Abstract:
A rotary product processing device that has a frame made of endplates and at least one sidewall of one piece and unitary construction that encompasses a product processing chamber and product conveyor that is rotatively supported by a plurality of bearings that are each of one-piece, unitary and homogeneous construction. A drive cantilevers outwardly from an upraised mount of one of the endplates disposing it so it overlies part of the chamber. The endplate also carries and helps enclose a drivetrain that rotatively couples the conveyor to the drive. At least one of the bearings also functions as a thrust bearing for part of the drivetrain. Complementary angled tabs and slots facilitate assembly of the endplates and sidewall producing an integral frame. In one frame assembly method, angled lugs are received slots locating and helping self-fixture the endplates and sidewall enabling them to be attached along adjoining regions.

Description:
FIELD OF THE INVENTION 
   The present invention relates to a rotary processing device and more particularly to a rotary food processing device that is capable of processing food related waste. 
   BACKGROUND OF THE INVENTION 
   In the past, conventional rotary processing devices utilized a frame from which components of the device were hung. These components included end plates, one or more sidewalls and the like. In addition, rotary components of the device are typically supported by trunnions, which are also mounted to the frame. While these devices have been commercially successful, improvements nonetheless remain. 
   What is needed is a rotary processing device made with a minimum of components. 
   SUMMARY OF THE INVENTION 
   The invention is directed to a rotary product processing device which is used to process product, such as food product, waste product, and the like, using a rotary action while the product is disposed in a product processing chamber. The device includes a frame, an inlet, an outlet, a product processing chamber in which product is processed, and a drive. The drive can be coupled to an auger that is disposed inside the product processing chamber. The auger can be engaged with the product processing chamber such that rotating the product processing chamber also rotates the auger. Where such engagement exists, rotation of the auger and product processing chamber occur substantially in unison therewith. 
   In a preferred embodiment, the frame is made up of a pair of end plates of one piece and unitary construction that are spaced apart by a sidewall that also is of one piece and unitary construction. The sidewall has a pair of side edges that are each preferably equipped with a pair of outwardly extending locator tabs that each are received in a complimentary locator slot in one of the end plates. In one preferred embodiment, each locator tab and its corresponding slot extend in a diagonal direction for providing both horizontal and vertical end plate and sidewall location during assembly. 
   In a preferred embodiment, there also is a hood that overlies the product processing chamber that is of one piece and unitary construction that also is equipped with integrally formed handles. In a preferred embodiment, the sidewall extends underneath the product processing chamber to form a fluid-holding tank therealong. 
   In a preferred embodiment, the drive is mounted to one of the end plates. Preferably, the drive is mounted to the inlet end plate and can be oriented such that it overlaps or overlies the product processing chamber. The drive preferably is coupled by a drive arrangement that is also mounted or otherwise carried by the same end plate as what carries the drive. A cover preferably mates with the end plate thereby helping to form a drive assembly enclosure therebetween that encompasses the drive arrangement. 
   In a preferred embodiment, there is a bearing cradle at each end that rotatively supports one end of the auger or the product processing chamber. Each bearing preferably is of one piece, unitary, non-metallic and homogenous construction. In one preferred embodiment, one bearing cradle is of two piece construction, forming an annular bearing cradle, and the other bearing cradle is annular in shape. Where such is the case, each bearing cradle component, excluding any mounting hardware, is of one piece, unitary, non-metallic and homogenous construction. In one preferred embodiment, at least one of the bearing cradles functions as both a rotary bearing and a thrust bearing. 
   Other objects, features, and advantages of the present invention will become apparent to those skilled in the art from the detailed description and the accompanying drawings. It should be understood, however, that the detailed description and accompanying drawings, while indicating at least one preferred embodiment of the present invention, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof, and the invention is intended to include all such modifications. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Preferred exemplary embodiments of the invention are illustrated in the accompanying drawings in which like reference numerals represent like parts throughout and in which: 
       FIG. 1  is a rear perspective view of a preferred embodiment of a rotary product processing device made in accordance with the invention; 
       FIG. 2  is an exploded view of the rotary product processing device of  FIG. 1 ; 
       FIG. 3  is front perspective view of the rotary product processing device; 
       FIG. 4  is a fragmentary front perspective view of the rotary product processing device of the invention with a cover and parts of a drive assembly removed for clarity; 
       FIG. 5  is a fragmentary front perspective view of the rotary product processing device of the invention with a cover removed to show parts of a drive assembly and a hood removed to show a product processing chamber and conduit; 
       FIG. 6  is a cross-sectional view of the rotary product processing device; 
       FIG. 7  is an enlarged cross sectional view of the inlet end of the rotary product processing device; 
       FIG. 8  is an enlarged cross sectional view of the outlet end of the rotary product processing device; 
       FIG. 9  is a front view of a preferred embodiment of an inlet end bearing cradle; 
       FIG. 10  is an end view of the inlet end bearing cradle; 
       FIG. 11  is a cross section of the inlet end bearing cradle taken along line  11 – 11  of  FIG. 9 ; 
       FIG. 12  is a front view of a preferred embodiment of an outlet end bearing cradle; 
       FIG. 13  is an cross sectional view of the outlet end bearing cradle taken along line  13 – 13  of  FIG. 12 ; and 
       FIG. 14  is an enlarged cross sectional view of the outlet end bearing cradle taken along line  14 – 14  of  FIG. 12 . 
