DE20207547U1 - Universal machine-based process machine for food - Google Patents

Description

Description

1. Process machine for food

The solutions presented to date in this area of vending machine construction are not producing machines but function purely as dispensing machines or can prepare a variety of drinks at most.

Until now, it was hardly possible for travellers at train stations to get hot and freshly prepared meals outside of the opening hours of the existing restaurants. The existing vending machines were limited to dispensing hot drinks or cold meals. The same applies to visitors to cinemas, sporting events in stadiums or visitors to amusement parks who like to have a quick, warm snack. We want to serve this target group with the invention ^specified in claim 1. We want to develop a vending machine that is very easy to use and very easy to clean inside in order to meet the requirements of the hygiene regulations for food.

During the development of the process automation we necessarily came across novel solutions, which are defined in more detail in claims 2 - 5.

The internal structure and the mode of operation of the machine is explained using the following sketch.

All the processes shown below are controlled by a system programmable controller (PLC). All the components required for this are housed behind a door (7).

Inside the refrigerator (2) (see also point 3) there is a storage container (1) for raw products. The storage temperature of the raw products is -5 ⁰ C. Depending on the size of the raw products, there is a weighing unit (3) below the storage container, e.g. for French fries, or a counting unit, e.g. for carrot rings.

The process inside the machine is started by inserting money into the front of the door. The machine gives out change via a coin acceptor (9). Change is placed in the cup (10). The cup (11) is designed as a cash register and is separately secured.

At the start of the process, a flap (3a) opens on the underside of the refrigerator. The raw product falls onto the fryer through a connecting piece (see also point 2). Only after the flap (3a) on the bottom of the refrigerator is closed again does a second flap (3b) above the fryer open and the raw product falls into the fryer (5) via a conveyor belt. The conveyor system inside the fryer gently transports the raw product into an oil bath that is heated to approx. 130 °C. The fryer is controlled by the control unit (4). The temperature in the fryer is controlled electronically. The level of the internal temperature cannot be manipulated by the operator. In addition to this electronic control, the fryer also has a mechanically read-out overtemperature controller. This can only be reset by qualified personnel.

During the frying process, an integrated ventilation system (6) cleans the air as much as possible of any odorous substances. The required air is taken from the surrounding room and returned to it.

While the product is being fried, the machine ensures that a plastic cup is made available via a cup conveyor (12) (see also point 5). At the same time, the machine releases a bag via a goods dispensing compartment (7). This bag contains packaged

Tomato ketchup, packaged mayonnaise, packaged salt, a plastic skewer and a napkin. This sachet can be removed via compartment (13). According to the confirmations we have received from the suppliers of ketchup and mayonnaise, this does not need to be refrigerated separately.

In the meantime, the scales (3) are filled with fresh raw products via a shaft in the storage container (1). If there are not enough raw products in the storage container, the machine will lock itself at the end of the current process. The machine will contact its operator without being asked to do so. The same applies if, at the end of the current process, it is detected that there are no more additions in the goods dispensing compartment (7).

After a frying time preset by the operator has elapsed, the finished product is removed from the oil bath using the conveyor belt mentioned above. The finished product is transferred to the previously prepared plastic cup via a drip grid on which the belt rests briefly. Only when this process is complete does the end customer have the option of removing his cup from the machine via the compartment (14). This removal flap is only unlocked for the short time that the goods are being removed. If an end customer "forgets" to remove his cup, the machine also locks itself as described above.

Depending on the frying time set, such a process takes about 120 seconds. The operator is forced to check the oil quality using the machine manual provided. He is given test strips on which the quality of the oil can be read precisely . Depending on the test result, actions (e.g. oil change due) can be taken.

All other error conditions can be forwarded as a fault message via a GSM interface as an SMS or as a fax to the operator or another central location (see also point 4).

When the door is opened, all functions (rotating doors and 230 V connections) are reset. It is not possible to switch these parts on when the door is open. After the door is closed, the machine carries out a self-test. This ensures that the basic state is established before the first portion is taken.

Attachment 1

Drawing for point 1

2. Thermal separation distance

To date, no such temperature differences have been realized in the food industry or in vending machine construction. This applies ⁱⁿ particular to compliance with hygiene requirements when handling perishable foods.

