Patent ID: 12232501

WRITTEN DESCRIPTION

Referring first toFIGS.1-5, shown therein are various views of a pan shaker100constructed in accordance with presently preferred embodiments. The pan shaker100is well-suited for use in a commercial bakery that employs automated assembly-line production processes. The pan shaker100is generally configured to perform a shaking operation on a series of pans200(FIGS.2-4) that are fed to the pan shaker100on an assembly line (not shown). Each of the pans200includes a series of pan molds202that are sized and shaped to hold the dough for a specific baked good (e.g., hamburger buns, bread loafs, etc.). The shaking operation helps to center the dough within each of the pan molds202to encourage the production of substantially uniform baked goods.

The pan shaker100includes several major assemblies, including a frame assembly102, a conveyor assembly104, a control assembly106and a shaker assembly108. The frame assembly102includes a series of legs110, structural cross-members112and dough guards114that support and protect the other components within the pan shaker100. Notably, the shaker assembly108is presented in an “underhung” configuration in which the shaker assembly108resides below the conveyor assembly104. The dough guards114prevent dough and other materials from falling into the shaker assembly108below the pan200and conveyor assembly104.

The frame assembly102also includes a pair of frame rails116and motor mounts118that support components within the shaker assembly108. The conveyor assembly104includes a conveyor belt120and conveyor belt motor122that carries the pan200through the pan shaker100. As used in this disclosure, the term “longitudinal” will refer to an axis followed by the pan200as it passes through the pan shaker100. The term “lateral” will refer to an axis that is transverse to the longitudinal axis. The lateral axis extends across the width of the pan shaker100.

The control assembly106includes operator controls, power supplies, warning systems, and control controls systems (not separately designated). The control assembly106receives input from various sensors located within the pan shaker100and controls the operation of the shaker assembly108and conveyor assembly104. In certain applications, the control assembly106is configured to receive input from upstream components within the bakery. For example, the control assembly106can be configured to proactively adapt the operation of the shaker assembly108and conveyor assembly104in anticipation of a change in the size, speed or configuration of the pans200approaching the pan shaker100.

Turning toFIGS.6-9, shown therein are various views of the pan shaker100and shaker assembly108. The shaker assembly108includes a carriage assembly124, a clamping assembly126and actuation assembly128. The carriage assembly124includes a lateral rail130that rides on a low-friction bearing connection to frame rails116. The carriage assembly124further includes a central support132that rides on the lateral rail130. The lateral rail130permits the carriage assembly124to move longitudinally back and forth along the frame rails116while also allowing the central support132to move back and forth laterally on the lateral rail130.

The clamping assembly126is supported by the central support132. The clamping assembly126includes a dual-acting pneumatic cylinder134, clamp rail136, a drive belt138, clamps140a,140b, exterior pulleys142and interior pulleys144. In the presently preferred embodiment, the clamps140a,140bride on the clamp rail136. Each clamp140a,140bis secured to the drive belt138. The interior pulleys144and exterior pulleys142are spaced and configured to route the drive belt138across the width of the shaker assembly108such that opposite sides of the drive belt138are placed in a linear relationship through the center of the central support132. Each clamp140a,140bis thereby centered above the central support132and attached to the drive belt138on opposite sides of the exterior pulleys142.

The first clamp140ais also attached to the pneumatic cylinder134and the first clamp140amoves back and forth on the clamp rail136in response to the bidirectional actuation of the pneumatic cylinder134. As the first clamp140amoves, it pulls the drive belt138. The drive belt138causes the second clamp140bto move on the clamp rail136in an opposite direction from the first clamp140a. In this way, the two clamps140a,140bare drawn together or pulled apart in unison in response to the controlled and automated actuation of the pneumatic cylinder134. Encoders on the exterior pulleys142provide the control assembly106with real-time information about the position of the drive belt138and clamps140a,140b. As best illustrated inFIGS.1and4, the clamps140a,140bextend upward through slots in the dough guards114. The slots in the dough guards114are long and wide enough to permit the lateral, longitudinal and compound (e.g., orbital) movements of the clamps140a,140b.

During use, the clamps140a,140bare rapidly drawn together to secure the pan200. Once the shaking operation is complete, the clamps140a,140bare separated to release the pan200. The clamping assembly126presents a significant advantage over prior art magnetic clamping systems. The clamping assembly126can be used for heavier pans200and pans200that are not constructed from ferromagnetic materials. The clamping assembly126can also adapt automatically and in real-time for use with pans200of various shapes, sizes and orientation. These features allow the pan shaker100to be used for a variety of pans and bakery products without extensive and time-consuming reconfiguration.

