Abstract:
A lubrication system is provided for a reciprocating mold plate patty-forming apparatus. The lubrication system includes a plurality of oil fed bearings, two bearings journaling each mold plate drive rod. A substantially sealed oil containing compartment is provided for a rotary member that drives the patty knockout mechanism. The rotary member is arranged within the oil containing compartment. The rotary member is at least partly submerged beneath a level of lubricating oil within the compartment. Two tube valve bushings are provided for journaling rotary movement of a tube valve that selects between two food pumps that deliver pressurized food product to the mold plate. Each of the tube valve bushings has provisions for being greased. The tube valve bushings journal opposite ends of the tube valve. The tube valve bushings are preferably mounted externally to opposite sides of the manifold.

Description:
[0001]     The application claims the benefit of provisional application Ser. No. 60/571,368 filed May 14, 2004; U.S. provisional application Ser. No. 60/503,354, filed Sep. 16, 2003; and U.S. provisional application Ser. No. 60/515,585, filed Oct. 29, 2003. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     Use of pre-processed foods, both in homes and in restaurants, has created a demand for high-capacity automated food processing equipment. That demand is particularly evident with respect to hamburgers, molded steaks, fish cakes, and other molded food patties.  
         [0003]     Food processors utilize high-speed molding machines, such as FORMAX F-6, F-12, F-19, F-26 or F-400 reciprocating mold plate forming machines, available from Formax, Inc. of Mokena, Ill., U.S.A., for supplying patties to the fast food industry. Prior known high-speed molding machines are also described for example in U.S. Pat. Nos. 3,887,964; 4,372,008; 4,356,595; 4,821,376; and 4,996,743 herein incorporated by reference.  
         [0004]     Although heretofore known FORMAX patty-molding machines have achieved commercial success and wide industry acceptance, the present inventors have recognized that needs exist for a forming machine having an even greater energy efficiency, an even greater durability and an even greater duration of maintenance free operation. The present inventors have recognized that needs exist for a smoother and quieter patty-forming machine operation.  
       SUMMARY OF THE INVENTION  
       [0005]     The invention provides a lubrication system for a patty-forming apparatus of the kind having a reciprocating mold plate driven by parallel drive rods from a cavity fill position to a patty discharge position, and two food product pumps alternatively operable to supply food product to the mold plate. The food product pumps are selected to communicate food product to the mold plate by a rotatable tube valve. A knockout mechanism includes knockout plungers that are reciprocal between a stand by position and a deployed position to displace patties from the mold plate. The knockout mechanism includes a rotary member that converts rotation input to reciprocation of the knockout plungers.  
         [0006]     According to one aspect of the invention, the lubrication system includes a plurality of bearings, at least one bearing journaling each drive rod. The bearings each have a lubrication oil channel therein. A lubrication oil reservoir is connected by a conduit to the lubrication oil channels. A pump is arranged to deliver oil from the reservoir through the conduit and through the channels to lubricate sliding movement of the rods through the bearings. The mold plate drive mechanism, being so lubricated, runs smoother, quieter, with greater energy efficiency and with greater durability.  
         [0007]     According to another aspect of the invention, a substantially sealed oil containing compartment is provided for the knockout mechanism. The rotary member is arranged within the oil containing compartment. The rotary member is at least partly submerged beneath a level of lubricating oil within the compartment. The knockout mechanism includes a crank rod pivotally connected to the rotary member within the compartment. The crank rod is also pivotally connected to a knockout frame which drives one or more knockout rods which drive the knockout plungers. The pivotal connections between the rotary member, the crank rod and the frame are all located within the compartment and are all lubricated by oil within the compartment. The knockout mechanism, being so lubricated, runs smoother, quieter, with greater energy efficiency, and with greater durability.  
         [0008]     According to another aspect of the invention, at least one tube valve bushing is provided for journaling rotary movement of the tube valve. The tube valve bushing has a channel therein for being filled with lubricating material. Preferably, the tube valve is fit within a manifold that directs food product from the food product pumps to the mold plate, and the tube valve bushing is externally mounted to the manifold.  
         [0009]     Preferably, the at least one tube valve bushing comprises two tube valve bushings. Each of the tube valve bushings has the channel therein arranged for being filled with lubricating material. The tube valve bushings journal opposite ends of the tube valve. The tube valve bushings are preferably mounted externally to opposite sides of the manifold. Because the tube valve is journaled with externally mounted bushings, rather than being journaled by the valve manifold itself, wear on the manifold is eliminated. The bushings can be replaced or repaired at significantly less cost than a similar repair to, or replacement of, the valve manifold.  
         [0010]     The preferred embodiment of the invention comprises a high-speed food patty molding machine that includes a molding mechanism having an inlet for receiving a moldable food material. The machine further comprises two food pumps, each pump including a pump cavity having an intake opening and an outlet opening, a plunger aligned with the cavity, and drives for moving the plunger between a retracted position clear of the intake opening in the cavity, and a pressure position in which the plunger is advanced inwardly of the cavity, beyond the intake opening, toward the outlet opening. Supply means are provided for supplying moldable food material to the intake opening of each pump cavity whenever the plunger for that pump is in its retracted position. A valve manifold connects the outlet openings of the two pump cavities to the inlet of the molding mechanism. Actuating means are provided to actuate the pumps in that at least one pump cavity always contains moldable food material under pressure.  
