Note: Descriptions are shown in the official language in which they were submitted.
CA 02484723 2004-10-12
CONICAL SHELL GRASPING AND RETAINING APPARATUS, METHOD
FOR COATING 1NVERTED'CONICAL SHELLS, AND MODULAR AND
RECONFIGURABLE FROZEN CONE CONFECTION MANUFACTURING
SYSTEM AND METHOD
Technical Field o~ he Invention
[0001] The present invenfion is in the field of conveyance and dispensing
apparatus and methods, especially those for ftozen confections and the like.
More
particularly, the present invention relates to apparatus and methods for
safely
grasping, transporting, and conveying such confections having frangible
conical
shells. The present invention is also related to a modular and reconfigurabie
system and method for optionally coating, filling, topping, and packaging
confections having such shells.
Back~around of the Invention
[0002] The present invention relates to grasping, transport, conveyance,
coating, filling, topping and padkaging apparatus, as well as grasping,
transport,
conveyance, coating, filling, topping and packaging methods for irregularly
shaped
articles and packages, such as for packaged food products as in the case of
conical packages for ice cream confections and the like.
(0003] Irregularly shaped articles and packages present several problems in
filling, conveyance and packaging in an industrial setting: For example, these
articles are typically unbalanced and difficult to handle; whether by workers
or by
machinery. The weight imbalance of such articles also makes it difficult to
design
conveyance and packaging systems because the articles are not well suited to
standard conveyance and packaging designs and protocols. Additionally, the
irregular shape of such articles makes it more difficult for human hands or
machinery to grasp them and repetitively, reliably, and safely transport them.
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CA 02484723 2004-10-12
[0004 With specific regard. to conical objects, such as cones, these objects
have the disadvantage of having relatively little surface area upon which to
apply a
static or kinetic force in order to move the object in a balanced way, without
the
object turning on its side or otherwise processing about its weight center.
When
such cones form a shell for a frozen confection or the tike, there is often
the added
risk of breakage upon application of a force sufficient to securely grasp
them.
[0005] One of the grasping methods cun-ently used with confection cones
involves piercing the cone, with or without the cone being in a paper wrapper,
in
order to provide for its transport' to a conveyor or filling statian. This
grasping
method often disadvantageously results in the fracture of the cone, or an
otherwise
less than perfect appearance to the product. With specific regard to frozen
ice
cream confections, these problems are multiplied by the need to move the
package quickly and securely without undue force being applied thereto.
Relatively rapid and safe movement is necessary to place the frozen cone
confection in a package without allowing the product to warm, and without
bringing
to bear forces that might damage the confection shell, its contents, or any
paper
wrapper.
[0006] Accordingly, there remains a need for a carrier that can grasp a
fragile
cone while reducing the risk of fracture, and without causing any negative
affect on
final product appearance.
[0007 To this end, one aspect of the present invention is directed to
apparatus
and meifiods for grasping, transporting; and conveying irregularly-shaped
articles,
particularly frozen confections having frangible conical shells (frozen cone
confections), wherein the articles can be grasped, transported, and conveyed
without fracturing or otherwise damaging the frangible conical shell.
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CA 02484723 2004-10-12
[0008] With respect to the manufacture of frozen cone confections, it is often
desirable to provide a coating of the interior surfaces andlor the open end
edge of
the cones, such as with a chocolate or other confectionery coating. It is most
advantageous to conduct this process with the cones in an inverted position.
Hence, another aspect of the present invention includes a system and method
for
grasping; inverting, conveying; and inverting cones for frozen confections: A
related aspect of the present invention is directed to coating the interior
surfaces
andlor the open end edge of these cones while they are in an inverted
position.
[0009] Because the manufacture of ftozen cone confections often requires
multiple process steps, there are generally a plurality of manufacturing
stations
disposed along a frozen cone confection manufacturing line. Each manufacturing
station is typically responsible for a particular manufacturing process step
such as,
for example, coating, filling, or ;topping. Normally; some delay, or dwelt
time, is
required between each process step. For example, applying a chocolate coating
to the interior surfaces andlor the open end edge of the cones is typically
accomplished using chocolate of an elevated temperature (i.e., meted
chocolate).
While elevated temperatures are desirable for the coating process, they are
undesirable for the filling process, which is normally the next process step
to be
performed. Therefore, in order to ensure that the cones are sufficiently cool
so as
not to melt the ice cream or other filling that has been added to the cones
during
the filling operation, a delay is provided between the coating and filling
steps. A
similar delay may be provided between the filling and topping operations, or
between other process steps.
[0010] Sufficient delays (dwell tines) may be accomplished by providing a
predetermined conveying distance between process steps. However, once a
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CA 02484723 2004-10-12
typical manufacturing line is so constructed, it is difficult, if not
impossible, to
change. It can be understood that this is an undesirable situation because it
severely limits the type and size of frozen confections that can be made, and
inhibits the addition of other process steps. Thus, what is needed is a system
and
method that allows a manufacturing line to easily adapt to changing frozen
confection designs or recipes:
[0011 Accordingly, yet another aspect of the present invention provides a
frozen cone confection manufacturing system and method that offers flexibility
in
terms of the number and type of coating; filling andlor topping components.
Many
of these components will require variation in the order and timing of their
dispensing, so as to obtain a final product of desirable quality in terms of
the
proper blending of fill components, the adhesion of toppings, and the overall
appearance of the final confection: This aspect of the presenfi invention
allows for
greater flexibility in the design and manufacture of frozen cone confections,
as will
be described in greater detail below.
[0012) Although described in terms of an apparatus and method for use with
conical ice cream confection products; advantages of the present invention
with
respect to other applications may become apparent from the present disclosure
or
through practice of the invention.
Summary of the Invention
[0013 The present invent~or~ includes apparatus and methods for grasping,
transporting, conveying, and packaging conical confection shells - without
damaging the shells such as through piercing or the like. The present
invention
also includes a system and method for grasping, inverting, conveying, and
coating
a frangible conical infection shell, or some portion thereof. The present
invention
CA 02484723 2004-10-12
further includes a modular and reconfigurable manufacturing system and method,
such as may be used to manufacture frozen cone confections. Preferred
embodiments of the present invention overcome some or all of the
aforementioned
problems.
[0014] One aspect of the present invention includes an apparatus for grasping
a frangible conical confection shetl: One exemplary embodiment of a conical
shell
grasping/retaining apparatus of the present invention comprises: (a) a carrier
plate
having first and second sides, the carrier plate having a plurality of
receiving
apertures, each adapted to accept a frangible conical confection shell from
the first
side; (b) a pair of support plates residing adjacent to the second side of the
carrier
plate and siidably coupled thereto; each of the support plates having a
plurality of
receiving apertures located to be aligned with the apertures in the carrier
plate and
adapted to accept a frangible conical confection shell; (c) a retaining pin
associated with each receiving aperture and residing adjacent to a bottom side
of
each support plate, each retaining pin having a pair of opposed arms moveable
between a closed position and an open position for grasping and releasing a
confection shell, respectively; (d) a guide post associated with each
retaining pin,
the guide posts for slidably coupling the support plates to the carrier plate
and for
securing each retaining pin; (e) ,a pair of actuators associated with each
retaining
pin and attached to the bottom side of each support plate, the pairs of
actuators
provided to move the opposed' arms of the retaining pins between the closed
position and the open position upon slidable displacement of the support
plates;
and (f) an actuating means, such as an activating pin attached to one end of
each
support plate, the actuating means for causing slidable displacement of the
support plates.
