Description:FIELD OF THE INVENTION

[0001] The present invention relates to a corn cob processing system that efficiently peels and removes husks from corn cobs with reduced manual labor while enhancing the hygiene and quality of the finished product.

BACKGROUND OF THE INVENTION

[0002] Corn is one of the most widely cultivated crops globally, producing a substantial amount of biomass, including the valuable kernels and the often-underutilized corn cobs. Corn cob processing is essential to efficiently extract and prepare the kernels for various applications, such as food products, snacks, and industrial uses. The need for effective processing arises from the necessity to remove husks, peels, and other impurities that affects the quality, safety, and appearance of the kernels. Proper processing ensures that the kernels are clean, uniform, and ready for further treatments like roasting or grinding. This not only improves the overall product quality but also enhances consumer acceptability. With the rising demand for healthy and natural food products, processed corn kernels have gained popularity.

[0003] Traditional methods of processing corn cobs to extract kernels typically involve manual husking and peeling, followed by hand-picking or simple mechanical tools to separate the kernels. Farmers often use hand tools or rudimentary machines, which are labor-intensive and time-consuming. These methods result in inconsistent quality due to uneven removal of husks and peels, leading to contamination and spoilage. Additionally, manual handling increases the risk of damage to the kernels, reducing their market value. Traditional techniques also lack efficiency and cannot meet the demands of large-scale production, causing delays and higher production costs. Moreover, improper disposal or burning of the leftover cobs causes environmental pollution. Overall, these traditional practices are inefficient, labor-heavy, and environmentally unfriendly.

[0004] US4053112A relates to a method and apparatus for processing shelled corn cobs. The cobs are graded, aspirated, and crushed for reducing the length of the cobs to between 1/2 inch and 3 inches. A second aspirator removes any remaining husks and hammer mills reduce the corn cobs into 3/8 inch to 1/2-inch pieces. The pieces are graded and oversized pieces are returned to a hammer mill while the remaining pieces are dried in a drier to reduce their moisture content. After grading, a portion of the pieces are sent through an attrition mill to further reduce the size of the pieces. After aspirating, the pieces are processed through roller mills to further reduce the size of the pieces and then passed through an attrition mill and graded into final product sizes.

[0005] CN210210538U relates to the technical field of corn cob processing. The utility model further discloses corn cob processing equipment. Included is a first support frame, the right side of the fixed rod is movably connected with a first pressing wheel; a first connecting saw blade and a second connecting saw blade are sequentially installed at the upper end of the right side of the second supporting frame. And a first vertical brush is connected to the upper surface of the left side of the second supporting frame, a first transverse brush and a second transverse brush are movably installed on the left side of the upper end of the second supporting frame, a third connecting saw blade and a second pressing wheel are connected to the inner wall of the front end of the second supporting frame, and an equant backup plate and an equant tray are installed on the left side of the second supporting frame. Corn cob processing equipment, according to the corn cob processing equipment, the transmission speed of corn is greatly increased through the arrangement of the transmission gear, the design of multiple small parts helps normal operation of the equipment, 15000 green corn cobs can be processed per hour after the corn cob processing equipment is adopted, the efficiency can be improved by more than 10 times compared with the manual efficiency, and 20 operators can be saved.

[0006] Conventionally, many systems are available in the market that helps the user in processing of corn cobs. However, these existing systems mentioned in the prior arts lack in peeling the corn cobs with reduced manual labor and improved processing speed. In addition, these existing systems also fail in removing husk from the translating cobs, while enhancing the hygiene and quality of the finished product.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a system that requires to be capable of of detecting a quality of the corn cobs, thereby improving the overall product consistency and reducing waste. In addition, the developed system also needs to be capable of roasting the peeled cobs thereby enhancing the flavour, texture, and shelf life of the corn cobs, making them ready for consumption or further use.

OBJECTS OF THE INVENTION

[0008] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0009] An object of the present invention is to develop a system that is capable of peeling the corn cobs with reduced manual labor and improved processing speed.

[0010] Another object of the present invention is to develop a system that is capable of removing husk from the cobs in order to enhance and maintain the hygiene and quality of the finished product.

[0011] Another object of the present invention is to develop a system that is capable of detecting quality of the corn cobs in view of improving overall product consistency.