         [0011]     The molding mechanism comprises a reciprocating mold plate having one or more rows of mold cavities that are filled via the inlet of the molding mechanism. The mold plate is reciprocated by a servo-drive that can precisely control the position of the mold plate, and the movement of the mold plate. Thus, the mold plate speed, acceleration, deceleration and dwell periods for filling and/or for discharging the cavities can be precisely controlled. These movements and dwell period can be tailored according to the type of food material and to the shape of the patties.  
         [0012]     According to the invention, the servo-drive reciprocates longitudinally arranged mold plate drive rods that are operatively connected to the mold plate. The drive rods are guided by sleeve bearings. The apparatus includes a bearing lubrication oil circulation system for lubricating the sleeve bearings. The system includes a lubrication oil pump and oil reservoir. The lubrication oil pump circulates lubrication oil through sleeve bearings located at both the front and rear of each of the drive rods. The sleeve bearings include helical lubrication grooves that distribute the lubrication oil around the entire circumference of each drive rod. The lubrication oil is filtered before being returned to the reservoir.  
         [0013]     The mold mechanism also includes a servo driven knockout mechanism wherein the speed, acceleration, deceleration and dwell periods of the knockout plungers can also be precisely controlled to be synchronized with the mold plate movements and positions, and for the type of food product and shape of the patties. According to the invention, the knockout mechanism includes a rotating eccentric that is submerged in a lubricating oil bath and includes provisions on the eccentric to sling oil to upper portions of the knockout housing. Also, a controlled knockout rod bearing lubrication system is employed to periodically lubricate the knockout rods.  
         [0014]     A tube valve is fit into the valve manifold to seal between the outlet opening of each pump cavity and the manifold whenever the plunger for that pump is moved toward its retracted position, thereby supporting a continuous supply of moldable food material, under pressure, to the inlet of the molding mechanism.  
         [0015]     According to the invention, the apparatus includes an improved tube valve mounting assembly. The tube valve mounting assembly includes inboard and outboard bearings or bushings located externally on opposite lateral sides of the valve manifold that are removably fastened to the outside of the valve manifold. The bushings include an internal grease groove fed by a grease fitting. Thus, the bushings can be periodically greased. A first O-ring seal is provided inside the valve manifold which is sealed via the insertion of the lead end of the tube valve that is inserted into the manifold during assembly. A second O-ring seal is applied to a trailing end of the tube valve for sealing against an inside surface of the valve manifold.  
         [0016]     The present invention provides an improved automated food patty molding machine capable of producing uniform molded food patties at a high rate of production. The invention also provides an improved high-speed food patty molding machine that is inherently subject to only minimal wear in operation, and that requires no more than minimal maintenance. The invention also provides an improved high-speed patty molding machine that is inherently quiet in operation. The invention also provides an improved patty molding machine that has and enhanced energy efficiency. The invention also provides an improved high-speed food patty molding machine that is simple and cost effectively manufactured, assembled, and repaired.  
         [0017]     Numerous other advantages and features of the present invention will be become readily apparent from the following detailed description of the invention and the embodiments thereof, and from the accompanying drawings.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0018]      FIG. 1  is a perspective view of a patty-forming machine of the present invention;  
         [0019]      FIG. 1A  is an elevational view of the patty-forming machine of  FIG. 1 ;  
         [0020]      FIG. 2  is a longitudinal sectional view of the patty-forming machine of  FIG. 1 , with some components and/or panels not shown, or broken away, for clarity;  
         [0021]      FIG. 3  is a sectional view taken generally along line  3 - 3  of  FIG. 2 , with some components and/or panels not shown, or broken away, for clarity;  
         [0022]      FIG. 4  is a sectional view taken generally along line  4 - 4  of  FIG. 2 , with some components and/or panels not shown, or broken away, for clarity;  
         [0023]      FIG. 5  is a sectional view taken generally along line  5 - 5  of  FIG. 2 , with some components and/or panels not shown, or broken away, for clarity;  
         [0024]      FIG. 6  is a sectional view taken generally along line  6 - 6  of  FIG. 2 , with some components and/or panels not shown, or broken away, for clarity;  
         [0025]      FIG. 7  is a sectional view taken generally along line  7 - 7  of  FIG. 2 , with some components and/or panels not shown, or broken away, for clarity;  
         [0026]      FIG. 8  is a sectional view taken generally along line  8 - 8  of  FIG. 2 , with some components and/or panels not shown, or broken away, for clarity;  
         [0027]      FIG. 9A  is an enlarged fragmentary sectional view taken from  FIG. 2 , showing the machine configuration as the mold plate in a fill position, with some components and/or panels not shown, or broken away, for clarity;  
         [0028]      FIG. 9B  is an enlarged fragmentary sectional view taken from  FIG. 2 , showing the machine configuration as the mold plate in a patty-discharge position, with some components and/or panels not shown, or broken away, for clarity;  
         [0029]      FIG. 10  is an elevational view of a tube valve of the present invention;  
         [0030]      FIG. 11  is an enlarged fragmentary sectional view taken generally along line  11 - 11  of  FIG. 5 , with some components and/or panels not shown, or broken away, for clarity;  
         [0031]      FIG. 12  is an enlarged fragmentary sectional view taken generally along line  5 - 5  of  FIG. 2 , with some components and/or panels not shown, or broken away, for clarity;  
         [0032]      FIG. 12A  is an elevational view of a bushing taken from  FIG. 11 ;  
         [0033]      FIG. 13  is a view taken generally of along line  13 - 13  of  FIG. 12 ;  
         [0034]      FIG. 13A  is a sectional view taken generally along line  13 A- 13 A of  FIG. 13 ;  
         [0035]      FIG. 14  is a diagrammatic view of a lube oil system of the invention;  
         [0036]      FIG. 15  is an enlarged, fragmentary sectional view taken from the right side of  FIG. 6 ;  
         [0037]      FIG. 16  is an enlarged, fragmentary longitudinal sectional view taken from the left side of  FIG. 2 , with some components and/or panels not shown, or broken away, for clarity;  
         [0038]      FIG. 17  is a sectional view taken generally along line  17 - 17  of  FIG. 2 , with some components and/or panels not shown, or broken away, for clarity;  
         [0039]      FIG. 17A  is a fragmentary sectional view taken from  FIG. 17 , with some components removed for clarity; and  
         [0040]      FIG. 18  is a sectional view taken generally along line  18 - 18  of  FIG. 17 , with some components and/or panels not shown, or broken away, for clarity. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0041]     While this invention is susceptible of embodiment in many different forms, there are shown in the drawings, and will be described herein in detail, specific embodiments thereof with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the specific embodiments illustrated.  