   

   Before explaining one or more embodiments invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments or being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting. 
   DETAILED DESCRIPTION 
     FIGS. 1–3  illustrate a rotary processing device  30  of the invention that includes a frame  32 , a product conveying arrangement  34 , and a drive assembly  36  coupled to the product conveying arrangement  34 . Referring additionally to  FIG. 2 , the product conveying arrangement  34  is supported adjacent an inlet  38  by a bearing arrangement  40  and is supported adjacent an outlet  42  by another bearing arrangement  44 . During operation, product to be processed enters the inlet  38 , is processed while being moved along by the product conveying arrangement  34 , and is expelled out the outlet  42 . 
   The frame  32  includes an outlet end plate  46  to which at least one longitudinally extending sidewall arrangement  48  is anchored. The frame  32  also includes an inlet end plate  50  to which the at least one longitudinally extending sidewall arrangement  48  is also anchored. In the preferred embodiment shown in the drawing figures, the sidewall arrangement  48  is made up of a pair of sidewalls  52 ,  54  with each one of the sidewalls attached at its outlet end to the outlet end plate  46  and attached at its inlet end to the inlet end plate  50 . 
   The outlet end plate  46  is of one-piece unitary and homogenous construction. In a preferred embodiment, the end plate  46  is cut from a sheet of stainless steel to a tolerance of about five thousandths of an inch using a cutting machine that preferably is a laser cutting machine. The outlet end plate  46  preferably rests directly upon the ground or upon a spacer or locator block (not shown) that is grounded. The end plate  46  has a generally planar section  56  and a pair of tabs  58 ,  60  that each serve as a foot for the rotary processing device. The pair of tabs  58 ,  60  is formed from the cut sheet such that they are integrally formed. As is shown in more detail in  FIG. 2 , the outlet end plate  46  has a relatively large circular bore  62  through which a journal  64  of the rotary product conveying arrangement  34  extends and a notch or bore  66  through which a conduit  68  is received. 
   Referring additionally to  FIG. 4 , the inlet end plate  50  is also of one-piece unitary and homogenous construction. The end plate  50  preferably is cut from a sheet of stainless steel such that a plurality of pairs of sidewall forming flanges  70  are formed along with a plurality of pairs of mounting arms  72  that is each carried by a flange  70 . The end plate  50  has a generally planar section  74  with a drive-carrying arm  76  that positions the drive assembly  36  such that it overlies a portion of a product conveying arrangement  34 . Each bent flange  70  forms an outturned sidewall  80  about the periphery of the generally planar section  74  of the end plate  50 , which increases end plate stiffness, structural rigidity and strength. Another pair of outturned integral flanges  82 ,  84  functions as a pair of feet for the rotary processing device  30 . 
   When each sidewall forming flange  70  is desirably bent in the manner depicted, it forms part of the drive assembly enclosure  78  shown in  FIGS. 3 and 4 . As is shown in  FIG. 3 , an outer cover  71  mates with the inlet end plate  50  to complete the drive assembly enclosure  78 . A plurality of fasteners  73  are used to attach the cover to the end plate  50 . For example, each fastener  73  extends through a bore in the cover (not shown) and engages one of the mounting arms  72  to attach the cover  71  to the end plate  50 . The cover  71  also includes an inlet conduit  75  that communicates matter to be processed to the inlet  38  of a product processing chamber  130 . 
   Referring once again to  FIG. 2 , to accommodate a shaft  86  of the drive assembly  36 , the drive-carrying arm  76  of the planar section  74  of the inlet end plate  50  has a bore  88  in it through which a portion of the shaft  86  extends. To accommodate a journal  90  of the inlet end of the rotary product conveying arrangement  34 , the planar section  74  below the arm  76  has a second bore  92  through it. 