In order to be able to manufacture our machine, this problem had to be resolved independently.

To approach this problem, a way had to be found to keep the hot air rising from the ^deep fryer away from the cold air of the refrigerator.

For a better understanding, please refer to Appendix 1. As already described, the storage temperature of the raw products is -5 ^° C. The frying temperature is fixed at max. 180 ^° C.

The spatial distance between both bodies is about 20 cm.

To start the process, a plate (3a) made of plastic (here PE - 1000 natural) opens underneath the scale (3). This plastic is not only food-neutral, but also has a very poor heat transfer coefficient. This ensures, among other things, a constant temperature in the refrigerator. Ice formation in this area of the flap (3a) is completely ruled out. This allows thermal separation to be achieved in the process. The scale (3), the frame of which is precisely tailored to the external dimensions of the connecting piece (15), closes the refrigerator at the bottom.

Another movable plate (3b) is fitted above the deep fryer. Due to the heat generated by the deep fryer, this plate is made of stainless steel V2A 1.4301. This stainless steel is ^approved in Germany for use in apparatus and equipment in the food industry. This plate (3b) separates the hot air from the deep fryer from the normal circulating air in the machine. The integrated control system of the machine is organised so that the plate (3b) above the deep fryer only opens when the plate (3a) below the refrigerator has already been closed again and the integrated ventilation (7) in the machine has started. This means that the rising hot air is immediately caught by the resulting negative pressure and pushed out of the machine via the various filter stages. Air inflow openings are fitted in the outer skin of the machine. This ensures that the machine receives the air it needs from the immediate surroundings and then returns it there.

In order to avoid heat build-up underneath the refrigerator, holes (16) are fitted all around the connecting piece. After assembly, these holes are located above the surface of the refrigerator. This heat is dissipated to the outside ^via normal convection together with the waste heat generated by the refrigerator convection.

As an additional safety circuit, the integrated ventilation (7) runs periodically. The periods are determined by the control system.

Annex 2
Drawing for point 2

j &iacgr; ^: ·%.&igr; :

The refrigerators and freezers available in Germany could previously only be purchased in the temperature classes +5 ⁰ C or -18 ⁰ C. In addition, different temperature ranges prevailed in the cabinets. These temperature ranges differed not only in terms of the storage height in the cabinet but above all in terms of various built-in features.

Our task was to develop a cabinet that would enable raw products to be stored at temperatures below 0 ⁰ C. The models that are available as standard on the market are available as pure freezer cabinets with many built-in components and different temperature layers or as refrigerators with a storage temperature of +5 ⁰ C. Both types of cabinet have different temperature layers. For hygiene reasons, a cabinet with a storage temperature of +5 ⁰ C cannot be used. The products offered by the manufacturers are all shock-frozen and would thaw at a temperature above 0 ⁰ C. All of the manufacturers' guidelines for such pre-blanched products state that they should be put into the freezer directly from the freezer. Product liability would therefore no longer apply.

In both model variants of refrigerators and freezers, internal recirculation is neither provided nor required (different storage temperatures for different food groups).

The innovation in this cabinet is that, despite all the built-in components, the internal temperature of the cabinet is at least -5 ^° C at all points. The fan (17) manages to reach this temperature both inside and outside the storage container (2). In the area of the scales (3) the temperature conditions are around -2°C.

This ensures that the shelf life of the raw product can be maintained as stated by the manufacturer.

The location of the refrigerator (1) was given great importance. The convectors on the back were designed in such a way that regular heat dissipation was ensured. In addition, a possibility was found to firstly choose a thick ^insulation for the refrigerator cabinet and secondly to design the cooling unit in such a way that there can be no temperature fluctuations inside the cabinet. The exception is an ambient temperature of over + 43°C.

The internal temperature of the refrigerator can be freely adjusted within certain limits using the controller (18).

