A copper gong burn integrated forming equipment and production process thereof

Abstract

The present application relates to the forming conveying technical field of food, and provides a copper bell burn integrated forming equipment and a production process thereof, which solves the technical problem of easy overflow of subsequent stuffing and poor taste caused by natural uplift of the top of the crust in the traditional copper bell burn baking process. The present application comprises a conveyor belt and a plurality of baking plates on the conveyor belt, a plurality of grooves for accommodating the batter of the crust are arranged on the baking plates at intervals; each of the baking plates comprises a turnover plate, a fixed rod and an opening and closing rod; the two ends of the oven are respectively provided with an opening plate rail and a closing plate rail, when the free end of the opening and closing rod is inserted into the opening plate rail, the second long edge of the turnover plate is separated from the fixed rod, and when the free end of the opening and closing rod is inserted into the closing plate rail, the second long edge of the turnover plate is buckled with the fixed rod; different from the traditional copper bell burn forming conveying line, the baking plates with different structures are used for conveying in the forming of the copper bell burn crust, the shaping process of the crust is intervened, and the produced copper bell burn stuffing will not overflow and has good taste.

Description

Technical Field

[0001] This invention relates to the field of food forming and conveying technology, specifically to an integrated forming equipment for dorayaki and its production process. Background Technology

[0002] Dorayaki, a traditional baked confectionery, is widely popular for its soft texture and rich fillings. With increasing market demand, its production methods have gradually shifted from manual to automated. Existing automated dorayaki production equipment typically includes a batter-pouring machine, a separate baking line, and subsequent filling and packaging equipment.

[0003] In traditional baking equipment, the dough expands due to heat, and due to surface tension, its top naturally bulges upward, forming a distinct arc-shaped convex surface. This shape leads to uneven filling distribution during subsequent automated filling and sealing, causing the filling to easily overflow from the edges, limiting the consistency of the filling dough, and resulting in a poor texture. Summary of the Invention

[0004] Therefore, in view of the above problems, the present invention provides a one-piece molding equipment for dorayaki and its production process, which solves the technical problem in the traditional dorayaki baking process that the filling is easy to overflow and the taste is poor due to the natural bulging of the top of the pancake.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solution:

[0006] A one-piece molding machine for dorayaki includes:

[0007] The conveyor belt and the oven mounted on the conveyor belt, the conveyor belt comprising two spaced-apart conveyor chains, the conveyor belt being provided with a plurality of baking plates, the baking plates being provided with a plurality of grooves spaced apart for receiving pastry batter;

[0008] The oven is equipped with an air blowing assembly, which includes a number of air blowing pipes spaced apart. Each air blowing pipe has a number of air blowing heads spaced apart at its bottom, and each air blowing head is arranged corresponding to a groove.

[0009] Each of the baking plates includes a flip plate, a sliding hook, at least one elastic element, a fixing rod, and an opening and closing rod. The two ends of the first long side of the flip plate are rotatably connected to each of the conveyor chains. The sliding hook is slidably connected to the flip plate. One end of the elastic element is connected to the bottom of the flip plate, and the other end of the elastic element is connected to the sliding hook. The second long side of the flip plate is fastened to the fixing rod by the sliding hook. The opening and closing rod is provided at both ends of the second long side of the flip plate.

[0010] The oven is provided with an opening rail and a closing rail at both ends. When the free end of the opening and closing rod is inserted into the opening rail, the second long side of the flip plate is disengaged from the fixing rod. When the free end of the opening and closing rod is inserted into the closing rail, the second long side of the flip plate is engaged with the fixing rod.

[0011] It also includes a demolding component located at one end of the conveyor belt in the conveying direction. The demolding component includes two symmetrically arranged mounting plates, a demolding cylinder on the mounting plate, a mounting rod connected to the drive end of each demolding cylinder, a vibration generator spaced apart on the mounting rod, a support plate connected to both sides below the mounting rod, and a disc receiving conveyor belt located between each support plate.

[0012] Furthermore, the first long side of the flip plate is provided with limiting blocks at both ends to restrict the flipping angle.

[0013] Furthermore, a cleaning component is provided on the side of the plywood rail away from the oven. The cleaning component includes two spaced-apart cleaning rods, a sliding block slidably disposed on each of the cleaning rods, a cleaning cylinder connected to one side of the sliding block, and a cleaning block disposed at the drive end of the cleaning cylinder.

[0014] Furthermore, the air blowing assembly also includes a hot air collecting hood disposed inside the oven and a fan disposed on the top of the oven. One side of the fan is connected to the hot air collecting hood, and the other end of the fan is connected to each of the air blowing pipes.

