Feed trough for a processing apparatus

A feed trough for a grader or other solid object processing system. The feed trough includes a plurality of feed channels, each having at least one flexible flap extending from a discharge end for transitioning a product from the feed channel to a processing region. Two converging flexible flaps may extend from the discharge end and contact a processing channel for guiding product to the processing channel.

BACKGROUND

The invention relates generally to apparatus and methods for processing solid objects and, more particularly, to feed troughs for processors.

Processors, such as graders, peelers, cleaners, freezers, coolers, and cookers, may process solid objects in batches. For example, graders may be used to sort objects into different sizes, or grades. Peelers may be used to removes shells or skins from objects. Solid objects that may be processed in batches include food products, such as fruits, vegetables, nuts, shellfish, portions of meat, poultry, and fish, and non-food products, such as ball bearings, castings, and aggregates.

Traditional feed troughs for processors include a plurality of channels for dividing a batch of objects to be separated and feeding the objects to a processing region. Feeding objects to a processing region can be difficult. Delicate objects require gentle handling and other objects may require precise placement and-or orientation in a processing region. For example, hard objects, such as clams and nuts, tend to accumulate energy and bounce when dropped from a feed trough to a processing region. Squid is delicate and generally difficult to feed to a processing region due to the risk of the tentacles snagging. Shrimp may also be difficult to feed to a processing region due to their non-uniform shape.

SUMMARY

The present invention provides an improved feed trough for a processor of solid objects. The feed trough employs a flexible flap extending from the end of a feed channel to facilitate the transfer of solid objects to a processor. In one embodiment, the feed trough comprises a plurality of feed channels for dividing a batch of solid objects into a stream of singulated objects and a plurality of flexible flaps extending from the ends of the feed channels to facilitate transfer of the solid objects to a processor.

According to one aspect of the invention, a feed trough for a processor comprises a base forming a plurality of feed channels, each feed channel extending from a first end to a second end, and a first flexible flap extending from the second end of a feed channel.

According to another aspect of the invention, a processor for solid objects comprises a feed trough and a processing section. The feed trough comprises a plurality of feed channels extending from a first end to a second end and a flexible flap extending from the second end of one of the feed channels. The processing section extends in length from an infeed end to an opposite end and in width from a first side to a second side and includes plurality of processing channels extending from the infeed end to the opposite end. The flexible flap contacts a processing channel at an infeed end.

According to another aspect of the invention, a method of grading squid is provided. The method comprises the steps of providing a batch of squid to a grader, and automatically separating the squid using the grader based on size.

DETAILED DESCRIPTION

The present invention provides an improved feed trough for feeding solid objects, such as shrimp, squid, clams, fish, chicken, and other food or non-food items, to a processor, such as a grader, peeler, cleaner, cooler, freezer or cooker. The feed trough divides a batch of solid objects into an array of feed channels, singulates the solid objects in each of the feed channels and gently passes the array of singulated solid objects to processing channels in the processor. Flexible flaps extending from the ends of the feed channels facilitate transfer and placement of the solid objects in the processing channels. The feed channels may also orient an object to be processed in a particular orientation and maintain that orientation during transfer to a processing region. The invention will be described relative to certain illustrative embodiments, though those skilled in the art will recognize that the invention is not limited to the illustrative embodiments.

FIGS. 1,2A and2B illustrate a grader10including a feed trough100of an illustrative embodiment of the invention. The feed trough100may be used with any suitable solid object processor having processing channels and is not limited to use with a grader with grading channels.

The grader10includes an infeed section26, a grading section16and an outfeed section28. The grading section16comprises planar array of grading channels, comprising grading rollers12separated across gaps14. In this example, the grading section has five cylindrical rollers, all of the same diameter. But more or fewer rollers could be used to match the throughput requirement. The grading section16extends in length in the axial direction of the rollers12from an infeed end18to an opposite exit end19and laterally in width from a first side20more or less at the outer side of one of the outermost rollers to a second side21at the outer side of the opposite outermost roller. Grading section16and all the other components of the grader are supported in a frame22having legs24. An example of a suitable grader is described in U.S. patent application Ser. No. 13/342,266 entitled “Grader,” the contents of which are incorporated by reference. Alternatively, the feed trough100may be used with another type of grader, such as the grading machines described in U.S. Pat. Nos. 6,065,607 and 6,321,914, or other processor, such as the shrimp peeling systems available from Laitram Machinery of Harahan, La.