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CA 02484723 2004-10-12
[0015] In this exemplary embodiment of the present invention, the retaining
pin
consists of a single loop of flexible material that is closed at one end and
that
embodies the pair of opposed arms at the opposite end. The opposed arms of
each retaining pin are adapted to be flexed between a relatively open
(released)
position and a relatively closed (gripping) position by slidable engagement
with the
actuator pairs attached to he bottom of each support plate. Each pair of
opposed
arms may employ flattened surfaces or some other structure that better permits
each retaining pin to engage a conical shell.
[0016] Actuation of this embodiment of a graspinglretaining apparatus
generally occurs as the apparatus is moved along a conveyor with which it may
be
fixedly or removabiy associated. The motion of the support plates may be
driven
by any one or more means positioned at the desired points of gripping and
release
along the transport path of the conveyor. For example, a cam may be associated
with the conveyor and adapted to cause an outwardly directed slidable
displacement of each support plate at certain locations along the conveyor.
This
outwardly directed slidable displacement of the support plates acts to open
the
retaining pins, allowing ones to be inserted to or removed from the apparatus,
such as during initial loading, for example. A release point may in tum be
provided with another means, such as another cam, to provide for release of
the
cones when and where along the transport path the cones are to be released,
such as after gating is completed: Such cams may cause slidable displacement
of the support plates by contacting the locating pins that are attached
thereto.
[0017] Displacement of the support plates to place the retaining pins in a
closed
(gripping) position may occurin carious ways in this embodiment of the
apparatus.
For example, absent an opposite-acting displacement force, such as that
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CA 02484723 2004-10-12
described above, the natural spring force of the retaining pins will tend to
bias the
support plates toward a position wherein the retaining pins are in a closed
(gripping) position. Alternatively, a cam or other similar means may be
provided to
forcibly move the support plates to such a position as the apparatus moves
along
the conveyor.
(0018] It is also preferred that a cylindrical cone-holding member be provided
to
extend through each aperture in the carrier plate. The cylindrical cone-
holding
members may also extend through the apertures in the support plates.
(0019 The present invention may additionally comprise a transport mechanism
adapted to move the apparatus from a position wherein a conical shell is held
upright to a position wherein the conical shell is held in an inverted
position, and to
convey the conical shell while held in the inverted position.
(0020) The present invention also includes a method for grasping, inverting
and
transporting a plurality of frangible conical confection shells. fn general,
this
method comprises the steps of: (1 ) providing at feast one conical shell
grasping/retaining apparatus described above; (2) placing the pairs of opposed
arms of the apparatuses) in an open position; (3) placing a confection shells
in an
upright position in each of the apertures; (4) placing the pairs of opposed
arms in a
closed position; (5) inverting thel apparatuses) so as to place the confection
shells
in an inverted position; (6) transporting the apparatuses) from a first point
to a
second point; and (7) again inverting the apparatuses) so as to place the
confection shells in art upright position: This method may additionally
comprise the
steps of: (8) placing the pairs of opposed arms in the open position; and (9)
removing the conical shells from the apertures.
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CA 02484723 2004-10-12
[0021] The present invention also generally includes a method of grasping,
inverting and transporting a plurality of frangible conical confection shells,
the
method comprising the Ceps of: (1) placing a plurality of conical confection
shells
in a upright position in' a conical shell graspinglretaining apparatus; (2)
inverting
the plurality of conical confection shells without piercing the conical
confection
shells; (3) transporting the apparatus from a first point to a second point;
and (4)
again inverting the plurality of conical confection shells so as to place the
conical
confection shells in an upright position. This method may comprise the
additional
step of: (5) moving the conical confection shells from the second point to a
third
point.
[0022] One of the advantages of the conical shell graspinglretatning apparatus
and methods) of the present invention includes the use of pin-less carriers
that do
not rely upon piercing of the shell for the retainment thereof. In the case of
products such as frozen cone confections, this improves product appearance and
reduces waste occasioned by broken shells.
[0023] Another aspect of the' present indention includes a system for
grasping,
inverting, and coating a frangible conical confection shell. One embodiment of
such a system comprises the, aforementioned conical shell grasping/retaining
apparatus in conjunction with a ' transport mechanism adapted to move the
apparatus from a position wherein the conical shell is held upright to a
position
wherein the conical shell is held in a inverted position, and to convey the
conical
shell while held in the inverted position. One embodiment of this system
further
includes a liquid dispenser disposed under the transpart mechanism and
arranged
to propel a liquid upward, such that the interior of each conical shelf is
provided
with a coating of the liquid while in the inverted position. The liquid
dispenser
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CA 02484723 2004-10-12
preferably may be selected from the group consisting of sprayers and bubblers.
Alternatively, or additionally, such a system may make use of a liquid bath
disposed under the transporf mechanism and adapted to be lifted upward so as
to
provide a liquid coating to the open end edge of each conical shell.
(0024] This aspect of the present invention also includes a method for
grasping,
inverting and coating a plurality of frangible conical confection shells. In
general
terms, this method includes the steps of: (1 ) providing the conical shell
grasping/retaining apparatus described above; {2) placing the pairs of opposed
arms of the apparatus in an open position; (3) placing a confection shell in
an
upright position in each aperture thereof; (4) placing the pairs of opposed
arms of
the apparatus in a closed position; (5) inverting the support plate so as to
place the
confection shells in an inverted position; (6) coating: the interior surface
and/or the
open end edge of the confection shells; and {7) again inverting the support
plate so
as to place the confection shells in an upright position: This method may
comprise
the additional steps of: (8) placing the pair of opposed arms in the open
position;
and (9) removing the oanicat shells from the apertures.
(0025] This aspect of the present invention also includes an alternate method
of grasping, inverting, coating and transporting a plurality of frangible
conical
confection shells, the method comprising the steps of: (1 ) placing a
plurality of
conical confection shells in a upright position; (2) inverting the plurality
of conical
confection shells without piercing the conical confection shells; (3) coating
the
interior surface of the confection shells; and (4) again inverting the
plurality of
conical confection shells so as to place the conical confection shells in an
upright
position. This method may additionally comprise the step of moving the conical
confection shells from a first point to a second point.
9
CA 02484723 2004-10-12
(0026] One advantage of a system and method for grasping, inverting, and
coating frangible conical confection shells acxording tn the present invention
is that
the cones are held in such a way that the grasping apparatus is not exposed to
the
coating material . Hence; unlike the cone-piercing method and devices
therefor,
the system and methods of the present invention reduce the need for cleaning
portions of the apparatus:
(0027] Yet another aspect ofi the present invention is directed to a modular
and
reconfigurable system and method of use for optionally, coating, filling,
and/or
topping a confection having a conical shell, particularly a frozen cone
confection.
This aspect of the present invention provides a frozen one confection
manufacturing system and method that offers flexibilityr in terms of the
number and
type of coating, filling or topping components.
(0028] The modular and reconfigurable manufacturing system makes use of
modular manufacturing stations 'that may be relocated along the length of a
frozen
cone confection manufacturing line. Servo-motors are provided to allow for
vertical
motion of any of the stations along he horizontal guide rods. The process
stations
can be Located' along the frozen cone confection manufacturing line as
necessary
to provide for the correct delay (dwell) time between process steps.
(0029] Preferably, servo motors or similar drive means are also provided to
allow for vertical movement of certain process equipment associated with the
various modular manufacturing stations. For example, movement of cone
spraying, dipping, or filling devices: toward or away from the cones may be
servo
controlled.
(0030] An advantage of the modular and reconfigurable manufacturing system
and method of the present invention is the flexibility of design afforded
thereby. In
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CA 02484723 2004-10-12
the past, manufacturing stations have generally been located at fixed points
along
a frozen cone confection manufacturing line. Consequently, designs for frozen
cone confections are generally limited by the manufacturing line on which they
will
be produced. In contrast; the modular and reconfigurable manufacturing system
and method of the present invention affords a manufacturer the ability to
easily
produce products having different characteristics and requiring different
processing
parameters on a single manufacturing line.