[0015] Furthermore, the blowing pressure of each of the air blowing pipes increases with the conveying direction of the conveyor belt.

[0016] Furthermore, the snap-fit ​​end of the sliding hook is wedge-shaped, and the corresponding snap-fit ​​surface of the fixing rod is a matching inclined surface.

[0017] Furthermore, the sliding hook is elongated, and its length is the same as that of the baking plate.

[0018] Furthermore, the elastic element is a contraction spring or a wave-shaped spring sheet, which always provides a preload force to the sliding hook in the direction of the fixed rod.

[0019] Furthermore, each of the aforementioned support plates has a sloping surface at its top.

[0020] A dorayaki production process using the aforementioned one-piece dorayaki molding equipment includes the following steps:

[0021] S1. Injection: A measured amount of dough batter is injected into the grooves of each baking plate.

[0022] S2. Baking and shaping: Start the conveyor belt and intermittently transport the baking plate carrying the crust batter through the oven. During the set time of each pause of the conveyor belt, the air blowing component blows air into the batter in the groove of the baking plate below it, so that the batter forms a depression in the middle during the heating and shaping process.

[0023] S3. Opening and flipping: The baking plate that has completed baking and shaping continues to be conveyed by the conveyor belt. When the opening and closing rods at both ends of the plate are inserted into the opening rail, the sliding hook is disengaged from the fixing rod under the action of the opening rail, and the flipping plate flips with its first long side as the axis.

[0024] S4. Vibration demolding: When the flipping plate flips at the end of the conveyor belt until the groove opening faces downward, the demolding component is activated. The demolding cylinder pushes the mounting rod and vibration generator close to the flipping plate, so that the support plate supports the bottom of the flipping plate. At the same time, the vibration generator contacts the top of the flipping plate and is activated. Through high-frequency vibration, the bottom layer of dough is shaken from the groove onto the dough receiving conveyor belt.

[0025] S5. Reset: After demolding is completed, the demolding cylinder resets, causing the vibration generator and support plate to separate from the baking plate. The unloaded baking plate continues to run with the conveyor belt. When its opening and closing rod enters the plate rail, the flipping plate is locked back to the horizontal state.

[0026] Compared with the prior art, the beneficial effects of the present invention are:

[0027] 1. This invention differs from traditional dorayaki forming conveyor lines by using baking plates with different structures for conveying the dorayaki dough during the forming process. During the baking process, an air blowing component blows air onto the surface of the batter, interfering with the shaping process of the dough. This causes a depression to form in the middle of the formed dough, providing space for subsequent filling and ensuring stable placement of the filling. It also allows the use of more fluid filling batter, resulting in dorayaki fillings that do not overflow and have a better taste.

[0028] 2. This invention solves the problem of slow demolding of the crust caused by the groove by the synergistic effect of the vibration demolding component and the flip-over baking plate. When the baking plate is flipped 180°, the crust will naturally fall out of the groove under the action of inertial force under high frequency vibration, thus achieving fast and non-destructive demolding. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the structure of Embodiment 1 of the present invention;

[0030] Figure 2 This is a schematic diagram of the side structure of the flip plate according to Embodiment 1 of the present invention;

[0031] Figure 3 This is a schematic diagram of the top structure of the flip plate according to Embodiment 1 of the present invention;

[0032] Figure 4 This is a schematic diagram of the demolding component structure according to Embodiment 1 of the present invention;

[0033] Figure 5 This is a schematic diagram of the open-plate rail structure according to Embodiment 1 of the present invention;

[0034] Figure 6 This is a schematic diagram of the side structure of the cleaning component according to Embodiment 1 of the present invention;

[0035] Figure 7 This is a schematic diagram of the top structure of the cleaning component according to Embodiment 1 of the present invention.

[0036] Explanation of icon numbers:

[0037] Conveyor belt 1;

[0038] Oven 2;

[0039] Baking plate 3; groove 31; flip plate 32; first long side 321; second long side 322; sliding hook 33; elastic element 34; fixing rod 35; opening and closing rod 36; limiting block 37;

[0040] Air blowing assembly 4; air blowing pipe 41; air blowing head 42; hot air collection cover 43; fan 44;

[0041] 5-slab track; 51-slab opening section;

[0042] 6-piece slab track; 61-piece closed section;

[0043] Demolding component 7; mounting plate 71; demolding cylinder 72; mounting rod 73; vibration generator 74; support plate 75; disc receiving conveyor belt 76;

[0044] Cleaning component 8; cleaning rod 81; sliding block 82; cleaning cylinder 83; cleaning block 84; drive cylinder 85; rack 851; pinion 86; fixed plate 87; drive gear 88; driven gear 89. Detailed Implementation

[0045] The following will describe in detail the implementation of the present invention with reference to specific embodiments, so that the process of how the present invention uses technical means to solve technical problems and achieve technical effects can be fully understood and implemented accordingly.

