Patent Description:
Food processors utilize high-speed molding machines, such as FORMAX® MAXUM700®, F-<NUM>™, F-<NUM>™, F-<NUM>™, F-<NUM>™, or F-<NUM>™ reciprocating mold plate forming machine, available from Formax, Inc. of Mokena, Illinois, U. , for supplying patties to the fast food industry. High-speed molding machines are also described for example in <CIT>:<CIT><CIT><CIT><CIT>, and <CIT>.

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 an enhanced controllability and ability to tune a patty-forming machine for particular food materials to be processed, for an enhanced effectiveness of a patty-forming machine in producing uniform patties, for an even greater output rate of patties from a patty-forming machine, for an enhanced convenience for cleaning and maintenance of a patty-forming machine, and for a smoother and quieter patty-forming machine operation.

Document <CIT> discloses a patty machine for forming successive patties of a predetermined size from a quantity of a bulk product, such as ground meat. The machine includes a charging chamber in which the product is pressure-fed into a patty mold cavity by means of intermeshing, positive displacement, self-wiping compressor screws. The product is delivered from a feed hopper to the entrance of the charging chamber by means of intermeshing, self-wiping conveyor screws which operate on a demand basis to convey the product to the compressor screws only as needed to thereby avoid unnecessary working or kneading of the product. Shafts for driving and supporting the conveyor and compressor screws extend throughout the length of the machine and each carries one conveyor and one compressor screw.

Document <CIT> discloses a machine for forming patties of a moldable material, such as a meat product, including a hopper having a paddle rotatably mounted in it and a feed screw leading from the bottom of the hopper to a mold charging piston and cylinder. A mold plate having a mold cavity formed in it slides back and forth over the mold charging device and receives a charge of the product each time the mold cavity communicates with the discharge opening of the charging device. A common drive is utilized for the paddle, the feed screw, the mold plate, the mold charging piston and cylinder, a knock-out device for ejecting patties from the molding plate and a conveyor for removing the molded patties away from the machine in stacks of preselected numbers. Therefore, it is an object to provide a food product forming machine comprising an improved hopper for holding a supply of food product.

This object is achieved by a food product forming machine according to claim <NUM>.

The food product forming machine of the invention provides an automated food product molding machine capable of producing uniform molded food products, such as food patties, at a high rate of production.

The food product machine has a food supply, a rotary food pump connected to the food supply, a molding mechanism having a mold plate and a knockout drive, and a mold plate configured to be driven to reciprocate between a fill position and a discharge position, The knockout dri ve is for reciprocating a knockout plunger to discharge molded food products from a cavity in the mold plate, the mold plate being reciprocated by a mold plate drive between a cavity fill position and a cavity discharge position. The machine further includes a manifold connected to an outlet of the food pump and having an outlet passageway connected to an inlet of the molding mechanism for filling the cavity of the mold plate. According to the invention, the outlet of the food pump is located below the mold plate and the manifold and an inlet of the pump is located above the mold plate and the manifold. The food pump is preferably a positive displacement pump. The pump preferably has two rotors configured to create a vacuum between the inlet and the outlet when driven to rotate for drawing food product to the outlet.

In one embodiment, the rotary food pump has two rotors. Each rotor has at least two wings and each rotor has an area of rotation that overlap with the other rotor. The pump has a drive shaft and a driven shaft, the drive shaft has a drive gear at a first end and one of the rotors at the second end, the driven shaft has a driven gear at a first end and the other of the rotors at the second end; the drive and driven gears are meshed to operate the rotors in sync.

The machine has a pump motor connected to a drive shaft of the rotary pump. The pump motor is a servo rotary actuator.

Preferably, the machine has a hopper for holding a supply of food product, and an auger system configured to force food product through an outlet of the hopper. The auger system has at least a feed screw configured to move food product longitudinally forward in the hopper toward die outlet.

The feed screw preferably is located in the hopper connected to a feed screw drive configured to rotate the feed screw. The feed screw is located at the bottom of the hopper. The feed screw is positioned horizontally in the bottom of the hopper and is configured to rotate and drive food product: toward the front of the hopper.

The hopper preferably has an outlet at the front of the hopper. The outlet extends from the floor of the hopper upward at the front of the hopper.

Preferably, the outlet extends forward of the main hopper body and encloses a forward portion of the feed screw. The outlet has a connecting section connected to the main hopper body, and a narrowing section opposite the connecting section.

Preferably, the hopper has an opening at the lower rear of the hopper configured to remove the feed screw therethrough for maintenance, and a cap for removably covering the opening; the feed screw journaled to rotate in an opening of the cap,.

Preferably, the feed screw drive is located outside of the hopper and is axially aligned and connected with a shaft of the feedscrew. The feed screw is longitudinally orientated at the bottom of die hopper.

Preferably, the auger system has a plurality of feed screws located in the hopper. The feed screws are located adjacent to each other and adjacent to the floor of the In one embodiment, the food product forming machine comprises a plunger fill system to assist in filling mold cavities. The plunger fill system comprises a pair of plungers which can be lowered into the intake manifold to provide an increase in fill pressure by displacing a predetermined volume of food mass. 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, from the claims and from the accompanying drawings.

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.

The food product forming machine or food patty molding machine <NUM> is illustrated in <FIG>. The molding machine <NUM> includes a machine base <NUM>, optionally mounted upon a plurality of feet <NUM>, rollers or wheels. The machine base <NUM> supports the operating mechanism for machine <NUM> and contains electrical actuating systems, and most of the machine controls. The machine <NUM> includes a food supply system <NUM> for supplying moldable food material, such as ground beef, fish, or the like, to the processing mechanisms of the machine. A control panel, such as a touch screen control panel <NUM>, is arranged on a forward end of the machine <NUM>.

As generally illustrated in <FIG>, <FIG>, <FIG>, the food supply system includes an auger system <NUM> and a hopper <NUM> that opens into the intake of a food pump system <NUM>. The food pump system <NUM> includes at least one food pump, described in detail hereinafter, that continuously, or Intermittently under a pre-selected control scheme controlled by a machine control or controller <NUM>, pump food, under pressure, into a manifold <NUM> flow-connected to a cyclically operated molding mechanism <NUM>. Generally during operation of the machine <NUM>, the pump is forcing food material under pressure into the intake of manifold <NUM>. The operation of the machine is controlled the machine control <NUM>.

In the operation of machine <NUM>, a supply of ground beef or other moldable food material is deposited into hopper <NUM> from overhead. An automated refill device (not shown) can be used to refill the hopper when the supply of food product therein is depleted. At the bottom of the hopper <NUM> is the auger system <NUM> for moving the food material longitudinally of the hopper <NUM> to the inlet <NUM> of the food pump system <NUM>.

The manifold <NUM> comprises a system for feeding the food material, still under relatively high pressure, into the molding mechanism <NUM>. Molding mechanism <NUM> operates on a cyclic basis, first sliding a multi-cavity mold plate <NUM> into a receiving position over manifold <NUM> and then away from the manifold to a discharge position aligned with a series of knock out cups <NUM>. When the mold plate <NUM> is at its discharge position, knock out cups <NUM> are driven downwardly, discharging hamburgers or other molded patties from machine <NUM>, as indicated by direction A in <FIG>. The molded parties are deposited onto a conveyor <NUM> that is positioned under the knockout cups <NUM>, to be transported away from the machine <NUM>.

The food supply system <NUM> includes the hopper and the auger system <NUM>, as shown in <FIG>, <FIG>, <FIG>. The auger system <NUM> is located at the bottom of the hopper <NUM>. The auger system includes two feed screws <NUM>, <NUM>, and two feed screw drive motors <NUM>, <NUM>. The feed screws <NUM>, <NUM> each have a center shaft <NUM>, <NUM>. The center shaft is journaled in and supported by front and rear feed screw supports <NUM>, <NUM>, The feed screw supports extend vertically from and attach to the machine base <NUM>. The feed screws are located adjacent to one another and extend longitudinally along the bottom of the hopper. The center shafts are parallel to the bottom <NUM> of the hopper.

As shown in <FIG>, the rear 25c of the hopper has an opening that is covered by a cap <NUM>. The cap <NUM> has holes <NUM> that the feed screw shafts are journaled to rotate therein on bearings. The shafts extend through the cap to connect to the motors <NUM>, <NUM>. The rear opening of the hopper has a vertical lip 529a. The back of the cap has a recessed portion 530a that mates with the lip 529a. The cap also has a non-recessed portion 530b that fits into the rear opening.

A hopper outlet <NUM> is formed to or attached to the front <NUM> of the hopper <NUM>. A portion of the outlet opening is aligned with the bottom floor <NUM> of the hopper and the opening extends upwardly from the floor <NUM>. The outlet extend forward of the main hopper body 25c as shown in <FIG>. The outlet has a connecting section <NUM> and a narrowing section <NUM> that narrows to an outlet flange <NUM> toward the food pump system <NUM>. The outlet has a width that is greater than its height. Upper and lower feed screw supports <NUM>, <NUM> extend from the conical section <NUM> to a bearing head or sleeve <NUM>. The supports <NUM>, <NUM> are perpendicular to the conical section <NUM> inside surface and extend therefrom to an elbow 421a, 421b and bearing sleeves <NUM>. The front of the shafts <NUM>, <NUM> have a recessed portion <NUM> that terminates in a conically reducing point end <NUM>. The point end <NUM> extends beyond the bearing sleeves <NUM>. The shafts <NUM>, <NUM> are journaled to rotate at the front on the recessed portion <NUM> in the bearing sleeves. As shown in <FIG>, a front portion 404a of each feed screw is enclosed by the outlet and extends beyond the main hopper body 25c.