         [heading-0042]     General Description Of the Apparatus  
         [0043]     The high-speed food patty molding machine  20  illustrated in these figures comprises a preferred embodiment of the invention. The complete machine is described in U.S. Ser. No. ______, identified as attorney docket number 2188P0390US, filed on the same day as the present application, and herein incorporated by reference. This application also incorporates by reference U.S. Application Ser. No. 60/503,354, filed Sep. 16, 2003 and U.S. Provisional Application Ser. No. 60/515,585, filed Oct. 29, 2003.  
         [0044]     The molding machine  20  includes a machine base  21 , preferably mounted upon a plurality of feet  22 , rollers or wheels. The machine base  21  supports the operating mechanism for machine  20  and can contains hydraulic actuating systems, electrical actuating systems, and most of the machine controls. The machine  20  includes a supply  24  for supplying moldable food material, such as ground beef, fish, or the like, to the processing mechanisms of the machine.  
         [0045]     A control panel  19 , such as a touch screen control panel, is arranged on a forward end of the apparatus  20  and communicates with a machine controller.  
         [0046]     As generally illustrated in  FIGS. 2-6 , supply means  24  comprises a large food material storage hopper  25  that opens into the intake of a food pump system  26 . The food pump system  26  includes at least two food pumps  61 ,  62 , described in detail hereinafter, that continuously, or intermittently under a pre-selected control scheme, pump food material, under pressure, into a manifold  27  flow-connected to a cyclically operated molding mechanism  28 .  
         [0047]     In the operation of machine  20 , a supply of ground beef or other moldable food material is deposited into hopper  25  from overhead. An automated refill device (not shown) can be used to refill the hopper when the supply of food product therein is depleted. The floor of hopper  25  comprises a conveyor belt  31  of a conveyor  30 , for moving the food material longitudinally of the hopper  25  to a hopper forward end  25   a.    
         [0048]     The food material is moved by supply means  24  into the intake of plunger pumps  61 ,  62  of pumping system  26 . The pumps  61 ,  62  of system  26  operate in overlapping alteration to each other; and at any given time when machine  20  is in operation, at least one of the pumps is forcing food material under pressure into the intake of manifold  27 .  
         [0049]     The manifold  27  comprises a system for feeding the food material, still under relatively high pressure, into the molding mechanism  28 . Molding mechanism  28  operates on a cyclic basis, first sliding a multi-cavity mold plate  32  into a receiving position over manifold  27  ( FIG. 9A ) and then away from the manifold to a discharge position ( FIG. 9B ) aligned with a series of knockout cups  33 . When the mold plate  32  is at its discharge position, knockout cups plungers or cups  33  are driven downwardly as indicated by  33 A in  FIG. 2 , discharging hamburgers or other molded patties from machine  20 . The molded patties are deposited onto a conveyor  29  ( FIG. 1A ), to be transported away from the apparatus  20 .  
         [heading-0050]     Food Supply System  
         [0051]     The food supply means  24  and associated hopper  25  are illustrated in  FIGS. 2-6 . As seen, the conveyor belt  31  spans completely across the bottom of hopper  25 , around an end of idler roller or pulley  35  and drive roller or pulley  36 , the lower portion of the belt being engaged by a tensioning idle roller  37 . A drum motor (not visible) is provided within the drive roller  36  for rotating the drive roller.  
         [0052]     The forward end  25   a  of hopper  25  communicates with a vertical pump  38  having an outlet  39  at least partly open into a pump intake chamber  41 . A vertically oriented frame  42  extends above hopper  25  adjacent the right-hand side of the outlet  39 . A motor housing  40  is mounted on top of the frame  42 . A support plate  43  is affixed to the upper portion of frame  42 , extending over the outlet  39  in hopper  25 . The frame comprises four vertical tie rods  44   a  surrounded by spacers  44   b  ( FIG. 5 ).  
