Press for form pressing meat products, and method of use
In an embodiment, a form press includes three die assemblies which form press a meat product along the height, width and length thereof. Each die assembly includes a single proportional directional valve which operates a hydraulic cylinder under control of a controller. The three die assemblies are first operated under position control, and are thereafter operated under force/position control. The form press has a single hydraulic circuit which operates the die assemblies.
1. A form press configured to form press a meat product, the form press comprising:
a frame having a press plate which defines a longitudinal axis;
a first die assembly mounted on the frame and configured to form press the meat product along a height of the meat product, the first die assembly including a first die configured to move along a first press axis which is normal to the longitudinal axis;
a second die assembly mounted on the frame and configured to form press the meat product along a width of the meat product, the second die assembly including a second die configured to move along a second press axis which is normal to the longitudinal axis and normal to the first press axis;
a third die assembly mounted on the frame and configured to form press the meat product along a length of the meat product, the third die assembly including a third die configured to move along a third press axis which is parallel to the longitudinal axis;
wherein the press plate and the plurality of dies define a press chamber therebetween;
each die assembly comprising a hydraulic cylinder having a piston and piston rod, each hydraulic cylinder defined by a bottom-side chamber and a rod-side chamber;
a closed-loop hydraulic control system configured to control each hydraulic cylinder of the corresponding die assembly, the hydraulic control system including:
a controller;
a proportional direction valve operatively coupled to the bottom-side chamber and to the rod-side chamber of each corresponding hydraulic cylinder;
a bottom-side pressure sensor operatively coupled to the bottom-s-de chamber of each corresponding hydraulic cylinder;
a rod-side pressure sensor opertatively coupled to the rod-side chamber of each corresponding hydraulic cylinder;
a position sensor configured to provide a relative position of the piston rod of each corresponding hydraulic cylinder;
the contoller operatively coupled to each corresponding proportional directional valve, the bottom-side pressure sensor, the rod-side pressure sensor, and the position sensor, of each corresponding hydraulic cylinder;
the controller configured to control the hydraulic cylinders in a closer-loop manner based on information for each corresponding hydraulic cylinder, the information including:
an operating position of each corresponding proportional directional valve;
pressure information provided by the bottom-side pressure sensor and the rod-side pressure sensor; and
position information provided by the position sensor; and
wherein the controller varies the operating position of each corresponding propertional directional valve iteratively between an open operating position, a neutral operating position, and a reverse operating position, until each die assembly provides a predetermined pressure level against the meat product exerted by each corresponding die assembly.
2. The form press of claim 1 , wherein the controller is configured to initially move each proportional directional valve to the first position based upon positional values from the respective position sensor, and wherein the controller is configured to thereafter move each proportional directional valve to one of the neutral and the reverse operating positions based upon pressure values from the respective pressure sensors.
3. The form press of claim 2 , wherein the controller is further configured to move each proportional directional valve to the neutral position based upon positional values from the respective position sensor.
4. The form press of claim 1 , further comprising a linkage coupled between the hydraulic cylinder of the first die assembly and the first die, wherein the position sensor of the first die assembly senses a vertical position of a component of the linkage.
5. The form press of claim 4 , wherein the position sensor of the first die assembly is a linear position sensor.
6. The form press of claim 4 , further comprising a linkage coupled between the hydraulic cylinder of the second die assembly and the second die, wherein the position sensor of the second die assembly senses a rotational position of a component of the linkage of the second die assembly.
7. The form press of claim 6 , wherein the position sensor of the second die assembly is an encoder.
8. The form press of claim 1 , further comprising a linkage coupled between the hydraulic cylinder of the second die assembly and the second die, wherein the position sensor of the second die assembly senses a rotational position of a component of the linkage.
9. The form press of claim 1 , wherein the position sensor of the first and third die assemblies is a linear position sensor.