   The frame  32  is formed with a minimum of components thereby advantageously simplifying assembly, maintenance and expenses associated therewith. The frame  32  is formed by attaching the sidewall arrangement  48  to the end plates  46 ,  50  by bonding them together. One preferred bonding method is welding. When assembly is completed, the resultant frame  32  is strong, stiff, and structurally rigid enough to meet the continuous operational demands of rotary processing device operation. 
   To facilitate assembly, each end plate  46 ,  50  has a plurality of pairs of diagonally extending slots  94 ,  96  that each receive a corresponding lug  98 ,  100  that extends outwardly from a side edge  102 ,  104  of each sidewall panel  52 ,  54 . For example, each side edge  102  and  104  of each sidewall panel  52 ,  54  has an upper lug  98  and a lower lug  100  that each extends outwardly from the side edge. During assembly, each end plate  46 ,  50  is vertically oriented and at least one of the sidewall panels  52 ,  54  is generally horizontally oriented with its upper lug  98  disposed adjacent an upper end plate slot  94  and its lower lug  100  disposed adjacent a lower end plate slot  96 . The end plates  46 ,  50  are brought toward the sidewall panel such that each lug  98 ,  100  is received in its corresponding slot  94 ,  96 . The same is done with the other sidewall panel. 
   The end result is a frame assembly  32  that is self-aligning, substantially self-supporting, and which helps form its own fixture. As a result, attachment of the frame components is simpler and easier because, once the lugs are seated in their respective slots, a fabricator only needs to make sure that each end plate  46 ,  50  is firmly abutted against the adjacent side edge of each sidewall panel  52 ,  54  before attaching the components together. For example, after assembly and making sure each end plate is firmly abutted against the adjacent side edge of each sidewall panel, each end plate is bonded, preferably by welding, to each adjacent sidewall panel, preferably along its side edge. 
     FIGS. 2–4  illustrate a drive assembly  36  of the invention in more detail. The drive assembly  36  includes a drive  106  that is mounted by a coupling arm  108  to a gearbox  110  that is fixed to the drive-carrying arm portion  76  of the inlet end plate  50 . The gearbox shaft  86  extends through bore  88  ( FIG. 2 ) in the end plate  50  where it receives a drive wheel  112  of a drive arrangement  114 . An endless flexible member  116  connects the drive wheel  112  to a driven wheel  118  for rotation substantially in unison therewith. The driven wheel  118  is mounted by a plurality of fasteners  120  ( FIG. 5 ) to a collar  122  ( FIG. 4 ) of the inlet end journal  90 . 
   In a preferred embodiment, the drive  106  is an electric motor that can be selectively controlled so as to vary its speed. The coupling arm  108  preferably is a tube that fixes the motor  106  to the gearbox  110  but which also couples the output shaft  124  of the motor  106  to an input (not shown) of the gearbox  110 . The gearbox  110  preferably comprises a gear reducer or the like. The gearbox  110  is mounted by a bracket  126  that permits positioning adjustments to be made to the gearbox  110  and the like. The drive wheel  112  preferably is a sheave, a pulley, a sprocket, or the like and the endless flexible member  116  preferably is a belt, a cable, a chain or the like. 
   Referring additionally to  FIG. 6 , the product conveying arrangement  34  rotates during operation. In the preferred embodiment shown in the drawing figures, the product conveying arrangement  34  includes an auger  128  disposed inside a product processing chamber  130 . The product processing chamber  130  preferably also rotates during operation, preferably in unison with the auger  128 . In the preferred embodiment shown in the drawing figures, the auger  128  consists of a plurality of pairs of axially, circumferentially and angularly spaced apart flights  132  that are each attached to an interior processing chamber surface  134 . Each auger flight  132  preferably is attached to the interior processing chamber sidewall surface  134  using a plurality of fasteners (not shown) or the like that fix the flight  132  thereto. The auger flights  132  preferably are arranged in a generally helical pattern so as to forwardly urge product  136  in the processing chamber  130  through the chamber  130  during rotation. 
   The product processing chamber  130  has a body  138  that is of tubular construction with it being oriented such that its inlet end is located adjacent the inlet  38  of the rotary processing device  30  and its outlet end is located adjacent the outlet  42  of the device. Preferably, the product processing chamber body  138  is of generally cylindrical and perforate construction. In one preferred embodiment, the chamber body  138  is comprised of a screen that preferably is a wedgewire screen or the like. 