         [0053]     As shown in  FIG. 5 , the vertical pump  38  comprises two feed screw motors  45 ,  46  that drive feed screws  51 ,  52 . The two electrical feed screw motors  45 ,  46  are mounted within the motor housing  40  upon the support plate  43 . Motor  45  drives the feed screw  51  that extends partly through opening  39  in alignment with a pump plunger  66  of the pump  61 . Motor  46  drives the feed screw  52  located at the opposite side of hopper  25  from feed screw  51 , and aligned with another pump plunger  68  of the pump  62 .  
         [0054]     A level sensing mechanism  53  is located at the outlet end of hopper  25 . The mechanism is shown in detail in  FIG. 45 . The mechanism  53  comprises an elongated sensing element  54 . As the moldable food material is moved forwardly in the hopper  25 , it may accumulate to a level in which it engages and moves the sensing element  54  to a pre-selected degree. When this occurs, a signal is generated to stop the drive for the roller  36  of conveyor  31 . In this manner the accumulation of food material at the forward end  25   a  of hopper  25  is maintained at an advantageous level.  
         [0055]     When machine  20  is in operation, the feed screw motor  45  is energized whenever plunger  66  is withdrawn to the position shown in  FIG. 2 , so that feed screw  51  supplies meat from hopper  25  downwardly through outlet  39  into one side of the intake  41  of the food pumping system  26 . Similarly, motor  46  actuates the feed screws  52  to feed meat to the other side of intake  41  whenever plunger  68  of the pump  62  is withdrawn. In each instance, the feed screw motors  45 ,  46  are timed to shut off shortly after the plunger is fully retracted, avoiding excessive agitation of the meat. As the supply of food material in the outlet  39  is depleted, the conveyor belt  31  continuously moves food forwardly in the hopper and into position to be engaged by the feed screws  51 ,  52 . If the level of meat at the outlet  39  becomes excessive, conveyor  31  is stopped, as described above, until the supply at the hopper outlet is again depleted.  
         [0056]     The wall of the outlet  39  immediately below conveyor drive rollers  36  comprises a belt wiper plate  57  that continuously engages the surface of the conveyor  31  to prevent leakage of the food material  38  from the hopper at this point.  
         [heading-0057]     Food Pump System  
         [0058]     The food pump system  26  of molding machine  20  is best illustrated in  FIGS. 2 and 6 . Pump system  26  comprises the two reciprocating food pumps  61 ,  62  mounted on the machine base  21 . The first food pump  61  includes a hydraulic cylinder  64 . The piston in cylinder  64  (not shown) is connected to an elongated piston rod  67 ; the outer end of the elongated piston rod  67  is connected to the large plunger  66 . The plunger  66  is aligned with a first pump cavity  69  formed by a pump cavity enclosure or housing  71  that is divided into two pump chambers. The forward wall  74  of pump cavity  69  has a relatively narrow slot  73  that communicates with the valve manifold  27  as described more fully hereinafter.  
         [0059]     The pump housing  71  and the manifold  27  are preferably formed as a one piece stainless steel part.  
         [0060]     The second food pump  62  is essentially similar in construction to pump  61  and comprises a hydraulic cylinder  84 . Cylinder  84  has an elongated piston rod  87  connected to the large plunger  68  that is aligned with a second pump cavity  89  in housing  71 . The forward wall  94  of pump cavity  89  includes a narrow elongated slot  93  communicating with manifold  27 .  
         [0061]     Advantageously, the plungers  66 ,  68  and the pump cavities  69 ,  89  have corresponding round cross sections for ease of manufacturing and cleaning.  
         [0062]     As shown in  FIG. 6 , an elongated proximity meter  75  is affixed to the first pump plunger  66  and extends parallel to piston rod  67  into alignment with a pair of proximity sensors  76  and  77 . A similar proximity meter  95  is fixed to and projects from plunger  68 , parallel to piston rod  87 , in alignment with a pair of proximity sensors  96 ,  97 . Proximity sensors  76 ,  77  and  96 ,  97  comprise a part of the control of the two pumps  61 ,  62 .  
         [0063]     In operation, the first pump  61  pumps the moldable food material into manifold  27  and the second pump  62  receives a supply of the moldable food material for a subsequent pumping operation. Pump  61  begins its pumping stroke, and compresses food product in pump cavity  69 , forcing the moldable food material through slot  73  into manifold  27 . As operation of molding machine  20  continues, pump  61  advances plunger  66  to compensate for the removal of food material through manifold  27 . The pump can maintain a constant pressure on the food material in the chamber  69  during the molding cycle, or preferably can provide a pre-selected pressure profile over the molding cycle such as described in U.S. Pat. No. 4,356,595, incorporated herein by reference, or as utilized in currently available FORMAX machines. The pressure applied through pump  61  is sensed by a pressure sensing switch  78  connected to a port of the cylinder  64 .  
         [0064]     As plunger  66  advances, the corresponding movement of proximity meter  75  signals the sensor  76 , indicating that plunger  66  is near the end of its permitted range of travel. When this occurs, pump  62  is actuated to advance plunger  68  through pump cavity  89 , compressing the food material in the second pump cavity in preparation for feeding the food material from the cavity into manifold  27 . The pressure applied through pump  62  is sensed by a pressure sensing switch  79  connected to one port of cylinder  84 .  
         [0065]     When the food in the second pump cavity  89  is under adequate pressure, the input to manifold  27  is modified so that subsequent feeding of food product to the manifold is effected from the second pump cavity  89  with continuing advancement of plunger  68  of the second pump  62 . After the manifold intake has been changed over, pump  61  is actuated to withdraw plunger  66  from cavity  69 .  