As shown in detail in <FIG> and <FIG>, the feed screw drive motors <NUM>, <NUM> are mounted to a feed screw drive motor support plate <NUM> by screws, studs, or bolts <NUM>. The support plate <NUM> is attached to a support mount <NUM> by screws or bolts <NUM>. The support mount <NUM> is attached to vertical support members <NUM>, <NUM> by fasteners <NUM>, <NUM> respectively. The vertical support members <NUM>, <NUM> extend vertically from the machine base <NUM> and are supported thereon. The support mount <NUM> has a ledge <NUM> defining a recessed area 435a. The support plate is located in the recessed area 435a and on the ledge <NUM>. The drive motors, <NUM>, <NUM> are enclosed by a drive motor housing <NUM>. The drive motor housing <NUM> is attached to the support plate <NUM>. The motors <NUM>, <NUM> are axially aligned with the corresponding feed screws <NUM>, <NUM> respectively. Output shafts 406a, 408a are coaxial with the corresponding feed screw shafts <NUM>, <NUM> respectively. The supports hold the feed screw slightly above the bottom <NUM> surface of the hopper <NUM> to form a small gap <NUM> between the feed screw and the bottom.

A cap retaining brace <NUM> is attached by a bolt <NUM> to the support plate <NUM> and extends forward to contact the cap <NUM> by a wide member base <NUM> to hold the cap engaged with the hopper <NUM>.

The feed screws <NUM>, <NUM> are removable from the hopper for service and cleaning. To remove the feed screws <NUM>, <NUM>, the support plate <NUM> and the support mount <NUM> are disconnected from the vertical support members <NUM>, <NUM> via the fasteners <NUM>, <NUM>. The support mount <NUM> is moved longitudinally rearward and the recessed portions <NUM> of the feed screw shaft are withdrawn from the bearing sleeves <NUM> at the front and the feed screws are withdrawn rearward from the hopper.

The hopper is shown in <FIG>, <FIG>, <FIG>, <FIG>, and <FIG>. As shown in <FIG>, the hopper <NUM> has a working position 25a and a service position 25b. When the hopper is in the service position it is tilted <NUM> degrees to the right or left side to permit a person to more easily clean or service the hopper.

As shown in <FIG>, the hopper <NUM> has front and rear pairs of mounting arms <NUM>, <NUM>, <NUM>, <NUM>. Each mounting arm has a horizontal support pin <NUM>, <NUM>, <NUM>, and <NUM>. The front mounting pins extend forwardly from the front mounting arms <NUM>, <NUM> and the rear mounting pins extend rearward from the rear mounting arms <NUM>, <NUM>. The pins engage a hopper support <NUM>, <NUM> , <NUM>, <NUM>, Each hopper support, as best shown in <FIG>, has a U-shaped end 550a, 550b (not labeled for front: hopper supports). The outer end of each pin lies in the U-shaped channel of die U-shaped end. Each U-shaped end has a part of co-linear holes 550c, 550d (labeled only for support <NUM>) penetrating an upper portion of the U-shaped end. The co-linear holes are located above the area that the pin would occupy in die U-shaped channel. Retaining pins are removably placed through the co-linear holes when the support pin is in the U-shaped channel to secure the hopper to the hopper supports.

To move the hopper from the working position to the service position, each of the retaining pins on one lateral side of the machine are removed and the hopper is tilted to the service position in the direction opposite of the lateral side where the retaining pins were removed. The hopper pivots toward die side were the retaining pins remain in place and the hopper pivots on die support pins. Likewise to move die hopper to die working position from the service position, the hopper is tilted toward the side of the machine where the retaining pins were removed, until die support pins on that side engage the U-shaped supports. Then the retaining pins are secured through the co-linear boles to secure the hopper in the working position.

The food pump system <NUM> of the machine <NUM> is shown in <FIG>, <FIG>, <FIG> <FIG>. The pump system <NUM> comprises a rotary pump <NUM>, a pump motor <NUM>, a mounting bracket <NUM>, a pump intake passage <NUM>, and a pump output passage <NUM>.

The outlet flange <NUM> of the hopper outlet <NUM> connects to a pump intake passage <NUM>. A gasket may be provided between the outlet flange <NUM> and the pump intake passage to seal the connection therebetween. The intake passage <NUM> has a vertically narrowing passage 310a to connect to the pump intake flange <NUM> which surrounding the intake opening inlet <NUM> of the food pump <NUM>. In one embodiment, the intake has a width in the transverse direction that is as wide as the food pump inlet <NUM> and the hopper outlet <NUM>. The intake passage narrows vertically as shown in <FIG>. The intake flange is located at a vertical position that is higher than the vertical position of the mold plate <NUM>.

The pump <NUM> is mounted and supported by a trunnion mount system <NUM>. The trunnion mount includes a rotatable cylinder <NUM> that rides within a front collar support <NUM> and a back collar support <NUM>. The support collars <NUM>, <NUM> are attached to a cross member <NUM> that is supported and connected to a pair of vertical frame supports <NUM>, <NUM> that are attached to the machine base <NUM> by bolts 632a, 634a. The front and back supports <NUM>, <NUM> have circular holes that are aligned and within which the cylinder <NUM> is supported. The cylinder connects at the rear end to a mounting bracket <NUM>, <NUM> that surrounds the gear area 332c of the pump <NUM>. The pump is connected to the bracket on at least one side by a four bolts <NUM>. A vertically extending support <NUM> is connected to the mounting bracket and extends upward to a vertical mounting plate <NUM>.

The pump <NUM> has an inlet that is located above the mold plate <NUM> and the manifold <NUM>. The pump has an outlet that is located above the mold plate <NUM> and the manifold <NUM>. To facilitate maintenance and cleaning, the pump <NUM> and pump motor <NUM> are rotatable on the trunnion mount system <NUM> between a working position as shown the location of the outlet 338d and a maintenance position as shown by the location of the outlet 338c in <FIG>. In the working position an outlet <NUM> of the pump <NUM> is connected to the output passage <NUM>. In one embodiment, the pump <NUM> and motor <NUM> are substantially perpendicular to the mold plate <NUM> when in the working position and the pump <NUM> and motor <NUM> are parallel to the mold plate <NUM> when in the maintenance position.

To move the pump <NUM> from the working position to the maintenance position, the output passage <NUM> is disconnected from the outlet <NUM> of the pump <NUM>, the intake passage <NUM> is disconnected from the flange <NUM> of the inlet <NUM> of the pump <NUM>, a lock mechanism (not shown) on the trunnion mount system <NUM> is released and the pump <NUM> is rotated about an axis of rotation 610a of the trunnion system <NUM>. As shown in <FIG>, the motor <NUM> rotates in direction D and the pump outlet <NUM> rotates in direction E about the axis of rotation 610a to bring the pump <NUM> and motor <NUM> to the maintenance position. The axis of rotation 610a is co-axial with the cylinder <NUM>. The locking mechanism of the trunnion system <NUM> may be tightened or secured to hold the pump <NUM> in position. While in one embodiment the motor <NUM> and pump <NUM> are substantially parallel to the mold plate <NUM> when in the maintenance position, in other embodiment the motor <NUM> and pump <NUM> may be placed at any position about the axis of rotation 610a wherein the motor <NUM> or pump <NUM> do not contact or impact other parts of the machine, such as the mold plate <NUM> or mold plate drive portion. However, if portions of the mold pate or mold plate drive are removed during maintenance, then the motor <NUM> and pump <NUM> may be further rotated.

As shown in <FIG>, the pump output passage <NUM> fans out laterally in a V-shape to connect with a correspondingly wide manifold inlet 111a. The pump output passage <NUM> is secured to the manifold inlet 111a by bolts <NUM> or stud and nut combinations.

The rotary pump is shown in detail in <FIG>. In one embodiment, the pump rotary pump is a Universal I Series Positive Displacement Rotary Pump, model number <NUM>-UI with a rectangular outlet flange manufactured by Waukesha Cherry-Burrell, with a place of business in Delavan, Wl, and affiliated with SPX Flow Technology. A positive displacement pump causes a food material to move by trapping a fixed amount of it then forcing that trapped volume into the discharge opening or pipe.

As shown in <FIG>, the pump <NUM> has a housing with a pump area 332a and a gear area 332c. The pump has an inlet <NUM> and an outlet <NUM> in communication with the pump area 332a. The pump area is separated from the gear area by a wall 332d. A portion of the gear area is shown in <FIG> were the back cover plate is removed. A drive gear <NUM> and a driven gear <NUM> are meshed across a meshed arch of each gear 356a, 364a. The drive gear is keyed to rotate in sync with the drive shaft <NUM> at a first end of the drive shaft. The drive gear has a locking nut and lock washer <NUM> that assists in securing the gear to the drive shaft. The driven gear is keyed to rotate the driven shaft <NUM>, The driven shaft has a locking nut and lock washer <NUM> that assists in securing the gear to the driven shaft at a first end of the drive shaft. The driven and drive shafts are journal through a support structure (not shown) in the housing to carry rotors 340a, 343a at second ends of the driven and drive shafts opposite the first ends. The support structure (not shown) in the housing contains high capacity, double tapered roller bearings that the drive and driven shafts rotate on. The rear cover plate (not shown) contains an opening to allow the drive shaft to extend outside of the housing to engage a drive source such as the motor <NUM>.

The second ends of the drive and driven shafts have a splined section (not shown). The rotors 340a 343a have a splined opening that mates with the splined section of the drive and driven shafts respectively. Each rotor 340a, 343a has two wings <NUM>, <NUM> and <NUM>, <NUM>, respectively. The wings have overlapping areas of rotation as shown in <FIG>. Each wing is located opposite the other wing on the rotor and gaps are located between the wings about the circumference of the rotor. The wings travel in annular-shaped cylinders 339c (not labeled for rotor 340a) machined into the pump body. The rotor is placed on the shaft with a plate portion <NUM>, <NUM> outwardly facing. Nuts <NUM>, <NUM> are screwed on a threaded end portion of the shafts to secure the rotor in place. The rotors have a close fit clearance between the outer surface of the wing 343a and the corresponding cylinder wall faces 339c of the pump area. As shown in <FIG>, the wing of one rotor will be located in the open area of the other rotor during a portion of an operation cycle. An operation cycle comprises a full <NUM> degree rotation of a rotor.

The splined mating of the rotors and shafts ensure that the rotors rotate in sync with the respective drive and driven shafts. The rotors are interference fitted in the pump area as shown by their overlapping areas of rotation. The meshed gearing 356a, 364a prevents the rotors from contacting each other during operation.