The axes of rotation of the rollers diverge from the infeed end18to the opposite end19. The gaps14between laterally consecutive rollers12form gauging passages that increase in width from a minimum gauge Gminat the infeed end18to a maximum gauge Gmaxat the opposite exit end19. In this case, the five grading rollers form four gauging passages. Products fed into the grading section16advance along its length in the gaps. When a product advancing along the gap reaches a position along the widening gauging passage at which the passage width exceeds the lateral dimension of the product, the product falls through the passage under the influence of gravity. Thus, smaller products fall closer to the infeed end18, and larger products, closer to the opposite end19. Products whose lateral dimensions exceed the maximum gauge Gmaxdrop off the exit end19of the grader into a chute28or other outfeed device for further processing.

Graded products that pass through the gauging passages14drop onto one or more collection devices. Suitable collection devices include a conveyor belt disposed below the grading section16and running transverse to the length direction of the grading section and collection bins. Other suitable means known in the art for grading or otherwise processing solid objects may be used.

Products to be processed are fed onto a processing section, such as the grading section16, at its upper infeed end by the feed trough100, embodiments of which are shown inFIGS. 3-8. The feed trough100includes a plurality of flexible flaps at a discharge end to facilitate transfer and placement of the products in the processing section. An infeed conveyor27or other infeed device may deliver product to the feed trough100.

Referring toFIGS. 3 and 4, in one embodiment, the feed trough100comprises a corrugated base forming a plurality of feed channels120extending from a first end118to a second end119. The first end118receives objects from a conveyor, pan, tank or other infeed device. The feed trough disperses the objects into the feed channels120, which singulate the objects and feed the objects to corresponding processing channels at the discharge end119. Preferably, the number and spacing of the feed channels in the feed trough at the discharge end119correspond to the number and position of the processing channels, such as the gauging passages14, at the infeed end18of the processing section of a corresponding processor.

In the embodiment ofFIGS. 3 and 4, each feed channel120comprises at least two channel walls121,122. The first channel wall121includes a bend1211, while the second channel wall122is straight. The walls121,122converge and intersect at an angle θ at the bottom of the feed channel to form a narrow angled slot133. A top portion121aof the first channel wall121bends away from the bottom portion121band meets the top of the second channel wall122of the adjacent channel. The plane of the top portion121aof the first channel wall121forms an angle φ with the first channel wall122. The top channel angle φ is greater than the bottom slot angle θ. Thus, each feed channel120has a greater angle between the first and second side walls at the top of the channel than at the bottom. In the illustrative embodiment, the lower portion121bof the first wall is substantially vertical to facilitate placement of a product in the feed channel120. This channel configuration is useful in orienting products on edge in the slots rather than resting on their broad sides spanning the first and second sides across the feed channel120for better presentation to the processing region.

In the embodiment shown inFIGS. 3 and 4, the feed channels have a consistent cross-section from the first end118to the second end119. Alternatively, the cross-section of the feed channels may vary. For example, the feed trough100may be fan-shaped, with the feed channels120widening from the first end to the second end. Alternatively, the feed channels120may narrow from the first end to the second end. The feed channels120may also shift to the right or left in order to place the outlet of each feed channel at the second end119at a desired location of a processing region.

While the first end118and second end119of the illustrative feed channels120correspond to the ends of the base of the feed trough, alternatively, the ends of the feed channels may be located at an intermediate portion of the base, or the feed channels120may branch within the base.

The feed trough100may vibrate to facilitate movement of the product from the first end to the second end. The vibration of the trough and gravity urge the product into the slot133at the bottom of the channel. An actuator attached to the feed trough may impart a cyclic upthrusting and translating motion to the feed trough. The actuator may be a crank mechanism having a motor whose shaft rotates a crank arm pivotally connected to one end of a connecting rod whose opposite end is pivotally connected to a block at the bottom of the feed trough100, imparts a cyclic upthrusting and horizontal translation to the feed trough that impulsively advances products along the feed trough and helps unstack piggy-backed products. The cyclic upthrusting of the feed trough tosses the products upward above the bottoms of the feed channels, while the horizontal translation pulls the feed trough rearward so that the tossed products land farther down the feed channels. The combined motion of the feed trough advances the products along and unstacks piggy-backed products. Alternatively, a linear actuator connected between the grader frame and the bottom of the feed trough could be used. The downward slant of the trough also helps urge products onto the grading section16with the aid of gravity. The feed trough100may be suspended from a feed framework by four links pivotally attached at both ends by pivot pins.

