Patent ID: 12241850

DETAILED DESCRIPTION

The following detailed description is provided to assist the reader in gaining a comprehensive understanding of the methods, apparatuses and/or systems of the present disclosure. Various changes, modifications, and equivalents of the systems, apparatuses and/or methods described herein will suggest themselves to those of ordinary skill in the art. Descriptions of well-known functions and structures are omitted to enhance clarity and conciseness.

The terms used in the description are intended to describe embodiments only, and shall by no means be restrictive. Unless clearly used otherwise, expressions in a singular from include a meaning of a plural form. In the present description, an expression such as “comprising” or “including” is intended to designate a characteristic, a number, a step, an operation, an element, a part or combinations thereof, and shall not be construed to preclude any presence or possibility of one or more other characteristics, numbers, steps, operations, elements, parts or combinations thereof.

As illustrated inFIG.1, in embodiments of the present disclosure, a food processing monitoring system1may comprise a food processing machine10(e.g. a meat grinder) and a data logging apparatus, such as a computer system100configured to collect data pertinent to product temperature at an input (e.g. a hopper5) of the food processing machine10and an output (e.g. an outlet40) of the food processing machine10. Further, the computer system100may be configured to collect data (e.g. current) pertinent to motor draw of a motor6of the food processing machine10. For example, the computer system100may communicate with a temperature sensor50, a temperature sensor55, and a current sensor70(generally designated at motor6inFIG.1and illustrated inFIG.2) to obtain temperature data of the hopper5, temperature data of the outlet40, and current data of the motor6, respectively. For example, the computer system100may be connected to the temperature sensor50, the temperature sensor55, and the current sensor70via one or more wires or a wireless connection.

According to an embodiment, the temperature sensor50and the temperature sensor55may be any type of sensor that is configured to sense temperature (e.g. a thermocouple). The temperature sensor50may be installed in a housing of the hopper5and the temperature sensor55may be installed in a housing of the outlet40. According to an embodiment, the current sensor70may be any type of sensor that is configured to sense current (e.g. an ammeter). The current sensor may be installed in a housing of the motor6and may be electrically connected to the motor6to detect a load of the motor6.

The hopper5may be provided with a set of mixing blades11that rotate. The motor6may be connected to a mixer shaft7to drive the mixing blades11, so that a product (e.g. meat) can be mixed by tumbling the product in the hopper5. In the bottom of the hopper5, there is provided an opening15through which the mixed product can pass. Positioned beneath the opening15from the hopper5there is provided a grinding chamber20where a feed screw25leading to a grinding head30is located. The motor6is also connected to a grinder shaft17. Grinding can be commenced by initiating driving of the feed screw25by the motor6. The motor6can comprise two separate driving devices to drive the mixer shaft7and the grinder shaft17, or may be configured so that a single driving device powers an output shaft and the output is then split between the mixer shaft7and the grinder shaft17. The feed screw25, which has may have a large pitch adjacent the opening15and a progressively smaller pitch toward the grinding head30, forces the mixed product through the grinding head30. The product exiting through an outlet40of the grinding chamber20may be a ground product such as ground meat.

As shown inFIG.2, the computer system100may comprise at least one processor101, a memory102, and a transmission module103. The transmission module103may comprise a wireless transmitter and receiver which communicates with external sensors and other components. In the case of wired connections, the transmission module103may comprise input and output ports. InFIG.2, elements are shown schematically connected with communication lines, however such communications lines are not required to necessarily be wired connections and could, for example, be wireless.

The temperature sensor50, the temperature sensor55, and the current sensor70may provide measurement data, for example, temperature information and/or current data, to at least one processor101of the computer system100. The computer system100is, for example, an electronic control unit which receives transmitted data, stores the data, and may control operations of the food processing machine10. The computer system100may comprise integrally or separately a display150, an input device160, and a battery backup170. An operator can control the machine speed and other operational parameters by manipulating the input device160.

The temperature sensor50and the temperature sensor55may be formed as probes extending through the housings and protruding into the interior of the respective chambers, wherein a seal member is interposed between the housing and the probe thereby forming a water-tight seal. For example, as illustrated inFIG.3, the temperature sensor50may be a probe that extends through a housing of the hopper5, and a seal member52may be interposed between the housing and the temperature sensor50thereby forming a water-tight seal. Alternatively, the temperature sensor50and the temperature sensor55may measure the temperature at the housing where they are installed, without protruding there through.