When the drive shaft <NUM> is rotated in direction C shown in <FIG>, the drive shaft rotate the first rotor in die same direction, direction A in <FIG>. Simultaneously, as provided by the meshed gearing <NUM>, <NUM> the second rotor is rotated in the opposite direction, as shown by direction B in <FIG>, of that of the first rotor.

The vacuum created by the rotation of the rotors 340a, 343a captures and draws food product in to an inlet <NUM>, through the pump and the outlet passage 338a, and out the outlet <NUM>. The outlet may have threads 338b on the outside of the outlet as shown in <FIG>. The pump area 332a face 339a is covered to enclose the pump area by a face plate <NUM>. The face plate has raised areas 332a, 332b for accommodating space required for the shaft ends and the corresponding nuts <NUM>, <NUM>. The face has a plurality of holes corresponding to the studs <NUM> that extend from the face 339a. Face plate wing nuts <NUM> secure the face plate to the face 339a.

The outlet <NUM> is a circular outlet and the inlet <NUM> is an oblong with a rectangular flange <NUM>. The rectangular flange <NUM> has an oval seal or gasket <NUM> surrounding the oblong inlet. The outlet <NUM> connects pump output passage <NUM>. The output passage <NUM> includes an expanding- V section 316a that connects with the manifold inlet 111a. The output passage <NUM> connected to the manifold <NUM> with a lower hinge <NUM>. When the output passage is connected to the rotary pump <NUM> and the output passage is in the deployed position, a flange <NUM> of the output passage is flush with the face <NUM> of the manifold at the inlet passage <NUM>. When the output passage is disconnected from the rotary pump and in a lowered position <NUM>, the flange and output passage pivots downward and away from the inlet passage about the lower hinge <NUM>.

The pump <NUM> is driven by the pump motor <NUM>. The motor is shown in <FIG>. in one embodiment, the motor <NUM> is a servo rotary actuator, such as the TPM+ Power <NUM> Stage <NUM> series rotary actuator with brake manufactured by Wittenstein, Inc. with a place of business in Bartlett, IL. In one embodiment, motor <NUM> is an electric servo rotary actuator, such as the model TPMP110S manufactured by Wittenstein, inc. The servo rotary actuator comprises a combined servo motor and gearbox assembly in one unit. The servo rotary actuator has a high-torque synchronous servo motor. The configuration of the servo motor and the gearbox gearing provides the actuator with a reduced length. The actuator has a helical-toothed precision planetary gearbox/gearhead for reduced noise and quiet operation, The rotary actuator has a <NUM>:<NUM> gearing ratio, <NUM> ft/lbs. of torque, and maximum speed of <NUM> RPMs.

The motor <NUM> has a housing <NUM>, an electrical connection 351b, a mounting face 315b, and an output coupling flange 358b. The mounting face 315b has a plurality of holes 315a. As shown in <FIG>, the pump is secured to a mounting plate by a plurality of bolts <NUM> a which engaged the back of the pump, such as by engaging threaded holes 332e at the back of the pump, The mounting plate is secured to the machine base <NUM> by bolts <NUM>, A circular mounting member <NUM> encloses the connection between the motor and the pump and attaches to the mounting plate <NUM>. Alternatively, the mounting member <NUM> may connect directly to the machine base. The mounting member <NUM> connects to the motor <NUM> at the mounting face. A number of bolts <NUM> secure the motor to the mounting member. A circular coupling <NUM> is attached to the output coupling flange 358b by bolts <NUM> threaded into the correspondingly threaded holes 358a of the output coupling flange 358b. At an opposite end, the coupling <NUM> receives the drive shaft <NUM> in an opening of the coupling <NUM>. The drive shaft <NUM> has a key 360a that engages a corresponding slot of the opening of the coupling <NUM> to lock the machine <NUM> to the drive shaft of the pump. The motor is angled to align with die output shaft of the pump.

As shown in <FIG>, <FIG>, <FIG>, the lower surface of the housing <NUM> that encloses the manifold <NUM> is positioned over a fill plate 121a that forms a flat, smooth mold plate support surface. The fill plate may be surrounded longitudinally by a guide plate (not shown) so that the fill plate is modular within the guide plate and thereby the fill plate can be quickly and easily changed. The mold top plate <NUM> and the fill plate 121a may be fabricated as two plates or a single plate bolted to or otherwise fixedly mounted to the housing <NUM>.

The housing <NUM>, manifold <NUM>, top plate <NUM>, fill plate 121a, and trunnion system <NUM> are supported by a plate <NUM>. The plate <NUM> may be integrated with the housing <NUM>, so that the plate <NUM> and housing <NUM> are one unitary piece. The plate <NUM> is connected to four towers <NUM> that are supported on the machine base <NUM>. A stud 632a extends from the bottom of the tower <NUM> into a hole in a machine base frame plate or beam <NUM>. A nut <NUM> is threaded on the stud 632a on the opposite side of the beam <NUM>. The tower <NUM> has a second stud <NUM> that extends from the upper portion of the beam <NUM> to be received into a hole of the plate <NUM>. On the lower side of die plate <NUM> is a collar <NUM> that is secured around the top of the tower <NUM>. The collar <NUM> is tightenable by a tightening mechanism, such as a screw or bolt and nut combination.

The fill plate 121a may include includes apertures or slots <NUM> e that form a lower portion of the manifold <NUM>. In one embodiment, the apertures or slots <NUM> e comprise additional smaller second fill apertures or slots 121b such as those disclosed in <CIT>. The slots 121b are shown for one of the slots <NUM> e in <FIG>, but it is understood that the each slot 121e may comprise slots such as 121e.

Mold plate <NUM> is supported upon a bottom plate <NUM>. Mold plate <NUM> includes a plurality of individual mold cavities <NUM> extending across the width of the mold plate and alignable with the manifold outlet passageways 111c. The mold plate may have a single row of cavities or may have plural rows of cavities, stacked in aligned columns or in staggered columns. A breather plate or bottom plate <NUM> is disposed immediately below mold plate <NUM>, closing off the bottom of each of the mold cavities <NUM>. The bottom plate <NUM> is mounted on a mold base plate <NUM>. In one embodiment, the spacing between bottom plate <NUM> and fill plate 121a is maintained equal to the thickness of mold plate <NUM> by support spacers (not shown) mounted upon bottom plate <NUM>.

The bottom plate <NUM> provides breather holes <NUM> and an associated air channel 122a flow connected to the breather holes for allowing the expulsion of air during filling of the mold cavities <NUM>, <NUM>. The breather boles <NUM> are minute air outlet boles formed in the bottom plate, in the part of the bottom plate adjacent fill slots 121e. As the food product is pumped into mold cavities <NUM>, it displaces the air in the mold cavities. The air is forced outwardly through the breather holes <NUM> and the channel 122a, escaping through the channel 122b and upward air channel 122c. Upward air channel 122c and channel 122b may each be connected to conduits <NUM> and <NUM> respectively which routes any food product back into the pump. Conduits receiving output from channels 122c and 122b may converge at any point prior to reaching the food pump, or may converge at the inlet to the food pump. Any food particles small enough to pass through the breather holes <NUM> follow this same path back into the pump. Alternatively, food particles may pass in a similar manner back to the food product hopper. The air channel 122a, 122b is connected to an upward air channel 122c that may be connected to the hopper by a suitable conduit (not shown) or connected to the pump <NUM> intake by a suitable conduit, such as a pipe 3000a, 3000b, 3000c, 3000d (<FIG>), to recycle food product that might be expelled with the air into the air channel. The pump may have a low pressure on the intake side which create vacuum to draw air through from the cavity and through the air channel 122a, 122b, 122c.

In another embodiment, the breather plate <NUM> and breather holes <NUM> may be configured as disclosed in <CIT> or <CIT>. As recognized by one skilled in the art, the breather plate of <CIT> or <CIT> would need to be inverted to operate in a top fill machine of the present application.

As best illustrated in <FIG>, <FIG>, and <FIG> mold plate <NUM> is connected to drive rods <NUM> alongside the housing <NUM> and are connected at one end to a transverse bar <NUM>. The mold plate drive system <NUM> comprises the drive rods <NUM>, the mold plate drive motors <NUM>, 138d and the associated linkages. The bar <NUM> is connected to the mold plate by two connecting links 129a. The connecting links are secured to the bar <NUM> by two bolts 129b and the links 192a are connected to the mold plate by at least one bolt 192c.

The other end of each drive rod <NUM> is pivotally connected to a connecting link <NUM> via a machine <NUM> plate 131a and a pivot connection 131c, shown in <FIG>. The pivot connection 131c can include a bearing (not visible in the figures) surrounding a pin within an apertured end of the connecting link <NUM>. The pin includes a cap, or carries a threaded nut, on each opposite end to secure the crank arm to the machine <NUM> plate 131a.

Each drive rod <NUM> is carried within a guide tube 132a having bearings that is fixed between a wall <NUM> and a rear support 132b. The connecting links <NUM> are each pivotally connected to a crank arm <NUM> via a pin <NUM> that is journaled by a bearing 141a that is fit within an end portion of the connecting link <NUM>. The pin crank arm <NUM> is fixed to, and rotates with, a circular horizontal guard plate <NUM>. The pin <NUM> has a cap, or carries a threaded nut, on each opposite end that axially fixes the connecting link <NUM> to the crank arm <NUM> and the circular guard plate <NUM>. The pin <NUM> rotates the link on an orbit 141c about the motor output 138a. The connecting link <NUM> also includes a threaded portion 131b to finely adjust the connecting link length.

The crank arm <NUM> is driven by a precise position controlled servo mold plate drive motor <NUM>. The motor is mounted vertically in the machine so that the output 138a rotates on a horizontal axis which is the same horizontal axis that the circular guard plate <NUM> rotates about The crank arm <NUM> is attached to the output 138a to rotate the crank arm about the output 138a. The motor <NUM> is mounted to a motor support plate 138b that is mounted to and supported by the machine base <NUM>. As shown in <FIG>, the motor is mounted with the output 138a perpendicular to the support plate. The motor has power and control cables that are routed through a wiring conduit 138c to connect those wires to power and machine control <NUM>. A precise position controlled servo mold plate drive motor 138d is identical to motor <NUM> but is mounted on the left side of the machine to drive the drive rod <NUM> on the left side of the machine as shown in <FIG>. The mechanical configuration on the left side, regarding the mold plate drive motor and related connection are the same as that described for the right side above.