         [0066]     Thereafter, when plunger  68  is near the end of its pressure stroke into pump cavity  89 , proximity sensor  96 , signals the need to transfer pumping operations to pump  61 . The changeover process described immediately above is reversed; pump  61  begins its compression stroke, manifold  27  is changed over for intake from pump  61 , and pump  62  subsequently retracts plunger  68  back to the supply position to allow a refill of pump cavity  89 . This overlapping alternating operation of the two pumps  61 ,  62  continues as long as molding machine  20  is in operation.  
         [0067]     The valve manifold  27 , shown in  FIGS. 2 and 6 , holds a valve cylinder or tube valve  101  fit into an opening  102  in housing  71  immediately beyond the pump cavity walls  74  and  94 .  
         [0068]     According to the embodiment illustrated in  FIGS. 5, 6  and  10 - 12 , the valve cylinder  101  includes two longitudinally displaced intake slots  107  and  108  alignable with the outlet slots  73  and  93 , respectively, in the pump cavity walls  74  and  94 . Slots  107  and  108  are angularly displaced from each other to preclude simultaneous communication between the manifold and both pump cavities  69  and  89 . Cylinder  101  also includes an elongated outlet slot  109 . The valve cylinder outlet slot  109  is generally aligned with a slot  111  (see  FIG. 9A ) in housing  71  that constitutes a feed passage for molding mechanism  28 .  
         [0069]     One end wall of valve cylinder  101  includes an externally projecting base end  103  that is connected to a drive linkage  104 , in turn connected to the end of the piston rod  105  of a hydraulic actuator cylinder  106  ( FIGS. 2 and 16 ).  
         [0070]     When the pump  61  is supplying food material under pressure to molding mechanism  28 , actuator cylinder  106  has retracted piston rod  105  to the inner limit of its travel, angularly orienting the valve cylinder  101 . With cylinder  101  in this position, its intake slot  107  is aligned with the outlet slot  73  from pump cavity  69  so that food material is forced under pressure from cavity  69  through the interior of valve cylinder  101  and out of the valve cylinder outlet slot  109  through slot  111  to the molding mechanism  27 . On the other hand, the second intake slot  108  of valve cylinder  101  is displaced from the outlet slot  93  for the second pump cavity  89 . Consequently, the food material forced into the interior of valve cylinder  101  from pump cavity  69  cannot flow back into the other pump cavity  89 .  
         [heading-0071]     Tube Valve System  
         [0072]      FIG. 10  illustrates the tube valve  101  separate from the apparatus  20 . The tube valve includes the base end  103  and a distal end  404 . The distal end  404  is inserted first into the opening  102  of the housing  71  during installation. The base end  103  includes an end flange  406  having two tapped holes  408  for connection to the drive link  104  by fasteners  409   a  and spacers  409   b  as shown in  FIG. 13 . The base end  103  further includes a groove  410  for an o-ring seal  411  and a smooth annular surface  412  that is journaled within a base end bearing or bushing  413  shown in  FIGS. 11, 12  and  12 A.  
         [0073]     The distal end  404  includes a reduced diameter guide portion  416  that positions a smooth annular surface  420  into a distal end bearing or bushing  421  as shown in  FIG. 11 . A ring seal  422  is positioned within an inside groove  423  of the opening  182 . A smooth annular surface  424  of the distal end  404  engages and seals against the ring seal  422  ( FIG. 11 ).  
         [0074]     As illustrated in  FIG. 12A , both bushings  413 ,  421  include a crown-shaped profile having openings  425  spaced around a circumferential surface that abuts the manifold  27  when installed. Each bushing  413 ,  421  include openings  426  for fasteners to fasten the bushings  413 ,  421  to the manifold  27 , and an inside circumferential grease groove  427  in communication with a grease fitting  428 .  
         [0075]     As illustrated in  FIG. 13 , the linkage  104  includes a lever bar  429  that is fastened to the base end  103  by the fasteners  409   a , and spacers  409   b . The rod  105  includes an extension  105   a  that has a square cross section. The extension has a rectangular notch  105   b  that is open towards a back side of the lever bar  429 .  
         [0076]     A follower block  430  is rotatably connected to the back side of the lever bar  429  by a threaded shank  431  of a knob  432 . In this regard, the follower block  430  includes a block portion  433   a  and a cylinder portion  433   b  having a threaded bore  434  to engage the shank  431 . The lever bar  429  includes a cylindrical bore  436  that receives the cylinder portion  433   b . The cylinder portion  433   b  is free to rotate in the bore  436 .  
         [0077]     The block portion  433   a  is free to vertically slide within the notch  105   b . Three positions of the block portion  433   a  are shown in  FIG. 25 :  433   a ,  433   ab ,  433   aa . Two positions of the lever bar  429  are shown:  429  and  429   aa.    
         [0078]     The valve cylinder  101  and corresponding slots or openings can alternately be as described in U.S. Provisional Application 60/571,368, filed May 14, 2004, or U.S. Ser. No. ______, filed on the same day as the present invention and identified by attorney docket number 2188P0381US, both herein incorporated by reference. According to these disclosures, rather than a single outlet  109 , two rows of progressively sized outlets, smallest closest to the active pump, are alternately opened to plural openings that replace the single opening  111 .  