[0012] Yet, another object of the present invention is to develop a system that is capable of roasting the peeled cobs, for enhancing the flavor, texture, and shelf life of the corn cobs, making them ready for consumption or further use.

[0013] The foregoing and other objects, features, and advantages of the present invention will become readily apparent upon further review of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings.

SUMMARY OF THE INVENTION

[0014] The present invention relates to a corn cob processing system that is capable of removing husk from the cobs in order to enhance and maintain the hygiene and quality of the finished product.

[0015] According to an embodiment of the present invention, a corn cob processing system, comprising an enclosure configured with a conveyor for feeding of corn cobs, a pair of flaps provided within the enclosure by means of motorised hinges for feeding of singular corn cobs, a first optical sensor embedded in the enclosure to detect a plurality of corn cobs to enable actuation of the hinges to facilitate passage of one corn cob at an instance, a peeling unit disposed along the conveyor belt comprises a housing, one or more clamps installed in the housing by means of sliders for securing the corn cob, a plurality of rollers with abrasive surfaces to remove husk from the translating cobs and an air blower mounted with the peeling unit for removal of removed husks from the corn cobs, a second optical sensor is embedded in the housing detecting partial removal of peel to actuate the sliders to translate the cob backwards for a second pass via the rollers, a compartment configured with a sensing unit to detect a quality of the corn cobs and flag corn cobs, the sensing unit comprises an imaging unit integrated with a processor and a spectral sensor to perform spectroscopy, a motorised gate connected with the compartment into which flagged cobs are discarded by means of a pusher attached within the compartment, a roasting unit installed along the conveyor comprises a receptacle with a plurality of heating elements arranged within the receptacle to heat the cob, and an articulated extendable clipper to grip and rotate the cob for an uniform heating.

[0016] According to another embodiment of the present invention, the system further comprises of a RGB (red, green, blue) sensor embedded in the receptacle to detect a colour of the cob to accordingly enable regulation of the heating element and the clipper to uniformly heat the cob to a predetermined temperature, a third optical sensor is installed in the compartment to detect a corn cob stuck in the gate to cause a speaker installed on compartment to generate an audio alert regarding required maintenance, a plurality of chambers is disposed within the compartment for storage of corn cobs in accordance with the determined quality, an articulated telescopic gripper is incorporated within the compartment to store the cobs in the chambers, a storage recess adjacent to the roasting unit to receive the roasted cob, a shelling unit positioned adjacent to the recess comprises a tank, a pair of holders to grip the cob, a curved member having abrasive elements mounted within the tank by means of a circular slider to separate the kernels by friction, and a motorised panel provided at a bottom portion of the tank to dispense the kernel into a tray positioned underneath the tank, a conveying belt is provided to convey the cobs from the recess to the shelling unit and a battery is associated with the system for supplying power to electrical and electronically operated components associated with the system.

[0017] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 illustrates an isometric view of corn cob processing system.

DETAILED DESCRIPTION OF THE INVENTION

[0019] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0020] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0021] As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0022] The present invention relates to a corn cob processing system that is capable of detecting the quality of corn cobs and roasts the peeled cobs, thereby improving product consistency, reducing waste, and enhancing flavor, texture, and shelf life for consumption or further use.

[0023] Referring to Figure 1, a corn cob processing system is illustrated, comprises of an enclosure 101 configured with a conveyor belt 102, a pair of flaps 103 provided within the enclosure, a peeling unit 104 disposed along the conveyor belt 102, the peeling unit 104 comprises a housing 104a, one or more clamps 104b installed in the housing 104a by means of sliders 104c for securing the corn cob, a plurality of rollers 104d and an air blower 104e mounted with the peeling unit 104, a compartment 105 provided along the conveyor, a motorised gate 106 connected with the compartment 105, a pusher 107 attached within the compartment 105, a speaker 108 installed on compartment 105, a plurality of chambers 109 disposed within the compartment 105, an articulated telescopic gripper 110 incorporated within the compartment 105.

[0024] Figure 1 further illustrates a roasting unit 111 installed along the conveyor, the roasting unit 111 comprises a receptacle 111a with a plurality of heating elements 111b arranged within the receptacle 111a, an articulated extendable clipper 111c, a storage recess 112 adjacent to the roasting unit 111, a shelling unit 113 positioned adjacent to the recess 112, the shelling unit 113 comprises a tank 113a, a pair of holders 113b, a curved member 113c mounted within the tank 113a, a motorised panel 113d provided at a bottom portion of the tank 113a, an extending ejector 113e, a conveying belt 114, a bin 115 adjacent to the tank 113a and a touch enabled display panel 116.

