Abstract:
A rounding apparatus for rounding dough pieces comprises a conveyer having a surface for supporting thereon and transporting dough pieces; and a plurality of rounder bars any one of which is selectively brought into contact with the surface of the conveyor to engage with the dough pieces conveyed by the conveyor thereby rotating the dough pieces on the surface of the conveyor to round the dough pieces.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    The present invention relates to a rounding apparatus for rounding dough. More specifically, it relates to an apparatus for taking dough that has been divided into dough pieces of a set size, and continuously rounding the dough pieces to form them into a given shape.  
           [0002]    Baked goods such as breads and pastries are made by dividing a set amount of dough into individual pieces and forming these divided dough pieces into a given shape. The shaped dough balls are then baked to produce the end product. At present, the forming of dough into dough pieces of a given shape is performed using rounding apparatus.  
           [0003]    The rounding methods used by the dough-rounding apparatus in use today include one method in which a cylindrical cup placed over and covering the dough piece is rotated eccentrically to round the dough, and another method in which dough pieces become progressively more rounded as they are moved in contact with rounder bars (cylindrical dies with dough-shaping surfaces). In the latter of these two methods, the rounder bars are placed above a conveyer carrying dough pieces, and the dough pieces are rounded by the rounder bars as they are continuously moved along by the conveyer. This method provides especially good production efficiency.  
           [0004]    Each of the rounder bars in such a system has its own particular dough-shaping surface for rounding the dough, and it performs a specific rounding action associated with this dough-shaping surface. The rounding apparatus setup procedure for switching production over from a product A lot to a product B lot requires removing the rounder bars for shaping product A and replacing them with rounder bars for shaping product B.  
           [0005]    Since the dough is gradually rounded by a rounder bar as it is moved along the conveyer, the contact surface of the rounder bar is formed long in the direction of travel, necessarily making the rounder bars long and bulky.  
           [0006]    This creates a problem in that it makes labor intensive the process of replacing each rounder bar with a different bar above the conveyer, causing excessive equipment setup time. Also the trend in recent years has been toward producing more kinds of bread in a greater number of low quantity production runs. This has increased the frequency of rounder bar replacement, resulting in significant losses in terms of rounding equipment setup time.  
           [0007]    The present invention was devised to solve the above problem. The present invention provides a rounding apparatus in which the changing of rounder bars is very simple and the equipment setup time short, i.e., a rounding apparatus that can quickly be adapted to accommodate different lots.  
         BRIEF SUMMARY OF THE INVENTION  
         [0008]    In light of the above problem, the present inventors conducted extensive research in which a configuration was found wherein, by rotating rounder bars, one rounder bar can easily be replaced with another switchable alternate rounder bar. The present invention was perfected based on the configuration found in this study.  
           [0009]    The present invention provides, in a first aspect thereof, a rounding apparatus for rounding divided dough pieces into a given shape. The apparatus comprises a conveyer for transporting the dough pieces and a rounder bar placed in contact with the conveyer for rounding the dough pieces. The rounder bar can be replaced by a different rounder bar by switching.  
           [0010]    Provided in a second aspect is a rounding apparatus for rounding divided dough pieces into a given shape. Such an apparatus comprises a conveyer for transporting the dough pieces and a plurality of rounder bars configured for rounding the dough pieces. The rounder bars can be selectively switched by rotating one of them into position in contact with the conveyer.  
           [0011]    Provided in a third aspect of the present invention is the rounding apparatus of the above second aspect, wherein the rounder bars comprise a first stage rounder bar in front and a second stage rounder bar therebehind.  
           [0012]    Provided in a fourth aspect of the present invention is the rounding apparatus of the above third aspect, wherein dough-shaping surfaces of respective rounder bars are placed on opposite sides thereof.  
           [0013]    Provided in a fifth aspect of the present invention is the rounding apparatus of the above second aspect, wherein a bottom edge piece of each rounder bar is a replaceable unit separate from the main rounder bar unit.  
           [0014]    Provided in a sixth aspect of the present invention is the rounding apparatus of the above second aspect that comprises two rounder bars placed at angular positions separated from each other by 90 degrees.  
           [0015]    Provided in a seventh aspect of the present invention is the rounding apparatus of the above second aspect, wherein the rounder bars are installed on a rotating frame supported by a main frame of the rounding apparatus.  
           [0016]    Provided in an eighth aspect of the present invention is the rounding apparatus of the above seventh aspect, wherein an upright bracket is attached to the rotating frame, and a securing bolt is inserted through a slot in the bracket into the mainframe for securing the bracket to the main frame.  