Height restrictors42extending across the width of the feed-trough above the feed channels120also serve as means for unstacking piggy-backed products advancing along the channels. The height restrictors could alternatively be rotatable with flaps or loops aligned with the feed channels and rotated opposite to the advance of products to knock piggy-backed products off lower products.

Flexible flaps extend from the second, discharge end119of the feed trough100to facilitate transfer of a product from the feed trough to a processing section. In the embodiment ofFIGS. 1-4, each feed channel120includes two flexible flaps161,162. The first flexible flap161extends from the lower portion121bof the first channel wall121. The second flexible flap162extends from the second channel wall122. The flexible flaps161,162converge towards the bottom to form a slot170. The second flexible flap162of the embodiment ofFIGS. 1-4has a length L2and a width W2that are larger than the length L1and width W1of the first flexible flap161.

Referring back toFIGS. 1,2A and2B, the flexible flaps161,162contact or come into close proximity with a corresponding processing channel of the processor. As shown inFIG. 2B, the first flexible flap161extends substantially vertically downwards, contacting the right outer surface of a corresponding roller12. The second flexible flap162contacts an upper left outer surface of a corresponding roller and extends over the gap14between the rollers12. In the embodiment shown inFIG. 2B, the flexible flaps are tangential to the rollers. Alternatively, the flexible flaps may wrap around the outer surfaces of the rollers. The flexible flaps161,162bridge the space between the discharge end of the feed channels120and the rollers12or other processing device.

The flexible flaps gently lay an article to be processed, for example a piece of seafood to be graded, directly onto the processing region. The flexible flaps161,162act as shoehorns or a funnel for placing the object in a precise location, such as directly onto a grading roller12. An object to be processed can push the flexible flaps apart, opening the slot170to allow transfer of the object to a processor, such as a grading roller12.

Preferably, the flexible flaps161,162stick to the rollers12, which are wet to facilitate grading. When the feed trough100vibrates or slides back and forth, the flexible flaps slide back and forth on the rollers, maintaining contact with the rollers. The flexible flaps161,162are preferably sized, positioned and oriented so as to maintain contact with the rollers throughout the motion of the feed trough100.

The flaps161,162may be formed of any suitable material, such as, but not limited to, plastic, rubber and combinations thereof. In one embodiment, the flexible flaps161,162are formed of 0.125 inch thick silicon rubber. In another embodiment, the flexible flaps161,162are formed of 0.020 inch thick plastic. The material preferably imparts some strength in the longitudinal direction of the flaps, so that the flaps extend from the discharge end of the feed channels without buckling. The flexible flaps161,162may taper in thickness from first ends1660,1664connected to the feed channel outlets to second ends1662,1666that contact the roller.

The flaps161,162may be formed from a single piece of material split to form the two flaps, or may comprise separate pieces separately attached to the base of the feed trough100. In another embodiment, a single flap base may span multiple channels and have a plurality of flexible flap pairs extending therefrom.

The flexible flaps161,162may be coupled to the discharge end of the feed trough through any suitable means. In the embodiment shown inFIGS. 3 and 4, fasteners171, illustrated as nuts and bolts, couple the flaps to the channel side walls121,122at the discharge end119.

The feed trough100ofFIGS. 3 and 4is particularly suitable for feeding clams to be sorted by size to a grader. The flexible flaps161,162allow the feed trough100to place clams to be graded directly on grading rollers, without dropping a larger distance from the discharge end of the feed trough to the grading roller. The use of two differently sized flaps161,162with different lengths allow the clam to contact and engage a first roller, preferably at an upward rolling portion, then slide down and contact a second roller, preferably at a downward rolling portion of the roller. The illustrative flexible flaps161,162prevent the clam or other object from bouncing and facilitate further processing of the clams.

FIGS. 5A-Cand6illustrate another embodiment of a feed trough100′ including flexible flaps1610,162′ extending from a discharge end to facilitate transfer of a product to a processing region. The feed trough100′ comprises a plurality of feed channels, each comprising a first side wall121′ and a second side wall122′. The first side wall121′ has an upper portion121a′ and a lower portion121b′ extending at an angle relative to the upper portion. In the embodiment ofFIGS. 5A-6, the first flexible flap1610includes a bend1612that aligns with the entire wall121′ of the feed trough, so that the top edges1613and1623of the flexible flaps of adjacent channels converge and meet. In the embodiment ofFIGS. 5A-Cand6, the first flexible flap1610is equal in length to the second flexible flap162′, but the invention is not so limited. The bend1612increases the strength and stiffness of the first flexible flap1610.