Brief Descriation of the Drav~ings
(0031) In addition to the features mentioned above, other aspects of the
present
invention will be readily apparent from the following descriptions of the
drawings
and exemplary embodiments, wherein like reference numerals across the several
views refer to identical or equivalent features, and wherein:
Figure 1 is an exploded perspective assembly view of a conical shell
grasping and retaining apparatus in accordance with one embodiment of the
present invention;
Figure 2 is a perspective view of the assembled conical shell grasping and
retaining apparatus of Figure 1;
Figure 3 is a side elevational view of the assembled conical shell grasping
and retaining apparatus of Figure 2
Figure 4a is an enlarged' perspective view in partial cutaway, showing an
optional conical shell receptacle attached to a carrier plate portion of the
apparatus
of Figures 1-3, with a conical shell passing therethrough;
Figure 4b is an enlarged perspective view in partial cutaway showing in
detail the assembled relationship between certain components of the conical
shell
grasping and retaining apparatus of Figures 1-3;
CA 02484723 2004-10-12
Figure 4c is the enlarged perspective view of Figure 4b, illustrating in
further
detail how the conical shell is retained by the graspinglretaining apparatus;
Figures 5a, 5b and 5c show a top plan, side elevational, and perspective
view, respectively, of the retainer clip visible in Figures 1-4;
Figure 6 is a perspective view depicting a plurality of the conical shell
grasping and retaining apparatuses installed to a portion of a conveyor;
Figure 7 is a side elevational view of the entirety of the conveyor shown in
Figure 6, wherein it can be; seen that the conical shell grasping/retaining
apparatuses are disposed substantially completely around the conveyor;
Figure 8 is a perspective view of a dip ladle assembly portion of a rim
dipping station designed to apply a coating material to the edge of a
plurality of
inverted conical shells in accordance with one embodiment of the present
invention;
Figure 9 is a perspective view of a spray nozzle manifold assembly portion
of a cone coating station designed to apply a coating material to the interior
of a
plurality of inverted conical shells in accordance with one embodiment of the
present invention;
Figure 10 shows an assembled arrangement of the dip ladle assembly and
spray nozzle manifold of Figures 8" and 9; along with other ancillary
components;
Figure 11 illustrates one embodiment of a filler head assembly portion of a
filling station designed to fill conical shells with a material in accordance
with one
embodiment of the present invention;
Figure 12 is a perspective view of one embodiment of an actuating
assembly that can be used to manipulate various manufacturing stations of the
present invention;
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CA 02484723 2004-10-12
Figure 13 is a side elevational view of he actuating assembly of Figure 12,
installed to a conveyor;
Figure 14 is an enlarged end view of one embodiment of an actuating
assembly pair of the present invention, coupled to a single manufacturing
station
and installed to a conveyor;
Figure 15 is a side elevational view of a portion of one embodiment of a
frozen cone confection manufacturing line of the present invention, wherein a
plurality of the actuating assemblies of Figures 12-14 are shown to be
installed to a
conveyor;
Figure 16 is a perspective view showing 'the frozen cone confection
manufacturing line of Figure 15 forming part of a larger frozen cone
confection
manufacturing system;
Figure 17 is a top plan view of the frozen cone confection manufacturing
system of Figure 16, detailing the specific manufacturing steps that are
performed
thereby; and
Figure 18 depicts the frozen cone confection manufacturing system of
Figure 17 with guarding and additional packaging equipment attached thereto.
Detailed Descriation of Exemalarv Embodiments
[0032 In accordance with the foregoing summary, the following presents a
detailed description of several exemplary embodiments of the present
invention,
wherefrom a better understanding of the subject matter of the present
invention
may be derived.
[0033) One aspect of the present invention includes a conical shell grasping
and retaining apparatus and its method of use: Figure 1 shows an exploded
assembly view of a conical shell grasping and retaining apparatus 5 in
accordance
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CA 024847232004-10-12
with one embodiment of the present invention. As can be seen in Figure 1, the
apparatus 5 includes an upper carrier plate 10 and a pair of lower support
plates
15, 15'. Both the carrier plate 10 and each of the support plates 15, 15' are
provided with a pluralifiy of conical shell receiving apertures 20, 25, 25',
respectively. Each conical shell-receiving aperture 20,25, 25' is designed to
allow
a portion of a conical shell 60 to pass therethrough. Hence, the conical shell
receiving apertures 25, 25' in each support plate 15, 15' are located to be
aligned
with corresponding ones of the ~nical shell receiving apertures 20 in the
carrier
plate 10. A number of retaining clips 30 are provided for the grasping of a
portion
of the conical shells- 60 that pass through the conical shell receiving
apertures 20,
25, 25' in the carrier plate l0 and support plates 25, 25'. The number of
retaining
clips 30 typically corresponds to the number of apertures 20. For example, in
this
particular embodiment of the conical shell: graspinglretai~ing apparatus 5
there are
a total of eight conical shell receiving apertures 20, thus, there are eight
retaining
clips 30. A guidepost 40 and an actuator pair 45 is also provided for each
retaining
clip present. An activating pin 50 is located on an outward facing end of each
support plate 15, 15'. Preferably, a cylindrical conical shell receptacle 55
is also
provided for each conical shell receiving aperture 20 present.
[0034 The assembled relationship of the components of the conical shell
grasping/retaining apparatus 5 cart be best observed- by reference to Figures
2-4.
As can be seen in Figures 2-3, the' conical shell receptacles 55 are installed
to the
carrier plate 10 such that a lower portion 55a thereof protrudes through the
conical
shell receiving apertures 20 of the carrier plate. The lower portion 55a of
the
conical shell receptacles 55 may or may not extend into the conical shell
receiving
apertures 25, 25' in the support plates 15,15'. In this particular embodiment
of the
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CA 02484723 2004-10-12
apparatus 5, the conical shelf receptacles 55 are secured to the carrier plate
10 by
means of an o-ring 65.
[0035) The guideposts 40 are designed to slidably connect the support plates
15, 15' to the carrier plate 10, which arrangement can be best understood by
reference to Figures 2-4. More specifically, a portion of each guidepost 40 is
designed to pass througi7 a guidepost receiving aperture 70, 75, T5' in the
carrier
plate 10 and support plates 15; 15'; respectively. Each guidepost 40 is
provided
with an upper portion 40a that protrudes from a first side 10a of the carrier
plate 10
after assembly. The guidepost 40 is secured to the carrier plate 10 by
trapping of
the carrier plate in a groove formed between the upper portion 40a and a
larger
intermediate portion 40b of the guidepost. Similarly, the support plates 15,
15' are
retained on the guideposts 40 by trapping the support plates in a grove formed
between the intermediate portion 40b and a lower portion 40c of each
guidepost.
In this particular embodiment of the conical shell graspinglretaining
apparatus 5,
the guidepost receiving, aperture 70 in the carrier plate 10 has a length
dimension
that extends in a substantially perpendicular direction to the length
dimension of
the guidepost receiving aperture 75; 75' in each support plate 15, 15'. Each
of the
upper portion 40a and tower portion 40c of each guidepost can also be seen to
have a shape and orientation similar to its respective receiving aperture 70,
75,
75'. Therefore, when the guideposts! 40 are properly oriented, the upper
portion
35a thereof will pass through the guidepost receiving apertures 70 in the
carrier
plate 10 and the lower portion -40c thereof will pass through the guidepost
receiving apertures 75, 75' in the support plates 15, 15'. Upon rotation of
the
guideposts 40, however, the carrier plate 10 and the support plates 15, 15'
will
become engaged therewith: in Figure 2, the guideposts 40 are shown to be
CA 02484723 2004-10-12
rotated approximately 90 degrees :from the installation position. When the
support
plates 15, 15' aye properly coupled to the carrier plate 10 via the guideposts
40,
the support plates are substantially parallel with, and adjacent to, a bottom
side
10b of the carrier plate. Because the guidepost receiving apertures 75, 75'
have a
dimension along the length direction of each support plate 15, 15' that is
larger
than the portion of the guidepost 40 residing therein, each support plate is
displaceable with respect to the carrier plate 10 in a direction along the
length
thereof.