As shown inFIG.4, a temperature sensor60may be installed upstream from the grinding head30of the food processing machine10. It should be noted that the number and positions of the sensors can be varied according to the desired measurements and expected batch size. Furthermore, the temperature sensors may alternatively comprise infrared thermometers which detect thermal radiation from an object at a distance.

The U.S. Department of Agriculture (USDA) may require the collection of certain data for food safety reasons, for example Hazard Analysis Critical Control Point (HACCP) data. According to embodiments, temperature data relevant to HACCP for meat processing may be automatically collected for this purpose. For example, the number and position of temperature sensors may correspond to specific Critical Control Points (CCPs) identified in the food manufacturing process for ground meat using the food processing machine10. Pursuant to the principles of HACCP, the computer system100may monitor, verify, and validate operations of the food processing machine10and establish a record accordingly.

According to embodiments of the present disclosure, the food processing monitoring system1may be configured to detect whether food is present in the food processing machine10.

For example, the computer system100may use a combination of temperature information logged from one or more temperature sensors (e.g. temperature sensor50and temperature sensor55) with power information (e.g. current information) from one or more current sensor (e.g. current sensor70), connected the motor6, to provide dynamic temperature limits. The dynamic temperature limits may be food safety temperature thresholds that the computer system100compares with the temperature information obtained from at least one temperature sensor only when food product is determined to be present at a location (e.g. the hopper5or the outlet40) corresponding to the at least one temperature sensor. According to embodiments, the at least one processor101of the computer system100may compare the detected motor power draw (e.g. current) to predetermined thresholds such as, for example, current thresholds in which values below indicate that the food processing machine10is operating without product present and values above indicate the food processing machine10is operating with various types of food product present. By using this power measurement along with the logged temperature data, the computer system100may determine when product is present and apply appropriate temperature thresholds at the appropriate times.

FIG.5illustrates a graph500that illustrates example temperatures and motor currents of the food processing machine10that are obtained by the computer system100using various temperature and current sensors according to embodiments. More particularly,FIG.5illustrates a temperature reading (labeled as “Hopper Temperature”) of the hopper5and a temperature reading (labeled at “Outlet Temperature”) of the outlet40of the food processing machine10, along with a current draw reading (labeled as “Motor Current”) from the motor6.

The graph500describes an example scenario in which an operator first loads meat into the hopper5, turns the equipment on, then allows the food processing machine10(e.g. a grinder) to completely process the meat before turning the food processing machine10off. With reference toFIG.5, the time at “0” seconds refers to a time in which the food processing machine10is off and the operator first loads meat into the hopper5.

As can be seen inFIG.5, the temperature of the hopper5and the outlet40start at 50° F. which, in this example, is the ambient temperature in the room. At around “5” seconds, the temperature of the hopper5drops to 33° F. which is the starting temperature of the food product once the product is loaded into the hopper5. When the motor6is first turned on at around “5” seconds, the current draw of the motor6rises to an initial peak of8A at around “8” seconds, then falls to a nominal grinding current draw of4A at around “13” seconds. At around “11” seconds, the outlet temperature starts to fall as the food product reaches the end of the outlet40through the food processing machine10. After operating for a period of time, the hopper5is emptied due to the operation of food processing machine10, thereby resulting in a rise in hopper temperature starting at around “32” seconds. Once the food product has been fully processed (at around “36” seconds, the motor current falls to a nominal2A as the resistance on the motor is reduced. The outlet temperature also begins to rise at this point as there is no longer any food product present at the outlet40.

The peak current may occur even if the hopper5is empty as the starting current of a motor is often larger than the nominal operating current. However, the peak current value may be higher when product is already present in the hopper5as opposed to when the motor6starts with the hopper5empty. According to embodiments, at an operation start time of the motor6, the at least one processor101of the computer system100may obtain the peak current based on the current information from the current sensor70, determine whether the peak current is above a threshold that corresponds to a current which indicates that the hopper5was already loaded with product before the motor6was started, and based on determining that the peak current is above the threshold, logging the temperature of the hopper5, measured at the time of starting the motor6, as the starting temperature of the food product. Alternatively, in a case where the peak current is determined to be lower than the threshold, the at least one processor101may determine that the hopper5was empty when the motor6was started, and log that no product was present in the hopper5at such time.