Annex 3
Drawing for point 3

The machines that exist and have been produced to date in the area of dispensing machines, e.g. for drinks or small snacks, have to be visited by attendants at certain intervals. If a machine developed a defect shortly after the attendant visited it, it often remained inoperative for days or attentive citizens reported this damage to the relevant service centers. Errors in the program of the respective control system (or installing an update) were previously solved by the relatively expensive trip of a technician from the manufacturer who installed a new program. Up to now, it was not possible to maintain the software on a long distance from the operator. Communication with a machine via a G3M modem has not yet been implemented.

The concept of the entire machine is to make it as customer-friendly as possible. This includes, among other things, forwarding any error messages to the operator without delay. The same applies, for example, to the number of portions sold in a certain period of time being reported to a remote station.

When selecting a suitable GSM modem, great importance was attached to the fact that commercially available SIM cards (3V) could be used. It is irrelevant which network operator you choose. However, in order to be able to carry out remote maintenance of the software, the data mode must be activated for the respective phone number. This data mode can be transmitted in addition to the voice mode (voice mode) upon request from the network operator. The so-called prepaid contracts do not offer this service. This applies to all GSM networks approved in Germany.

Depending on the customer's requirements, different types of messages can be generated via the PLC and the GSIVl modem. The following options are available:

1. All types of fault reports (including faulty components) are to be sent as SMS to the operator's cell phone. The message is repeated at cyclical intervals (e.g. every 9 minutes) until the operator has corrected the fault.

2. Status reports to another location (e.g. number of portions sold in a certain time unit) can be sent by fax. To do this, the machine contacts the other location at a previously agreed time without being asked.

PLC and GSM modems detect when information has not been forwarded. Both systems also detect when there are problems with a radio network. The necessary information is stored and only transmitted when error-free transmission is possible.

The configuration of GSM - Mcdem and PLC that we have made makes it possible to carry out remote maintenance of the software. This not only required a new connection cable between the two components. We were able to configure the GSM - Modem and PLC components to work in a bidirectional system (sending and receiving) depending on the requirements.

Description

5. Bucket elevator

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Automatic separation of plastic cups has so far only been described and implemented for cups with a maximum volume of 0.2 l.

Due to the flanged edge (upper edge diameter 95 mm), the previously used solution using an inductor cannot be implemented. We therefore had to find a new technical solution for our machine.

Automatic separation was necessary because the end customer should only take the finished product from the machine. The provision of a cup (and the associated separation) was absolutely necessary.

This development can be used in all automatic and semi-automatic machines that require cups of the above-mentioned size. The cups used in the machines have a volume of 0.31 and, as described above, a rim diameter of 95 rrm

The bucket elevator is located below a bucket guide that can hold approximately 60 buckets.

The basic requirement for the implementation was the movable ring (A). This ring is attached to the base body (B) via the sleeves (C). The mounting points of the sleeves (C) are the bolts (1). The six impellers (D) also run between the ring (A). These impellers are made of PE. This PE is characterized by the fact that it runs without any lubricant. The impeller is installed in the bucket elevator in such a way that the bore (2a) is mounted in the corresponding bolts (2a) as a free-running fit. The bore (2a) is designed as a through-bore.

The hole (2b) is only drilled to a depth of ^2/3 of the total thickness of the impeller (D). This hole is simply a guide for the corresponding bolts (2b) on the ring (A). On the base body (B) there is a motor which uses a connecting rod to move the ring (A) out of the middle position by approx. 30°. In the process, the six impellers (D) on the bolt (2a) also rotate in a common direction. A corresponding profile was applied to the impeller which allows the 60 cups to slide down by approx. 3mm in this step. Without a break, the ring is now deflected past the middle position by approx. 30° in the other direction. The profile of the impeller grips under the edge of the lowest cup and pushes it downwards. All the other cups remain in the cup guide.

After the ring (A) returns to its central position, the motor is switched off via a sensor from the PLC.