           [0017]    Provided in a ninth aspect of the present invention is a rounding apparatus for rounding divided dough pieces into a given shape. The apparatus comprises a conveyer for transporting the dough pieces, and a first stage rounder bar in front and a second stage rounder bar therebehind for rounding the dough pieces. Each of the rounder bar stages has a plurality of rounder bars, including a switchable alternate rounder bar, and each rounder bar is installed on a rotating frame that is rotatably installed on a main frame. A bracket is installed upright on the rotating frame, and provided on the main frame is a securing bolt that is inserted through a slot in the bracket for being tightened to secure the bracket to the main frame. One of the rounder bars in each stage can be selectively switched by rotating it such as to place it in contact with the conveyer.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0018]    These and other features, aspects, and advantages of the present invention will become apparent with reference to the following description, claims, and accompanying drawing, where:  
         [0019]    [0019]FIG. 1 shows a simplified plan view of an entire rounding apparatus;  
         [0020]    [0020]FIG. 2 shows a simplified side view of an entire rounding apparatus;  
         [0021]    [0021]FIG. 3 shows a side view of rounder bars in a rounding apparatus of the present invention;  
         [0022]    FIGS.  4 (A),  4 (B) and  4 (C) show various cross section views of a rounder bar in a rounding apparatus of the present invention;  
         [0023]    FIGS.  5 (A) and  5 (B) show the rounder bar switching mechanism of a rounding apparatus of the present invention: FIG. 5(A) shows the apparatus prior to switching; and FIG. 5(B) shows a main frame supporting a rotating frame;  
         [0024]    [0024]FIG. 6 shows the rounder bar switching mechanism of a rounding apparatus of the present invention, after switching;  
         [0025]    [0025]FIG. 7 shows typical grooves formed in the dough-shaping surface of a rounder bar of the present invention;  
         [0026]    [0026]FIG. 8 is a simplified of rounding action as performed in the present invention; and  
         [0027]    FIGS.  9 (A) and  9 (B) show examples of different rounder bar placements in the present invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0028]    The best mode for implementing a rounding apparatus according to the present invention is described below, with reference to the drawings. The present mode will be described using an example of a rounding apparatus provided with two stages of rounder bars  1 .  
         [0029]    Shown in FIGS. 1 and 2, respectively, are simplified plan and side views of the entire rounding apparatus. A dividing apparatus  100 , at the left side of the drawing, continuously supplies dough pieces containing a set amount of dough to a rounding apparatus A. That is, dough brought into the system from above through a hopper  101  is pressed out horizontally through a collar, using a screw. As the dough is pressed out, it is divided into individual dough pieces, each containing a prescribed amount of dough, by a cutter  102  rotating at a given cycle period. Dough pieces divided in this manner are supplied to a rounding apparatus positioned downstream of the dividing apparatus.  
         [0030]    The rounding apparatus A has a conveyer  6  for moving dough thereon, and rounder bars  1  for gradually rounding the dough. The conveyer  6  and rounder bars  1  are installed on a main frame  3  of the rounding apparatus A. Provided at the bottom of the main frame  3  are casters  7  for enabling the entire rounding apparatus A to be moved. The rounder bars  1  are placed in contact with the conveyer  6  in the direction of motion thereof.  
         [0031]    As shown in these drawings, a first stage rounder bar  1  (V) is provided at the first half of the conveyer. This first stage rounder bar  1  is followed by a second stage rounder bar  1  (W) placed downstream thereof. The first stage rounder bar  1  (V) is generally aligned with the direction of travel of the conveyer  6 , but inclined at an angle thereto (slanting from the right side of the conveyer toward its center, as shown in FIG. 1). The second stage rounder bar  1  (W) is similarly aligned with the direction of travel of the conveyer  6 , at an incline from the left side of the conveyer toward its center, as shown in FIG. 1.  
         [0032]    As mentioned above, the conveyer  6  and rounder bars  1  are installed on the main frame  3  of the rounding apparatus A. This installation of the rounder bars  1  on the conveyer  6  is such that it enables them to be rotated by a switching mechanism to a standby position at a given height of separation over the conveyer  6 , as appropriate.  
         [0033]    FIGS.  5 (A) and  5 (B) show a switching mechanism for a rounder bar  1  of a rounding apparatus A of the present invention. FIG. 5(A) shows the switching mechanism, and FIG. 5(B) shows the main frame  3  on which the switching mechanism is rotatably supported. FIG. 6 shows the same rounder bars  1  of the rounding apparatus A of the present invention after switching.  