[0036 An improved understanding of,retaining clip 30 retention and operation
can be gained by reference to Figures 3-5. As can be observed therein, the
lower
portion 40c of each guidepost 40 is adapted to receive a portion of a
corresponding retaining clip 30: In this particular embodiment of the conical
shell
graspinglretaining apparatus 5; the lower portion 40c of each guidepost 40 is
provided with a groove 40d to engage a closed end 30a of each retaining clip
30,
although other methods of engagement are also possible. Consequently, the
guideposts 40 prevent the retaining clips 30 from being displaced along with
the
support plates 15, 15'.
[0037 Retaining clip 30 actuation is achieved by contacting an open end 30b of
each retaining clip 30 with a corresponding actuator pair 45 during
displacement of
the support plates 15, 15'. As can best be observed in figure 4, due to the
opposing orientation of the retaining clips 30 associated with each support
plate
15, 15', an outward displacement of the, support plates will cause the open
end
30b of each retaining clip to expand; thereby resulting in a release of any
conical
shells 60 protruding through the cone receiving apertures 25, 25'. In
contrast, an
inward displacement of the support plates will cause the open end 30b of each
16
CA 02484723 2004-10-12
retaining clip to contract, thereby resulting in a gripping of any conical
shells 60
protruding through the cone receiving apertures 25, 25'.
[0039 Several enlarged views of the particular embodiment of the retaining
clip
30 shown in Figures 1-4 can be seen by reference to Figures 5a-5c. As can be
seen, this particular retaining clip 30 consists of a single length of
substantially
round material that has been repeatedly bent to produce the desired shape. The
retaining clip 30 has a closed end 30a.; which is adapted to engage the groove
40d
in the lower portion 40c of each guidepost 40. Extending from the closed end
30a
of the retaining clip 30 are two opposed, arms 35, 35' that terminate at
opposite
sides of an open end 30b of the retaining clip. Consequently, the design of
the
retaining clip 30 allows for an inward and outward flexing of the opposed arms
35,
35'. In this regard, it is preferred that he retaining clip 30, or at least
the opposed
arms 35, 35' thereof, be constructed from a resilient material. The use of a
resilient material allows the opposed arms 35, 35' of the retaining clip 30 to
quickly
spring back into shape after being displaced.
[0040) The particular retaining clip 30 used in this embodiment of the
apparatus
5 is also shown to have an optional flat area 30c located on each of its
opposed
arms 35, 35'. The flat areas 30c are employed to provide improved grasping of
the conical shells 60 by the retaining clips 30. More specifically, in this
particular
embodiment, the flat areas 30c increase the area of contact between each of
the
opposed arms 35, 35' of the retaining clips 30 and the angled outer surface of
the
conical shells 60 (see particularly, ;Figures 4b and 4c). It can be understood
that
many other techniques, such as,;, for example, mechanical grippers or surface
treatments may also be used in injunction with the retaining clips 35 in order
to
17
CA 02484723 2004-10-12
further improve the grasping of the conical shells 60, and such is considered
within
the scope of the presenf invention.
(0041 A plurality of the conical shell graspinglretaining apparatuses 5 of the
present invention are shown to be releasably affixed to a conveyor 100 in
Figure 6.
A conical shell loaderlunloader is also shown to be positioned above the
conveyor
100 in order to better illustrate one method for loading conical shells to the
apparatuses 5. Generally; the conveyor 1OO will be an endless conveyor (such
as
that shown), wherein when traveling along a top portion of the conveyor the
apparatuses 5 are maintained in an upright position, and when traveling along
a
bottom portion of the conveyor the apparatuses are maintained in an inverted
position. Such a conveyor may be continuously moving, or may be an indexing-
type conveyor. Of course, the apparatus 5 of the present invention can also be
used with other types of conveyors. When used in conjunction with a conveyor
100 such as that shown in Figure 6, ;the apparatuses 5 will normally be
carried
along by chains, belts, or some other similar type of drive mechanism. As can
be
understood with respect to such a conveyor 100, a framework 105 will typically
be
provided for support, a portion of which commonly resides between the top and
bottom portions thereof. The framework may also be operative to support end
shafts, rolls, drive motors, and various other items commonly used to
construct
conveyors.
(0042 In this particular embodiment of he present invention, cams (not shown)
or similar contacting structures are preferably located at one or more
positions
along the length of the conveyor 100. Although such cams will typically reside
along the top portion of the conveyor, it is also possible that such cams may
be
located along the bottom portion of the conveyor. In this embodiment, the cams
18
CA 02484723 2004-10-12
are prouided to engage with the activating pins 50 located on each support
plate
15, 15' of the apparatus. Preferably, the cams ac;tualty contact a bushing 80
affixed to each of the activating pins 50. The bushing 80 may-be a roller
bearing or
similar device. The bushing 80 may also simply be a plastic (such as nylon)
element, or an element constructed from some other material that protects the
cams and the activating post from damage during contact. Preferably, the
bushing
80 is made from a material thafi has good wear characteristics.
[0043] As can be understood from a review of preceding drawing Figures 1-4
and reference to Figures~ 6 and 7, when this particular, embodiment of the
conical
shell graspinglretaining apparatus 5 is axed to the conveyor 100, the
activating
pins 50 extend into an interior portion fhersof. That is; when the apparatuses
5 are
traveting along the top portion of the conveyor 100 the activating pins 50
will be
directed substantially downward; and when the apparatuses are traveling along
the
bottom portion of the conveyor the activating pins will be directed
substantially
upward. When an apparatus 5 is traveling around ~n end of the conveyor 100,
the activating pins will point in same direction into the area between the top
and
bottom of the conveyor. As can be seen; the apparatuses 5 are designed such
that their length is slightly less than the width of the conveyor frame 105:
Thus, as
the apparatuses 5 travet along the conveyor 100, the activating pins 50 are
located
within an area bounded by the inside edges of the conveyor frame 105.
Normally,
there will be some gap between the activating pins 50 and the conveyor frame
105. At locations along the conveyor 100 where it is desired to place the
apparatuses 5 in a state wherein conical shells 60 may be loaded thereto or
removed therefrom, cams may bye employed to contact the activating pins 50.
19
CA 02484723 2004-10-12
[0044] By reference to the detailed assembly view of Figure 4, it can be
understood that when there is no e~eternal force being exerted on the support
plates 15, 15' of the conical shelf graspinglretaining apparatus 5; the
natural spring
force of the retaining clips 30 will maintain the apparatus in a closed, or
gripping,
state (i.e., each support plate will be biased inward). Hence, when it is
desired to
place the apparatus 5 in an -open, or release, state, each support 15, 15'
plate
must be forced outward against the spring force of the retaining clips 30.
This can
be accomplished by contacting the activating pins 50 with the cams located
along
the conveyor. More specifically; by locating a cam to contact an inward face
of the
each of the pins 50; an outwardly-directed force will be exerted on the
support
plates 15, 15' of each apparatus 5 as it passes the cams. This outwardly-
directed
force is sufficient to produce an outward displacement of each support plate
15,
15', overcoming the spring force of the retaining clips 30 and causing the
open
ends 30b thereof to expand as they contact the actuator pairs 45 mounted to
the
support plates. F_xpansion of the open ends 30b of the retaining clips 30
results in
an outward movement of opposed arms 35, 35' thereof, causing the apparatus 5
to
be placed in a state wherein conical shells may be inserted thereto, or
removed
therefrom.