In a similar manner, the at least one processor101of the computer system100may determine whether product is present at the outlet40of the food processing machine10based on the current draw of the motor. However because the product requires a certain amount of time to reach the outlet40through the food processing machine, the at least one processor101may use a time delay to dynamically adjust when the temperature limits are applied. Referring toFIG.5, it can be seen that even though product was already loaded into the equipment before the motor6was started, the temperature at the outlet40did not drop below the ambient room temperature until roughly 5 seconds after the motor6had been turned on. According to embodiments, the at least one processor101of the computer system100may determine a starting point at which product is determined to be in the hopper5with the motor running That is, for example, the at least one processor101may determine the starting point is a time in which the motor6was first turned on due to a detected starting current condition (e.g. a peak current above a threshold current) of the motor6, or is a particular time after starting the motor6in which the motor current increases from a nominal current to a known grinding current. According to embodiments, the known grinding current may be a threshold current that the at least one processor101compares to a detected current of the motor6to determine whether the product is present in the hopper5. The at least one processor101may determine a time in which the product is present at the outlet40based on a predetermined time delay from the point in time in which the product is first determined to be present at the hopper5. For example, the processor may determine the time delay based on the length of the feed screw25and the outlet40.

According to embodiments, the at least one processor101may continue to measure the motor current draw based on the current sensor70while the food processing machine10is operating and, based on determining that the measured motor current draw falls (e.g. below a predetermined threshold corresponding to the food fully being processed), the processor may cause a data buffer of the computer system100to retroactively remove food safety temperature limits based on the known period of time required for product to reach the end of the outlet40from the hopper5. Alternatively or additionally, the at least one processor101may disable the food safety temperature limits at the outlet40at the point in time at which the measured motor power draw of the motor6drops below a predetermined current threshold indicating that grinding of food product is not occurring, which the at least one processor101may determine as meaning food product is no longer present.

According to embodiments, processor101may set the power draw thresholds and timing determinations differently based on different sizes and types of equipment, and the values used may be different depending on the type of equipment.

According to embodiments, the at least one processor101of the computer system100may perform wear rate determinations concerning the food processing machine10. For example, by performing data collection concerning operation of the food processing machine10, the at least one processor101may determine wear rate of components within the food processing machine10, and use such wear rates to predict when maintenance should be done on a component of the food processing machine10. According to embodiments, the at least one processor101may determine the wear rates based on operating time of the food processing machine10, and also measured current draw and measured temperatures such as the motor current draw and inlet and outlet temperatures described in the present disclosure. The amount of motor current drawn correlates to mechanical resistance of the grinding medium (including whether a food product is present), and inlet or outlet temperature, when measured to be below freezing, is indicative of a solid frozen product in the food processing machine10as opposed to a thawed product. For example, when a grinder is operating empty for one hour, the mechanical wear on the grinder may be significantly less than when it is grinding food product. Additionally, the grinding of thawed food product (above 32° F.) may result in less mechanical wear on a system than when it is grinding frozen food product (below 32° F.). To account for this, the computer system100may use a weighted average approach for component wear rates and adjust the weighting based on component type. For example, electrical components such as a power supply or set of relays of a food processing machine may have an increased wear rate based solely on temperature, whereas wear rate of a set of bearings or grinding plate may be more based on the amount of time spent grinding thawed product, frozen product, and the amount of time spend rotating with no product present.

According to embodiments, the at least one processor101of the computer system100may determine wear rates of individual components (e.g. electrical components and mechanical components) by calculating, for each individual components, a weighted average by applying a set of respective weights to parameters. The parameters may include, for example, a total time in which a food processing machine (e.g. the motor) grinds food product that is frozen, a total time in which a food processing machine (e.g. the motor) grinds food product that is thawed, a total time in which a food processing machine (e.g. the motor) operates without grinding food product, and a time at one or more specified temperatures. The at least one processor101may set the weights for each of the parameters for an individual component based on the type of the individual component.

The at least one processor101may determine the value of the parameters (before the weights are applied) based on the temperature and current information that is obtained by the at least one processor101, as described in embodiments of the present disclosure. For example, the at least one processor101may determine that food product is present (or not present) in the food processing machine10while the food processing machine10is operating, based on current values obtained from the current sensor70, and further obtain temperatures of the food processing machine10and temperatures of the food product that is determined to be present (and therefore a frozen or thawed state of the food product) based on temperature values obtained from the temperature sensors including, for example, the temperature sensor50and the temperature sensor55.