[0025] The system discloses herein includes an enclosure 101 configured with a conveyer for feeding of corn cobs. This enclosure ensures a controlled environment, safeguarding from external contaminants such as dust and moisture, while also enhancing operator safety by enclosing moving parts. The conveyor is configured to handle multiple cobs at a time, maintaining a steady and consistent flow to improve processing efficiency. The conveyor is made from food-grade materials such as PVC, polyurethane, or plastic modular belts, which are safe for handling agricultural products and easy to clean. The conveyor frame and rollers are constructed from stainless steel to withstand wear and facilitate maintenance.

[0026] A user is required to activate the system manually by pressing a button installed on the enclosure 101 and linked with an inbuilt control unit associated with the system. The button is a type of switch that is internally connected with the system via multiple circuits that upon pressing by the user, the circuits get closed and starts conduction of electricity that tends to activate the system and vice versa.

[0027] Upon activation of the system, the control unit activates an inbuilt communication module for establishing a wireless connection between the
control unit and a computing unit that is inbuilt with a user-interface and accessed by the user for enabling the user to give input commands for processing the corn. The user interacts with the interface through a touch screen, keyboard, or other input methods available on the computing unit. The computing unit mentioned herein includes, but not limited to smartphone, laptop, tablet.

[0028] The communication module mentioned herein includes, but not limited to Wi-Fi (Wireless Fidelity) module, Bluetooth module, GSM (Global System for Mobile Communication) module. The communication module used in the system is preferably the Wi-Fi module. The Wi-Fi module enable wireless communication by transmitting and receiving data over radio frequencies using IEEE 802.11 protocols. It connects to a network via an access point, converting digital data into radio signals. The module processes TCP/IP protocols for data exchange, interfaces with control unit through UART/SPI, and ensures encrypted communication using WPA/WPA2 security standards for secure and efficient wireless connectivity.

[0029] Further, a touch enabled display panel 116 is provided to enable inputting parameters for processing the corn. The display panel 116 allows the user to input parameters for processing the corn. The touch interactive display panel 116 as mentioned herein is typically an (Liquid Crystal Display) screen that presents output in a visible form.

[0030] The screen is equipped with touch-sensitive technology, allowing the user to interact directly with the display using their fingers. A touch controller IC (Integrated Circuit) is responsible for processing the analog signals generated when the user inputs details regarding parameters for processing the corn. The touch controller is typically connected to an inbuilt control unit linked with the panel through various interfaces which include but are not limited to SPI (Serial Peripheral Interface) or I2C (Inter-Integrated Circuit). The control unit processes user commands and actuates the required components for processing the corn.

[0031] A pair of flaps 103 provided within the enclosure by means of motorised hinges to facilitate feeding of singular corn cobs. The hinges contain small electric motors that provide controlled rotational movement, enabling the flaps 103 to swing smoothly. When the feeding process begins, the motorized hinges rotate the flaps 103 outward to create a gap for a single corn cob to pass through. After the cob moves forward, the hinges rotate the flaps 103 back to their closed position, effectively blocking additional cobs from entering simultaneously. This coordinated movement of the flaps 103 and hinges ensures precise control of the feeding process, allowing corn cobs to be fed one at a time without jamming or overlap.

[0032] Additionally, a first optical sensor embedded in the enclosure to detect a plurality of corn cobs being fed via the conveyor belt 102 to enable actuation of the hinges to facilitate passage of one corn cob at an instance. The optical sensor works by emitting a beam of light, typically infrared, across the conveyor path where the corn cobs pass through. When one or more corn cobs interrupt this light beam, the sensor detects the change in the light intensity and sends a signal to a control unit.

[0033] Specifically, the sensor distinguishes between a single cob and a plurality of cobs based on the duration and intensity of the interruption multiple cobs cause a longer or stronger interruption of the beam compared to just one. When the sensor detects multiple corn cobs, it triggers the motorized hinges controlling the flaps 103 to open, allowing only one cob to pass through at a time. After one cob passes, the flaps 103 close to block the rest, and the sensor continues monitoring the flow.

