Abstract:
A dough divider comprises a dough receiving hopper, a pressurizing chamber positioned beneath the hopper, a manifold positioned beneath the pressurizing chamber, a plurality of cut off heads positioned beneath the manifold, and a cut off knife assembly positioned beneath the cut off heads. At least one auger is positioned within the hopper for forcing dough received therein into the pressurizing chamber. Pressure applied to the dough within the pressurizing chamber releases CO 2  therefrom. The manifold provides uniform distribution of the dough to all of the cut off heads. The cut off heads form the dough into a plurality of dough streams comprising individually regulated diameters. The cut off knife assembly severs the dough streams into equal length dough balls thereby producing dough balls that are substantially identical in weight.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority based on provisional application Ser. No. 60/883,085 filed Jan. 2, 2007, the entire contents of which are incorporated herein by reference. 
     
    
     TECHNICAL FIELD 
       [0002]    This invention relates generally to dough dividers of the type utilized in the commercial baking industry, and more particularly to a dough divider useful in the processing of doughs having a wide range of consistencies. 
       BACKGROUND AND SUMMARY OF THE INVENTION 
       [0003]    Numerous dough dividers intended for use in the commercial baking industry have been designed and patented heretofore. Notwithstanding the considerable effort and investment that has been expended in dough divider development two deficiencies continue to characterize virtually all dough divider designs. 
         [0004]    First, existing dough dividers are designed and manufactured for use with specific dough consistencies. The result is that a dough divider designed for use in processing, for example, bun dough may not be able to be used in the processing of dough having a different consistency, for example, tortilla dough. Therefore, should a bakery that has been manufacturing products such as hot dog and hamburger buns decide to introduce a new pro duct such as tortillas the bakery must incur the expense and delay inherent in purchasing an entirely new dough divider. 
         [0005]    Second, most existing dough dividers are horizontally oriented. Because horizontally oriented dough dividers cannot utilize gravity to effect dough movement, the dough must be pumped therethrough. As is well known to those skilled in the art, pumping of dough nuts more work into the dough resulting in an undesirable increase in dough temperature. 
         [0006]    The present invention comprises a dough divider design which overcomes the foregoing and other problems which have long since characterized the prior art. The dough divider of the present invention processes dough without significantly increasing the temperature thereof thereby producing dough balls that are considerably superior to the dough balls produced by prior art dough dividers. Additionally, the dough divider of the present invention is adapted to the processing of a wide range of dough consistencies including those utilized in all of the products typically manufactured by commercial bakeries. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    A more complete understanding of the present invention may be had by reference to the following Detailed Description when taken in connection with the accompanying Drawings, wherein: 
           [0008]      FIG. 1  is a front view of a dough divider comprising a first embodiment of the present invention in which certain component parts have been broken away more fully to illustrate the construction and operation of the dough divider; 
           [0009]      FIG. 2  is a side view of the dough divider of  FIG. 1  in which certain component parts have been broken away more fully to illustrate the construction and operation of the dough divider; 
           [0010]      FIG. 3  is a side view of a cut off head utilized in the dough divider of  FIGS. 1 and 2  in which certain component parts have been broken away more fully to illustrate the construction and operation of the cut off head; 
           [0011]      FIG. 4  is a sectional view taken along the line  4 - 4  in  FIG. 3  in the direction of the arrows; 
           [0012]      FIG. 5  is a sectional view taken along the line  5 - 5  in  FIG. 3  in the direction of the arrows; 
           [0013]      FIG. 6  is a bottom view of a cut off blade assembly utilized in the dough divider of  FIGS. 1 and 2 ; 
           [0014]      FIG. 7  is a top view of a metering pump useful in conjunction with the dough divider of  FIGS. 1 and 2  in which certain parts have been broken away more fully to illustrate certain features thereof; 
           [0015]      FIG. 8  is a sectional view taken along the line  8 - 8  in  FIG. 7  in the direction of the arrows; 
           [0016]      FIG. 9  is a perspective view further illustrating the metering pump of  FIGS. 7 and 8 ; 
           [0017]      FIG. 10  is a view similar to  FIG. 1  illustrating the metering pump of  FIGS. 7 ,  8 , and  9  installed in the dough divider thereof; 
           [0018]      FIG. 11  is a front view of a dough divider comprising a second embodiment of the invention in which certain component parts have been broken away more fully to illustrate the construction and operation thereof; 
           [0019]      FIG. 12  is a side view of the dough divider of  FIG. 11  in which certain component parts have been broken away more fully to illustrate the construction and operation thereof; 
           [0020]      FIG. 13  is a side view of a cut off head which may be utilized in the practice of the invention in lieu of the cut off head shown in  FIGS. 3 ,  4 , and  5 ; 
           [0021]      FIG. 14  is a sectional view further illustrating the cut off head of  FIG. 13 ; 
           [0022]      FIG. 15  is a bottom view of the cut off head of  FIG. 13 ; 
           [0023]      FIG. 16  is a flowchart illustrating a method of controlling the pressure of the dough within the pressurizing chamber of the dough divider illustrated in  FIGS. 1 and 2 ; and 
           [0024]      FIG. 17  is a flowchart illustrating a method of operating of the cutoff head illustrated in  FIGS. 3 ,  4 , and  5  and the metering pump Illustrated In  FIGS. 7 ,  8 , and  9 . 