[0045] It should be realized that. displacement of the support plates 15, 15'
can
occur by a means other than that of frame-mounted cams. For example,
moveable cylinders, solenoids, and-other similar type devices may be used to
form
actuators capable of causing displacement of the support plates 15, 15' when
desired. Such actuators may be attached to a frarnework or another suitable
structure at any location along the length of the conveyor. It should also be
realized that it is possible to attach a moving actuator to the support plates
15, 15',
20
CA 02484723 2004-10-12
whereby extension of the actuator against a framework or some other fixed
structure will cause an outward displac8ment of the support plates. It is
further
contemplated that, whether using, cams or moveable actuators, the devices
could
be designed to allow for easy relocation along the length of the conveyor 100,
In
this manner, additional flexibility is imparted to the manufacturing process
employing the conveyor; because conical shell removal maybe caused to occur at
a wide variety of conveyor positions.
[0046] As can be observed by reference to Figures 6 and 7, the conical shell
graspinglretaining apparatus 5 can be used to retain conical shells 60 even in
an
inverted position. In the particular manufacturing systems shown, the conical
shells 60 are inverted while traveling along the bottom portion of the
conveyor 100.
However, the apparatus 5 may also be used with other transport mechanisms,
such as, for example; with pick-and-place: type robotic transfer devices. In
such a
case, a robot could be adapted to move a plurality of the apparatuses 5 from
one
location to another, and in an upright or inverted position.
(0047] The ability of the conical shell grasping/retaining apparatus 5 to
maintain a conical shell in an upright position can be advantageous to a
manufacturing process, particularly to a frozen cone confection manufactureng
process. More particularly, there may be manufacturing steps that are best
accomplished with the conical shells in an inverted position. For example,
performing rim dipping and cone coating during a frozen cone confection
manufactureng process es best accomplished with the conical confection shells
in
an inverted position. Such will become more obvious upon a reading of the
following disclosure, which describes in more detail a modular and
reconfigurable
21
CA 02484723 2004-10-12
frozen cone confection manufacturing system, said being yet another aspect of
the
present invention.
[0048] Another aspect of the present invention involves providing a modular
and reconfigurable manufacturing system by which frozen cone confections and
the like can be produced. The modular and reconfigurable manufacturing system
of the present invention and its,method of use allows for greater flexibility
in the
design and manufacture of frozen cone confections. The modular and
reconfigurable frozen cone confection manufacturing system of the present
invention permits flexibility in terms of he number and type of coating,
filling or
topping components used, the precise point in the manufacturing process when
coating, filling or flopping is initiated, and the time between successive
process
steps. The modular and reconfigurable frozen cone confection manufacturing
system and its method of use makes use of individual manufacturing stations,
or
assemblies, each of which are tasked with pertorming. a particular
manufacturing
process step, or steps. Each manufacturing station may be interconnected or
otherwise placed in communication with other manufacturing stations involved
in
the overall frozen confection manufacturing process. Each station or an
assembly
of multiple stations can be automatically relocated to various points along a
manufacturing line - depending on the specific characteristics of the
particular
product being manufactured,
(0049] For example; the aforementioned inverted rim dipping and cone coating
processes may be performed: by manufacturing stations that are part of the
modular and reconfigurable frozen Bone confection manufacturing system and
method of the present invention,. These processes, and use of the modular and
reconfigurable frozen cone confection manufacturing system of the present
22
CA 02484723 2004-10-12
invention to pert'orm them, can' be best understood by reference to Figures 8-
10.
Figure 8 illustrates one embodiment of a rim dip ladle assembly 110 that can
be
used in conjunction with the conical shell grasping/retaining apparatus 5 and
modular and reconfigurable frozen cone confection manufacturing system and
method of the present invention to apply a coating to the open end edge of a
conical shell, while the conical shell is in an inverted position. For
example, when
the conical shell is a cone for a frozen cone confection, the rim dip ladle
assembly
110 can be used to coat the rim of the cone with chocolate or some other
confectionary coating. This is accomplished by locating the rim dip ladle
assembly
110 in a manner that allows it to contact the inverted cone edge. To this end,
the
rim dip ladle assembly 110 is but one portion of a rim dipping manufacturing
station 110' (see Figures 8, 10, and 15-16). In thin particular embodiment,
the rim
dip ladle assembly 110 is adapted to be located beneath the lower portion of a
conveyor, such as the conveyor 100 shown in Figures 6 and 7. As the inverted
cones pass overhead, the rim dip ladle assembly 1 ~L0 is repeatedly raised and
lowered to bring the cone edges into contact with the confectionary coating
residing therein. As shown in Figure 8, the rim dip ladle assembly 110
includes a
dip ladle 115 and associated supporting structure 125 ; The dip ladle 115 is
shown
to include a plurality of cone guides 120 to help ensure that the cones
properly
contact the contents of the ladle. The supporting structure 125 has a
connecting
means 130 that is designed for connection to an actuating unit assembly
(described in more detail later) that acts to raise and lower the dip ladle
115 as
necessary to intact its contents with the edges of the cones passing ovefiead.
The actuating unit assembly may also be adapted to automatically relocate the
rim
dip ladle assembly 110 to various points along the length of a conveyor. A
remote
23
CA 02484723 2004-10-12
supply of coating material (such as chocolate) may be connected to the dip
ladle
115. The amount of material in a dip ladle 115 may be monitored and new
material may be automatically supplied thereto as needed.
[0050 Figure 9 is a perspective view of a cone spraying nozzle assembly 150
that may be used in accordance with one embodiment of the modular and
reconfigurable frozen cone confection manufacturing system and method of the
present invention to spray coat the interior of a plurality of conical shells
with a
desired material. As with the rim dip ladle assembly 110 of Figure 8, when the
conical shell is a cone for a frozen cone confection, the cone spraying nozzle
assembly 150 can be used to coat the. interior of the cone with chocolate or
some
other confectionary coating. As can be seen in Figure 9, the cone spraying
nozzle
assembly 150 includes a spray nozzle manifold 155 to which is mounted a
plurality
of spray nozzles 160. The spray nozzles 160 are adapted to direct a supply of
coating material into the interior of a plurality of conical shells. Each of
the spray
nozzles 180 may be supplied with a coating material through liquid conduits
(not
shown), in accordance with know an-angements and materials. In this particular
embodiment, quick connectldisconnect-type fittings 165 are provided for this
purpose - although a multitude of other suitable connectors are also
available. The
spray nozzle manifold 155 is affixed to a supporting structure 170 that is
designed
for connection to an actuating unit assembly .(described: in more detail
later) via a
connecting means 175. The actuating unit assembly may be adapted to raise and
lower the cone spraying nozzle assembly' 150 as necessary to properly direct
the
coating material into the interior of the conical shells. Other cone spraying
assembly designs may also be used of this purpose. For example; different
numbers of spray nozzles may be provided: A control system may also be
24
CA 02484723 2004-10-12
provided that limits operation fo only particular ones of the spray nozzles,
as
desired by an operator. Such a control system may operate automatically, for
example, when a number of cones that is less than the ryumber of spray nozzles
is
detected by a sensors) or the like. The cone spraying assembly 150 is one
portion of a cone spraying manufacturing station 160' (see Figures 9, 10 and
15-
16).