[0034] For peeling the fed corn cobs, a peeling unit 104 is disposed along the conveyor belt 102. The peeling unit 104 comprises a housing 104a, one or more clamps 104b installed in the housing 104a by means of sliders 104c for securing the corn cob. The housing 104a is made from robust materials like stainless steel or mild steel to ensure durability and resistance to wear. When activated, the clamps 104b move inward, closing around the cob. This movement is typically controlled by a pneumatic clamping arrangement; compressed air is used to control the opening and closing of the clamps 104b that secure the corn cob during peeling.

[0035] When the control unit receives a signal to clamp, compressed air is directed into a pneumatic cylinder connected to the clamp arrangement. The air pressure pushes the piston inside the cylinder, which in turn moves a linkage or directly actuates the clamp jaws to close around the corn cob. The jaws are typically lined with rubber or a textured material to ensure a firm grip without damaging the cob. The amount of air pressure controls the clamping force, allowing the clamps 104b to hold the cob securely but gently. Once the peeling process is complete, the compressed air is released or redirected to the opposite side of the piston, causing the jaws to open and release the corn cob.

[0036] The sliders 104c, mounted on rails or guideways within the housing 104a, facilitate smooth and controlled movement of the clamps 104b towards or away from the corn cob. These sliders 104c are often equipped with bearings or low-friction materials to reduce resistance and enable easy adjustment of the clamp position, ensuring that the corn cob is firmly secured regardless of its size. This arrangement ensures controlled linear movement of the clamps 104b either toward or away from the corn cob. The sliders 104c incorporate ball bearings or roller bearings to facilitate smooth motion and reduce wear. When the clamping arrangement is actuated often by pneumatic or electric actuators the sliders 104c enable the clamps 104b to glide accurately into position, securely gripping the cob without jerky or uneven movements.

[0037] To remove husk from the translating cobs, a plurality of rollers 104d with abrasive surfaces is embedded within the housing 104a. The rollers 104d are made from durable materials such as steel or heavy-duty plastic, with the outer surface coated or embedded with abrasive materials like sandpaper grit, rubber with embedded abrasive particles, or specialized abrasive coatings. The rollers 104d are mounted on shafts and positioned so that the corn cobs pass between them, allowing the abrasive surfaces to come into direct contact with the husk. As the rollers 104d rotate driven by electric motors they create friction against the cob’s surface, effectively loosening and scraping away the outer husk layers. The abrasive texture is selected to remove the husk without damaging the underlying corn cob. The continuous rotation and pressure exerted by these abrasive rollers 104d enable efficient, uniform husk removal as the corn cobs move along the peeling unit 104.

[0038] Additionally, a second optical sensor is embedded within the housing 104a to detect partial peel removal and to trigger the sliders 104c to move the cob backward for a second pass through the rollers 104d. The second optical sensor mentioned here works in the similar manner to first optical sensor as discussed above.

[0039] Further, an air blower 104e mounted with the peeling unit 104 for removal of removed husks from the corn cobs. The air blower 104e consists of a high-speed centrifugal or axial fan powered by an electric motor, which generates a strong, focused stream of air directed toward the corn cobs and surrounding area. As the corn cobs pass through the peeling unit 104, loose husk pieces are blown away by the forceful airflow, preventing accumulation. The blower 104e airflow is adjusted to provide the optimal balance between effective husk removal and avoiding damage to the cobs. Additionally, the air blower 104e helps maintain cleanliness inside the peeling unit 104, improving overall hygiene and reducing maintenance requirements.

[0040] A compartment 105 provided along the conveyor, with a sensing unit configured in the compartment 105, to detect a quality of the corn cobs and flag corn cobs with quality below a threshold quality. The quality is determined in accordance with the number of defective kernels in a cob. The compartment 105 provided is constructed from durable and non-corrosive materials such as stainless steel or high-grade aluminium to ensure structural integrity and long-term reliability. Transparent inspection windows made of tempered glass or polycarbonate is included for maintenance access or observation, without disrupting the process. The compartment 105 is designed to house the sensing unit in a clean, vibration-free, and light-controlled environment, enabling it to accurately scan each corn cob for quality assessment. By isolating the sensing unit from external environmental factors such as dust, variable lighting, and mechanical vibrations, the compartment 105 ensures precise detection of defective kernels.

