Title of Invention: Cylinder-piston kneading machine with primary kneading mechanism and multi-row rotating tray

Technical Field

[0001] This invention relates generally to bakery machines utilized in the commercial baking industry, and more particularly to a dough divider useful in the processing of doughs having a wide range of usage.

Background Art

[0002] The dividing machines are used to split the dough into smaller pieces of equal weight and shape, which can then be used to make various types of bread and pastries. Some of the latest achievements in the dividing machines used in the bakery industry are:

[0003] The Accurist2.1 ^TM Washdown Divider from Baker Perkins, which offers high accuracy, reliability and low cost of ownership. It also has a washdown feature that allows easy cleaning and hygiene.

[0004] The Volumetric Dough Dividers™, which can divide dough into different shapes such as squares, circles or hexagonal. They also have a selection of optional extras such as oiling systems, flour dusters and dough hoppers.

[0005] The WP Haton Parta U2 ™, which is a low-maintenance dough divider and round-molder machine that can process dough gently and flexibly. It also has a touchscreen control panel and a self-learning weight control system.

[0006] The US. patent document NO. US4948611 entitled “Apparatus and method for dividing and cutting dough and the like” discloses the multi-outlet kneading machine, that each of the separate streams of dough is converted into identical pieces of dough by a four-bar mechanism simultaneously by a rotating actuator.

[0007] The European patent No. EP0570113 B1 entitled” An apparatus for dividing bread dough or the like” discloses a dividing device, which separates the dough at the bottom of the tank and performs the separation operation from the moving dough tank in the form of movable valves. [0008] Other patents related to this field, such as patents US4960601 , US5443854, and US5286185, are all different from the present invention in terms of components and application.

Summary of Invention

[0009] The summary of disclosed invention is intended to provide an overview of the subject matter of the invention, and is not intended to identify essential elements or key elements of the subject matter, nor is it intended to be used to determine the scope of the claimed implementations. The proper scope of the present disclosure may be ascertained from the claims set forth below in view of the detailed description below.

[0010] The invention is a dough-kneading device that includes a shaping pistoncylinder mechanism, a reciprocating mechanism, a round shaping assembly, and a multi-row revolving tray. The shaping piston-cylinder mechanism consists of a dough tank, a chassis, and a cylindrical tube with a piston. The dough is poured into the tank, and the piston moves up and down to separate a specific weight of dough. The reciprocating mechanism allows the tank to move back and forth while the cylinder and piston remain fixed. When the tank moves, a shaft passes through the dough, removing any air in it. The divided dough is then placed between the plate connected to the tank and the chassis plate, and the reciprocating movement of the tank kneads the dough. The round shaping assembly is responsible for shaping the dough into desired forms. The multi-row revolving tray includes a tray holder, a tray plate, a power generation and transmission system, a mobile chassis, and a motor and gearbox. The tray holder supports the tray plate, which rests on it. The power generation and transmission system drives the tray holder, enabling longitudinal movement of the multi-row rotating tray. Multiple wheels are placed under the chassis to aid in the movement of the tray.

[0011] In this invention by moving the tank, the shaft removes air from the dough, reducing error in separating a specific weight of dough balls from the initial dough mass. The dough is kneaded through reciprocating movement of the dough tank. This invention includes a multi-row revolving tray that increases tray capacity, allowing for more dough balls to be placed on the tray. Technical Problem

[0012] There are different devices for kneading bread dough, each of which uses a special and unique mechanism. One of the common kneading devices is a piston kneader that has a weight fault for air captured in the dough balls, and the other is a kneader with screw systems. The use of screw systems for separating dough pieces destroys the texture of the dough.

[0013] n a conventional piston press machine, the dough tank is fixed, and the piston is moved. In the said mechanism, the separation of dough with a certain weight is not done accurately because the dough swells in the tank after some time and its volume increases. In the invention disclosed in this document, the piston and cylinder are fixed and do not move, and the dough tank moves, and due to this reciprocating movement, the aerator shaft passes through the dough and releases the gases created in the fermentation process.

[0014] This increases the accuracy of dough ball separation with a certain weight and reduces the percentage of weight error because the dough does not bulk up in this method.

[0015] In most bakery systems a fixed small tray accumulates the dough balls for baking in the oven. The small unmoved tray with low capacity reduces the speed of bakery operations

Advantageous Effects of Invention

[0016] The amount of error in separating a certain weight(dough balls) from the initial dough mass is reduced, due to the fact that with the movement of the tank, the shaft passes through the dough and the air in the dough is removed.

[0017] The dough is kneaded by reciprocating movement of the dough tank.

[0018] In this invention, the presence of a multi-row revolving tray increases the capacity of the tray and more chins can be placed on the tray.

Brief Description of Drawings

[0019] The figures of the present document are intended to be illustrative, not limiting.

[0020] Fig.1 shows a perspective view of the dividing device with a multi-row rotating tray. [0021] Fig. 2 shows another view of the dividing device with the multi-row rotating tray, where the main parts of the device are specified.