10. The form press of claim 9 , wherein the position sensor of the second die assembly is an encoder.
11. The form press of claim 1 , wherein the position sensor of the second die assembly is an encoder.
12. The form press of claim 1 , wherein the controller is configured to perform a referencing process for each die assembly, wherein the controller is configured to move the respective die assembly to a first predetermined position based upon information from the position sensor thereof and measure the pressure from the pressure sensors thereof and generate a value to which the respective hydraulic cylinder is to be extended, and the controller is configured to move the respective die assembly to a second predetermined position based upon the information from the position sensor thereof and measure the pressure from the pressure sensors thereof and generate a value to which the respective hydraulic cylinder is to be retracted.
13. The form press of claim 1 , further comprising:
a reservoir containing hydraulic fluid;
a compensator defining a cavity having air therein, the compensator being attached to the reservoir and in sealed communication with the cavity within the reservoir, wherein air from the compensator is configured to move into the reservoir and air from the reservoir is configured to move into the compensator; and
a bi-directional air breather mounted on the reservoir and in communication with the cavity, the air breather being configured to open upon predetermined pressures within the reservoir.
14. The form press of claim 1 , further comprising:
a reservoir containing hydraulic fluid and an hydraulic pump;
a flow divider in communication with a return line of each proportional directional valve;
a heat exchanger in communication with the flow divider,
wherein the flow divider is configured to divert the hydraulic fluid from the return lines directly to the reservoir when a predetermined pressure is reached in the return lines.
15. The form press of claim 14 , further comprising:
a compensator defining a cavity having air therein, the compensator being attached to the reservoir and in sealed communication with the cavity within the reservoir, wherein air from the compensator is configured to move into the reservoir and air from the reservoir is configured to move into the compensator; and
a bi-directional air breather mounted on the reservoir and in communication with the cavity, the air breather being configured to open upon predetermined pressures within the reservoir.
16. The form press of claim 15 , further comprising a diffuser at an inlet to the reservoir, and a baffle plate within the reservoir, wherein the baffle plate is between the inlet and the pump.
17. A form press configured to form press a meat product, the form press comprising:
a frame having a press plate which defines a longitudinal axis;
a first die assembly mounted on the frame and configured to form press the meat product along a height of the meat product, the first die assembly including a first die configured to move along a first press axis which is normal to the longitudinal axis;
a second die assembly mounted on the frame and configured to form press the meat product along a width of the meat product, the second die assembly including a second die configured to move along a second press axis which is normal to the longitudinal axis and normal to the first press axis;
a third die assembly mounted on the frame and configured to form press the meat product along a length of the meat product, the third die assembly including a third die configured to move along a third press axis which is parallel to the longitudinal axis;
wherein the press plate and the plurality of dies define a press chamber therebetween;
each die assembly comprising a hydraulic cylinder having a piston and a piston rod, each hydraulic cylinder defined by a bottom-side chamber and a rod-side chamber;
a closed-loop hydraulic control system configured to control each hydraulic cylinder of the corresponding die assembly, the hydraulic control system including:
a controller;
a proportional directional valve operatively coupled to the bottom-side chamber and to the rod-side chamber of each corresponding hydraulic cylinder;
a bottom-side pressure sensor operatively coupled to the bottom-side chamber of each corresponding hydraulic cylinder;
a rod-side pressure sensor operatively coupled to the rod-side chamber of each corresponding hydraulic cylinder; and
a position sensor configured to provide a relative position of the piston rod or piston of each corresponding hydraulic cylinder;
the controller operatively coupled to each corresponding proportional directional valve, the bottom-side pressure sensor, the rod-side pressure sensor, and the position sensor, of each corresponding hydraulic cylinder, the controller configured to control the hydraulic cylinders in a closed-loop manner based on information for each corresponding hydraulic cylinder, the information including:
an operating position of each corresponding proportional directional valve;
pressure valves provided by the bottom-side pressure sensor and the rod-side pressure sensor; and
position information provided by the position sensor;
the form press further including:
a reservoir containing hydraulic fluid and a pump configured to pump configured to communication the hydraulic fluid to each of the hydraulic cylinders;
a compensator defining a cavity having air therein, the compensator being attached to the reservoir and in sealed communication with the cavity within the reservoir, wherein air from the compensator is configured to move into the reservoir and air from the reservoir is configured to move into the compensator;
a bi-directional air breather mounted on the reservoir and in communication with the cavity, the air breather being configured to open upon predetermined pressures within the reservoir; and
wherein the controller varies the operating position of each corresponding propertional direction valve iteratively between an open operating position, a neutral operating position, and a reverse operating position, until each die assembly provides predetermined pressure level exerted against the meat product.