[0051] In Figure 10; it can be observed that the rim dip ladle and spray
nozzle
assemblies 110, 150 of Figures 8 and 9 can be combined with other components
to form a portion of a rim dip station 110' and a cone spraying station 150',
respectively (see Figures 7; and 16-17), In Figure 10, the rim dip assembly
110
and cone spraying assembly 150 are -arranged in a position for installation to
a
conveyor, such as the conveyor 100 depicted in Figures 6 and 7. As Figure 10
shows, the rim dipping assembly 110 and cone spraying assembly 150 may also
include components such as an overtlow tank 180 and spray tank 185,
respectively. The overflow tank 180 can be provided to contain excess material
used in the rim dipping process. The spray tank 185 can be provided to monitor
and control the temperature of the ingredients of the rim dip process, As can
be
observed, the rim dipping assembly 110 and cone spraying assembly 150 may be
provided with a series of drip trayslpans 190, 195, 200, 205 that further act
to
contain excess material that may fall from the conical shells during or after
the rim
dipping andlor cone spraying operations. In a non-reconfigurable version of
the
present invention, a varietyof support rods 210 and hangers 215 may be
provided
to connect the drip trayslpans X90, 195, 200, 205 to: a conveyor frame or to a
similar support structure. Various hangers 220, 22~ may also be provided to
support the overflow tank 180 and spray tank 185, respectively. The overflow
tank
25
CA 02484723 2004-10-12
180, spray tank 185, and a number of the hangers 220, 225 of a non-
re~nfigurable embodiment of the rim dipping and cone coating stations 110',
150'
of the present invention can be seen located beneath the bottom portion of the
conveyor in Figure 7.
(0052] When used in a modular and reconfigurable frozen cone confection
manufacturing system of the present invention, each of the rim dipping
assembly
110 and the cone spraying assembly 15~ is adapted to be displaceable along the
length of a conveyor. In such an embodiment, the drip trayslpans may be
connected to a support structure that is also moveable. For example the drip
trays/pans labeled as 190 and 195 may mova along with a rim dipping station
110',
while the drip trays/pans labeled as 200 and 205 may move along with a cone
coating station 150'. The overflow pan 180 and spray pan 185 may move along
with the rim dipping statioh 110' and cone coating station 150' in a similar
manner.
(0053] A filling station and - a topping and/or coating station may also be
employed by the modular and ceconfigurable frozen confection manufacturing
system of the present invention. One embodiment of a filler head assembly 250
for use in a filling station ~n be seen in Figure 11. The filler head assembly
250 is
shown to include a number of dispensing- heads 255 to each of which may be
attached one or more noales 260: A supp4rt structure 265 is provided to mount
the dispensing heads and various other components, such as a flow controller
270.
A connecting means 275 is affixed to the support structure 265 for coupling
the
filler head assembly 250 to an actaafor assembly of a fiNing station.
(0054] In a manner similar o that of the rim dipping station 110' and the cone
spraying station 150', a modular filling station 250' may be constructed using
the
filler'head assembly 250 and requisite other components. For example, the
filling
26
CA 02484723 2004-10-12
station 250' will generally be connected to a supply of one or more filling
materials,
such as ice cream, as can be seen in Figures 16 and 18. Also like each of the
rim
dipping station 110' and the cone spraying: station 150', the filling station
250' is
adapted to be displaceable along the length of a conveyor. A coating station
and/or a topping station may be corvstructed in a similar manner. In a frozen
cone
confection manufacturing process, the coating station can be used to dispense
a
canfectionary coating to an ice cream Olled cone. -Similarly, the topping
station can
be used to dispense nuts or other confectionery toppings. Like the filling
station
250', each of the topping station and coating station can be connected to an
appropriate supply of material.
[0055] The modularity and reconfigurability of the modular and reconfigurable
frozen cone confection manufacturing system of the present invention is
achieved
in one exemplary embodimenf by providing each manufacturing station with a
support and guide system that serves o properly locate each manufacturing
station with respect to a conveyor, as well as allow each manufacturing
station to
be accurately located at various points along the length of the conveyor. In
an
exemplary embodiment of the modular and reconfigurable frozen cone confection
manufacturing system of the present invention, drive motors; more preferably,
servo motors, are used to automatically position each manufacturing station as
necessary to produce a given product. The positianing/repositioning may be
accomplished manually.
[00561 An exemplary embodiment of an actuating unit assembly 280 as
described above, can be seen in Figure 12. As can be observed in Figure 12,
this
embodiment of the actuating unit assembly 280 includes a corresponding pair of
vertical supports 285, 285' that are designed to reside on opposite sides of a
27
CA 02484723 2004-10-12
conveyor (not shown for purposes of clarity). In this particular embodiment,
each
of the vertical supports 285, 285' is associated with an assisting support
290; 290'.
The use of assisting supports X90, 290' is optional, but may be beneficial
when
heavier' or larger manufacturing station components will be attached to the
vertical
supports 285, 285'. Each of the vertical supports 285, 285' and assisting
supports
290; 290' is shown to have a guide damp 300 afFxed thereto.
[0057 The guide clamps 300 are provided to engage with guide railslrods 330
(see Figures 13-16) that are attached #o, or near, the conveyor 375 with which
the
manufacturing stations are associated: The guide clamps 300 serve to both
direct
the movement of the manufacturing stations along the length of the conveyor,
as
well as to secure the position of each manufacturing station along the length
of the
conveyor. The guide clamps 300 may be caused to exert a gripping force on the
guide railslrods 330 by numerous means. For example; a fasteners) may be used
to draw two halves of the guide clamps 300 together, or an actuator may be
used
to pivot one guide half toward the other. Many other means and methods of
accomplishing this function would be apparent to one skilled in the art.
Consequently, the design and construction of the guide clamps is not limited
to
that hown. Additionally, it is also contemplated that guides may be provided
on
the actuating unit assembly 280 only to' direct movement of the manufa~uring
stations along the length of the conveyor, while ecuring the position of each
manufacturing station with respect to the conveyor can be accomplished by one
or
more other devices that are unrelated to the guides.
[0058 The actuating unit assembly 280 is also shown to include a vertical lift
unit 305 that, in this particular embodiment; 'is comprised of the vertical
supports
285, 285', a drive motor 310, optional speed reducer 315, gear boxes 320,
320',
28
CA 02484723 2004-10-12
and connecting shaft 325. Preferably, the drive motor 310 is a servo motor.
The
vertical lift unit 305 is employed- to provide a vertical displacement of
various
manufacturing station components, such as the aforementioned rim dipping and
cone coating assemblies 110; 150. Such components may be affixed to the
vertical supports 285, 285' by the connecting means 130, 175 portion of their
support structure 125, 170.
[0059] The drive motor 310 is used to drive the gear boxes 320, 320' which, in
turn; are adapted to engage a portion of their respective vertical supports
285;
285', thereby causing the height of each vertical support to be increased or
decreased by some amount. In this manner, a component, or components, of the
manufacturing station with which the actuating unit assembly 280 is
associated,
may be raised or lowered as needed to perform a particular manufacturing
process
step, or steps. For example; an actuating unit assembly 280 may be used to
raise
and lower each of the above-described rim dipping assembly 110, cone coating
assembly 150, and filler head assembly 250: An actuating unit assembly 280, in
conjunction with each of the rim dipping assembly 110, cone coating assembly
150, filler head assembly 250 and related ancillary components, form the rim
dipping station 110', cone coating station 150', and filling station 250',
respectively.
(0060) In another embodiment of the present invention, a separate drive system
(not shown) may be included on the actuating unit X80 to provide for automatic
movement of each manufacturing station along the length of a conveyor.