         [heading-0079]     Molding Mechanism  
         [0080]     As best illustrated in  FIG. 9A , the upper surface of the housing  71  that encloses the pump cavities  69  and  89  and the manifold  27  carries a support plate or wear plate  121  and a fill plate  121   a  that forms a flat, smooth mold plate support surface. The mold support plate  121  and the fill plate  121   a  may be fabricated as two plates as shown or a single plate bolted to or otherwise fixedly mounted upon housing  71 . The fill plate  121   a  includes apertures or slots that form the upper portion of the manifold outlet passage  111 . In the apparatus illustrated, a multi fill orifice type fill plate  121   a  is utilized. A simple slotted fill plate is also encompassed by the invention.  
         [0081]     Mold plate  32  is supported upon plates  121 ,  121   a . Mold plate  32  includes a plurality of individual mold cavities  126  extending across the width of the mold plate and aligned during a portion of its reciprocating travel with the manifold outlet passageway  111 . Although a single row of cavities is shown, it is also encompassed by the invention to provide plural rows of cavities, stacked in aligned columns or in staggered columns. A cover plate  122  is disposed immediately above mold plate  32 , closing off the top of each of the mold cavities  126 . A mold cover or housing  123  is mounted upon cover plate  122 . The spacing between cover plate  122  and support plate  121  is maintained equal to the thickness of mold plate  32  by support spacers  124  mounted upon support plate  121 . Cover plate  122  rests upon spacers  124  when the molding mechanism is assembled for operation. Cover plate  122  is held in place by six mounting bolts, or nuts tightened on studs,  125 .  
         [0082]     As best illustrated in  FIGS. 3 and 6  mold plate  32  is connected to drive rods  128  that extend alongside housing  71  and are connected at one end to a transverse bar  129 . The other end of each drive rod  128  is pivotally connected to a connecting link  131  via a coupling plate  131   a  and a pivot connection  131   c , shown in  FIG. 16 . The pivot connection  131   c  can include a bearing (not visible in the figures) surrounding a pin  131   d  within an apertured end  131   e  of the connecting link  131 . The pin  131   d  includes a cap, or carries a threaded nut, on each opposite end to secure the crank arm to the coupling plate  131   a.    
         [0083]     Each drive rod  128  is carried within a guide tube  132  that is fixed between a wall  134  and a front bearing housing  133 . The connecting links  131  are each pivotally connected to a crank arm  142  via a pin  141  that is journaled by a bearing  141   a  that is fit within an end portion of the connecting link  131 . The pin crank arm  142  is fixed to, and rotates with, a circular guard plate  135 . The pin  141  has a cap, or carries a threaded nut, on each opposite end that axially fixes the connecting link  131  to the crank arm  142  and the circular guard plate  135 . The connecting link  131  also includes a threaded portion  131   b  to finely adjust the connecting link length.  
         [0084]     The crank arms  142  are each driven by a right angle gear box  136  via a “T” gear box  137  having one input that is driven by a precise position controlled motor  138  and two outputs to the gearboxes  136 . The “T” gear box  137  and the right angle gear boxes  136  are configured such that the crank arms  142  rotate in opposite directions at the same rotary speed.  
         [0085]     The precise position controlled motor can be a 6-7.5 HP totally enclosed fan cooled servo motor. The servo motor is provided with two modules: a power amplifier that drives the servo motor, and a servo controller that communicates precise position information to a machine controller.  
         [0086]     The controller and the servo motor  138  are preferably configured such that the servo motor rotates in an opposite rotary direction every cycle, i.e., clockwise during one cycle, counterclockwise the next cycle, clockwise the next cycle, etc.  
         [0087]     A bearing housing  143  is supported on each gearbox  136  and includes a rotary bearing  143   a  therein to journal an output shaft  136   a  of the gear box  136 . The output shaft  136   a  is fixed to the crank arm  142  by a clamp arrangement formed by legs of the crank arm  142  that surround the output shaft and have fasteners that draw the legs together to clamp the output shaft between the legs (not shown), and a longitudinal key (not shown) fit into a keyway  136   b  on the output shaft and a corresponding keyway in the crank arm  142  (not shown).  
         [0088]     A tie bar  139  is connected between the rods  128  to ensure a parallel reciprocation of the rods  128 . As the crank arms  142  rotate in opposite rotational directions, the outward centrifugal force caused by the rotation of the crank arms  142  and the eccentric weight of the attached links  131  cancels, and separation force is taken up by tension in the tie bar  139 .  
         [0089]     One circular guard plate  135  is fastened on top of each crank arm  142 . The pin  141  can act as a shear pin. If the mold plate should strike a hard obstruction, the shear pin can shear by force of the crank arm  142 . The guard plate  135  prevents an end of the link  131  from dropping into the path of the crank arm  142 .  
         [0090]     During a molding operation, the molding mechanism  28  is assembled as shown in  FIGS. 2 and 9 A, with cover plate  122  tightly clamped onto spacers  124 .  
         [0091]     In each cycle of operation, knockout cups  33  are first withdrawn to the elevated position as shown in  FIG. 9B . The drive for mold plate  32  then slides the mold plate from the full extended position to the mold filling position illustrated in  FIGS. 2 and 9 A, with the mold cavities  126  aligned with passageway  111 .  