       
    
    
     DETAILED DESCRIPTION 
       [0025]    Referring to the drawings, and in particular to  FIGS. 1-6 , inclusive, a dough divider  20  comprising a first embodiment of the invention is illustrated. The dough divider  20  includes a dough receiving hopper  22 . Dough is transported from a dough mixer (not shown) into the hopper  22  by a pump or other device (not shown) and one or more dough transporting conveyors (not shown). A transmitter  24  located adjacent the top of the hopper  24  controls the flow of dough into the dough divider  20 . 
         [0026]    One or more augers  30  are mounted within the hopper  22  for actuation by a drive motor  32  and a drive train including a right angle drive  34  and a bevel drive  36 . Each auger  30  includes an auger shaft  38 , an auger flight  40 , and a wheel  42  secured to the distal end of the auger shaft  38 . As will be appreciated by those skilled in the art as the hopper  22  of the dough divider  20  is filled, the wheel(s)  42  comprising the auger(s)  40  are lifted out of engagement with the side wall of the hopper  22  by resistance of the dough. However, at the end of a run of dough the transmitter  24  is deactivated and the flow of dough into the hopper  22  is terminated. As the level of dough in the hopper  22  falls below the level of the wheel (s)  42  the wheel (s) engage the side wall of the hopper  22  whereupon the auger(s) travel circumferentially around the side wall of the hopper  22 . In this manner the side wall of the hopper  22  is swept completely clear of dough at the end of a dough run. 
         [0027]    The function of the auger(s)  30  is to force dough downwardly from the hopper  22  into a pressurizing chamber  50 . Referring simultaneously to  FIGS. 1 ,  2 , and  16 , a transmitter  52  monitors the pressure within the pressurizing chamber  50 . The speed of operation of the auger(s)  30  is regulated in accordance with the pressure within the chamber  50  with the speed of operation of the auger(s)  30  being increased if the operating pressure in the chamber  50  is too low and decreased if the operating pressure within the chanter  50  is too high. A relief valve may be provided for reducing the pressure of the dough within the pressurizing chamber  50  if the speed of operation of the auger(s)  30  cannot be reduced sufficiently to do so. From the pressurizing chamber  55  the now degassed dough flows into a manifold  54  which functions to distribute the dough evenly to a plurality of cut off heads  60 . 
         [0028]    The construction and operation of the cut off heads  60  is illustrated in  FIGS. 3 ,  4 , and  5 . Each cut off head  60  comprises a frame  62  having a pair of identical but oppositely configured cut off wheels  64  rotatably supported therein by a pair of shafts  66 . Referring particularly to  FIG. 5  each of the cut off wheels  64  has a semicircular groove  68  formed therein. Each semicircular groove  68  is defined by a continuously varying diameter extending from a fully open configuration at one end to a fully closed configuration at the opposite end. As will therefore be understood by those skilled in the art, depending upon the relative positioning thereof the semicircular grooves  63  of the cut off wheels  64  create a dough flow controlling aperture which is both infinitely variable and continuously perfectly circular. 
         [0029]    Referring to  FIGS. 3 and 4 , each of the shafts  66  has a precision gear  70  secured thereto. A worm gear  72  is rotatably supported on the frame  62  by bearings  74  and is mounted in mesh with one of the precision gears  70 . The shaft  76  of the worm gear  72  extends to a micrometer-type handle  78  which actuates the worm gear  72  to rotate the gears  70  thereby positioning the cut off wheels  70  to position the semicircular grooves  68  at precisely the locations required to provide a discharge diameter which precisely matches the requirements of any particular utilization of the dough divider  20 . 