         [0034]    As will be understood from the drawings, first, the main frame  3  is provided with gate-shaped support members  3 ′ straddling the conveyor  6  in a position traversing the conveyor. Each of the support members  3 ′ has a hanger provided on a center horizontal cross member thereof. A rotating member  2  is rotatably supported by the hangers. The rotating member  2  can be removed from the hangers by removing split portions  31  of the hangers.  
         [0035]    Multiple rounder bars  1  can be installed on a rotating member, but in this case there are two: an ‘in-use’ rounder bar  1  (X); and a ‘switchable alternate’ rounder bar  1  (Y). The switchable alternate rounder bar  1  (Y) is positioned so that it can be switched onto the conveyer  6  in place of the currently in-use rounder bar  1  (Y), when required. This will be described in detail later.  
         [0036]    A bracket  4  is mounted on the rotating member  2 . Formed in this bracket  4  is an elongated arc-shaped slot  41  that extends through an arc of 90 degrees. A securing bolt  5  extends through this slot  41  of the bracket  4  and is threadably engaged with the frame. The bracket  4  can be easily secured to the main frame  3  by tightening a handle  51  on this securing bolt  5 .  
         [0037]    The switchable alternate rounder bar  1  (Y) and the in-use rounder bar  1  (X) are installed on the rotating member  2  to form a right angle therebetween. Normally, the in-use rounder bar  1  (X) is placed in contact with the conveyer  6  by tightening the securing bolt  5  when it is positioned at one end of the elongated slot  41  (point P 1 ) as shown in FIG. 5(A). If, from this state, the rotating member  2  is rotated as far as possible in the counter-clockwise direction the securing bolt  5  will then be positioned at the other end of the slot  41  of the bracket  4  (point P 2 ).  
         [0038]    This rotation lifts the in-use rounder bar  1  (X) above the conveyer  6 , and lowers the switchable alternate rounder bar  1  (Y) onto the conveyer  6  in its place. Now, the securing bolt  5  is tightened, securing the bracket  4  to the main frame  3 , to thus lock the switchable alternate rounder bar  1  (Y) firmly in position on the conveyer.  
         [0039]    The cross-sectional shapes of the dough-shaping surfaces  11  of the rounder bars are arc-shaped curves that differ from one rounder bar to another.  
         [0040]    FIGS.  4 (A),  4 (B) and  4 (C) are cross-section views of the rounder bar and show the relationship between the dough-shaping surface  11  of a rounder bar  1  and the dough (shown in dotted lines). The example shown here is of a first stage rounder bar in which the dough is being rotated and rounded as it moves along from A to B to C in contact with the dough-shaping surface.  
         [0041]    First, a divided dough piece D is received (FIG. 4(A)); then, the dough is momentarily pressed downward to consolidate it (FIG. 4(B)); and finally, the dough is urged upward to form the desired spherical shape (FIG. 4(C)).  
         [0042]    A large number of thin vertical grooves (anti-slip grooves  16 ) are formed in the dough-shaping surface  11 . The reason for this is that dough, while being in contact with the dough-shaping surface  11 , tends to slip thereon, thereby failing in performing proper rounding function.  
         [0043]    Typical grooves of this kind are shown in FIG. 7. The first stage rounder bar  1  (V) shown here has vertical grooves formed throughout the entire length of the surface. The first half of the second stage rounder bar  1  (W) also has the same kind of vertical grooves as the first stage rounder bar  1  (V), but its second half has narrow horizontal grooves.  
         [0044]    Although proper dough-rounding action is obtained in the first stage rounder bar  1  (V) and the first half of the second stage rounder bar  1  (W), the dough-shaping surface  11  leaves undesirable vertical groove marks in the surface of the dough. These groove marks are repaired/removed by the horizontal grooves in the second half (the groove mark repair section  17 ) of the second stage rounder bar  1  (W).  
         [0045]    Note that the rounder bar has a removable bottom edge piece  12  that is separate from the main rounder bar unit.  
         [0046]    [0046]FIG. 3 shows a side view of a rounder bar, and FIGS.  4 (A),  4 (B) and  4 (C) show cross-sectional views of the same rounder bar at sections A-A, B-B, and C-C of FIG. 3. As can be seen from these drawings, a blade-shaped bottom edge piece  12  is supported in the main unit of the rounder bar by spring pressure in such a manner that the bottom edge piece  12  is urged against the conveyor under pressure applied by springs  13  through pins  14 .  
