Title of Invention

AN AUTOMATIC CHAPPATHI MAKING MACHINE

Abstract

An automatic chappathi making machine consists of a rotatably drivabale top plate and a bottom plate movable up and down. The top and bottom plates are electrically heated and are provided with thermostats. A dough dispensing container having a tapered opening dispenses predetermined quantity of dough on to the bottom plate which is pressed and baked. The rotation of the top plate remove the cooked chappathi from the bottom plate. A cutting means for cutting predetermined quantity of dough from the dough dispensing container and a micro processor for controlling the temperature and the drive are also provided.

Full Text

This invention relates to an automatic parietal acing machine. Traditional ( happathiimaking includes kneading attach to form a dough, rolling to the desired shape and cooking the rolled dough on heated have. This apart, recent trend is to use electrically heated plates to press predetermined quantity of dough which gets cooked thereafter. This requires pressing by hand and often turning the pressed dough at least once to effect proper cooking of both the sources. An industrial chappathi making plant which uses conveyor plates heated by means of gas has also been developed. This invention relates to a filly automatic table top model which’s capable of separating the desired quantity of dough, pressing it to make uniform round sale and then cooking it evenly on both the sides for a specific set time. The cooked chappathi is automatically removed from the cooking plate while the next lot of dough on the plate to be processed into a chappathi. This automatic making machine consists of a dough pressing unit, cutting means to cut the dough and a dough processing unit which cooks the chappathi and removes the cooked ^chappathi) A motor connected to power source drives the different components mounted on shafts. Thickness adjusting means and cooking time adjusting means are also provided. A microprocessor controls the action of the different components. Different parts of the machine will now be described in detail: DOUGH PRESSING UNIT: Dough pressing unit is mounted on a frame member. A main shaft mounted on the frame member is drivable connected to a drive lever, connecting lever, crank arm provided with ratchet and pawl arrangement. A piston is connected to this arrangement and is provided with a screw and nut arrangement which facilitates only downward movement of the piston. Gear box is coupled to the shaft and consists of worm and worm wheel. A container for kneaded dough is positioned inside the structure of the frame member. This container has a centrally positioned tapered opening and a divider for allowing predetermined quantity of the dough kept therein to be discharged. The ratchet, pawl, screw and nut arrangement enables the piston to be moved only upwards and downwards and prevents its rotation. DOUGH PROCESSING UNIT: It consists of a bottom plate and a top plate both of which are electrically heated and are provided with thermostats for a temperature control. The top plate is fixed on top plate drive shaft and is provided with stopper means which acts as a support to the top plate when bottom plate presses thereon. The bottom plate is mounted on a cam sliding cylinder such that it moves up with the cylinder. A limit switch is provided on a limit switch operating cam which has a groove which enables the bottom plate to be stopped at a preset distance. Dough cutting means consists of a cutting wire assembly mounted on the top plate. A cutting wire holder and a holder pin holds tiie cutting wire assembly which is held in such a way that it touches the taper portion of the container"s mouth. Cutting of the dough is done when the top plate moves and the cutting wire touches the taper of the dough container. Cutting wire assembly is mounted in such a way that tiie load on the cutting wire is equal on both the sides of the container mouth. This is required to make sure that the cut dough Ms at the center of the bottom plate. The taper guides the cutting wire. When the motor is started, drive is transmitted and the bottom plate moves towards the top plate to press the dough that has been deposited on it. The heating sources of the top and the bottom plates are convex and concave in nature respectively. This allows the air to escape during baking. The plates are also voided with plurality of profiles on its sources. The dough is pressed and baked thereafter. Cooking time depends on the viscosity and such other qualities of the dough. The control panel fitted with a micro processor ensures that the drive is switched on at a preset time. Adjustment means are also provided to adjust the time of cooking. Both the top and the bottom plates are provided with plurality of small profiles. When the dough is {Hissed between the top and the bottom