Preferably, one or more guide rails/rods 330 are provided to control the
direction of
movement of the manufacturing stations as;they are moved along the conveyor:
The drive system may be comprised of; for example, a drive motor that engages
a
gear rack or the guide rails/rods 330. In such a case; the drive motor is
preferably
29
CA 02484723 2004-10-12
a servo motor, which provides for accurate positioning. Alternatively, the
drive
system may employ pneumatic or hydraulic cylinders or other similar actuators
to
move the manufacturing stations along the length of the conveyor. When a drive
system is provided that employs a drive means other than a servo motor, some
means of position detection is preferably also provided, such as a limit
switch,
proximity switch, encoder, or other known devices.
[0061) Various manufacturing stations can be observed to be displaceably
associated with a conveyor- 375 in Figures 14-16. In figure 14; an enlarged
end
view of a pair actuating unit assemblies 280 that are associated with the
conveyor
375 is presented. In this particular example, both of the actuating assemblies
280
are associated with a single manufacturing station 380, which multi-actuating
assembly association is another feature of the present invention. In other
embodiments of the present invention, such as the embodiment of Figures 15 and
16, each actuating unit may be associated with a single manufacturing station.
[0062) In the embodiment of Figure 14, the manufacturing station 380 can be
seen to perform a process above the top portion 385 of the conveyor 375 (i.e.,
while the conical shells are in an upright position). Fpr example, when used
in a
frozen cone confection manufacturing process, the manufacturing station 380
could fill, coat, or top the cones, or could dispense or crimp package lids.
[0083) Figures 15 and 16 illustrates how a plurality of manufacturing stations
405, 410, 415, 420, 425; 430, can be located along the length of a conveyor
435 in
order to produce the desired product. In this particular embodiment of the
present
invention, a modular and reconfigurable frozen cone confection manufacturing
line
400 and process is depicted. As can be een, various process steps associated
therewith can be performed across the length of the conveyor 435. In this
CA 02484723 2004-10-12
particular embodiment, sleeves (not shown) are dispensed into the various
conical
shell receptacles 55 of a plurality of the conical shell gcasping/retaining
apparatuses 5 described previously, as each apparatus moves around a first end
of the conveyor 435 and onto a top portion thereof. Other conical shell
graspinglretaining means could also be employed, and this aspect of the
present
invention is not limited to use with the conical shell graspinglretaining
apparatuses
5 shown. Once a predetermined, number of sleeves have been loaded into the
appropriate number of apparatuses 5, a plurality of conical shells (not shown)
may
be loaded thereto. In this particular embodiment of the modular and
reconfigurable
frozen cone confection manufacturing line 400, a robot is used to load the
conical
shells to the apparatuses 5: Other known means of loading conical shells to
the
apparatuses 5 may also be used, and such is within the scope of the present
invention.
[0064j One the conical shells have been loaded to the apparatuses 5, the
apparatuses proceed toward the first of the frozen cone confection
manufacturing
stations. In this particular embodiment of the modular and reconfigurable
frozen
cone confection manufacturing line 400, the first manufiacturing station is a
chocolate plug or spray station 4a5, which is provided to coat the inside of
the
conical shells with chocolate. When a spray coating is applied, the vertical
fift unit
of the chocolate plug or spray station's 405 actuating assembly 280 preferably
acts
to locate the spray nozzles thereof in an appropriate vertical position to
best spray
the inside of the cones passing fherebeneath. In another embodiment of the
present invention, the process steps and manufacturing stations of the modular
and reconfigurable frozen cone confection manufacturing system could be
arranged such that the first manufacturing stations) encountered is the rim
dipping
31
CA 02484723 2004-10-12
andlor cone coating stations 110', 150' previously described. In such a case,
loading of the sleeves and conical shells may occur on the opposite end of the
conveyor; for example, such that the dipping and or spraying of the conical
shells
can occur while the conical shells are inverted (see Figure 7).
[00G5j The next manufacturing station shown in the example of Figures 15 and
16 is a filling station 410, such as the previously-described filling station
250' that
makes use of Oller head assembly 250. Of course, other filling station designs
are
also possible. When used in a frozen cone confection manufacturing process,
the
filling station is used to fill he conical shells with ice cream or other
frozen
foodstuffs. In this particular embodiment of the modular and reconfigurable
frozen
cone confection manufacturing lin~ 400; two separate filling stations 410 are
used
to accomplish the filling process: The use of two filling stations 410 may
allow
different materials to be added to the conical shells or may allow the
creation of
complex filling shapes, for example: As with the other manufacturing stations,
the
filling stations 410 are preferably adapted to be relocated to different
points along
the length of the conveyor 435: The filling stations are also preferably
provided
with a vertical lift assembly 305; as described above; so that the filling
heads, or
other nozzles or dispensing devices, can be properly located with respect to
the
conical shells passing beneath. At least with respect to a frozen cone
confection
manufacturing process, the fiNing stations 410 are also preferably operative
for
vertical displacement while the filling operation is ongoing.
[0066j Additional manufacturing tations may also be provided; as can be seen
in Figures 15 and 16. In the particular embodiment of the modular and
reconfigurable frozen cone confection manufacturing line 400 shown, a wet
topping station 415, a dry topping station 420, and lid dispensing and
crimping
32
CA 02484723 2004-10-12
stations 425; 430 are depicted. Therefore, as can be understood; virtually any
number and manner of rnarEUfacturing stations may be employed as necessary to
produce a given product. It can also be understood, particularly by reference
to
Figures 15 and 16 in light of the foregoing description, that a modular and
reconfigurable frozen cone confection manufacturing line of the present
invention,
such as manufacturing line 400; allows for a very flexible manufacturing
operation.
For example, when the particular frozen cone confection manufacturing process
performed by the system of Figures 15 and 16 is considered, it should be
realized
that the manufacturing stations 405; 410, 415, 420, 425, 430 thereof must be
set
apart by some substantially specific and predetermined distance. Particularly,
some dwell time must occur in between the cone dipping and/or coating process
that occurs at the first, chocolate pluglspray, manufacturing station 405, and
the
subsequent filling stations) 410. Such a dwell time is required to allow the
chocolate or other coating material to set up before a filling material, such
as ice
cream, is introduced to the conical shells. Similarly, a particular dwell time
must
exist between the filling stafion(s) 410 and the wet topping station 415, in
order to
ensure that the wet #opping, which is often applied at an elevated
temperature,
does not cause excessive melting of the frozen filling material, such as an
ice
cream filling material. The same is true with respect to the following
manufacturing
stations. For example, the dry topping material should preferably be applied
to the
frozen cone confection when the wet topping material is still in a somewhat
liquid
state, as if the wet topping material is allowed to solidify, the dry topping
material
likely will not stick thereto. Consequently, some predetermined dwell time is
necessary between the wet topping station 415 and the dry topping station 420.
A
predetermined dwell time is also preferably caused to exist between the last
of the
33
CA 02484723 2004-10-12
manufacturing stations and the first of the packaging stations, such as, for
example, the lid dispensing and crimping stations 425, 430 shown. In this
manner,
it can be ensured that the frozen cone confections will be in a state wherein
damage thereto from contact with packaging materials is least likely. For
example,
in the particular frozen cone confection manufacturing process described
herein, it
would be desirable to allow the wet topping to substantially solidify and the
dry
topping material to be secured thereby prior to subjecting the frozen cone
conf~ctions to a packaging operation.
[006TJ When producing a single product (or products having substantiaNy
identical manufacturing parameters) ~ is possible to design a manufacturing
line
having the necessary equipment location and, hence, the necessary dwell times.
However, such manufacturing lines and their equipment are not amenable to the
manufacturing of products having dissimilar manufacturing parameters. If an
additional manufacturing step must be added, or different dwell times are
required
between manufacturing process steps, it may be difficult (not to mention cost
prohibitive}, if not impossible, fio modify an existing manufacturing line.