[0022] Fig.3 shows an isometric view of the dividing device and shaping assembly.

[0023] Fig. 4 shows a view of the suction piston-cylinder mechanism and piece separation and the connection between the gear and the engine and the gearbox.

[0024] Fig. 5 shows a view of the reciprocating mechanism of the dough tank in the dough-kneading process and the parts that provide the reciprocating movement.

[0025] Fig. 6 shows an above view from the reciprocating mechanism of the dough tank, where the chassis and plate are connected to the tank, and the details of the movement mechanism are illustrated in more detail.

[0026] Fig. 7 shows a view of the dough rolling mechanism.

[0027] Fig. 8 shows a perspective view of the rotating tray assembly.

[0028] Fig. 9 shows details of the tray holder and the tray moving components.

Description of Embodiments

[0029] The dough kneading device (10) in the present invention is a multifunctional device that performs all the dough preparation operations before going into the oven. The device and its main mechanisms are shown in figures 1 &2. In the present invention, dough refers to all types of dough that can be used in the pastry industry, especially in the bakery industry, and is not limited to a specific type of dough. The size and the shape of the tank and the dimensions of the components can be changed depending on the type of use and the dimensions, numbers, and examples mentioned in the present document are not restrictive. Changes in the geometry and shape of the components and parts that do not change the scope of the invention and common changes in the bakery, confectionery, and pastry industry which are applicable to this device, are within the technical scope of this invention.

[0030] In the present invention, the change in the weight of the divided doughs in the process of baking especially in the rest step has been solved by installing the air intake shaft (13) and the moving tank (12), i.e. the reciprocating mechanism of the tank (30) and the cylinder-piston mechanism (20) separate the balls or pieces from the initial mass dough in the tank(12) which will be explained hereinafter. The said mobile hopper or tank(12) with different shapes is made of materials acceptable in the food industry, such as suitable steel types. In Figure 3, a three-dimensional view of the bakery kneading device (10) is shown in details, which is used for kneading dough of all kinds of bread, especially thin loaves of bread. This device consists of a tank (12) into which the bakery dough is poured and stored. A shaft (13) has been used to remove air and prevent the dough from puffing (during rest time) inside the dough tank. This shaft (13) is connected and fixed to the chassis (11 ) for example by some connectors such as bolts. Every time the dough tank (12) moves back and forth, the shaft (13) passes through the dough and stirs it, and releases the gas captured inside the dough. This operation has a great effect on reducing the error rate and problems in the dough separation process.

[0031] Shaping piston-cylinder mechanism (20): After preparation of the initial dough, the dough is poured into the dough tank (12). In one embodiment of the invention, the dough tank (12) is a funnel-shaped container with a perforated bottom (12a), which is connected to a plate (31 ) and placed on the chassis (11 ) of the machine. In one embodiment of the invention, the material of the container is steel, but it is not limited to this material. The chassis of the device (11 ) is a perforated plate, and a tube or pipe as a cylinder (21 ) is placed exactly under its opening where the dough exits. The chassis (11 ) is fixed in all movement states of the device and the components and movement mechanisms of the dough tank are located on it.The operation of the device in the present invention is that first a specific weight of dough must be separated as a ball from the set of doughs in the dough tank. As mentioned, in this machine, under the dough tank (12) and the chassis plate (11 ), a cylindrical tube (21 ) is placed inside which the piston (22) moves. Every time the piston (22) goes down (suction process), the dough piece is sucked from the dough tank (12) into the cylinder (21 ). Then in the separation process, the piston (22) rises and the separated piece inside the cylinder tube (21 ) is moved by the piston (22) and placed between the plate connected to the tank (31 ) and the chassis plate (11 ) and kneads it with the reciprocating movement of the dough tank which is explained in the article. The dough ball weight of each type of bread is specific (170 to 720 grams) and is different from other types. In this device, the weight of the dough is determined by the moving stroke of the piston (22). The stroke of the piston is determined by a sensor and control unit. In one embodiment of the invention, the sensor is a metal detector sensor and the control unit is PLC.

[0032] The driving force required for the upward and downward movement of the piston (22) is provided by the power generation and transmission system. In one embodiment of the invention, the generation and transmission system includes an electric motor and the gearbox (24) connected to it. A small gear (pinion or drive) (26) is connected to the output shaft of the gearbox. On the other hand, the end of the piston shaft (22) is also connected to a rack gear (25) and it goes up and down with the rotation of the pinion(26), in other words, due to the engagement of the pinion (26) with the rack gear (25), the rack gear (25) moves up and down, and the piston (22) connected to it also makes a similar reciprocating movement. In one embodiment of the invention, the cylinder and piston are made of steel. It is anti-rust and anti-bacterial due to compliance with health issues but is not limited to this material.