plates, air pockets are created because of these profiles. When the pressed dough is heated, these air pockets get filled with steam. This steam moves up, creating a dent in the pressed dough which becomes a bubble. The top plate being fixed on logitudinal axis, the movement of the top and the bottom plate controls the diameter of the pressed dough. Return stroke stoking mechanism consists of a pawl and ratchet, where the pawl engages a pinion in one direction and disengages therefrom in the opposite direction. Return stroke may be stopped by engaging the pinion during the return stroke also. Final stopping mechanism consists of a switch activating plate provided with a limit switch. This invention relates to an automatic making machine which comprises a frame member, housing "a dough pressing means consisting of drivable piston movable within a dough container, said container having an opening and a taper at its base, a cutting means for cutting predetermined quantity of dough ejected from said container, a dough means consisting of a drivable cam assembly slidably disposed in a cylinder housing, a drivable bottom plate member and a rotatably drivable top plate member, said top and bottom plate members being provided with heating means and a microprocessor based control means for controlling the drive and the temperature of said top and bottom plate. A specific embodiment of this invention will now be described with reference to Fig.I of the accompanying drawings which represents the sectional view of the chappathi making machine. Parts of the machine are indicated by the reference numerals specified thereagainst. Frame member 54, motor 78, coupling 75, coupling pin 74, worm 73, worm wheel 71, gear box 76, main drive shaft 65, drive lever 77, step pin 80, connecting lever 81, crank arm pin 83, crank arm 82, pawl 30, pawl spring 27, pawl bottom follower 24, ratchet pinion 50, pawl plate 23, pawl plate follower 46, key 51, screw rod 21, screw rod rotating pin 20, spacer 19 and piston 18, container 17 and divider 44. Gearbox 76 consists of worm 73 and worm valise 72. Worm 73 is mounted in the gear box 76 coupled to the motor shaft by coupling 75, through coupling pin 74. Cooping pin 74 is located in loose fit condition, so that it can withstand the alignment between motor shaft and worm 73. Gearbox 75 is mounted on the motor 78 itself Worm wheel 72 is mounted on the main drive shaft 65. Hence when motor 78 rotates reduced drive is transmitted to the main drive shaft 65. Main drive shaft 65 is supported by bush bearings 56 and 67 by means of screw and spacer 53. Drive starts food motor 78 and goes through gear box 76 to Age main drive shaft 65. The main drive shaft 65 rotates screw rod 21 through following series of elements (levers). Drive lever 77 is fitted to main drive shaft 65 by means of screw. The other end is fixed to the connecting lever 81 by means of step pin 80 and locked by means of a pin. The other end of connecting lever 81 is fixed to the crank arm 82 by a step pin 83 by means of a pin. The crank arm 82 is mounted on main feed nut 22 and it rotates keeping main feed nut 22 as its center. Pawl plate 23 is also mounted on main feed nut 22 and rotates keeping main feed nut 22 as its center. Pawl 30 is fixed on pawl plate 23. One end of the pawl 30 is mounted with stepped pin 26 by means of a circle. The over end of the pawl 30 engages ratohet pinion 50. Pawl bottom follower 24 is fixed at the bottom of the stepped pin 26. Ratohet 50 is mounted to the screw rod by means of a key and it rotates keeping nut 22 as center. Container 17 is seated on said foamed member 54. Divider 44 is fixed at mouth of the container 17. When the crank arm 82 rotates, it pushes pawl bottom follower 24. Same moment, the pawl 30 engages with ratchet 50. When the ratohet 50 is rotated it rotates the screw rod 21 as the main feed nut 22 is fixed to the structure 54 by means of screws. Ratchet 50 is mounted on main feed nut 22. When crank arm pushes the pawl plate 23, it also engages the pawl 30 to the ratchet 50. When the pawl plate 23 is pulled back a spring 27 disengages the pawl 30. The ratchet 50 has a key 51 fixed to it. When the ratchet 50 rotates, it turns screw rod 21. As the screw rod 21 turns, it moves through the main feed nut 22. Screw rod 21 moves down with piston 18 through the container 17. When the piston 18 is pushed down, it {Noses the dough to the bottom of the container 17. Dough is pressed through the mouth of the container 17 through the divider 44. PROCESSING THE DOUGH TO THE REQUIRED SHAPE: Processing the dough to the required shape consists of. The frame member 54, motor 78, coupling 75, coupling pin 74, worm 73, worm wheel 72, gear box 76, main drive shaft 65, spacer 71, bush bearing 67, bush bearing 56, drive sprocket 58, circlip 57, chain 59, driven sprocket 4, main cam 5, thrust bearing 35, (TC lever 3, TC