintaining precision.
Solution Approach 2:
The dynamic speed adjustment capability allows the same cutting head to adapt to different product requirements in real-time. This eliminates the need for static specialized heads for each product, reducing changeover time while preserving cutting precision through programmable speed profiles.
3Productivity
If cutting speed is increased to improve productivity, then the productivity is improved, but the manufacturing precision deteriorates due to inconsistent portion separation and placement
Solution Approach 1:
The variable speed drive system allows dynamic optimization of cutting speed during the cutting cycle. The system can use higher speeds for cutting through the material and lower speeds for precise separation and placement phases, achieving both high productivity and consistent precision that fixed-speed systems cannot attain.
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.