18. The form press of claim 17 , further comprising:
a flow divider in communication with a return line of each proportional directional valve;
a heat exchanger in communication with the flow divider,
wherein the flow divider is configured to divert the hydraulic fluid from the return lines directly to the reservoir when a predetermined pressure is reached in the return lines.
19. The form press of claim 17 , further comprising a diffuser at an inlet to the reservoir, and a baffle plate within the reservoir, wherein the baffle plate is between the inlet and the pump.
20. The form press of claim 17 , further comprising a filter between the reservoir and the proportional directional valves.
21. A form press configured to form press a meat product, the form press comprising:
a frame having a press plate which defines a longitudinal axis;
a reservoir defining a cavity having hydraulic fluid therein;
a first die assembly mounted on the frame and configured to form press the meat product along a height of the meat product, the first die assembly including a first die configured to move along a first press axis which is normal to the longitudinal axis;
a second die assembly mounted on the frame and configured to form press the meat product along a width of the meat product, the second die assembly including a second die configured to move along a second press axis which is normal to the longitudinal axis and normal to the first press axis;
a third die assembly mounted on the frame and configured to form press the meat product along a length of the meat product, the third die assembly including a third die configured to move along a third press axis which is parallel to the longitudinal axis;
wherein the press plate and the plurality of dies define a press chamber therebetween;
each die assembly comprising a hydraulic cylinder having a piston and a piston rod, each hydraulic cylinder defined by a bottom-side chamber and a rod-side chamber;
a closed-loop hydraulic control system configured to control each hydraulic cylinder of the corresponding die assembly, the hydraulic control system including:
a controller;
a proportional directional valve operatively coupled to the bottom-side chamber and to the rod-side chamber of each corresponding hydraulic cylinder;
a bottom-side pressure sensor operatively coupled to the bottom-side chamber of each corresponding hydraulic cylinder;
a rod-side pressure sensor operatively coupled to the rod-side chamber of each corresponding hydraulic cylinder; and
a position sensor configured to provide a relative position of the piston rod or piston of each corresponding hydraulic cylinder;
the controller operatively coupled to each corresponding proportional directional valve, the bottom-side pressure sensor, the rod-side pressure sensor, and the position sensor, of each corresponding hydraulic cylinder, the controller configured to control the hydraulic cylinders in a closed-loop manner based on information for each corresponding hydraulic cylinder, the information including:
an operating position of each corresponding proportional directional valve;
pressure valves provided by the bottom-side pressure sensor and the rod-side pressure sensor; and
position information provided by the position sensor;
wherein the controller varies the operating position of each corresponding proportional directional valve iteratively between an open operating position, a neutral operating position, and a reverse operating position, until each die assembly provides a predetermined pressure level exerted against the meat product;
a single hydraulic pump configured to pump the hydraulic fluid from the reservoir to an input line of each proportional directional valve of the corresponding die assembly;
a flow divider in communication with a return line of each proportional directional valve;
a heat exchanger in communication with the flow divider; and
wherein the flow divider is configured to divert the hydraulic fluid from the return lines directly to the reservoir when a predetermined pressure is reached in the return lines.
22. The form press of claim 21 , further comprising a diffuser at an inlet to the reservoir, and a baffle plate within the reservoir, wherein the baffle plate is between the inlet and the pump.