screw 34, TC nut 2, TC cap 1), circlip 33, cam sliding cylinder 6, follower 37, follower pin 36, bottom plate 9, bottom plate cover 7, bottom plate guide 8, top plate 11, stopper 40, limit switch operating cam 79, limit switch 45, top plate cover 14. Motor 78 is fixed the topside of fortune member 54 as shown in the figure 1 by the means of bolts. The motor shaft coupling 75 is mounted by means of coupling pin 74; other side of coupling is threaded to the worm 73. Gear box 76 is mounted on the motor &ce by mean of screw. Worm wheel 72 engages with the worm 73 inside tiie gear box 76. Worm wheel 72 is mounted on Ifae main drive shaft 65 by means of key. Main drive shaft 65 is fixed on the structure 54 by means of bush bearing 67, aiul by bush bearing 56. Drive sproket 58 is mounted the bottom of main drive shaft 65 by means of key. Main cam 5 is sui^rted on the structure housing 54 at two places as shown in figure 2 and it is locked to the structure housing 54 by meims of circlip 57, main cam 5 rotates on the thrust bearing 35. Driven sprocket 4 is mounted on the main cam 5 by means of key. Chain 59 links the driven sprocket 4 and drive sprocket 58. Cam sliding cylinder 6 is fitted on the main cam 5 (follower 37 is inserted in the groove of main cam 5). Follower 37 is fixed on the cam sliding cylinder 6 by means of follower pin 36. Bottom plate 9 is mounted on the cam sliding cylinder 6 by means of split pin. Bottom plate 9 is covered by bottom plate cover 7; bottom plate 9 is guided on the structure housing 54 by bottom plate guide 8. Top plate 11 is fixed on the structure housing 54 thrust top plate drive shaft 64 as shown in the figure. Stopper 40 is fixed on the structure housing 54 as shown in figure 2 by means of bolts, which acts as support to the top plate 11 ^en bottom plate 9 is pressed. When motor 78 is started drive is transmitted through a reduction gearbox to the main drive shaft 65. From the main drive shaft 65, the drive is transmitted to the main cam 5 by means of sprockets and chain 59. When the main cam 5 is rotated, tiie follower 37 pushes the cam sliding cylinder 6 up or down according to the groove formation in the main cam 5. As the bottom plate 9 is mounted on cam sliding cylinder 6, it also moves up v^ith the cylinder. As the bottom plate 9 moves towards the top plate 11, it presses the dough inside. After pressing the dough completely the bottom plate 9 is placed at a preset distance fix>m the top plate 11. It is achieved by operating Umit switch 45 by means of limit switch operating cam 79. The groove on the cam is also got a provision to stop the plate at preset distance. CUTTING THE PRESSED DOUGH: Cutting the pressed dough contains following components: Main drive shaft 65, top plate drive cam 70, follower 42, follower pin 41, top plate driving lever 68, top plate drive shaft 64, top plate cover 14, bush bearing 56, 67, top plate 11, hex bush 63, top plate bush bearings 62,66, washer 61, screw 60, cutting wire holder 12, wire tensioning plate 13, cutting wire 15, wire holder pin 16, bottom plate 9, container 17, divider plate 44. The top plate 11 is fixed to the structure 54, inside the holding bushes as shown in figure by means of bushes 62 and 66. Top plate 11 is mounted on top plate drive shaft 64 by means of a pin. Cutting wire assembly is mounted on top plate 11 as shown in figure by means of screws. In cutting wire assembly, cutting wire 15 is mounted on cutting wire holder 12 by means of wire holder pin 16, cutting wire 15 is set in such a way that it touches the taper portion of the container 17 mouth. On the top plate drive shaft 64, top plate drive lever 68 is mounted by means of a pin. Follower pin 41 is fixed on the top plate drive lever 68 by means of a nut. Top plate drive cam 70 is mounted on the main drive shaft 65 by means of key. When the drive is given to the main drive shaft 65, the top plate drive cam 70 is rotated. By means of the follower 42, rotational motion is converted into linear motion. Follower pin 41 pushes the top plate drive lever 68 in to and fro motion. As the top plate drive lever 68 is fixed to the main drive shaft 65 rotates the top plate 11 side ways. When the top plate 11 moves, it cuts the protruding dough from the container 17. Cutting is done efficiently as the cutting wire 15 touches the taper portion of container 17 initially. This taper portion guides the cutting wire 15 same moment, it increases the tension of the cutting wire 15. Cutting wire assembly is mounted in such a way that the load on the cutting wire 15 is equal on both the side of the container 17 mouth. This aspect makes sure that cut dough &lls at the center of the bottom plate 9. PROCESSING THE BACKED DOUGH: When the baked dough is pressed as explained on part two, the cooking time has to be controlled according to the dough viscosity and quality. The control panel 43 is fitted with