         [0047]    The bottom edge piece  12  is attached to the rounder bar main unit by fastening bolts  15  such as to limit the downward travel of the bottom edge piece  12  to a set length. When the rounder bar is set on the conveyer  6 , its bottom edge piece  12  receives constant spring pressure urging it against the surface of the conveyer  6 . The reason the rounder bar must be kept in firm contact with the conveyer  6  is that if a gap were allowed to exist at this point, dough would get caught in the gap and be damaged.  
         [0048]    The disadvantage of this is that constant contact between the rounder bar  1  and the surface of the conveyer  6  results in friction that quickly wears down the tip of the bottom edge piece  12 , and when this wear becomes excessive, it requires replacement. In the rounder bar of the present invention, however, when replacement becomes necessary, only the bottom edge piece  12  need be replaced; not the entire rounder bar. This is cost-effective, and the replacement procedure is also quite easy in that it requires only removal of the fastening bolts  15 .  
         [0049]    Next, the operation of the rounding apparatus A for rounding a dough piece D will be described. FIG. 8 is a simplified diagram of this operation. First, a dividing apparatus  100  divides dough into dough pieces D containing a set amount of dough. These divided dough pieces D are continuously supplied to a conveyer  6  of a rounding apparatus A. When thus supplied, the dough pieces D are loaded onto the conveyer in a position corresponding to that of a dough-shaping surface  11  of a rounder bar  1  placed on the conveyer. As they move, the dough pieces D loaded on the conveyer come into contact with the dough-shaping surface  11  of the rounder bar  1 , which causes them to rotate.  
         [0050]    When this occurs, as the conveyer moves (from left to right in the drawing), the dough pieces D move sideways across the conveyer (from up to down normally on FIG. 8). As each dough piece D is thus rotated in contact with the dough-shaping surface  11  of the rounder bar  1 , its surface is gradually rounded until it comes to the end of the first stage rounder bar  1  (V), at which point the first stage rounding operation is complete. In this first stage rounder bar  1  (V), the dough receives proper rounding action because vertical grooves formed in the dough-forming surface keep the dough from slipping.  
         [0051]    The dough piece D is now handed off from the first stage rounder bar  1  (V) to the second stage rounder bar  1  (W). Because the dough-shaping surface  11  in this rounder bar  1  (W) and the dough-shaping surface  11  of the first stage rounder bar  1  (V) face each other along the direction of the conveyor, the transfer of the dough piece D is smooth. The dough piece D then goes on to be rounded by the shaping surface  11  of the second stage rounder bar  1  (W).  
         [0052]    In this stage, as the conveyer  6  moves (from left to right) the dough pieces D move sideways across the conveyer (from down to up normally on FIG. 8). In this second stage rounder bar  1  (W), in the first half of the dough-shaping surface  11  (the anti-skid section), the dough pieces D are rounded without slipping because of the vertical grooves formed therein. In the second half (the groove mark repair section), the marks in the dough caused by the vertical grooves of the preceding rounding process are repaired/removed by horizontal grooves  17  formed in this section of the dough-shaping surface  11 . Completion of the above process marks the end of the operation to effect proper rounding of the dough pieces.  
         [0053]    When it is desired to change over to process dough for a different lot, the in-use rounder bar  1  (X) is rotated up to a standby position, while at the same time, a switchable alternate rounder bar  1  (Y) that had been in the raised standby position is rotated down to be placed in contact with the conveyer.  
         [0054]    Although the preferred mode for carrying out the invention was described above, the present invention is not limited to the above mode. A variety of modifications thereto are possible while still remaining within the scope of the stated objectives. For example, although the above example described only first and second stage rounder bars  1 , a third, fourth, or even more stages of rounder bars could be added, depending on the product. Also, the number of available switchable alternate rounder bars for each stage needs not be limited to two. The number of switchable alternate rounder bars is limited only by the amount space available on the rotating frame for installing them. Also, there are dividing machines that simultaneously output several divided dough pieces from several output opening. Rounding apparatus following such dividing machines can be provided with rounder bars arranged in rows, as shown in FIG. 9(A). In addition, although the example described two serial stages of rounder bars, there could be more stages, or there could be only one stage, as shown in FIG. 9(B).  
         [0055]    According to the present invention as described above, alternate rounder bars can easily be switched into position for use, thus greatly reducing setup time. This makes it possible to quickly support a variety of different lots, for a major improvement in productivity.