[0041] The sensing unit comprises an imaging unit integrated with a processor and a spectral sensor to perform spectroscopy. The imaging unit consists of a high-resolution camera or sensor array that captures detailed images of each corn cob as it passes through the compartment 105. This visual data helps identify visible defects such as missing or discoloured kernels. Working in conjunction with the imaging unit, the spectral sensor performs spectroscopy analysing the reflected light from the surface of the corn cob across multiple wavelengths, including visible and near-infrared spectra. This spectral data allows the control unit to detect subsurface issues or subtle variations in kernel composition, color, or moisture content that is not visible to the naked eye. The processor compares the results against pre-set quality thresholds. If the cob is found to have a number of defective kernels exceeding the acceptable limit, it is automatically flagged for rejection.

[0042] Additionally, a motorised gate 106 connected with the compartment 105 into which flagged cobs are discarded by means of a pusher 107 attached within the compartment 105. The pusher 107 comprises a pneumatic or electric actuator attached to a horizontal arm or plate. When a defective cob is detected, the control unit sends a signal to the pusher 107 actuator, which then extends the arm swiftly to push the flagged cob off the main conveyor path. This action directs the cob toward a separate discard area. At this point, the control unit signals the motorized gate 106 to automatically opens to discard the rejected cob. The motorized gate 106 consists of a hinged or sliding panel controlled by a compact electric or pneumatic motor. Once the cob passes through, the gate 106 closes to contain the discarded item.

[0043] Further, a third optical sensor installed in the compartment 105 detects a corn cob stuck in the gate 106 to cause a speaker 108 installed on compartment 105 to generate an audio alert regarding required maintenance. The third optical sensor mentioned here works in the similar manner to first optical sensor as discussed above.

[0044] The speaker 108 consists of audio information, which is in the form of recorded voice, synthesized voice, or other sounds, generated or stored as digital data. The digital audio data is converted into analog electrical signals. Further the analog signal is amplified by an amplifier and the amplified electrical audio signal is then sent to a diaphragm, which is typically made of a lightweight and rigid material like paper, plastic, or metal, and is designed to vibrate or move back and forth when electrical signals are fed to it. This movement creates pressure variations in the surrounding air, generating sound waves in order to generate the audio alert regarding required maintenance.

[0045] For storage of corn cobs in accordance with the determined quality, a plurality of chambers 109 disposed within the compartment 105. The chambers 109 are constructed from durable, food-grade materials such as stainless steel or high-quality plastic like polyethylene or polypropylene. These materials are chosen for their corrosion resistance, ease of cleaning, and compliance with food safety standards. Each chamber acts as a separate storage bin 115 designed to hold cobs sorted based on their quality classification.

[0046] To store the cobs in the chambers 109 in a segregated manner, an articulated telescopic gripper 110 incorporated within the compartment 105. The telescopic gripper 110 is powered by a pneumatic unit that includes an air compressor, air cylinder, air valves and piston which works in collaboration to aid in extension and retraction of the gripper 110. The pneumatic unit is operated by the control unit, such that the control unit actuates valve to allow passage of compressed air from the compressor within the cylinder, the compressed air further develops pressure against the piston and results in pushing and extending the piston. The piston is connected with the gripper 110 and due to applied pressure the gripper 110 extends and similarly, the control unit retracts the gripper 110 by closing the valve resulting in retraction of the piston. Thus, the control unit regulates the extension/retraction of the gripper 110 to hold the cobs for storing in the chambers 109. The gripping end is equipped with specially designed fingers or pads made from soft, food-grade materials such as silicone or rubber to securely hold the corn cob without causing damage.

[0047] For roasting the cobs, a roasting unit 111 installed along the conveyor. The roasting unit 111 comprises a receptacle 111a with a plurality of heating elements 111b arranged within the receptacle 111a to heat the cob, and an articulated extendable clipper 111c to grip and rotate the cob for a uniform heating. The heating element made from heat-resistant materials such as stainless steel or cast aluminium, the receptacle 111a provides a durable and safe environment capable of withstanding high temperatures. Its design ensures efficient retention and distribution of heat generated by the plurality of heating elements 111b arranged within it.