The machine control <NUM> has instructions for maintaining the two motors <NUM>, 138d operating in sync so that each of the right and left drive rods have the same longitudinal position along their respective ranges of motion, This is necessary to ensure that both lateral sides of the mold plate are in the same longitudinal position with respect to the other and they operate in a parallel reciprocation. The mold plate is reciprocated by the synchronous output both motors <NUM> and 138d.

The precise position controlled motors <NUM>, 138d can be a <NUM>-<NUM> 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 the machine controller <NUM>. In one embodiment, motors <NUM> comprise a motor 138e driving a gearbox or gear reducerl38f by a motor driveshaft <NUM> as shown in <FIG>. The motor may be model 1FK7082-7AF71 manufactured by Siemens AG capable of <NUM> RPMs and <NUM> in/lbs of torque. The gearbox may be an in-line gear box such as, an Alpha TP+<NUM> MP manufactured by Wittenstein, Inc. with a place of business in Bartlett, IL.

The controller <NUM> and the servo motors <NUM>, 138d 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..

A tie bar <NUM> is connected between the rods <NUM> to ensure a parallel reciprocation of the rods <NUM>. As the crank arms <NUM> rotate in opposite rotational directions, the outward centrifugal force caused by the rotation of the crank arms <NUM> and the eccentric weight of the attached connecting links <NUM> cancels, and separation force is taken up by tension in the tie bar <NUM>.

One circular guard plate <NUM> is fastened on top of each crank arm <NUM>. The pin <NUM> 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 <NUM>. The guard plate <NUM> prevents an end of the link <NUM> from dropping into the path of the crank arm <NUM>.

<FIG> illustrates a proximity sensor <NUM> in communication with the machine control <NUM>. A target 144a is clamped onto output shaft 138a of the gear box 138f. The proximity sensor <NUM> communicates to the controller <NUM> that the crank arm <NUM> is at a particular rotary position corresponding to the mold plate <NUM> being at a pre-se!ected position. Preferably, the proximity sensor <NUM> can be arranged to signal to the controller that the crank arm <NUM> is in the most forward position, corresponding to the mold plate <NUM> being in the knockout position. The signal confirms to the controller that the knockout cups <NUM> can be safely lowered to discharge patties, without interfering with the mold plate <NUM>.

During a molding operation, the molding mechanism <NUM> is assembled as shown in <FIG> and <FIG>, with bottom plate <NUM> tightly clamped onto spacers (not shown).

In each cycle of operation, knockout cups <NUM> are first withdrawn to the elevated position as shown in <FIG>. The drive for mold plate <NUM> then slides the mold plate from the full extended position to the mold filling position with the mold cavities <NUM> aligned with passageway <NUM><NUM> c.

During most of each cycle of operation of mold plate <NUM>, the knockout mechanism remains in the elevated position, shown in <FIG>, with knockout cups <NUM> clear of mold plate <NUM>. When mold plate <NUM> reaches its extended discharge position 32b, the knockout cups <NUM> are driven downward in direction A to discharge the patties from the mold cavities.

The discharged patties may be picked up by the conveyor <NUM> or may be accumulated in a stacker.

If desired, the discharged patties may be interleaved with paper, by an appropriate paper interleaving device. Such a device is disclosed in <CIT> or <CIT>. In fact, machine <NUM> may be used with a wide variety of secondary equipment, including steak folders, bird rollers, and other such equipment.

By using a servo motor to drive the mold plate, the mold plate motion can be precisely controlled. The motion can have a fully programmable dwell, fill time, and advance and retract speeds as controlled by the machine control <NUM>.

During mold plate change or to clean the apparatus, it is necessary to lower the mold base plate <NUM> from above the mold plate <NUM> and the fill plate 121a. The collars <NUM> are loosened as a first step for lowering the mold base plate <NUM>.

A mold base lift mechanism <NUM> is mounted inside the machine base <NUM> and extends upward to mold base <NUM>. The lift mechanism includes two jacks <NUM>, <NUM> shown in Figure 3A. The jacks are operatively connected to right angle drives <NUM>, <NUM>, which are operative!}/ connected to a T type right angle drive <NUM>, via drive shafts <NUM>, <NUM> and respective couplings <NUM>, <NUM>, <NUM>, <NUM>, <NUM>. The right angle drive <NUM> is driven into rotation by a motor <NUM>.

The jack <NUM> is described below with the understanding that the jack <NUM> is identically configured and functions identically, in tandem, as the jack <NUM>.

As shown in Figure 3A the drive <NUM> turns a threaded rod or jackscrew <NUM> that drives a nut drive assembly <NUM> vertically. The jack screw <NUM> is journaled for rotation at a top end by a guide <NUM>. The jack screw <NUM> can include a bearing therebetween for smooth journaled rotation of the jackscrew. The drive assembly <NUM> is operatively connected to a lift column <NUM> via a bracket <NUM> which is aligned over the jackscrew. The lift column has an opening 851a. The bracket is connected at the column on each side of the opening at the bottom of the column. Thereby the bracket and the jackscrew are received in a portion of the opening 815a. The columns <NUM> of the jacks <NUM>, <NUM>, have keys 815c extending from the tops of the columns. The key s engage corresponding slots of the mold base and the mold base rest on top surfaces 815d of the columns. In one embodiment, the columns <NUM> are hollow and can also serve as wire and tube conduits. The columns <NUM> are journaied through frame plate <NUM> and guides <NUM>. Bearings may be included within the journaled areas to reduce friction from contact between the columns and the frame plate.

A sensor <NUM> is mounted on or adjacent to the lift mechanism for signaling to the machine control the position of the jacks. In one embodiment, the jacks have a corresponding reading strip on the surface 804a of the jacks that the sensor reads to provide a jack location signal to the machine control. The machine control may be programmed to prevent operation of the machine when jacks are in a predetermined position, such as a lowered position. Further a proximity sensor (not shown) is mounted at an elevated position within the machine base along the vertical path of the target (not shown) mounted to the jacks and signals a pre-determined raised maximum height or depth of the mold base for a mold plate change out procedure. The proximity sensor signals the machine controller to stop the motor <NUM> at that point.

In another embodiment, the lift mechanism <NUM> may be that disclosed in <CIT>.

Molding mechanism <NUM> further comprises a knockout mechanism or apparatus <NUM> shown in <FIG>, <FIG>. The knockout apparatus comprises the knockout plungers or cups <NUM>, which are fixed to a carrier bar <NUM> by bars 145a. Knockout cups <NUM> are coordinated in number and size to the mold cavities <NUM> in die mold plate <NUM>. One knockout cup <NUM> is aligned with each mold cavity <NUM>. The mold cavity size is somewhat greater than the size of an individual knockout cup.

The knockout apparatus <NUM> is configured to drive the carrier bar <NUM> in timed vertical reciprocation. The knockout apparatus includes a knockout drive mechanism 140a, a knockout cup system 140b. The knockout drive mechanism is positioned below the mold plate and at least partially enclosed in the machine base <NUM>. The knockout cup system 140b is located about the mold plate during at least a portion of any knockout cycle. The knockout shaft connects 147a the knockout drive to the knockout cup system and may be considered a part of either.

<FIG> illustrate the knockout apparatus <NUM> in more detail. The carrier bar <NUM> is fastened to knockout support brackets 146a, 146b. The knockout support brackets 146a, 146b are carried by two knockout rods <NUM>. Each knockout rod <NUM> is disposed within a wall of a knockout housing <NUM> and is connected to a knockout beam <NUM>. The knockout beam <NUM> is pivotally mounted to a crank rod <NUM> that is pivotally connected to a fastener pin <NUM> that is eccentrically connected to a crank hub <NUM> that is driven by a knock out cup drive motor <NUM>,.

The motor <NUM> is preferably a precise position controlled motor, such as a servo motor. An exemplary servomotor for this application is a <NUM> RPM, <NUM> kW servo motor provided with a brake, such as a permanent-magnet synchronous servo motor made by Siemens AG having a model number of 1FK7064-7AF71-1GB0. 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 <NUM>.

The controller <NUM> and the motor <NUM> 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..

A heating element <NUM> surrounds, and is slightly elevated from the knockout carrier bar <NUM>. A reflector <NUM> is mounted above the heating element <NUM>. 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. The bearing element <NUM> can be configured as disclosed in <CIT>.

In <FIG> and <FIG>, the crank hub <NUM> is rotated into a position wherein the crank rod <NUM> is vertically oriented and the knockout beam <NUM> is lifted to its maximum elevation. The knockout rods are fastened to the knockout beam <NUM> by fasteners <NUM>. The knockout support bracket(s) <NUM> are in turn fastened to the knockout shafts 147a by fasteners (not shown). The knockout shafts 147a are connected to the knockout beam <NUM> by fasteners such as holts 147c, 147d. The knock-out shafts are connected to the knockout beam at positions outside of those where the knockout rods <NUM> are attached as shown in <FIG>.

An air flap or air check valve 33a can be provided within each cup to assist in dispensing of a meat patty from the knockout cup <NUM>,.

As shown in <FIG>, the motor <NUM> is supported by a bracket <NUM> from a support plate <NUM>. The bracket <NUM> includes one or more slotted holes, elongated in the longitudinal direction (not shown). One or more fasteners <NUM> penetrate each slotted hole and adjustably fix the motor <NUM> to the frame member. The motor <NUM> includes an output shaft <NUM> that is keyed to a base end of the crank bub <NUM>. The fastener pin <NUM> retains a roller bearing <NUM> thereon to provide a low friction rotary connection between an annular base end 151a of the crank rod <NUM> and the pin <NUM>.

The crank rod <NUM> has an apertured end portion <NUM> on an upper distal end 151b opposite the base end 151a. The apertured end portion <NUM> is held by a fastener pin assembly <NUM> through its aperture to a yoke <NUM>. The yoke <NUM> is fastened to the knockout beam <NUM> using fasteners. The fastener pin assembly <NUM> can include a roller or sleeve bearing (not shown) in like fashion as that used with the fastener pin <NUM> to provide a reduced friction pivot connection.