Annex 4

Drawing for point 5

Reference list

&igr; ... storage containers for raw food products

2 ... Refrigerator

3 ... scale

3a ... operable flap

3b ... operable flap

4 ... Control unit of the fryer

5 ... deep fryer

6 ... Ventilation module

7 ... screw conveyor;door;goods dispensing compartment;ventilation

in the machine

9 ... coin slot;coin acceptor

10 ... cup for change

11 ... cup (designed as a cash register and secured)

12 ... Bucket elevator

13 ... compartment (for removing the supplement)

14 ... compartment (for removing the filled plastic cup)

15 ... connecting piece

16 ... holes in the connector

17 ... Fan (to generate air circulation in the refrigerator 2)

18 ... Controller (for the internal temperature of refrigerator 2)

Reference sign relating to the device for providing the plastic cup for the food portion:

A... Ring (movable) B... Base body C Sleeve T... Wheel 1 bolt 2.3 , . . bolt 2a ... drilling 2 B ... bolt 2 B ... drilling

Claims (9)

1. A vending machine for a portion of food with operating elements that can be controlled by inserting a coin by a requesting customer to trigger the provision and dispensing of the portion of food, characterized in that arranged in a cabinet are - a storage device for frozen goods, with a refrigerator ( 2 ) in which there is a storage container ( 1 ) for blanched, frozen raw food products, a dosing device arranged below the storage container ( 1 ) for portion-appropriate dosing of the frozen raw food products and a flap ( 3a ) arranged below the dosing device on the underside of the refrigerator ( 2 ) and operable to open or close, - a thermal separation section, with a connecting piece ( 15 ) for transferring the raw food products with holes arranged in it for an air exchange with the environment, which is arranged below the flap ( 3 a) and with an opening or closing actuable flap ( 3 b) on the underside of the connecting piece ( 15 ) and a ventilation module ( 6 ) for generating an air vortex in the area of the connecting piece ( 15 ) before opening the flap ( 3 b) to prevent hot air from rising up to under the flap ( 3 a) from a - a deep fryer ( 5 ) arranged underneath for receiving the portioned raw food products for cooking with a control unit ( 4 ), - a device for providing a plastic cup to hold the portion of food to be served to the customer, - a device for dispensing a pre-packaged side dish, in particular mayonnaise, tomato ketchup, salt, spices, cutlery and napkins, parallel to the plastic cup containing the food portion, - a system-programmed control device for the vending machine, - a communication module for establishing bidirectional data connections between the vending machine and a maintenance point for the purpose of transmitting messages about the conditions in the vending machine, in particular faults due to missing plastic cups, side dishes or raw food products, to and remote maintenance of the software of the system-programmed control device of the vending machine by the maintenance point. 2. Vending machine according to protection claim 1, characterized in that a fan ( 17 ) for generating an internal recirculation mode and a controller ( 18 ) for maintaining a largely uniform storage temperature of at least -5°C in the entire room are arranged in the refrigerator ( 2 ) of the storage device for frozen goods. 3. Vending machine according to claim 1, characterized in that in the holding device for frozen goods the operable flap ( 3a ) consists of a food-neutral plastic. 4. Vending machine according to one of the protection claims 1 to 3, characterized in that in the thermal separation section the operable flap ( 3 b) consists of a food-neutral stainless steel. 5. Dispenser according to one of the claims 1 to 4, characterized in that a conveyor belt is present in the deep fryer ( 5 ) for receiving the raw food products released from the opened flap ( 3b ) and gently conveying them into an oil bath with a temperature of 180°C and, after a preset frying time has elapsed, for conveying the cooked food portion further via an oil drip grid into the plastic cup. 6. Dispenser according to one of the claims 1 to 4, characterized in that the device for providing the plastic cup has a cup elevator ( 12 ) for separating the plastic cups held in a cup guide with a holding capacity of 60. 7. Dispenser according to claim 6, characterized in that the bucket elevator ( 12 ) has a movable ring (A) which is held on a base body (β) via sleeves (C), the mounting locations of the sleeves (C) are bolts ( 1 ), wheels (D) for separating are arranged between the ring (A) and a motor is located on the base body ( 8 ) for deflecting the ring (A), via a connecting rod, from its central position by 30° in both directions. 8. Dispenser according to claim 7, characterized in that the running wheels (D) have milled tracks for separating the plastic cups. 9. Vending machine according to claims 7 to 8, characterized in that the running wheels (D) consist of a plastic and the other parts of the bucket elevator ( 12 ) consist of stainless steel.