   The conduit  68  is disposed above the product processing chamber  130  and is equipped with a plurality of pairs of longitudinally spaced apart discharge orifices  140  that each preferably comprises a discharge nozzle. The spaced apart nozzles  140  preferably extend substantially the full length of the processing chamber  130  to enable coverage therealong. One end of the conduit  68  is cradled in a notch  66  ( FIG. 2 ) in the outlet end plate  46  and the other end is received in a mounting block  142  that is attached to the inlet end plate  50 . A mounting bracket  144  that is attached to the outlet end plate  46  helps keep the conduit  68  captive to the end plate  46 . 
     FIG. 6  illustrates a cross sectional view of the inlet tube  75 . The inlet tube  75  has a sidewall  146  of generally cylindrical construction and a downwardly extending discharge plate  148  that defines a generally downwardly opening discharge outlet  150 . During operation, product and the like entering the inlet tube  75  can impinge against the discharge plate  148  before falling downwardly into the product processing chamber  130 . 
   Referring once again to  FIGS. 1 and 2 , a hood  152  overlies the conduit  68 , the auger  128 , and the product processing chamber  130 , and preferably abuts or adjoins both end plates  46  and  50 . The hood  152  is of one-piece, unitary and homogenous construction and it includes a pair of spaced apart and integrally formed handles  154 . The hood  152  has two halves  156 ,  158  with one hood half  156  being obtusely angled relative to the other hood half  158 . 
   Referring to  FIG. 7 , the inlet tube  75  is generally coaxial with and received in the inlet end journal  90 . As is shown in  FIG. 7 , the inlet tube  75  has a diameter that is less than the diameter of the inlet end journal  90  to permit the journal  90  to rotate relative to the tube  75 . 
   The inlet end journal  90  preferably is generally cylindrical so as to facilitate rotation of the product processing chamber  130  to which it is coupled. In the preferred embodiment shown in  FIG. 7 , the journal  90  is attached at one axial end by fasteners  120  to driven wheel  118  and at its other axial end by fasteners  160  to an end cap  162  that is attached to an axial end of the body  138  of the product processing chamber  130 . In one preferred embodiment, the end cap  162  is attached to an axial end of the body  138  of the product processing chamber  130  by a plurality of pairs of fasteners (not shown). In another preferred embodiment, the end cap  162  is attached by a weld (not shown) to the processing chamber body  138 . 
   The inlet end bearing arrangement  40  is a bearing ring assembly  164  that encompasses the bore  92  in the inlet end plate  50  and that encircles the inlet end journal  90 . Referring once again to  FIG. 2 , the annular bearing ring  164  is made up of an arcuately shaped upper bearing cradle  166  that overlies the journal  90  and an arcuately shaped lower bearing cradle  168  that underlies the journal  90 . Each bearing cradle  166 ,  168  is attached to the inlet end plate  50  by a plurality of fasteners  170 . 
   Referring additionally to  FIGS. 9–11 , each bearing cradle  166  and  168  is of one-piece, unitary and homogeneous construction. Each bearing cradle  166 ,  168  preferably is of semicircular construction with integrally formed bolt hole pockets  167  equiangularly spaced about the cradle. Each bearing cradle  166  and  168  is made of a nonmetallic material. One preferred material is nylon. Another preferred material is ultra-high molecular weight polyethylene. Each bearing cradle preferably also is lubricant impregnated. Where the rotary processing device  30  is used for food processing applications, the lubricant preferably is a food grade lubricant that can be mineral oil based. 
   Each bearing cradle  166  and  168  has a pair of bearing surfaces  169  and  171  with one of the bearing surfaces  169  being a thrust bearing surface and the other one of the bearing surfaces  171  being a bearing surface that supports the inlet end journal  90 . During operation, collar  122  and/or driven wheel  118  bear against the thrust bearing surface  169 . 
   During operation, the inlet end journal  90  bears against the rotary bearing surface  171 . As is shown more clearly in  FIG. 11 , the rotary bearing surface  171  has a curvilinear outer profile that preferably is spherical or elliptical. Such a curvilinear bearing surface advantageously wears uniformly and provides increased bearing surface area contact as wear occurs. This helps increase bearing life while also being capable of handling widely varying bearing loads. 
   When wear of the bottom portion of the bearing surface  171  of the lower bearing cradle  168  becomes too great, the bearing mounting arrangement permits the lower bearing cradle  168  to be switched with the upper bearing cradle  166  to provide a less worn bearing surface  171 . As a result, bearing life is advantageously further improved. 