The housing <NUM> 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 huh <NUM>, the pin <NUM>, roller bearing <NUM>, the apertured end portion <NUM>, the fastener pin <NUM> and the yoke <NUM> are all contained within the oil bath having an oil level <NUM>. The limits of the oil bath are defined by a housing <NUM> having a front wall <NUM>, a rear wall <NUM>, side walls <NUM>, <NUM>, a top wail <NUM> and a sleeve <NUM>. The sleeve <NUM> is a square tube that surrounds a substantial portion of the crank rod <NUM> and is sealed around its perimeter to the top wall <NUM> by a seal element 196a. The sleeve <NUM> is connected to the beam <NUM> and penetrates below the top wall <NUM><NUM>. As the yoke <NUM> reciprocates vertically, the beam <NUM> and the sleeve <NUM> reciprocate vertically, the sleeve <NUM> maintaining a sealed integrity of the oil bath. The apertured end portion <NUM> connects to the knockout beam <NUM> at the center of the knockout beam.

The crank rod <NUM> includes side dished areas 151c that act to scoop and propel oil upward during rotation of the hub <NUM> to lubricate the pin <NUM> and surrounding areas.

The knockout rods <NUM> are guided to reciprocate through the side walls <NUM>, <NUM>, particularly, through upper and lower bearings <NUM> a, <NUM> b. The rods <NUM> are sealed to the top wall by seals <NUM>. The bearings <NUM> a can include an internal groove <NUM> that is in flow-communication with a lubricant supply through port <NUM>.

A lubricant system 194a is provided to provide lubricant to the bearings 191a, 191b. The system 194a includes a lubricant reservoir 194b that is filled with lubricant, such as oil, and connected to plant air 194c via an electronically controlled valve 194d. The machine controller <NUM> periodically, according to a preset routine, actuates the valve 194d to propel some lubricant into the bearings 191a. Lubricant can run down the knockout rod <NUM> into a dished top <NUM> c of the lower bearings 191b to allow oil to penetrate between the knockout rods <NUM> and the lower bearings 191b.

As shown in <FIG>, an outer cover <NUM> is fastened and sealed around the side walls <NUM>, <NUM> and front and rear walls <NUM>, <NUM> by fasteners, spacers <NUM> and a seal <NUM>. 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.

The front wall <NUM> includes an oil level sight glass 185a, a fill port 185b (shown dashed In <FIG>), a drain port 185c (<FIG>); and an access hole closed by a screw 185d (<FIG>).

The crank hub <NUM> is journaled for rotation by two roller bearings <NUM>, <NUM>. The roller bearings <NUM>, <NUM> are supported by a collar assembly <NUM> bolted to the rear wall <NUM> and to the motor <NUM>.

The knockout assembly is changeable to extend further forwardly to minimize knockout cup cantilever. This is accomplished by loosening the bracket <NUM> from the frame member <NUM> and sliding the motor and all the connected parts forward or rearward and replacing circular adapter plates for the knockout rods <NUM>,.

The housing <NUM> is fastened to a support plate <NUM> by fasteners 201a. The support plate <NUM> has holes 201c that surround the bearings 191b and associated bearing assemblies 191c. The support plate <NUM> is connected to the machine base frame plate or beam <NUM> of the base <NUM>, by four upward extending support members <NUM> e. The support members <NUM> e have threaded studs 201f that extend downward through corresponding holes in the support plate <NUM>. Nuts <NUM> are secured to the corresponding studs <NUM> f to secure the support plate <NUM> to the support members <NUM> e. The support members connect to the support plate <NUM> at or about the four corners of the support plate.

In one embodiment there are two knockout shafts 147a. The knockout shafts are journaled through a guide 71c. The guide is attached to the top 71e of the manifold <NUM> as shown in <FIG> and <FIG>. The guide has openings or bearing guides 71d that the knockout shafts 147a are journaled through. The openings 71d may contain bearings (not shown). The knockout shafts 147a extend through openings in the carrier bar <NUM>.

The knockout shafts extend upwards through the machine base. The knockout shafts extend on either side of the mold plate <NUM> in the lateral direction as shown in Figure 3A, Therefore, the mold plate <NUM> is positioned in between the knockout shafts 147a when the mold plate cavities are aligned with the knockout cups.

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 <NUM> from the frame member <NUM> and sliding the motor <NUM> and the connected parts forward or rearward and replacing the circular adapter plates that guide the knockout rods <NUM>. The guide is also adjustable in its connection to the <NUM> manifold to slidably move the guide forward or backward within a range longitudinally to adjust the location of the knockout cups in concert with the adjustment of the knockout drive mechanism 140a.

A proximity sensor <NUM> is bolted to the outer cover <NUM>, and a target <NUM> is provided on the crank bar <NUM> to be sensed by the proximity sensor <NUM>. The proximity sensor <NUM> communicates to the controller <NUM> that the knockout cups are raised and the mold plate can be retracted without interfering with the knockout cups.

The movement of the knockout cups is fully programmable for different motion profiles, including dwell, accelerations and extend and retract speeds. Such motion profiles may be useful depending on the properties of the food product to be discharged from the mold plate cavities. Because both the mold plate and the knockout cups can be driven by programmable, controlled servo motors, they can be flexibly sequenced without being restricted in motion by a common mechanical system.

The hopper tilt system and the touch screen control panel <NUM> are configured such that apparatus can be easily factory converted from a right side operating apparatus to a left side operating apparatus, that is, factory reversible across the longitudinal centerline of the apparatus.

The operation of the machine is controlled by the machine control <NUM>. The machine control is schematically shown in <FIG>. The machine control is signal connected to the rotary pump motor <NUM>, the feed screw drive motors <NUM>, <NUM>, die mold plate drive motors <NUM>, 138d, sensor <NUM>, and the knock out cup drive motor <NUM>. These connections allow the machine to control die operation of the various components of the machine. The connections allow the machine control to know the operating status of each component. The machine control has computer readable instructions for carrying out the functions and operations of the various parts of the machine as described above and for receiving and recording data about the same.

The machine control <NUM> can be implemented as a programmed general purpose computer, or a single special purpose integrated circuit: (e.g., ASIC) having a main or central processor section for overall, machine control, and separate sections dedicated to performing various different specific computations, functions and other processes under control of the central processor section. The machine control <NUM> can be implemented using a suitably programmed general purpose computer, e.g., a microprocessor, microcontroller or other processor device (CPU or MPU), either alone or in conjunction with one or more peripheral (e.g., integrated circuit) data and signal processing devices. In general, any device or assembly of devices on which a finite state machine capable of implementing the procedures described or carrying out functions described herein can be used as the machine control <NUM>.

In an alternate embodiment, the molding machine comprises an alternate pump system <NUM> connected to a fill plunger system <NUM> for pressurizing the food mass as illustrated in <FIG>. The pump system <NUM> and fill plunger system <NUM> are together interfit between outlet flange <NUM> of the hopper and the fill plate 121a of the molding apparatus, as in the previously described embodiment. The pump system includes the rotary pump <NUM> and the pump motor <NUM> together as previously described but mounted <NUM> degrees from the previously described embodiment to a horizontal motor-to-pump orientation (see <FIG>). The rotary pump output passage <NUM> channels the food mass from the pump into an alternate intake manifold <NUM>. The intake manifold is similar to the manifold <NUM> except a truncated triangular cross-section block 1027a is bolted inside the manifold <NUM> to decrease the degree of flare or expansion of the manifold in the longitudinal direction. This is done for example for single cavity filling of ground beef products through a slot fill to for operational reasons to reduce manifold volume to make some products more responsive to compression or pressurizing. The pump output passage <NUM> is connected to the intake manifold <NUM> at the manifold inlet passage 111a. The intake manifold <NUM> is enclosed within a lower housing <NUM>. An upper housing <NUM> is disposed above the lower housing <NUM> and secured to the lower housing <NUM> using flange nuts and studs <NUM>. The manifold inlet passage 111a is open into the upper housing <NUM>.

In one embodiment, the fill plunger system <NUM> comprises a pair of plungers <NUM>. Plungers <NUM> move between a raised position and an extended position. In its raised position, the tip <NUM> of the plunger is within the upper housing <NUM> just above the intake manifold <NUM>. In an extended position, the plunger extends into the intake manifold <NUM> to displace a pre-determined volume of food mass in the intake manifold. The upper housing <NUM> comprises a plunger channel <NUM> in communication with an opening <NUM> into the intake manifold to allow vertical movement of the plunger through the plunger channel <NUM> and into the intake manifold. The vertical movement of the plunger <NUM> into the intake manifold <NUM> varies the volume, and accordingly the pressure of the food mass within the intake manifold. The increase in food mass pressure as a result of the displacement of the food mass in the manifold can be coordinated with the reciprocating movement of the mold plate. For example, pressure may be increased within the intake manifold using the fill plunger system prior to the mold cavity coming into communication with the intake manifold by beginning the downward stroke of the plunger, and continuing the downward stroke of the plunger into the manifold as the mold plate slides into the fill position. Various other timing combinations of the plunger movement and the mold plate movement can be used to achieve the desired mold cavity filling dynamic.

To ensure a secure seal between the plunger channel <NUM> and the plunger <NUM> such that food mass does not escape from the plunger channel <NUM>, a seal, such as a rubber or silicone O-ring is disposed along the circumference of the plunger channel <NUM>. Any other suitable seal known to one skilled in the art can also be used.

Movement of the plungers <NUM> are controlled by a linear actuator <NUM>. Plungers <NUM> are connected to a plunger shaft <NUM>, which are connected to an actuating rod <NUM> (<FIG>) as part of the linear actuator <NUM>. The actuators <NUM> are supported on top of a platform <NUM>, which is secured to the lower housing <NUM> by a support frame <NUM> comprising vertical supports <NUM>. Vertical supports <NUM> each comprise an external tube 1031a with an internal threaded shaft 1031b (<FIG>). The shaft extends out opposite ends of the tube and is threaded into the lower housing <NUM> and receives a nut <NUM> on top to secure the platform <NUM> to the vertical supports <NUM>, and to the lower housing <NUM>.