The at least one processor101may obtain a wear rate of each component by obtaining a weighted average for each of the components using their respective weights and parameters, and predict when maintenance should be done on a component of the food processing machine10based on the obtained wear rates.

According to embodiments, the at least one processor101of the computer system100may analyze the obtained temperature information and current information locally to identify and aggregate data on operation modes (e.g. grinding, operating while empty, operating above temperature limits) and report the data at the end of an operation (e.g. operation of the food processing machine10) to limit the amount of data transfer in situations where data costs may be excessive. According to embodiments, the at least one processor101of the computer system100may aggregate data as summarized in table600, illustrated inFIG.6. With reference to table600, values for “duration”, “peak motor current”, “average motor current”, “product present”, “product temperature (hopper)”, “product temperature (outlet)”, and “ambient temperature”, and the corresponding operation modes in which the values belong, may be determined based on the obtained temperature information and/or current information from sensors. In further reference to table600, an “x” is illustrated to indicate that a value is aggregated, and no “x” may indicate that no value is aggregated.

According to embodiments, a food processing monitoring system that includes a food processing machine that was operating for one hour may report a very small amount of data. In contrast, in a comparative embodiment, a system that uses a remote location for data analysis may require sensor readings to be transmitted once per second, requiring a significantly higher amount of data to be sent over a network.

According to embodiments, based on determining that food product is present in the food processing machine10and determining that a measured temperature of the food product in the food processing machine10is approaching an unsafe level for health (e.g. above a predetermined threshold), the at least one processor101of the computer system100may control the food processing machine10to prevent the temperature of the food product from exceeding the unsafe level for health. For example, the at least one processor101may control the feed rate of the feed screw25to decrease, by slowing a speed of the motor6, based on determining that the measured temperature of the food product present at the outlet40rises above 38° F. By reducing the speed of the motor6, the amount of temperature rise of the food product may be reduced. Alternatively or additionally, the at least one processor101may activate active temperatures controls. For example, the at least one processor101may cause a supply of chilled CO2, from a CO2 gas feed to the hopper5or the feed screw25of the food processing machine10, to be supplied to decrease temperature of the food product. According to embodiments, the supply of the gas feed may be adjusted automatically based on the measured temperature of the food product.

FIG.7illustrates an example of computer code700that may be stored the memory102of the computer system100. The computer code700, when executed by the at least one processor101, may be configured to cause the at least one processor101to perform its functions as described in the present disclosure. For example, the computer code700may comprise sensor information obtaining code710, product presence determining code720, product temperature determining code730, aggregation and analysis code740, and control code750.

The sensor information obtaining code710may be configured to cause the at least one processor101to obtain information (e.g. temperature information and/or current information) from sensors (e.g. the temperature sensor50, the temperature sensor55, and/or the current sensor70), as described with respect to embodiments the present disclosure.

The product presence determining code720may be configured to cause the at least one processor101to determine when product is present in the food processing machine10(e.g. at the hopper5and/or the outlet40), and for how long, based on the current information and predetermined thresholds, as described with respect to embodiments of the present disclosure.

The product temperature determining code730may be configured to cause the at least one processor101to determine the temperature of product, based on determining that the product is present in the food processing machine10and based on the temperature information obtained while the product is present, as described with respect to embodiments of the present disclosure. The product temperature determining code730may also be configured to cause the at least one processor101to determine whether the temperature of the product is at or approaching unsafe levels by comparing the obtained product temperatures with predetermined thresholds. The product temperature determining code730may also be configured to cause the at least one processor101to determine whether the product is frozen or thawed based on the obtained temperature information.

The aggregation and analysis code740may be configured to cause the at least one processor101to aggregate and analyze the data obtained by the computer system100, as described with respect to embodiments of the present disclosure. The analysis may include, for example, determining wear rate of components within the food processing machine10, and using such wear rates to predict when maintenance should be done on a component of the food processing machine10.

The control code750may be configured to cause the at least one processor101to control the food processing machine10to prevent the temperature of the food product from exceeding the unsafe level for health, as described with respect to embodiments of the present disclosure. For example, the at least one processor101may control the feed rate of the feed screw25to decrease, by slowing a speed of the motor6, based on determining that the measured temperature of the food product present at the outlet40rises above 38° F. Alternatively or additionally, the at least one processor101may cause a supply of chilled CO2, from a CO2 gas feed to the hopper5or the feed screw25of the food processing machine10.