[0048] These heating elements 111b are made from high-resistance alloys, which efficiently convert electrical energy into heat when an electric current passes through them. The elements are strategically positioned inside the receptacle 111a to provide uniform heat distribution around the corn cob. When powered, the heating elements 111b radiate heat, warming the air inside the receptacle 111a and directly heating the surface of the corn cobs. The temperature and power supplied to the elements are precisely controlled through a thermostat or electronic controller to maintain the desired roasting temperature, preventing overheating or burning. This controlled heating ensures that the corn cobs are roasted evenly, enhancing flavour and texture.

[0049] The heating element in the roasting unit 111 is regulated by a Proportional–Integral–Derivative (PID) control protocol integrated within a control unit to maintain precise temperature control. The PID controller continuously monitors the actual temperature inside the receptacle 111a through sensors, comparing it with the desired set point temperature. The “Proportional” component responds to the current temperature error—the difference between the set point and the measured temperature—by adjusting the heating power proportionally to reduce this error. The “Integral” component considers the accumulation of past errors over time, helping to eliminate any persistent offset by gradually correcting the temperature to the set point. The “Derivative” component predicts future errors based on the rate of change of the temperature, providing a damping effect that prevents overshooting and improves stability. By combining these three components, the PID controller provides smooth and accurate regulation of the heating element’s power output, ensuring the temperature inside the roasting unit 111 remains stable and consistent. This precise control is critical for achieving uniform roasting of the corn cobs, preventing fluctuations that lead to undercooking or burning. The control unit processes these calculations in real time and adjusts the heating element accordingly, optimizing energy use and maintaining product quality throughout the roasting process.

[0050] The articulated extendable clipper 111c comprises multiple jointed segments (articulations) connected by pivot points, allowing the clipper 111c to extend, retract, and maneuver with flexibility in multiple directions. The extendable feature enables the clipper 111c to reach into the receptacle 111a, firmly grasp the cob, and then retract or adjust its position as needed during the roasting process. The gripping ends of the clipper 111c are equipped with padded or rubberized jaws that conform to the shape of the corn cob, providing a secure hold without causing damage. The entire arrangement is driven by electric motors or pneumatic actuators that control the extension, articulation, and rotation movements. During operation, the clipper 111c grips the cob and slowly rotates it along its longitudinal axis, ensuring that all sides of the cob are evenly exposed to the heat generated by the heating elements 111b.

[0051] Further, an RGB (red, green, blue) sensor embedded in the receptacle 111a to detect a colour of the cob to accordingly enable regulation of the heating element and the clipper 111c to uniformly heat the cob to a predetermined temperature. The sensor operates by emitting light onto the surface of the cob and measuring the intensity of reflected light in the red, green, and blue wavelengths. By analysing the combination of these three primary colors, the sensor accurately determines the current color of the cob, which correlates with its roasting stage. The sensor continuously sends this color data to the control unit, which uses it to assess whether the cob has reached the desired roast level.

[0052] Based on the detected color, the control unit dynamically adjusts the power supplied to the heating elements 111b and controls the rotation speed of the articulated extendable clipper 111c. If the sensor detects that the cob is not yet uniformly roasted or has not reached the target color indicative of the predetermined temperature, the heating elements 111b continue to operate, and the clipper 111c maintains or adjusts the rotation to ensure even exposure. Conversely, when the desired color is achieved, the control unit reduces or stops heating, preventing over-roasting.

[0053] Additionally, a storage recess 112 positioned adjacent to the roasting unit 111 to receive and temporarily hold the roasted corn cob immediately after the roasting process. The storage recess 112 constructed from heat-resistant and food-grade materials such as stainless steel or durable plastic, the recess 112 ensures safety and hygiene while withstanding residual heat from the freshly roasted cob. Its ergonomic design facilitates easy placement and retrieval of the cob, minimizing handling time and potential damage. The articulated extendable clipper 111c, after completing the uniform roasting and rotation of the cob, precisely maneuvers and deposits the roasted cob into this recess 112 by rotating it towards the storage area.

[0054] Further, a conveying belt 114 is provided to convey the cobs from the recess 112 to a shelling unit 113. The conveying belt 114 is made of food-grade, heat-resistant materials such as polyurethane (PU) or PVC, ensuring durability, hygiene, and compliance with food safety standards. The surface of the belt is textured or feature guide rails to prevent the cob from rolling or slipping during transport. The speed of the conveyor is adjusted to synchronize with the operating cycle of the shelling unit 113, ensuring a steady and uninterrupted flow.