One embodiment of the drive mechanism for the linear actuators <NUM> is illustrated in <FIG>. Revolution of a pair of toothed driven gears <NUM> disposed at the top of the pair of linear actuators <NUM> extends and retracts the actuating rods <NUM> by an internal screw drive or other rotary- to-linear movement converter. The toothed driven gears are driven by a toothed belt <NUM>, driven by a toothed driving gear <NUM>. Toothed driving gear <NUM> is connected at the center of the gear to a motor <NUM>, such as a servomotor. The motor drives the gear <NUM> which simultaneously drives both toothed driven gears <NUM> such that the movement of the two plungers are in synchronization. Any other suitable method of driving the driving gear, such as the use of a drive belt, can also be used.

Other means of driving the plungers can be used, such as servo-motor linear actuators, pneumatic or hydraulic cylinders, etc..

Plungers can be any suitable size or shape, providing the desired cross-sectional area and volume of food mass displacement, and accordingly, the desired increase in pressure for a particular type of food mass and/or mold plate. The shape of the intake manifold opening <NUM> and the plunger channel <NUM> are shaped accordingly to complement the shape and size of the plungers. The extension distance of the plungers into the manifold can vary according to the desired fill pressure. The fill plunger system can be used with any type of mold plate <NUM>. in one embodiment, the plunger in its raised position may be raised such that the tip <NUM> of the plunger is above the upper housing <NUM>, as illustrated in <FIG>.

In one embodiment, die plunger in its extended position extends into the upper housing <NUM>, but remains above the manifold.

<FIG> illustrates an alternate embodiment wherein a hopper <NUM> is tilted toward the back of the machine for cleaning. The hopper is shown in a tilted-back position and up cleaning position 25a and a normal operating position 25b. The hopper is supported on the machine base by two laterally spaced apart pinned connections <NUM> at the rear (only foreground one being visible in the Figure) and by two laterally spaced apart plastic pads or pucks <NUM> at the front (only foreground one being visible in the Figure). The pinned connections and pads are arranged in a rectangular grid pattern. A pneumatic or hydraulic cylinder actuator, or other known linear actuator <NUM> is used to tilt the hopper. The actuator is shown in an extended-hopper tilt position 3008a and a retracted-hopper in use position 3008b.

A further alternate food product forming machine or food patty molding machine <NUM> is illustrated in <FIG>. The molding machine <NUM> includes a machine base <NUM>, optionally mounted upon a plurality of feet <NUM>, rollers or wheels. The machine base <NUM> supports the operating mechanism for machine <NUM> and contains electrical actuating systems, and most of the machine controls, The machine <NUM> includes a food supply system <NUM> for supplying moldable food material, such as ground beef, fish, or the like, to the processing mechanisms of the machine. A control panel, such as a touch screen control panel <NUM>, is arranged on a forward end of the machine <NUM>.

As generally illustrated in <FIG>, the food supply system includes an auger system <NUM> and a hopper <NUM> that opens into the intake of a food pump system <NUM>. The food pump system <NUM> includes at least one food pump, described in detail above, that continuously, or intermittently under a pre-selected control scheme controlled by a machine control <NUM>, pumps food, under pressure, into a manifold <NUM> flow-connected to a cyclically operated molding mechanism <NUM>. Generally during operation of the machine <NUM>, the pump is forcing food material under pressure into the intake of manifold <NUM>. The operation of the machine is controlled by the machine control <NUM>.

In the operation of machine <NUM>, a supply of ground beef or other moldable food material is deposited into hopper <NUM> from overhead. An automated refill device (not shown) can be used to refill the hopper when the supply of food product therein is depleted. At the bottom of the hopper <NUM> is the auger system <NUM> for moving the food material longitudinally along the hopper <NUM> to the inlet <NUM> of the food pump system <NUM>.

The manifold <NUM> comprises a system for feeding the food material, still under relatively high pressure, into the molding mechanism <NUM>. Molding mechanism <NUM> operates on a cyclic basis, first sliding a multi-cavity mold plate <NUM> into a receiving position over manifold <NUM> and then away from the manifold to a discharge position aligned with a series of knock out cups <NUM>. When the mold plate <NUM> is at its discharge position, knock out cups <NUM> are driven downwardly, discharging hamburgers or other molded patties from machine <NUM>, as indicated by direction A in <FIG>. The molded patties are deposited onto a conveyor (not shown) that is positioned under the knockout cups <NUM>, to be transported away from the machine <NUM>.

The food supply system <NUM> includes the hopper and the auger system <NUM>, as shown in <FIG>. The auger system <NUM> is located at the bottom of the hopper <NUM>. The auger system includes two feed screws <NUM>, <NUM>, and two feed screw drive motors <NUM>, <NUM>. The feed screws <NUM>, <NUM> each have a center shaft <NUM>, <NUM>. The center shaft is journaled in and supported by front and rear feed screw supports <NUM>, <NUM>. The feed screw supports extend vertically from and attach to the machine base <NUM>. The feed screws are located adjacent to one another and extend longitudinally along the bottom of the hopper. The center shafts are parallel to the bottom <NUM> of the hopper.

As shown in <FIG>, the rear 4025c of the hopper has an opening that is covered by a cap <NUM>. The cap <NUM> has holes <NUM> that the feed screw shafts are journaled to rotate therein on bearings. The shafts extend through the cap to connect to the motors <NUM>, <NUM>. The rear opening of the hopper has a vertical lip 4529a. The back of the cap has a recessed portion 4530a that mates with the lip 4529a. The cap also has a non-recessed portion 4530b that fits into the rear opening,.

A hopper outlet <NUM> is formed to or attached to the front <NUM> of the hopper <NUM>. A portion of the outlet opening is aligned with the bottom floor <NUM> of the hopper and the opening extends upwardly from the floor <NUM>. The outlet extend forward of the main hopper body 4025c as shown in <FIG>. The outlet has a connecting section <NUM> and a narrowing section <NUM> that narrows to an outlet flange <NUM> toward the food pump system <NUM>. The outlet has a width that is greater than its height Upper and lower feed screw supports <NUM>, <NUM> extend from the conical section <NUM> to a bearing head <NUM>. The supports <NUM>, <NUM> are perpendicular to the conical section <NUM> inside surface and extend therefrom to an elbow 4421a, 4421b and bearing sleeves <NUM>. The front of the shafts <NUM>, <NUM> have a recessed portion <NUM> that terminates in a conically reducing point end <NUM>. The point end <NUM> extends beyond the bearing sleeves <NUM>. The shafts <NUM>, <NUM> are journaled to rotate at the front on the recessed portion <NUM> in the bearing sleeves. As shown in <FIG>, a front portion 4404a of each feed screws is enclosed by the outlet and extend beyond the main hopper body 4025c.

As shown in detail in <FIG> and <FIG>, the feed screw drive motors <NUM>, <NUM> are mounted to a feed screw drive motor support plate <NUM> by screws, studs, or bolts <NUM>, The support plate <NUM> is attached to a support mount <NUM> by screws or bolts <NUM>. The support mount <NUM> is attached to vertical support members <NUM>, <NUM> by fasteners <NUM>, <NUM> respectively. The vertical support members <NUM>, <NUM> extends vertically from the machine base <NUM> and is supported thereon. The support mount <NUM> has a ledge <NUM> defining a recessed area 4435a. The support plate is located in the recessed area 4435a and on the ledge <NUM>. The drive motors, <NUM>, <NUM> are enclosed by a drive motor housing <NUM>. The drive motor housing <NUM> is attached to the support plate <NUM>. The motors <NUM>, <NUM> are axially aligned with the corresponding feed screws <NUM>, <NUM> respectively. Output shafts 4406a, 4408a are coaxial with the corresponding feed screw shafts <NUM>, <NUM> respectively. The supports hold the feed screw slightly above the bottom <NUM> surface of the hopper <NUM> to form a gap <NUM> between the feed screw and the bottom.

The feed screws <NUM>, <NUM> are removable from the hopper for service and cleaning. To remove the feed screws <NUM>, <NUM>, the support plate <NUM> and the support mount <NUM> disconnected from the vertical support members <NUM>, <NUM> via the fasteners <NUM>, <NUM>. The support mount <NUM> is moved longitudinally rearward and the recessed portions <NUM> of the feed screw shaft are withdrawn from the bearing sleeves <NUM> at the front and the feed screws are withdrawn rearward from the hopper.

The hopper is shown in <FIG>, <FIG>, <FIG>, <FIG> and <FIG>. As shown in <FIG>, the hopper <NUM> has a working position 4025a and a service position 4025b. When the hopper is in the service position it is tilted <NUM> degrees to the right or left side to permit a person to more easily clean or service the hopper.

As shown in <FIG>, the hopper <NUM> has front and rear pairs of mounting arms <NUM>, <NUM>, <NUM>, <NUM>. Each mounting arm has a horizontal support pin <NUM>, <NUM>, <NUM>, and <NUM>. The front mounting pins extend forwardly from the front mounting arms <NUM>, <NUM> and the rear mounting pins extend rearward from the rear mounting arms <NUM>, <NUM>. The pins engage a hopper support <NUM>, <NUM>, <NUM>, <NUM>, Each hopper support, as best shown in <FIG>, has a U-shaped end 4550a, 4550b (not labeled for front hopper supports). The outer end of each pin lies in the U-shaped channel of the U-shaped end. Each U-shaped end has a part of co-linear holes 4550c, 4550d (labeled only for support <NUM>) penetrating an upper portion of the U-shaped end. The co-linear holes are located above the area that the pin would occupy in the U-shaped channel. Retaining pins are removably placed through the co-linear holes when the support pin is in the U-shaped channel to secure the hopper to the hopper supports.

To move the hopper from the working position to the service position, each of the retaining pins on one lateral side of the machine are removed and the hopper is tilted to the service position in the direction opposite of the lateral side where the retaining pins were removed. The hopper pivots toward the side were the retaining pins remain in place and the hopper pivots on the support pins. Likewise to move the hopper to the working position from the service position, the hopper is tilted toward the side of the machine where the retaining pins were removed, until the support pins on that side engage the U-shaped supports. Then the retaining pins are secured through the co-linear boles to secure the hopper in the working position.