For
example, in a frozen cone confection manufacturing process, it could be very
difficult to add a second failing or topping step, as equipment related to
preceding
or subsequent process steps would ypicafly be fixed in position. Therefore,
aside
from the general problem of finding room to install the additional equipment,
it is
unlikely that the dwell times between process steps would thereafter remain
acceptable.
[0068 Therefore; the advantages to utilizing an adaptive manufacturing line,
such as the above-described modular and reconfigurable frozen cone confection
manufacturing fine 400, are quite clear. The manufacturing stations of such a
line
34
CA 02484723 2004-10-12
may generally be moved to' substantially any point along the length of a
conveyor
or other device provided to move the product being manufactured from one
manufacturing step to the next: A conveyor of extra length may be used; if
desired, to allow for the addition of a number of initially nonexistent
manufacturing
stations, or the use of a number of initially unused manufacturing stations.
Space
may be created between manufacturing stations by displacing the manufacturing
stations along the length of the conveyor as needed. In this manner,
additional
manufacturing stations can be installed, and dwell timed between manufacturing
steps can be adjusted as needed,
[0069 Figure 16 illustrates how more than one modular manufacturing line may
be employed to form a larger and more complex overall modular and
reconfiigurable frozen cone confection manufacturing system 450. In this
particular
embodiment of such a system 450, the modular and reconfigurable frozen cone
confection manufacturing Line 400 shown in detail in Figure 15, has been
combined
with a second modular and' reconfigurable frozen cone confection manufacturing
line 440. An overhead schematic diagram detailing the operations performed by
the system 450 of Figure 16 can be observed in Figure 17. As can be seen, the
first modular and reconfigurable frozen cone confection manufacturing line 400
pertorms the process sfeps described above with reference to Figure 15. The
second modular and reconfigurable frozen cone confection manufacturing line
440
is shown to perform additional manufacturing steps that must precede those
performed by the first manufacturing line 400. For example, modular and
reconfigurable manufacturing stations, such as a rim dipping station 110' and
a
cone coating station 150', may be included on the second manufacturing line
440.
The manufacturing stations may operate in a similar manner to those described
CA 02484723 2004-10-12
above. In this particular embodiment of the modular and reconfigurable frozen
cone confection manufacturing system 450, the conveyor 375 of the first
modular
and reconfigurable frozen cone confection manufacturing line 400 is shown to
be
at a substantially right angle to the conveyor 445 of the second modular and
reconi'Igurable frozen cone confection manufacturing line 440: It should be
realized, however, that this is merely an exemplary embodiment of such a
system
450, and nothing herein is intended to limit the configuration of such a
system to
that shown.
(0070] The modular and reconfigurable frozen cone confection manufacturing
system 450 shown in Figures 16 and 17 also illustrates how other equipment may
be integrated into the manufacturing process. For example, the system 450 is
shown to employ both a conical shell loading robot 455 and a frozen cone
confection unloading robot 460 'to assist in the manufacturing process.
Various
attachments and other ancillary devices rnay be associated with each of the
robots
455, 460 for completing the particular manufacturing steps with which each is
tasked. A collection tray(s)/pan(s) 465 can be seen to reside near the bottom
of
the conveyor 375 to facilitate cleanup: Similarly, various ejection chutes
470, 475
may provided to collect and transport excess materials, broken conical shells,
reject frozen cone confections, and similar other items from the manufacturing
lines 400, 440 at certain locations along ~ach conveyor 375, 445.
(0071 The modular and reconfigurable frozen cone confection manufacturing
system 450 of Figures 16 and 17 (with robots 455; 460 removed for purposes of
clarity) is shown in Figure 18 with one form of operator guarding 480 in
place.
Additional packaging-related equipment 485, 490 has also been installed to the
36
CA 02484723 2004-10-12
manufacturing lines 400, 440 of the modular and reconfigurable frozen cone
confection manufacturing system 450 in Figure 18.
[0072] A processor-based control system is preferably provided to control a
modular and reconfigurable frozen cone confection manufacturing line, or
system,
of the present invention; such as the manufacturing lines 400, 440 shown in
Figures 15-18, and/or the system 450 shown in Figures 16-18. Each
manufacturing station of the manufacturing lines, as well as ancillary
equipment;
may be controlled by a centralized microprocessor. Thus; there may be a single
processor-based controller for an entire modular and reconfigurable frozen
cone
confection manufacturing sys#ern of the present invention. Alternatively, more
than one microprocessor may be used to control all of the elements of such a
system. When other automated equipment having its own processor-based
controls) is utilized along with a modular and reconfigurable frozen cone
confection manufacturing line or system of the present invention, he processor-
based controllers may be in electronic communication. For example; in the
system
450 depicted in figures 16-18the controllers) for the robots 455, 460 may
communicate with the controllers) for the manufacturing lines 400, 440 and
other
related equipment to ensure that the system 450 works as a whole.
[0073] When a single controller is provided for a modular and reconfigurable
frozen cone confection manufacturing system of the present invention, such may
be located in a single enclosure,, such as the enclosure 495 shown in Figure
13.
One or more operator's panels 500 may be included to provide information to an
operator of the system. it is contemplated that one, or both, of the
controller
enclosure 495 and the operator's panel 500 may be adapted to move along the
length of the conveyor as do the manufacturing stations. In alternate
embodiments
37
CA 02484723 2004-10-12
of the present invention, multiple enclosures may be provided to contain
multiple
processors. In yet another embodiment of the present invention, it is possible
that
a remotely located control system - can be used to control one or more
manufacturing systems: In such a case; it should be understood that process
configuration/reconfiguration; monitoring, and general control, can take place
from
a remote location.
[0074] In one embodiment of the present invention, the processor-based control
system also preferably allows the manufacturing stations to be automatically
provided with parameters necessary to properly produce a particular product.
Such information may be provided to the control system in a number of ways.
The
operator may provide positioning information with respect to the vertical
movement
of the manufacturing station components, such as filling heads and the like,
that
will be used in the manufacturing process: Alternatively, all information
necessary
to produce a particular product may be stored in a database or on a computer-
readable medium, whereby the proper data may be provided to the control system
upon selection of a particular program by an operator. Programs may be
associated with numbers, names, codes, or virtually- any other designator that
associates a program and its data with a particular product. Program selection
may be accomplished by the pressing of a button, the flipping of a switch, or
by
selection of an icon on a computer screen; for example. In yet another
embodiment of the present invention; it is contemplated that program selection
may be automatic, and initiated by detection of a particular product
component.
[0075] In an automatically reconfigurable system of the present invention; an
operator may have to do little more than select between programs to
manufacture
dissimilar products. Once a program is selected, each manufacturing system
will
38
CA 02484723 2004-10-12
automatically move to the correct position along the conveyor, and will also
be
provided with the data necessary to carryout the manufacturing steps) for
which it
is responsible. Consequently, manufacturing station spacing will also be
automatically set, ensuring that the dwell times necessary between
manufacturing
steps are correct.
[0076 The exemplary embodiments herein disclosed are not intended to be
exhaustive or to unnecessarily limit-the scope of the invention. The exemplary
embodiments were chosen and described in order to explain the principles of
the
present invention so that others skilled in the art may practice the
invention.
Having shown and described exemplary embodiments of the present invention, it
will be within the ability of one of ordinary skill in the art to make
alterations or
modifications to the present invention; such as through the substitution of
equivalent materials or structural arrangements, or through the use of
equivalent
process steps, so as to be able to practice the invention without departing
from its
spirit as reflected in the appended claims, the text and teaching ofi which
are
hereby incorporated by reference herein. It is the intention, therefore, to
limit the
invention only as indicated by the scope of the claims and equivalents
thereof.
39