[0055] To separate kernels from the cob, the shelling unit 113 positioned adjacent to the recess 112. The shelling unit 113 comprises a tank 113a, a pair of holders 113b to grip the cob. The tank 113a is constructed from stainless steel or another food-grade, corrosion-resistant material to ensure durability and hygienic processing. Inside the tank 113a, the pair of holders 113b is mounted to grip the corn cob firmly during the shelling process. These holders 113b are often equipped with textured or rubber-coated gripping surfaces to securely hold the cob without causing damage. When the cob is fed into the unit via the conveyor, the holders 113b engage from opposite sides, aligning and clamping the cob in place.

[0056] Once secured, a curved member 113c having abrasive elements mounted within the tank 113a by means of a circular slider to separate the kernels by friction. The curved member 113c surface is embedded with abrasive elements such as rough-textured rubber, sandpaper-like coatings, or grit-lined pads, specifically designed to create friction against the cob’s surface. As the cob is rotated or held in position, the curved member 113c moves along or around it, gently but effectively abrading the kernels away from the cob without crushing them.

[0057] The circular slider allows the member 113c to move in a controlled, circular path around the cob. This circular slider is driven by a motor or actuator, enabling smooth, continuous motion and ensuring even exposure of the entire cob surface to the abrasive elements. The slider’s design allows precise positioning and pressure control, which helps in maximizing kernel separation efficiency while minimizing damage to the kernels. This combination of friction-based abrasion and circular motion ensures thorough and uniform shelling, making the process both efficient and mechanically reliable.

[0058] Further, a motorised panel 113d provided at a bottom portion of the tank 113a to dispense the kernel into a tray positioned underneath the tank 113a. The panel acts as an outlet, allowing the processed kernels to be efficiently released from the tank 113a into the tray positioned directly beneath it. The panel 113d is made from stainless steel or food-grade plastic, the panel is typically hinged or sliding in design and is operated by a compact electric or pneumatic motor connected to the control unit.

[0059] Once the kernel separation process is complete, the motorized panel receives a signal to open, allowing the accumulated kernels to drop down into the tray. The tray is designed to catch and hold the kernels in an organized manner for further handling, inspection, or packaging. The motorized panel ensures precise control over the timing and quantity of kernel discharge, reducing spillage and maintaining hygiene.

[0060] A fourth optical sensor embedded in the tank 113a detect an empty corn cob to enable an actuation of an extending ejector 113e to push the empty cob into a bin 115 adjacent to the tank 113a. The fourth optical sensor mentioned here works in the similar manner to first optical sensor as discussed above.

[0061] The ejector 113e in the shelling unit 113 designed to automatically remove empty corn cobs from the tank 113a once the shelling process is complete. The ejector 113e typically consists of a linear actuator or a pneumatic cylinder connected to a pushing arm or rod, which is aligned with the position of the corn cob held by the gripping holders 113b.

[0062] When the fourth optical sensor detects that the cob has been fully shelled, it sends a signal to the control unit, which in turn activates the ejector 113e. Upon activation, the actuator extends the pushing arm forward in a straight line, applying controlled force to the cob. This motion dislodges the cob from the holders 113b and pushes it toward a discharge bin 115 positioned adjacent to the tank 113a. The ejector 113e movement is precise and gentle enough to avoid damage to the equipment or cause splintering of the cob, yet strong enough to ensure complete ejection.

[0063] Lastly, a battery is installed within the system which is connected to the control unit that supplies current to all the electrically powered components that needs an amount of electric power to perform their functions and operation in an efficient manner. The battery utilized here, is preferably a dry battery which is made up of Lithium-ion material that gives the system a long-lasting as well as an efficient DC (Direct Current) current which helps every component to function properly in an efficient manner. As the system is battery operated and do not need any electrical voltage for functioning. Hence the presence of battery leads to the portability of the system i.e., user is able to place as well as moves the system from one place to another as per the requirements.