The food pump system <NUM> of the machine <NUM> is shown in <FIG> and <FIG>. The pump system <NUM> comprises a rotary pump <NUM>, a pump motor <NUM>, a mounting bracket <NUM>, a pump intake passage <NUM>, and a pump output passage <NUM>.

The outlet flange <NUM> of the hopper outlet <NUM> connects to a first flange 4310a of the pump intake passage <NUM>. A gasket may be provided between the outlet flange <NUM> and the first flange 4310a to seal the connection therebetween. The intake passage <NUM> has a second flange 4310b at an end opposite the first flange 4310a. The second flange 4310b connects to the pump intake flange <NUM> which surrounding the intake opening <NUM> of the food pump <NUM>. A gasket <NUM> may be provided between die outlet flange <NUM> and the first flange 4310a to seal the connection therebetween. The intake flange is located at a vertical position that is higher than the vertical position of the mold plate and manifold <NUM>.

The pump <NUM> is mounted and supported by an upper brace <NUM> and an angled wall <NUM> of the machine base <NUM>. The machine base <NUM> has a vertical wall <NUM> connecting to the angled wall <NUM> that angles downward and toward the molding mechanism <NUM>. The angled wall connects to a lower horizontal wall <NUM>. In one embodiment, the pump is mounted and orientated in a plane that is substantially parallel or co-planar to the angled wall <NUM>. The pump has an inlet that is located above the mold plate and die manifold <NUM>. The pump has an outlet that is located below die mold plate and the manifold <NUM>. The pump may be angled on a slant between the location of the inlet and the location of the outlet.

The rotary pump is shown in detail in <FIG> and described above.

The outlet <NUM> is a circular outlet and the inlet <NUM> is an oblong with a rectangular flange <NUM>. The rectangular flange <NUM> has an oval seal or gasket <NUM> surrounding the oblong inlet. The outlet <NUM> connects pump output passage <NUM>. The output passage <NUM> includes an expanding- V section 316a that connects with the manifold inlet passage <NUM>. The output passage <NUM> connected to the manifold <NUM> with a lower hinge <NUM>. When the output passage is connected to the rotary pump <NUM> and the output passage is in the deployed position, a flange <NUM> of the output passage is flush with the face <NUM> of the manifold at the inlet passage <NUM>. When the output passage Is disconnected from the rotary pump and in a lowered position <NUM>, the flange and output passage pivots downward and away from the inlet passage about the lower hinge <NUM>,.

A fill plunger system as described above can also be incorporated into this further alternate embodiment.

As shown in <FIG> and <FIG>, the upper surface of the housing <NUM> that encloses the manifold <NUM> carries a support plate or wear plate <NUM> and a fill plate <NUM> a that forms a flat, smooth mold plate support surface. The manifold is supported by four support columns 4071a, 4071b. The support columns are connected to the machine base <NUM>. The mold support plate <NUM> and the fill plate 4121a may be fabricated as two plates as shown or a single plate bolted to or otherwise fixedly mounted upon housing <NUM>. The fill plate 4121a includes apertures or slots <NUM> b that form the upper portion of the manifold inlet passage <NUM>. In the apparatus illustrated, a multi fill orifice type fill plate 4121a is utilized. A simple slotted fill plate is also encompassed by the Invention.

Mold plate <NUM> is supported upon plates <NUM>, 4121a. Mold plate <NUM> includes a plurality of individual mold cavities <NUM> extending across the width of the mold plate and alignable with the manifold outlet passageway 4111c. The mold plate may have a single row of cavities or may have plural rows of cavities, stacked in aligned columns or in staggered columns. A breather plate or cover plate <NUM> is disposed immediately above mold plate <NUM>, closing off the top of each of the mold cavities <NUM>. A mold cover casting or housing <NUM> is mounted upon cover plate <NUM>. The spacing between cover plate <NUM> and support plate <NUM> is maintained equal to the thickness of mold plate <NUM> by support spacers (not shown) mounted upon support plate <NUM>. Cover plate <NUM> rests upon spacers <NUM> when the molding mechanism is assembled for operation. Cover plate <NUM> and mold cover casting <NUM> are held in place by four mounting bolts, or nuts tightened on studs <NUM>.

The cover plate <NUM> can be configured as a breather plate as part of a molding mechanism air-arid-fines removal system, such as described in <CIT>, <CIT>, or <CIT>. In one embodiment, the breather plate <NUM> provides breather holes <NUM> and an associated air channel <NUM> flow connected to the breather holes for allowing the expulsion of air during filling of the mold cavities <NUM>, The breather holes <NUM> are minute air outlet holes formed in the breather plate, in the part of the breather plate adjacent fill slots 4121b. As the food product is pumped into mold cavities <NUM>, it displaces the air in die mold cavities. The air is forced outwardly through the apertures <NUM> and the air channel <NUM> and an upwardly extending channel 4122c. Any food particles small enough to pass through the apertures <NUM> follow this same path back into the food product hopper. The air channel <NUM> is connected to an upward air channel 4122c that may be connected to the hopper by a suitable conduit, such as a pipe (not shown) to recycle food product that might be expelled with the air Into the air channel, Alternatively the air channel may be connected to the intake of the pump <NUM>. The pump may have a low pressure on the intake side which create vacuum to draw air through from the cavity and through the air channel <NUM>, 122c.

As best illustrated in <FIG> and <FIG>, mold plate <NUM> is connected to drive rods <NUM> that extend alongside housing <NUM> and are connected at one end to a transverse bar <NUM>. The mold plate drive system <NUM> comprises the drive rods <NUM>, the mold plate drive motors <NUM>, 4138d and the associated linkages. The other end of each drive rod <NUM> is pivotally connected to a connecting link <NUM> via a machine <NUM> plate 4131a and a pivot connection <NUM> c, shown in <FIG>. The pivot connection 4131c can include a bearing (not visible in the figures) surrounding a pin within an apertured end of the connecting link <NUM>. The pin includes a cap, or carries a threaded nut, on each opposite end to secure the crank arm to the machine <NUM> plate 4131a.

Each drive rod <NUM> is carried within a guide tube <NUM> that is fixed between a wall <NUM> and a front bearing housing <NUM>. The connecting links <NUM> are each pivotally connected to a crank arm <NUM> via a pin <NUM> that is journaled by a bearing 4141a that is fit within an end portion of the connecting link <NUM>. The pin crank arm <NUM> is fixed to, and rotates with, a circular horizontal guard plate <NUM>. The pin <NUM> has a cap, or carries a threaded nut, on each opposite end that axially fixes the connecting link <NUM> to the crank arm <NUM> and the circular guard plate <NUM>. The pin <NUM> rotates the link on an orbit 4141c about die motor output 4138a. The connecting link <NUM> also includes a threaded portion 4131b to finely adjust the connecting link length.

The crank arm <NUM> Is driven by a precise position controlled servo mold plate drive motor <NUM>. The motor is mounted vertically in the machine so that the output 4138a rotates on a horizontal axis which is the same horizontal axis that the circular guard plate <NUM> rotates about. The crank arm <NUM> is attached to the output 4138a to rotate the crank arm about the output 4138a. The motor <NUM> is mounted to a motor support plate 4138b that is mounted to and supported by the machine base <NUM>. As shown in <FIG>, the motor is mounted with the output 4138a perpendicular to the support plate. The motor has power and control cables that are routed through a wiring conduit 4138a to connect those wires to power and machine control <NUM>. A precise position controlled servo mold plate drive motor 4138d is identical to motor <NUM> but is mounted on the left side of the machine to drive the drive rod <NUM> on the left side of the machine as shown in <FIG>. The mechanical configuration on the left side, regarding the mold plate drive motor and related connection are the same as that described for the right side above.

The machine control <NUM> has instructions for maintaining the two motors <NUM>, 4138d operating in sync so that each of the right and left drive rods have the same longitudinal position along their respective ranges of motion. This is necessary to ensure that both lateral sides of the mold plate are in the same longitudinal position with respect to the other and they operate in a parallel reciprocation, The mold plate is reciprocated by the synchronous output both motors <NUM> and 4138a.

The precise position controlled motors <NUM>, 4138d can be a <NUM>-<NUM> 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 the machine controller <NUM>. In one embodiment, motors <NUM> comprise a motor 4138e driving a gearbox or gear reducer 4138f by a driveshaft <NUM> as shown in.

The motor may be model 1FK7082- 7AF71 manufactured by Siemens AG capable of <NUM> RPMs and <NUM> in/lbs of torque. The gearbox may be an in-line gear box such as, an Alpha TP+<NUM> MP manufactured by Wittenstein, inc. , with a place of business in Bartlett, IL.

In one embodiment, die controller <NUM> and the servo motors <NUM>, 4138d are 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..

A tie bar <NUM> is connected between the rods <NUM> to ensure a parallel reciprocation of the rods <NUM>. As the crank arms <NUM> rotate in opposite rotational directions, the outward centrifugal force caused by the rotation of the crank arms <NUM> and the eccentric weight of the attached links <NUM> cancels, and separation force is taken up by tension in the tie bar <NUM>.

One circular guard plate <NUM> is fastened on top of each crank arm <NUM>. The pin <NUM> 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 <NUM>. The guard plate <NUM> prevents an end of the link <NUM> from dropping into the path of the crank arm <NUM>.

<FIG> illustrates a proximity sensor <NUM> in communication with the machine control <NUM>. A target 4144a is clamped onto output shaft 4138a of the motor <NUM>. The proximity sensor <NUM> communicates to the controller <NUM> that the crank arm <NUM> is at a particular rotary position corresponding to the mold plate <NUM> being at a pre- selected position.

Preferably, the proximity sensor <NUM> can be arranged to signal to the controller that the crank arm <NUM> is in the most forward position, corresponding to the mold plate <NUM> being in the knockout position. The signal confirms to the controller that the knockout cups <NUM> can be safely lowered to discharge patties, without interfering with the mold plate <NUM>.

During a molding operation, the molding mechanism <NUM> is assembled as shown in <FIG> and <FIG>, with cover plate <NUM> tightly clamped onto spacers <NUM>.