[0033] The back-and-forth mechanism of the dough tank (30):

[0034] In common divider machines, the piston of the machine is moved and the tank of the machine is fixed. In main embodiment of the present invention, the cylinder (21 ) and the piston (22) are fixed, but the dough tank (12) is mobile and moves back and forth. The advantage of this is to reduce the error rate in dividing the dough(separating a certain weight from the dough as a dough ball). When the tank (12) is moved, the shaft (13) passes through the dough and the air in the dough is exhausted and removed. This paste is placed in the space between the plate connected to the tank and the chassis plate. Now, with the help of reciprocating movement of the dough tank, it is kneaded and transferred to the grinding section.

[0035] The reciprocating movement is also done with the help of the power transmission system including the rack gear (33a) and its drive gear (34a) and its necessary driving force is provided by the motor (36). In this way, the rotational movement of the engine is transferred to the set of gears (39) by the power transmission system including the belt and pulley (37) installed on the output shaft of the engine. As a result of the rotation of the set of gears (39), the rotational movement is finally transferred to the pinion gear (34a) and with the engagement between this gear (34a) and the rack gear (33a), the rack gear (33a) will have a back-and-forth movement, after which the dough tank (12) connected to the rack gear will also make a similar back-and-forth movement. In the gear assembly, the purpose is to transfer power from the engine to the pinion gear, and gear assembly (39) with different numbers and diameter ratios can also be used. In other embodiments of this invention, the power transmission mechanism was changed, for example, belts and pulleys or chain wheels were used.

[0036] The method of connecting the rack gear to the plate connected to the dough tank (31 ) is that the rack gear (a33) is connected to a number of interface pieces (38) (welding, etc.). On the other hand, the plate (31 ) is also connected to the interface parts (38), and by moving back a, the rack gear of these interface parts moves inside the guide shafts (32) and the dough tank (12) They move. Rail wagon, wheel, etc. can also be used to move the dough tank and plate assembly.

[0037] The round shaping part (40):

[0038] In one of the embodiments of this invention, a strip rolling mechanism is used so that the dough pieces placed in the space between the chassis plate (11 ) and the plate connected to the dough tank (31 ) are kneaded with the help of reciprocating motion and into a round part.

[0039] In the round shaping part (40), there are two belts or strips (41 and 42) that move or slide in opposite directions and at different speeds (the speed of one of the strips is higher than the other). This causes the dough ball to change from shapeless to spherical while moving through the strips. The movement mechanism of this part is such that the rotational movement of the motor (45) is transferred to the gear (44) by the belt and pulley (46). This gear (44) rotates the gears (43) connected to the tape. The speed of the machine can be adjusted between 100 and 750 dough balls per hour and is determined in the control unit.

[0040] Most of the common dough-shaping devices are equipped with a rounding part, and the parts of device are explained in this document to complete the process of the kneading process.

[0041] Multi-row revolving tray (50): [0042] In other step, the dough with a specific shape and size for example the spherical shape is transferred to the tray. In common examples of bakery device, a fixed or rotating tray with a single row is used. In such a way that the dough pieces(balls) are placed on the tray to tray capacity or space be full and then the contents of the tray are emptied and the process is repeated.

[0043] The rotating tray in the device presented in this document is multi-row which arranger the dough balls in radial or linear arrangements. This type of tray increases the capacity of the tray and more dough pieces are placed on the tray plate(51 ), which is very efficient for industrial bakeries with a high number of bread baking. The multi-row revolving tray (50) consists of a tray holder (53). This holder (53) is in the form of a cross or in a radial form and has several blades, and the tray plate (51 ) is placed on the said holder(53). The holder (53) is connected to a shaft (52) and rotates by the power generation and transmission system(54). In one embodiment of the invention The system(54) includes a set of an engine and a gearbox (54). The rotary set of the table tray including holder (53), shaft (52), and motor and gearbox (54) is placed on a mobile chassis (55) and are moved along the table at a certain distance. In the multi-row rotating tray (50), the longitudinal movement is done by a separate motor and gearbox (57), which transfer the movement to the fixed rod connected to the moving chassis (55) using the number of rotating arms (58). This movement is converted by the linear guide mechanism including the rail (b56) and the wheel (a56) into the linear movement of the chassis (55). There are two rows of rails on the table and a number of wheels are placed under the chassis, which makes longitudinal movement possible.

[0044] The way the sub-assembly (50) works is that the shaft (52) rotates with the holder (53) and the tray plate (51 ). A metal piece (60) is placed on the shaft (52) of the motor, and when it reaches the metal-sensitive sensor (59), the motor and the gearbox (57) are commanded to move the rotary assembly to a certain amount. On the output shaft of the longitudinal motion gearbox (57), there are also two metal objects (660) which, if detected by the sensor, the motor stops moving, in other words, the metal objects and the sensors are for control the movement and the displacement of the rotary assembly. In this way, when the dough balls are arranged on the tray in a circular manner, the tray is moved and another number of dough balls are placed on it again. The moving process can be done twice or more until the tray is completely filled with dough balls. Metal signs and their corresponding sensors are exemplary in this embodiment of the invention, and other similar methods can be used to control the range of motion instead.