[0064] The present invention works best in the following manner, where the enclosure with the conveyor to feed multiple cobs consistently. The motorized hinges with flaps 103 and the first optical sensor ensure single cob feeding. The control unit activates the Wi-Fi-based communication module for wireless interaction with the computing unit through the touch-enabled display panel 116 with the touch controller IC. Inside the enclosure, the peeling unit 104 clamps 104b each cob using the pneumatic clamping arrangement on sliders 104c with ball bearings, and abrasive rollers 104d driven by electric motors remove the husk. The second optical sensor ensures complete peeling, and the air blower 104e removes loosened husk. The quality of each cob is assessed in the compartment 105 by the imaging unit and spectral sensor, and defective cobs are discarded using the pusher 107 and motorized gate 106. The third optical sensor and speaker 108 provide alerts for blockages. The cobs are stored in chambers 109 using the telescopic gripper 110. The roasting is performed in the roasting unit 111 with heating elements 111b assisted by the RGB sensor and articulated extendable clipper 111c. The roasted cob is transferred to the shelling unit 113 where abrasive curved member 113c on the circular slider separate kernels, which are dispensed through the motorized panel into the tray. The fourth optical sensor triggers the ejector 113e to push the empty cob into the bin 115.

[0065] Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. , Claims:1) A corn cob processing system, comprising:

i) an enclosure 101 configured with a conveyor for feeding of corn cobs;
ii) a pair of flaps 103 provided within the enclosure by means of motorised hinges to facilitate feeding of singular corn cobs;
iii) a peeling unit 104 disposed along the conveyor belt 102 to peel the fed corn cobs;
iv) a compartment 105 provided along the conveyor, with a sensing unit configured in the compartment 105, to detect a quality of the corn cobs and flag corn cobs with quality below a threshold quality, wherein the quality is determined in accordance with the number of defective kernels in a cob;
v) a motorised gate 106 connected with the compartment 105 into which flagged cobs are discarded by means of a pusher 107 attached within the compartment 105;
vi) a roasting unit 111 installed along the conveyor to roast the peeled cobs;
vii) a storage recess 112 adjacent to the roasting unit 111 to receive the roasted cob, wherein the clipper 111c rotates the roasted cob towards the recess 112; and
viii) a shelling unit 113 positioned adjacent to the recess 112, to separate kernels from the cob.

2) The system as claimed in claim 1, wherein a first optical sensor embedded in the enclosure to detect a plurality of corn cobs being fed via the conveyor belt 102 to enable actuation of the hinges to facilitate passage of one corn cob at an instance.

3) The system as claimed in claim 1, wherein the peeling unit 104 comprises a housing 104a, one or more clamps 104b installed in the housing 104a by means of sliders 104c for securing the corn cob, a plurality of rollers 104d with abrasive surfaces to remove husk from the translating cobs and an air blower 104e mounted with the peeling unit 104 for removal of removed husks from the corn cobs.

4) The system as claimed in claim 1, wherein a second optical sensor is embedded in the housing 104a, detect as a partial removal of peel to actuated the sliders 104c to translate the cob backwards for a second pass via the rollers 104d.

5) The system as claimed in claim 1, wherein the sensing unit comprises an imaging unit integrated with a processor and a spectral sensor to perform spectroscopy.

6) The system as claimed in claim 1, wherein a third optical sensor is installed in the compartment 105 detects a corn cob stuck in the gate 106 to cause a speaker 108 installed on compartment 105 to generate an audio alert regarding required maintenance.

7) The system as claimed in claim 1, wherein a plurality of chambers 109 is disposed within the compartment 105 for storage of corn cobs in accordance with the determined quality, wherein an articulated telescopic gripper 110 is incorporated within the compartment 105 to store the cobs in the chambers 109 in a segregated manner.

8) The system as claimed in claim 1, wherein the roasting unit 111 comprises a receptacle 111a with a plurality of heating elements 111b arranged within the receptacle 111a to heat the cob, and an articulated extendable clipper 111c to grip and rotate the cob for a uniform heating.

9) The system as claimed in claim 1, wherein an RGB (red, green, blue) sensor embedded in the receptacle 111a to detect a colour of the cob to accordingly enable regulation of the heating element and the clipper 111c to uniformly heat the cob to a predetermined temperature, wherein the heating element is regulated based on a Proportional–integral–derivative protocol configured with a control unit.

10) The system as claimed in claim 1, wherein the shelling unit 113 comprises a tank 113a, a pair of holders 113b to grip the cob, a curved member 113c having abrasive elements mounted within the tank 113a by means of a circular slider to separate the kernels by friction, and a motorised panel 113d provided at a bottom portion of the tank 113a to dispense the kernel into a tray positioned underneath the tank 113a, wherein a conveying belt 114 is provided to convey the cobs from the recess 112 to the shelling unit 113.