   Referring to  FIG. 8 , the outlet end journal  64  is attached to the body  138  of the product processing chamber  130 , preferably using fasteners, one or more welds, or the like. The outlet end journal  64  is ringed by an annular bearing arrangement  40  that preferably is a bearing ring  172  of one-piece, unitary and homogenous construction. The bearing ring  172  is attached to the outlet end plate  46  by a plurality of pairs of fasteners  174  that are circumferentially spaced about the ring  172 . 
   Referring additionally to  FIGS. 12–14 , the bearing ring  172  is made of a nonmetallic material. One preferred material is nylon. Another preferred material is ultra-high molecular weight polyethylene. The bearing ring preferably also is lubricant impregnated. Where the rotary processing device  30  is used for food processing applications, the lubricant preferably is a food grade lubricant that can be mineral oil based. 
   The bearing ring  172  preferably is circular in shape. The inner peripheral surface  176  of the bearing ring  172  is a bearing surface that rotatively supports the outlet end journal  64 . The bearing ring  172  has a plurality of pairs of equiangularly spaced apart bolt hole pockets  178 . When wear of the bottom of the bearing surface  176  becomes too great, this an arrangement permits the bearing ring  172  to be removed and rotated to move the worn portion of the bearing surface  176  away from the bottom, thereby moving a less worn portion of the bearing surface  176  to the bottommost position. 
   During operation, the outlet end journal  64  bears against the rotary bearing surface  176 . As is shown more clearly in  FIG. 14 , the rotary bearing surface  176  has a curvilinear outer profile that preferably is spherical or elliptical. Such a curvilinear bearing surface advantageously wears uniformly and provides increased bearing surface area contact as wear occurs. This helps increase bearing life while also being capable of handling widely varying bearing loads. 
   In use, a rotary processing device  30  of the invention is well suited, for example, for processing food product, classifying applications, sieve and screen applications, and grading and sorting applications. In one preferred embodiment, a rotary processing device  30  fabricated in accordance with the invention is well suited for use as a reclaim screen. In another preferred embodiment, a rotary processing device  30  fabricated in accordance with the invention is well suited for use as a grader or classifier. In a still further preferred embodiment, a rotary processing device  30  fabricated in accordance with the invention is well suited for use as a blancher, cooker or cooler. 
   When configured as a reclaim screen, the rotary processing device  30  is configured as depicted in the drawing figures. During operation, waste product  136  to be processed passes through the inlet tube  75  where it enters the product processing chamber  130 . Auger rotation urges the waste product  136  from adjacent the inlet end of the product processing chamber  130  toward the outlet end. As the waste product  136  travels along the chamber  130 , matter, primarily water, falls through the perforations in the chamber body  138  into a collector (not shown) below a bottom opening  180  ( FIG. 6 ) created between the frame sidewalls  52 ,  54 . Waste product  136  exiting the outlet  42  is gathered in a separate collector (not shown) where it preferably awaits disposal. During operation, liquid preferably is expelled from the discharge nozzles  140  of the conduit  68  to keep waste product  136  from plugging perforations in the chamber body  138  and to dislodge waste product  136  that is plugging such perforations. 
   When configured as a grader or classifier, product  136  entering the processing chamber  130  is graded or classified according to the size of the perforations in the chamber body  138 . Product  136  sized about the same or smaller than perforations in the chamber body  138  falls through the perforations into a collector (not shown) below the body  138 . Larger product  136  travels along the length of the chamber  130  where it is expelled out the outlet. 
   When configured as a blancher, cooker or cooler, the sidewalls  52 ,  54  are joined or configured to form a sidewall of one-piece and unitary construction that forms a fluid-holding tank that underlies and encompasses at least part of the product processing chamber  130 . The fluid-holding tank preferably holds a liquid, preferably water, which is used in the processing of product  136  as it travels along the product processing chamber  130 . The product  136  preferably is a food product, such as pasta, beans, peas, corn, syrup, sauce, or the like. If desired, the product  136  being processed can be pouched food product. 
   It is understood that the various preferred embodiments are shown and described above to illustrate different possible features of the invention and the varying ways in which these features may be combined. Apart from combining the different features of the above embodiments in varying ways, other modifications are also considered to be within the scope of the invention. 
   The invention is not intended to be limited to the preferred embodiments described above, but rather is intended to be limited only by the claims set out below. Thus, the invention encompasses all alternate embodiments that fall literally or equivalently within the scope of these claims.