         [0030]    In lieu of the handle  78  a servo system responsive to the weight of the dough balls formed by the dough divider  20  may be employed to control the rotational positioning of the shaft  76  thereby precisely controlling the positioning of the semicircular grooves and ultimately the weight of the dough balls formed by the dough divider  20 . The upper portion of  FIG. 17  comp, rises a flowchart illustrating a method of operating the servo system to control the weight of the dough balls formed by the dough divider  20 . 
         [0031]    Referring to  FIGS. 1 ,  3 , and  4 , the dough divider  20  comprises a plurality of cut off heads  60 , it being understood that the number thereof depends upon the requirements of particular applications of the invention. The cut off heads  60  are positioned in a side by side relationship and extend across the entirety of the discharge end of the manifold  54 . Referring particularly to  FIGS. 3 and 4 , a pair of rods (not shown) are extended through aligned apertures  80  formed in the frames  62  of the cut off heads  60  thereby maintaining the cut off heads  60  in precise alignment with one another. With the cut off heads properly aligned each of the handles  78  is manipulated until all of the cut off heads  60  produce streams of dough that are substantially identical in diameter. 
         [0032]    Referring to  FIGS. 1 ,  2 ,  4 , and  6  a dough cut off mechanism  82  is positioned directly beneath the cut off heads  60 . A slider  84  is positioned for reciprocation in a track  86 . A motor  88  operates an eccentric mechanism  90  which reciprocates the slider  84  relative to the track  86 . 
         [0033]    Referring particularly to  FIG. 6  the slider  84  has a rectangular aperture  92  formed therein. A plurality of lengths of piano wire or knife blades or other cutting devices  94  extend across the aperture  92  and are maintained in a taut condition. As the slider  84  is reciprocated under the action of the motor  88  and the eccentric  90  the cutting devices  94  move between the positions shown in full lines and the positions shown in dashed lines in  FIG. 6  thereby moving fully across the discharge apertures  96  of the cut off heads  60  on each reciprocation. 
         [0034]    Referring to  FIGS. 1 and 2  the cut off heads  60  comprising the dough divider  20  function to form streams of dough having individually controlled diameters. The cut off mechanism  82  severs the streams of dough at precise intervals thereby forming dough balls DE which are substantially identical in weight. The dough balls DB are received by a conveyor  100  which transports the dough balls DB to subsequent dough processing devices particularly including a dough rounder. 
         [0035]      FIGS. 7 ,  8 , and  9  illustrate a metering pump  110  useful in the practice of the invention. The metering pump  110  does not function to increase the pressure of the dough flowing therethrough but instead functions to control the flow of dough into the cut off heads  60 . Although the metering pump  110  comprises a double cavity metering pump those skilled in the art will appreciate the fact that the metering pump  110  may comprise whatever number of cavities is best suited for any particular application of the invention. 
         [0036]    Each cavity  112  comprising the metering pump  110  comprises a pair of four-lobed impellers  114  mounted in mesh with one another which rotate with n a cavity  116 . Dough enters the metering pump  110  through an inlet aperture  118  as a result of the pressure in the pressurizing chamber  50  and is discharged from the discharge pump  110  through a metering aperture  120 . 
         [0037]    Referring particularly to  FIGS. 7 and 9 , the impellers  114  are driven by precision gears  122  thereby maintaining the correct angular relationship between the two impellers  114  comprising the metering pump and thereby assuring a continuous seal therebetween. Referring particularly to  FIG. 9 , the gears  122  are driven by pulleys  124  which are in turn driven by a variable speed motor  126 .  FIG. 10  illustrates the dough divider  20  illustrated in  FIGS. 1-6 , inclusive, and described hereinabove in conjunction therewith having the metering pump  110  positioned between the pressure chamber  50  and the manifold  54 . The bottom portion of  FIG. 17  comprises a flowchart illustrating a method of operating a servo system or controlling the operation of the metering pump  110 . As will be understood by those skilled in the art,  FIG. 17  in its entirety illustrates a method of assuring that all of the cutoff heads produce dough balls of equal weight. 