         [0092]     During most of each cycle of operation of mold plate  32 , the knockout mechanism remains in the elevated position, shown in  FIGS. 17 and 18 , with knockout cups  33  clear of mold plate  32 . When mold plate  32  reaches its extended discharge position as shown in  FIG. 9B  the knockout cups  33  are driven downward to discharge the patties from the mold cavities. The discharged patties may be picked up by the conveyor  29 .  
         [0093]      FIG. 14  illustrates a mold drive rod lubricating system  1000  incorporated into the apparatus  20 . The lubrication system  1000  includes front bearings  1002  and rear bearings  1002  for each drive rod  128 . The location of the bearings is shown in  FIG. 6 .  
         [0094]     A pump  1008  takes suction from reservoir  1010  holding lubricating oil  1012 . A motor  1016  being either an electric, hydraulic, pneumatic or other type motor, drives the pump. The pump circulates lubricating oil through tubing and/or passages through the machine base area to the bearings  1002 ,  1004  and returns the lubricating oil through a filter  1022  to the reservoir. The pump, motor, reservoir and filter are all located within the machine base  21 .  
         [0095]      FIG. 15  illustrates a front bearing  1002 . The other front bearing and the rear bearings  1004  are configured in substantially identical manner. The front bearing  1002  includes a housing  1032  having an internal bore  1036  for holding a sleeve bearing element  1038 . The sleeve bearing element  1038  has an inside surface sized to guide the drive rod  128  and has a helical groove  1042  facing and surrounding the drive rod  128 . An oil inlet port  1050  communicates lubricating oil into an open end of the helical groove. Lubricating oil proceeds through the helical groove to an opposite end of the bearing element  1038  to a first outlet groove  1052  in communication with a second outlet groove  1054  through a longitudinal channel (not shown). The second outlet groove  1054  is in communication with an outlet port  1056 . The inlet port  1050  is in fluid communication with the pump  1008  and the outlet port  1056  is in fluid communication with the oil return lines to the filter  1022 . A front seal  1060  and a rear seal  1062  retain oil within the housing  1032 .  
         [heading-0096]     Knockout System  
         [0097]     Molding mechanism  28  further comprises a knockout apparatus  140  shown in  FIGS. 2, 9A ,  17 - 18 . The knockout apparatus comprises the knockout plungers or cups  33 , which are fixed to a carrier bar  145 . Knockout cups  33  are coordinated in number and size to the mold cavities  126  in the mold plate  32 . One knockout cup  33  is aligned with each mold cavity  126 . The mold cavity size is somewhat greater than the size of an individual knockout cup.  
         [0098]     The knockout apparatus  140  is configured to drive the carrier bar  145  in timed vertical reciprocation.  
         [0099]      FIGS. 17-18  illustrate the knockout apparatus  140  in more detail. The carrier bar  145  is fastened to knockout support brackets  146   a ,  146   b . The knockout support brackets  146   a ,  146   b  are carried by two knockout rods  147 . Each knockout rod  147  is disposed within a wall of a knockout housing  148  and is connected to a knockout beam  149 .  
         [0100]     The knockout beam  149  is pivotally mounted to a crank rod  151  that is pivotally connected to a fastener pin  156  that is eccentrically connected to a crank hub  155  that is driven by a motor  157 .  
         [0101]     The motor is preferably a precise position controlled motor, such as a servo motor. An exemplary servomotor for this application is a 3000 RPM, 2.6 kW servo motor provided with a brake. The servo motor is provided with two modules: a power amplifier that drives the servo motor, and a servo controller that communicates precise position information to the machine controller.  
         [0102]     The controller and the motor  157  are preferably configured such that the motor rotates in an opposite direction every cycle, i.e., clockwise during one cycle, counterclockwise the next cycle, clockwise the next cycle, etc.  
         [0103]     A heating element  160  surrounds, and is slightly elevated from the knockout carrier bar  145 . A reflector  161  is mounted above the heating element  160 . The heating element heats the knock out cups to a pre-selected temperature, which assists in preventing food product from sticking to the knock out cups.  
         [0104]     In  FIGS. 17-18 , the crank hub  155  is rotated into a position wherein the crank rod  151  is vertically oriented and the knockout beam  149  is lifted to its maximum elevation. The knockout rods are fastened to the knockout beam  149  by fasteners  152 . The knockout support brackets  146   a ,  146   b  are in turn fastened to the knockout rods  147  by fasteners  153 . Each knockout cup  33  is fastened to the knockout carrier bar by a pair of fasteners  154   a  and spacers  154   b . An air flap or air check valve  33   a  can be provided within each cup to assist in dispensing of a meat patty from the cup  33 .  
         [0105]     As shown in  FIG. 18 , the motor  157  is supported by a bracket  170  from a frame member  172  that is mounted to the casting  123 . The bracket  170  includes one or more slotted holes, elongated in the longitudinal direction (not shown). One or more fasteners  173  penetrate each slotted hole and adjustably fix the motor  157  to the frame member. The motor  157  includes an output shaft  176  that is keyed to a base end of the crank hub  155 . The fastener pin  156  retains a roller bearing  178  thereon to provide a low friction rotary connection between an annular base end  151   a  of the crank rod  151  and the pin  156 .  