In each cycle of operation, knockout cups <NUM> are first withdrawn to the elevated position as shown in <FIG>. The drive for mold plate <NUM> then slides the mold plate from the full extended position to the mold filling position with the mold cavities <NUM> aligned with passageway <NUM>.

During most of each cycle of operation of mold plate <NUM>, the knockout mechanism remains in the elevated position, shown in <FIG>, with knockout cups <NUM> clear of mold plate <NUM>. When mold plate <NUM> reaches its extended discharge position 4032b, the knockout cups <NUM> are driven downward in direction A to discharge the patties from the mold cavities.

The discharged patties may be picked up by the conveyor (not shown) or may be accumulated in a stacker. If desired, the discharged patties may be interleaved with paper, by an appropriate paper interleaving device, and such a device is disclosed in <CIT> or <CIT>. In fact, machine <NUM> may be used with a wide variety of secondary equipment, including steak folders, bird rollers, and other such equipment.

Molding mechanism <NUM> further comprises a knockout mechanism or apparatus <NUM> shown in <FIG>, <FIG>. In one embodiment, the knockout mechanism may be that which is disclosed in <CIT>. The knockout apparatus comprises the knockout plungers or cups <NUM>, which are fixed to a carrier bar <NUM>. Knockout cups <NUM> are coordinated in number and size to the mold cavities <NUM> in the mold plate <NUM>. One knockout cup <NUM> is aligned with each mold cavity <NUM>. The mold cavity size is somewhat greater than the size of an individual knockout cup. The knockout apparatus <NUM> is configured to drive the carrier bar <NUM> in timed vertical reciprocation.

<FIG> illustrate the knockout apparatus <NUM> in more detail. The carrier bar <NUM> is fastened to knockout support brackets 4146a, 4146b. The knockout support brackets 4146a, 4146b are carried by two knockout rods <NUM>. Each knockout rod <NUM> is disposed within a wall of a knockout housing <NUM> and is connected to a knockout beam <NUM>. The knockout beam <NUM> is pivotally mounted to a crank rod <NUM> that is pivotally connected to a fastener pin <NUM> that is eccentrically connected to a crank hub <NUM> that is driven by a knock out cup drive motor <NUM>. The knock out drive motor is located above the mold plate.

A heating element <NUM> surrounds, and is slightly elevated from the knockout carrier bar <NUM>. A reflector <NUM> is mounted above the heating element <NUM>. 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.

In <FIG> and <FIG>, the crank hub <NUM> is rotated into a position wherein die crank rod <NUM> is vertically oriented and the knockout beam <NUM> is lifted to its maximum elevation. The knockout rods are fastened to the knockout beam <NUM> by fasteners <NUM>. The knockout support brackets 4146a, 4146b are in turn fastened to the knockout rods <NUM> by fasteners <NUM>. Each knockout cup <NUM> is fastened to the knockout carrier bar by a pair of fasteners 4154a and spacers 4154b. An air flap or air check valve 4033a can be provided within each cup to assist in dispensing of a meat patty from the cup <NUM>.

As shown in <FIG>, the motor <NUM> is supported by a bracket <NUM> from a frame member <NUM> that is mounted to the casting <NUM>. The bracket <NUM> includes one or more slotted holes, elongated in the longitudinal direction (not shown). One or more fasteners <NUM> penetrate each slotted hole and adjustably fix the motor <NUM> to the frame member. The motor <NUM> includes an output shaft <NUM> that is keyed to a base end of the crank hub <NUM>. The fastener pin <NUM> retains a roller bearing <NUM> thereon to provide a low friction rotary connection between an annular base end 4115a of the crank rod <NUM> and the pin <NUM>.

The crank rod <NUM> has an apertured end portion <NUM> on an upper distal end 4151b opposite the base end 4151a. The apertured end portion <NUM> is held by a fastener pin assembly <NUM> through its aperture to a yoke <NUM>. The yoke <NUM> is fastened to the knockout beam <NUM> using fasteners. The fastener pin assembly <NUM> can include a roller or sleeve bearing (not shown) in like fashion as that used with the fastener pin <NUM> to provide a reduced friction pivot connection.

The housing <NUM> 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 <NUM>, the pin <NUM>, roller bearing <NUM>, the apertured end portion <NUM>, the fastener pin <NUM> and the yoke <NUM> are all contained within the oil bath having an oil level <NUM>. The limits of the oil bath are defined by a housing <NUM> having a front wall <NUM>, a rear wall <NUM>, side walls <NUM>, <NUM>, a top wall <NUM> and a sleeve <NUM>. The sleeve <NUM> is a square tube that surrounds a substantial portion of the crank rod <NUM> and is sealed around its perimeter to the top wall <NUM> by a seal element 4196a. The sleeve <NUM> is connected to the beam <NUM> and penetrates below the top wall <NUM>. As the yoke <NUM> reciprocates vertically, the beam <NUM> and the sleeve <NUM> reciprocate vertically, the sleeve <NUM> maintaining a sealed integrity of the oil bath.

The crank rod <NUM> includes side dished areas 4151c that act to scoop and propel oil upward during rotation of the hub <NUM> to lubricate the pin <NUM> and surrounding areas.

The knockout rods <NUM> are guided to reciprocate through the side walls <NUM>, <NUM>, particularly, through upper and lower bearings 4191a, 4191b. The rods <NUM> are sealed to the top wall by seals <NUM>. The bearings 4191a can include an internal groove <NUM> that is in flow-communication with a lubricant supply through port <NUM>.

A lubricant system 4194a is provided to provide lubricant to the bearings 4191a, 191b. The system 4194a includes a lubricant reservoir 4194b that is filled with lubricant, such as oil, and connected to plant air 4194c via an electronically controlled valve 4194d. The machine controller <NUM> periodically, according to a preset routine, actuates the valve 4194d to propel some lubricant into the bearings 4191a. Lubricant can run down the knockout rod <NUM> into a dished top <NUM> c of the lower bearings 4191b to allow oil to penetrate between the knockout rods <NUM> and the lower bearings 4191b.

An outer cover <NUM> is fastened and sealed around the side walls <NUM>, <NUM> and front and rear wails <NUM>, <NUM> by fasteners, spacers <NUM> and a seal <NUM>. 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.

The front wail <NUM> includes an oil level sight glass 4185a, a fill port 4185b (shown dashed in <FIG>), a drain port 4185c (<FIG>); and an access hole closed by a screw 4185d (<FIG>).

The knockout assembly is changeable to extend further forwardly to minimize knockout cup cantilever. This is accomplished by loosening the bracket <NUM> from the frame member <NUM> and sliding the motor and ail the connected parts forward or rearward and replacing circular adapter plates for the knockout rods <NUM>.

The housing <NUM> is fastened to a support plate <NUM> by fasteners 4201a. The support plate <NUM> is fastened to circular adapter plates 4201b by fasteners 4201c. The circular adapter plates 4201b are removably fit into circular holes <NUM> d in the casting <NUM>. The circular adapter plates 4201b include a bottom flange <NUM> e which abuts the casting <NUM>. The circular adapter plates 4201b surround die bearings 4191b and associated bearing assemblies 4191c.

As shown in <FIG>, the left bracket 4146a is fixedly connected to the left knockout rod <NUM> using the fastener <NUM> while the right bracket 4146b is connected for a sliding connection. In this regard the right fastener <NUM> passes through an inverted T-nut 4153a that passes through the bracket 4146b and fits into a back up washer 4153b that abuts the top side of the bracket 4146b. The bracket 4146b includes an oversized opening in the lateral direction that allows the bracket 4146b to shift laterally with respect to die T-nut and knockout rod <NUM>. This arrangement allows the bar <NUM> to expand and contract laterally with respect to the knockout rods <NUM>. When the knockout cups <NUM> are heated by the heating element <NUM>, the carrier bar <NUM> can become heated as well. Preferably, the carrier bar <NUM> is composed of aluminum which can expand to a significant degree. The sliding connection of the bracket 4146b accommodates this thermal expansion.

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 <NUM> from the frame member <NUM> and sliding the motor <NUM> and the connected parts forward or rearward and replacing the circular adapter plates that guide the knockout rods <NUM>.

A proximity sensor <NUM> is bolted to the outer cover <NUM>, and a target <NUM> is provided on the crank, beam <NUM> to be sensed by the proximity sensor <NUM>. The proximity sensor <NUM> communicates to the controller <NUM> that the knockout cups are raised and the mold plate can be retracted without interfering with the knockout cups.

The hopper tilt system and the control panel <NUM> are configured such that apparatus can be easily factory converted from a right side operating apparatus to a left side operating apparatus, that is, factory reversible across the longitudinal centerline of the apparatus.

The operation of the machine is controlled by the machine control <NUM>. The machine control is schematically shown in <FIG>. The machine control is signal connected to the rotary pump motor <NUM>, the feed screw drive motors <NUM>, <NUM>, the mold plate drive motors <NUM>, 4138d, sensor <NUM>, and the knock out cup drive motor <NUM>. These connections allow the machine to control the operation of the various components of the machine. The connections allow the machine control to know the operating status of each component. The machine control has computer readable instructions for carrying out the functions and operations of die various parts of the machine as described above and for receiving and recording data about the same.

Claim 1:
A food product forming machine comprising:
a) a food supply (<NUM>);
b) a rotary food pump (<NUM>) in communication with the food supply (<NUM>) and including a food pump inlet and a food pump outlet;
c) a molding mechanism having a mold plate (<NUM>) with a mold cavity (<NUM>), the mold plate (<NUM>) arranged to be reciprocated by a mold plate drive (<NUM>) between a cavity fill position and a cavity discharge position;
d) a knockout drive (<NUM>) for reciprocating a knockout plunger (<NUM>) to discharge molded food products from the mold cavity (<NUM>) in the mold plate (<NUM>); and
e) a manifold (<NUM>) connected to an outlet (<NUM>) of the rotary food pump (<NUM>) and having an outlet passageway connected to an inlet of the molding mechanism for filling the mold cavity (<NUM>) of the mold plate (<NUM>), wherein
f) the food pump outlet is located below the mold plate (<NUM>) and below the manifold (<NUM>),
characterized in that
g) the food pump inlet is located above the mold plate (<NUM>) and above the manifold (<NUM>).