Turning toFIGS.10-12, shown therein a various views of the actuation assembly128. The actuation assembly128generally includes a first actuator assembly146a, a second actuator assembly146b, and an actuator post148connected to the central support132. Each of the first actuator assembly146aand second actuator assembly146bincludes an electric motor152that drives a rotating shaft154, which in turn drives an eccentric cam156. The first and second actuator assemblies146a,146beach includes a linkage158that is connected to the corresponding eccentric cam156on one end and to the actuator post148on the other end. On each end, the linkage158includes a bearing162that permits the eccentric cam156and actuator post148to rotate within the linkage158. The rotation of each eccentric cam156therefore induces a reciprocating linear-orbital movement in the corresponding linkage158. This linear-orbital movement is conveyed through the linkages158to the actuator post148.

Because the first and second actuator assemblies146a,146bare positioned in an offset relationship, the actuator post148is moved in different directions by the two linkages158a,158b. As best seen in the top views ofFIGS.6-7and10, the first actuator assembly146ais positioned substantially along the central longitudinal axis of the pan shaker100and configured with respect to the actuator post148to induce a primarily longitudinal motion. The second actuator assembly146bis positioned substantially along the central lateral axis of the pan shaker100and configured with respect to the actuator post148to induce a primarily lateral motion. The actuator post148transfers the combined, composite movement of the first and second actuator assemblies146a,146bto the central support132of the shaker assembly108, which in turn moves the clamping assembly126and pan200.

Rotational encoders160are used to detect the rotational position and speed of each motor152a,152b. In response to input from the rotational encoders158and the operational profile selected by the operator or automatically by the control assembly106, the control assembly106energizes each motor152a,152baccording to an independent motor control signal. By independently controlling the relative starting positions and rotational speeds of each motor152a,152b, the actuation assembly128can induce an infinite number of movement profiles in the clamping assembly126.

For example, in a first mode of operation, the first actuator assembly146ais controlled to induce a mode of movement in which the clamping assembly126reciprocates in a substantially linear path along the longitudinal axis of the pan shaker100. Because of the geometry of the eccentric cam156aand linkage158, rotating only the motor152aof the first actuator assembly146awould induce some lateral movement in the actuator post148. To cancel this lateral movement, the second actuator assembly146bis positioned and slightly rotated back and forth to compensate for the unwanted lateral movement produced by the first actuator assembly146a.

In a second mode of operation, the second actuator assembly146bis used to induce a mode of movement in which the clamping assembly126reciprocates in a substantially linear path along the lateral axis of the pan shaker100. To cancel any unwanted longitudinal movement in the pan200, the first actuator assembly146ais positioned and slightly rotated back and forth to compensate for the unwanted longitudinal movement produced by the second actuator assembly146b.

In a third mode of operation, the first and second actuator assemblies146a,146bcooperate to produce an orbital motion in the clamping assembly126. By coordinating the starting position and speed of each motor152a,152b, the shape of the orbital movement can be made predominately longitudinal, predominately lateral, or circular by precisely controlling the starting position and matching the rotational speed of the motors152a,152b.

Complex movement profiles can be created by setting the motors152a,152bat different rotational speeds or varying the rotational speeds of the motors152a,152bduring a shaking operation. Additionally, the actuation assembly128can be configured to switch between movement profiles within a single shaking operation. For example, it may be desirable to first shake the pan200along a longitudinal axis before shaking the pan200in a lateral direction. An additional benefit of the novel actuation assembly128is the ability to rapidly land the pan200within the center of the conveyor assembly104. Based on feedback from the rotational encoders160, the control system can stop the motors152a,152bin a position that places the pan200in the center of the conveyor belt120.

Thus, as described herein, the pan shaker100overcomes a number of deficiencies in the prior art and provides a mechanism that can be easily and automatically adapted to carry out a customized shake movements on pans of varying shapes, sizes and configurations. It is to be understood that even though numerous characteristics and advantages of various embodiments of the present invention have been set forth in the foregoing description, together with details of the structure and functions of various embodiments of the invention, this disclosure is illustrative only, and changes may be made in detail, especially in matters of structure and arrangement of parts within the principles of the present invention to the full extent indicated by the broad general meaning of the terms expressed herein and within the appended claims. It will be appreciated by those skilled in the art that the teachings of the present invention can be applied to other systems without departing from the scope and spirit of the present invention.