         [0106]     The crank rod  151  has an apertured end portion  179  on an upper distal end  151   b  opposite the base end  151   a . The apertured end portion  179  is held by a fastener pin assembly  180  through its aperture to a yoke  182 . The yoke  182  is fastened to the knockout beam  149  using fasteners. The fastener pin assembly  180  can include a roller or sleeve bearing (not shown) in like fashion as that used with the fastener pin  156  to provide a reduced friction pivot connection.  
         [0107]     The housing  148  is a substantially sealed housing that provides an oil bath. Preferably, the housing walls and floor is formed as a cast aluminum part. The crank hub  155 , the pin  156 , roller bearing  178 , the apertured end portion  179 , the fastener pin  180  and the yoke  182  are all contained within the oil bath having an oil level  183 . The limits of the oil bath are defined by a housing  184  having a front wall  185 , a rear wall  186 , side walls  187 ,  188 , a top wall  189  and a sleeve  190 . The sleeve  190  is a square tube that surrounds a substantial portion of the crank rod  151  and is sealed around its perimeter to the top wall  189  by a seal element  196   a . The sleeve  190  is connected to the beam  149  and penetrates below the top wall  189 . As the yoke  182  reciprocates vertically, the beam  149  and the sleeve  190  reciprocate vertically, the sleeve  190  maintaining a sealed integrity of the oil bath.  
         [0108]     The crank rod  151  includes side dished areas  151   a  that act to scoop and propel oil upward during rotation of the hub  155  to lubricate the pin  180  and surrounding areas.  
         [0109]     The knockout rods  147  are guided to reciprocate through the side walls  187 ,  188 , particularly, through upper and lower bearings  191   a ,  191   b . The rods  147  are sealed to the top wall by seals  192 . The bearings  191   a  can include an internal groove  193  that is in flow-communication with a lubricant supply through port  194 .  
         [0110]     A lubricant system  194   a  is provided to provide lubricant to the bearings  191   a ,  191   b . The system  194   a  includes a lubricant reservoir  194   b  that is filled with lubricant, such as oil, and connected to plant air  194   c  via an electronically controlled valve  194   d . The machine controller C periodically, according to a preset routine, actuates the valve  194   d  to propel some lubricant into the bearings  191   a . Lubricant can run down the knockout rod  147  into a dished top  191   c  of the lower bearings  191   b  to allow oil to penetrate between the knockout rods  147  and the lower bearings  191   b.    
         [0111]     An outer cover  195  is fastened and sealed around the side walls  187 ,  188  and front and rear walls  185 ,  186  by fasteners, spacers  196  and a seal  197 . Any lubricating oil that passes through the seal can be returned to the oil bath via dished out drain areas and drain ports through the top wall.  
         [0112]     The front wall  185  includes an oil level sight glass  185   a , a fill port  185   b  (shown dashed in  FIG. 17 ), a drain port  185   c  ( FIG. 18 ); and an access hole closed by a screw  185   d  ( FIG. 18 ).  
         [0113]     The crank hub  155  is journaled for rotation by two roller bearings  198 ,  199 . The roller bearings  198 ,  199  are supported by a collar assembly  200  bolted to the rear wall  186  and to the motor  157 .  
         [0114]     The knockout assembly is changeable to extend further forwardly to minimize knockout cup cantilever. This is accomplished by loosening the bracket  170  from the frame member  172  and sliding the motor and all the connected parts forward or rearward and replacing circular adapter plates for the knockout rods  147 .  
         [0115]     The housing  148  is fastened to a support plate  201  by fasteners  201   a . The support plate  201  is fastened to circular adapter plates  201   b  by fasteners  201   c . The circular adapter plates  201   b  are removably fit into circular holes  201   d  in the casting  123 . The circular adapter plates  201   b  include a bottom flange  201   e  which abuts the casting  123 . The circular adapter plates  201   b  surround the bearings  191   b  and associated bearing assemblies  191   c.    
         [0116]     As shown in  FIG. 17A , the left bracket  146   a  is fixedly connected to the left knockout rod  147  using the fastener  153  while the right bracket  146   b  is connected for a sliding connection. In this regard the right fastener  153  passes through an inverted T-nut  153   a  that passes through the bracket  146   b  and fits into a back up washer  153   b  that abuts the top side of the bracket  146   b . The bracket  146   b  includes an oversized opening in the lateral direction that allows the bracket  146   b  to shift laterally with respect to the T-nut and knockout rod  147 . This arrangement allows the bar  145  to expand and contract laterally with respect to the knockout rods  147 . When the knockout cups  33  are heated by the heating element  160 , the carrier bar  145  can become heated as well. Preferably, the carrier bar  145  is composed of aluminum which can expand to a significant degree. The sliding connection of the bracket  146   b  accommodates this thermal expansion.  
         [0117]     The knockout assembly is changeable to extend further forwardly to minimize knockout cup cantilever and stress in supporting members. This is accomplished by loosening the bracket  170  from the frame member  172  and sliding the motor  157  and the connected parts forward or rearward and replacing the circular adapter plates that guide the knockout rods  147 .  
         [0118]     A proximity sensor  202  is bolted to the outer cover  195 , and a target  203  is provided on the crank beam  149  to be sensed by the proximity sensor  202 . The proximity sensor  202  communicates to the controller that the knockout cups are raised and the mold plate can be retracted without interfering with the knockout cups.  
         [0119]     From the foregoing, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the invention. It is to be understood that no limitation with respect to the specific apparatus illustrated herein is intended or should be inferred.