         [0038]    A dough divider  140  comprising a second embodiment of the invention is illustrated in  FIGS. 11 and 12 . The dough divider  140  includes a hopper  142  which receives dough from a source thereof including a mixer, a pump, and one or more conveyors. A transmitter  144  mounted within the hopper  142  may be employed to maintain the quantity of dough within the hopper  142  at a predetermined level. 
         [0039]    The dough divider  140  further comprises three augers  146 ,  148 , and  150 . The augers  146 ,  148 , and  159  are located at the bottom of the hopper  142  and define a live bottom thereof. Referring particularly to  FIG. 11 , each of the augers  146 ,  148 , and  150  is received in conduits  152  and  154  located at the upper and lower ends thereof, respectively, and is driven by an individual drive motor  156  one or more of which may be a variable speed drive motor. 
         [0040]    Referring simultaneously to  FIGS. 11 and 12 , the augers  146 ,  148 , and  153  deliver dough from the hopper  142  into a pressurizing chamber  50 ′ which corresponds in construction and function to the pressurizing chamber  50  of the dough divider  20  as illustrated in  FIGS. 1 and 2  and described hereinabove in conjunction therewith. The pressurizing chamber  50 ′ is provided with a transmitter  52   e  which corresponds to the transmitter  52  of the dough divider  20  as illustrated in  FIG. 1  and described hereinabove in conjunction therewith. 
         [0041]    The three augers  146 ,  148 , and  150  operate continuously. The speed of operation of the augers is regulated by the output of the transmitter  2 . If the three augers cannot maintain adequate pressure in the pressurizing chamber  50 ′ the speed of the augers is increased. 
         [0042]    The dough divider  140  may be provided with a metering pump  110 ′ which is identical in construction and function to the metering pump  110  illustrated in  FIGS. 7 ,  3 , and  9  and described hereinabove in conjunction therewith. If used the metering pump  110 ′ directs dough into a manifold  54 ′ which is substantially identical in construction and function to the manifold  54  illustrated in  FIGS. 1 and 2  and described hereinabove in con-unction therewith. As will be appreciated by those skilled in the arm, many applications of the invention do not require the use of the metering pump  110 ′ in which case the manifold  54 ′ is connected directly to the pressurizing chamber  54 ′ in the same manner that the manifold  54  of the dough divider  20  is connected to the pressurizing chamber  50  thereof as illustrated in  FIGS. 1 and 2  and described hereinabove in conjunction therewith. 
         [0043]    The manifold  54 ′ directs dough uniformly into a plurality of cut off heads  60 ′ which are identical in construction and function to the cut off heads  60  of the dough divider  20  as illustrated in  FIGS. 3 ,  4 , and  5  and described hereinabove in conjunction therewith. The cut off heads  60 ′ direct substantially identical streams of dough to a cut off knife assembly  82 ′ which is identical in construction and function to the cut off knife assembly  82  of the dough divider  20  as illustrated in  FIGS. 1 ,  2 , and  6  and described hereinabove in conjunction therewith. The cut off knife assembly  82 ′ severs the streams of dough flowing from the cut off heads  60 ′ into a plurality of dough balls DB which fall onto a conveyor  100 ′ which is substantially identical in construction and function as the conveyor  100  as illustrated in  FIGS. 1 and 2  and described hereinabove in conjunction therewith. 
         [0044]      FIGS. 13 ,  14 , and  15  illustrate a cut off head  160  which may be utilized in the practice of the invention in lieu of the cut off head  160  as illustrated in  FIGS. 1-5 , inclusive, and described hereinabove in conjunction therewith. The cut off head  160  comprising a modified ball valve  162  which fine tunes the flow of dough through the cut off head  160  and also serves as a shut off valve. Dough cannot be forced through a valve that presents sharp, protrusions or obstacles that might tear the dough. Therefore, ball valve  162  is modified as shown at  164  to relieve sharp edges as the valve  162  is rotated under the action of a handle  166  and a shaft  168 . The seas  170  of the ball valve  162  is also relieved to prevent sharp edges as the ball is rotated. Similar to the mounting of the cut off heads  60  as illustrated in  FIGS. 1-5  and particularly as illustrated in  FIG. 4  a plurality of cut off heads  160  may be mounted side by side and maintained in proper alignment by rods which are extended through passageways  172 . 
         [0045]    Although preferred embodiments of the invention have been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiments disclosed, but is capable of numerous rearrangements, modifications and substitutions of parts and elements without departing from the spirit of the invention.