According to embodiments, the at least one processor101may perform any number of the following.

The at least one processor101may determine temperature of food product based on temperature sensors at an inlet and outlet of a food processing machine and motor draw of a motor of the food processing machine and determine whether temperature of food product is at an unsafe level based on the measured temperatures. The at least one processor101may measure inlet (e.g. a hopper) and outlet temperature of a food processing machine (e.g. a grinder for meat) using respective temperature sensors; measure motor draw (e.g. current) of a motor of the food processing machine with a sensor (e.g. a current sensor); determine whether the food processing machine is operating with or without food product present by comparing the measured motor draw of the motor with at least one predetermined threshold that indicates food is being grinded (e.g. a first predetermined threshold at start of motor operation and/or a second predetermined threshold while the motor is continuously operating); log temperature of the inlet when the motor starts as temperature of food product in a case where peak measured motor draw at motor start is above the first predetermined threshold (which indicates food is within the inlet at motor start); logging that no food was present in inlet at motor start if peak measured motor draw at motor start is below or equal to first predetermined threshold (which indicates food product is not within inlet at motor start); determine that food product is presently within the inlet in a case where measured motor draw while motor is continuously running is above second predetermined threshold (and possibly logging temperature of inlet as temperature of food product based on such case); log temperature of the outlet as temperature of food product after processing based on a time delay (e.g. 5 seconds) after food product is first detected to be at the inlet; determine that processing of food product is complete (e.g. food product is not at the inlet and the outlet) based on measured motor draw dropping below a third predetermined threshold after it is determined that food product was previously at the inlet; compare temperatures of the inlet and the outlet, that are determined to correspond temperature of food product, with temperature thresholds to determine whether food is at a safe temperature (e.g. below a temperature which causes bacteria to grow); not comparing temperatures of the inlet and/or the outlet with the temperature thresholds when it is determined that food is not at the inlet and/or the outlet based on the measured voltage draw; and/or indicate (e.g. with an alarm) when food product is determined to be at an unsafe temperature.

The at least one processor101may determine wear rates of components of the food processing machine based on various weighted averages that are based on operating time, motor current draw, and temperature that are measured. The at least one processor101may determine wear rate of components of the food processing machine, and predict when maintenance on the components of the food processing machine should be performed, based on operating time, motor current draw, and temperature (e.g. at the inlet and/or the outlet). The at least one processor101may determine greater wear when motor current draw is a level that indicates that there is mechanical resistance of a grinding medium (i.e. grinding is occurring), and less wear when no grinding is occurring; determine greater wear when a temperature measurement(s) indicates that food product is frozen, and lesser wear when a temperature measurement(s) indicates food product is thawed; using weighted averages based on operating time, motor current draw, and temperature to determine wear of the various components (e.g. electrical components such as power supply and relays, and mechanical components such as bearing and grinding plate) of the food processing machine, wherein different weights are set for operating time, motor current draw, and temperature based on types of components for determining component wear rate (e.g. electrical component may solely use temperature for determining component wear rate, while mechanical components may use weights of each characteristic to different degrees).

The at least one processor101may perform analysis locally and report data over internet after a process is complete. The analysis may identify operational modes (e.g. startup, operating without product, grinding, grinding complete) and applicable data concerning operational modes (e.g. duration of mode, peak motor current during mode, average motor current during mode, whether food product is present during mode, food product temperature at the inlet during mode, food product temperature at outlet during mode, ambient temperature during mode) may be aggregated. The at least one processor101may report data from the analysis over a network (e.g. the internet) after completion of an operation (e.g. grinding complete).

The at least one processor101may control a motor or add chilled CO2 based on inlet and outlet temperature. For example, the at least one processor101may control a feed rate of a screw drive of the food processing machine or an amount of chilled CO2 introduced via a gas feed into the food processing machine based on inlet (e.g. hopper) or screw temperature to avoid the temperature of the food product that is measured at the outlet rising above a predetermined temperature (e.g. 38 degrees F.).

It should be noted that although a few non-limiting example embodiments have been described, those skilled in the art will readily appreciate that many modifications are possible to the example embodiments without departing from the scope of the present disclosure. Therefore, it is to be understood that the foregoing is illustrative of various example embodiments and is not to be construed as limited to the specific example embodiments described herein.