microprocessor, which ensures that the drive is switched on preset time. Baking time can be increased or decreased by turn off a knob. Coil 39 is fixed on top plate 11 and bottom plate 9 as shown in figure 1. Thermostat 38 is fixed on the bottom plate 9. When the knob is turned, it increases or decreases the baking time. Preset temperature is maintained by means of thermostat 38. For increasing the quality of the roti, i.e. to control the softness, texture and taste of the roti or chaf^lfaies, the following aspects employed. The top plate 11 and bottom plate 9 has a sUght convex and concave curve respectively. This helps air to escape in the side, this increasing the softness. Small profiles are machined out of top plate 11 and bottom plate 9 as shown in the top plate 11 and bottom plate 9 drawings. When the dough is pressed between top plate 11 and bottom plate 9 air pockets are created on these sur&ces. When the pressed dough is heated, these air pockets are fitted with steam. This steam when dries to move up due to heat, it creates a dent in the pressed dough, which becomes a bubble. These bubbles gives a good look to the roti"s as it is cooked on the steam. That is created fi"om the pressed dough itself quality of the roti"s increased manifold. The main cam 5 is designed in such a way that it doesn"t press too hard or too light. Just Ihe right amount of pressure is applied when pressing, so that the softness of the roti"s are increased. The top plate 11 temperature is set at a higher value, this is being done because when the pressed dough is baked only the bottom plate 9 comes in contact. The top plater 11 is staying few millimeters above the pressed dough. The heat is conducted through air. This improves the quality of the product. THICKNESS CONTROL MECHANISM: Thickness adjusting mechanism contains following components: TC cap 1, TC nut 2, TC screw 34, TC lever 3, Thrust bearing 35, main cam 5, circlip 33, structure 54. TC nut 2 is fixed to the structure 54 by means of screw as shown in figure 1. On the TC nut 2, a TC screw 34 is mounted. TC lever 3 is fixed to the TC screw 34 by means of pin. Thrust bearing 35 is fixed on the TC screw 34. Main cam 5 is rest on the thrust bearing 35. TC cap 1 is fixed to the structure 54 by means of screws. TC cap 1 acts as a guide to the main cam 5. Circlip 33 locks tiie main cam 5 When the TC lever 3 is pushed from one side to another, it rotates the TC screw 34. When the TC screw 34 is rotated, it moves up or down inside the TC nut 2. As the TC nut 2 is already locked with the structure 54 with TC screw 34, the thrust bearing 35 and main cam 5 also moves up or down. With the main cam 5, bottom plate 9 is also moves up or down. The top plate 11 is fixed on longitudinal axis. They according to the bottom plate 9 movement, the thickness and diameter of the pressed dough can be varied. RETURN STROKE STOPPING MECHANISM: Return stroke-stopping mechanism consists of following components:- Pawl 30, pawl control plate 28, pawl spring 27, pawl top follower 29, pawl bottom follower 24, pawl stepped pin 26, spacer bush 25, pawl plate 23, crank arm 82, pawl plate reverse pin 46. Pawl control plate 28 is seated on the ratchet SO, pawl spring 27 is fixed on one end on pawl 30 and on the other end on pawl plate 23. At one end of the pawl 30, pawl stepped pin 26 is fixed on top of the pawl stepped pin 26, pawl top follower 29 is mounted and locked through circlip. Spacer bush 25 is mounted on structure 54, which maintains the height of the pawl control plate 28. When the cutting wire 15 crosses the container 17, the dough is cut. On returning to the original position for the next cycle, there is a small amount of dough projecting out because of the viscose properties of the dough. This is correct^ by taking the piston back for a certain distence after pressing the dough for cutting stroke. Normally in ratchet mechanism, pawl 30 is engages to pinion in one direction and in other direction, it is not engaged. To control the return stroke, we engage the pinion while returning also for require distance. This is achieved by following sequence of operation. On the oscillation of crank arm 82, it comes in contact with pawl 30 at a pawl bottom follower 24. By this movement, pawl 30 is engages to the ratchet 50 and also pushes forward. On the return stroke. Crank arm 82 pushes pawl plate reverse pin 46, thus reversing the direction of pawl 30. As it reversed, pawl spring 27 disengages the pawl 30 from ratchet 50. As the pawl 30 moves further on return stroke, it comes in contact with pawl control palte 28 at pawl top follower 29. This activates engagement of pawl 30 to the ratchet 50. This engagement ceases once, the profile on pawl control plate 28 crosses the pawl top follower 29. FINAL STOPPING MECHANISM: Final stopping mechanism contains following components:- Over switch activating plate 49, spring 