The bent first flexible flap1610facilitates processing of squid or another delicate object. Squid is difficult to process due to their tentacles, which may get caught, and their delicate nature. The feed trough100′ allows automated grading of squid using a grader, such as the grader10ofFIG. 1. The feed trough100′ divides a batch of squid into the feed channels and singulates the squid within each channel. The singulated squid pass through the feed channels to a discharge end. The flexible flaps1610,1620at the discharge end gently transfer a squid from a feed channel through the slot170′ and onto a roller or processing region at the same time, preventing tentacles from getting caught and preventing damage to the squid. The squid may then be graded using the rollers12.

FIGS. 7A,7B and8illustrate another embodiment of a feed trough100″ including flexible flaps to facilitate transfer of a product to a processing region. The feed trough100″ includes a first flexible flap261that extends from a lower portion121b″ of a first side wall121″ and a second flexible flap262that extends from the second side wall122″ and is similar to the flexible flap162ofFIG. 3. The first flexible flap261extends above the lower portion121b″ of the channel side wall121″, and may extend farther out past the discharge end of the channel than the second flexible flap262.

The feed trough100″ also includes channel insert180in each feel channel120″. The insert180is placed in a lower section of the feed channel. As detailed inFIG. 8, the illustrative channel insert180includes a first end181extending across the top portion121a″ of the channel wall. The first end181has a transversely extending portion181aand an angled portion181bfor pushing product towards the middle of the feed channel. A longitudinally extending central portion182extends from the lower portion of the channel wall121b. The central portion182is angled towards the interior of the channel to force product into the slot133at the bottom of the channel. The insert further includes an angled second end183. The insert180and feed channel cooperate to singulate product and prevent piggy-backing of the product in the channel.

The feed trough100″ shown inFIGS. 7A,7B and8is particularly suitable for grading shrimp. The vertical first flap261cooperates with the second flap262to prevent the tail of a shrimp from fanning out. The flexible flaps261,262funnel the tail down through the slot270and off the ends of the flexible flaps onto a processing region.

FIGS. 9A-9Cillustrate a feed trough300according to another embodiment of the invention. The feed trough300includes a plurality of feed channels320having a similar configuration to the feed channels120inFIGS. 3 and 4. As shown inFIG. 9B, the feed trough300and feed channels320narrow from a first end318to a discharge end319. The feed channels include an insert380for narrowing the channel towards the discharge end. The insert380is similar to insert280ofFIG. 8, except the central portion382is parallel to the channel wall322. The feed trough300may also include flexible flaps (not shown) extending from the discharge ends of the feed channels320to facilitate transfer of solid objects from the feed channels to a processing region of a corresponding processor.

FIGS. 10A-10Cillustrate another embodiment of a feed trough1000including flexible flaps at a discharge end for facilitating the transfer of products onto a processing region. The feed trough1000includes a plurality of feed channels1120for conveying and-or singulating a product to be processed. The feed trough includes a plurality of flexible flaps1161,1162at the discharge end of each channel. The flexible flaps1161,1162cooperate to facilitate the transfer of products from the trough. One or more channels includes an insert1180for narrowing the channel, similar to the insert180described above. One or more channels may further include a valving device1190. The illustrative valving device1190comprises a plurality of check valves or gills extending at an angle from the insert1180. The check valves extend across the feed channel, sloping towards the discharge end. The check valves are formed of a flexible material, such as rubber or plastic. The valving device increases throughput and reduces piggy-backing of the product by holding back doubled up products and forcing the products into a single file through the channel and into the discharge area. The illustrative check valves of the valving device1190are triangular in shape and may extend from a base that overlies the sidewall1122of the channel into windows1181in the insert1180. Other suitable means for singulating products in a channel may be used.

According to one embodiment of the invention, a plurality of cascading feed troughs, at least one of which has flexible flaps for facilitating discharge of product from the feed trough, may be used at an infeed end of a processor.

The flexible flaps may have any suitable size, shape, orientation, configuration and location, and are not limited to the illustrative embodiments described above.

Although the invention has been described in detail with reference to a few exemplary versions, other versions are possible. For example, more than four feed channels could be used to increase capacity. The feed channels can have various sizes, shapes, orientations and configurations. The flexible flaps may also have various sizes, shapes, materials, orientations and configurations, depending on the particular product or processing application. So, as these few examples suggest, the scope of the claims is not meant to be limited to the versions described in detail.