48, limit switch 47, roller 31, handle cam 52, handle 32. On completion of baking, entire quanity of dough, the machine stops all the activities. This is achieving by following sequence of action. On removal of product from top plate 11, whatever protrudins material from container 17 will be cut. This will create a cleaning problem on the machine. Finally the pawl 30 is continuously engages for both to and fro motion, so as to stop protruding of dough on final cutting stroke. On completion of dough on the container 17, the screw rod handle cam 52 reaches the bottom most position. In this position, it comes in contact with roller 31, which pushes over switch activation plate 49 forward which comes in contact with pawl top follower 29. As the pawl 30 is continuously engages on both to and fro motion, the screw rod 21 stays in the same position. Same moment, over switch activating plate 49 activates limit switch 47, w^ich stops all the machine activity. REMOVING & STORING THE BAKED PRODUCT: Removing and storing the baked product contains following components: Main drive shaft 65, top plate drive cam 70, follower 42, follower pin 41, top plate driving cover 68, top plate drive shaft 64, bush bearing 56 and 67, top plate 11, top plate tmsh bearing 62 and 66 washer 61, bottom plate 9, removal shoes 10 and storing area 55. The top plate 11 is fixed to the structure 54, inside the holding bushes as shown in figure by means of bushes 62 and 64. The top plate 11 is mounted on top plate drive shaft 64 by means of a pin. On top plate drive shaft 64, top plate drive lever is mounted by means of a pin. Follower pin is fixed on the top plate drive lever by means of a nut. Top plate drive cam is mounted on the top plate drive shaft by means of a nut. Removal shoes 10 are fixed at the bottom of top plate. When the drive is given to the main drive shaft, the top plate dirve cam is rotated. By means of the follower rotational motion is converted into linear motion. Follower pin pushes the drive lever in to and fro motion. As the top plate driving lever is fixed to the main drive shaft, it rotates the top plate side ways. When the top plate moves the removal shoes 10, moves just above the bottom plate without scrapping the surface, but removing the baked product. Removed product is stored in storing area SS. WE CLAIM: 1. An automatic chappathi making machine comprising a frame member housing a dough processing means consisting of a drivable piston movable within a dough container, said container having an opening and a at its base, a cutting means for cutting predetermined quantity of dough ejected from said container, a dough processing means consisting of a drivable cam assembly slidably disposed in a cruder housing, a drivable bottom plate member and a rotatly drivable top plate member, said top and bottom plate members being provided with heating means and a micro processor based control means for controlling the drives and the temperatures of said top and bottom plates. 2. The machine as claimed in claim 1, wherein said top and bottom plates are provided with thermostate controls. 3. The machine as claimed in claims 1 and 2, wherein said top plate is mounted on a drive shaft and is provided with stopper means. 4. The machine as claimed in claims 1 to 3, wherein said bottom plate is mounted on a cam sliding cylinder to provide upward and downward movement. 5. The machine as claimed in claim 4, wherein said bottom plate is provided with a limit switch mounted on a grooved cam, 6. The machine as claimed in claims 1-5, wherein said dough cutting means consists of a cutting wire assembly mounted on the said top plate. 7. The machine as claimed in claim 6, wherein said cutting wire assembly has a cutting wire held by cutting wire holder and a pin. 8. The machine as claimed in any of the preceding claims 1-7, wherein the sources of said top and bottom plates are provided with plurality of profiles. 9. The machine as claimed in any of the preceding claims 1-8, wherein said top plate is convex and the bottom plate is concave in nature. 10. The machine as claimed in any of the preceding claims, wherein said top plate is provided with return stroke stopping means consisting of a pawl and ratchet arrangement which engages a pinion in one direction and disinfest therefrom in the opposite direction. 11. An automatic chappathi making machine substantially as herein described with particular reference to the accompanying drawings.

Documents:

781-mas-2000 abstract-duplicate.pdf

781-mas-2000 abstract.pdf

781-mas-2000 claims-duplicate.pdf

781-mas-2000 claims.pdf

781-mas-2000 correspondence-others.pdf

781-mas-2000 correspondence-po.pdf

781-mas-2000 description (complete)-duplicate.pdf

781-mas-2000 description (complete).pdf

781-mas-2000 drawings.pdf

781-mas-2000 form-1.pdf

781-mas-2000 form-19.pdf

781-mas-2000 form-26.pdf

781-mas-2000 form-3.pdf