[0046] Example 1: As Figures 1 to 7 As shown, a one-piece molding equipment for dorayaki includes: a conveyor belt 1 and an oven 2 disposed on the conveyor belt 1. The conveyor belt 1 includes two conveyor chains arranged at intervals. The oven 2 provides the heat source required for baking the dough. The conveyor belt 1 is provided with a plurality of baking plates 3. The baking plates 3 are provided with a plurality of grooves 31 at intervals for accommodating dough batter.

[0047] The preferred diameter of each groove 31 is 80-100mm, and the preferred depth is 1.5-2.5mm. In this embodiment, the diameter of each groove 31 is 100mm and the depth is 2.5mm.

[0048] The oven 2 is equipped with an air blowing assembly 4, which includes a plurality of spaced-apart air blowing pipes 41. Each air blowing pipe 41 has a plurality of spaced-apart air blowing heads 42 at its bottom, and each air blowing head 42 is provided corresponding to each of the grooves 31. The air blowing assembly 4 also includes a hot air collecting hood 43 located inside the oven 2 and a fan 44 located on the top of the oven 2. One side of the fan 44 is connected to the hot air collecting hood 43, and the other end of the fan 44 is connected to each of the air blowing pipes 41. This not only utilizes the waste heat of the oven 2 as an air source, ensuring the consistency of the air blowing temperature with the baking process and avoiding cold air interference with shaping, but also significantly reduces energy consumption.

[0049] Furthermore, each air blowing pipe 41 is equipped with an independent regulating valve to achieve an increase in air blowing pressure along the conveyor belt 1 conveying direction; the gradient pressure control can match the gradually increasing surface strength of the crust during the baking process, so that the crust depression shaping effect is uniform and controllable.

[0050] The air blowing assembly 4 is located in the front half of the oven 2. The number of air blowing pipes 41 is adjusted according to the length of the oven 2. The spacing between adjacent air blowing pipes 41 is consistent with the spacing between grooves 31 on adjacent baking plates 3.

[0051] Each of the baking plates 3 includes a flip plate 32, a sliding hook 33, four spaced elastic elements 34, a fixing rod 35, and an opening / closing rod 36. The two ends of the first long side 321 of the flip plate 32 are rotatably connected to each of the conveyor chains. The sliding hook 33 is slidably connected to the flip plate 32. One end of each of the elastic elements 34 is connected to the bottom of the flip plate 32, and the other end of each of the elastic elements 34 is connected to the sliding hook 33. The second long side 322 of the flip plate 32 is fastened to the fixing rod 35 by the sliding hook 33. The opening / closing rod 36 is located at both ends of the second long side 322 of the flip plate 32.

[0052] The snap-fit ​​end of the sliding hook 33 is wedge-shaped, and the corresponding snap-fit ​​surface of the fixing rod 35 is a matching inclined surface. The wedge-shaped inclined surface design makes the snap-fit ​​and disengagement of the sliding hook 33 and the fixing rod 35 smoother and more reliable, reducing mechanical impact and jamming.

[0053] The sliding hook 33 is elongated and its length is the same as that of the baking plate 3. The elongated sliding hook 33 can provide uniform locking force along the second long side 322 of the flip plate 32, ensuring that the flip plate 32 remains flat and stable during baking and conveying, and will not warp due to uneven force.

[0054] In this embodiment, the elastic element 34 is a contraction spring, which always provides a preload force to the sliding hook 33 in the direction of the fixed rod 35, ensuring that the sliding hook 33 always has a tendency to automatically lock in the non-unlocked state.

[0055] In other preferred embodiments, the elastic element 34 may also be a wave-shaped spring. Both the contraction spring and the wave-shaped spring are commercially available and will not be described in detail here.

[0056] In addition, limiting blocks 37 are provided at the pivots at both ends of the first long side 321 of the flipping plate 32 to limit its flipping angle and ensure that the flipping does not exceed 180°. The limiting blocks 37 ensure that the angle of the flipping plate 32 is accurate and consistent during the flipping process, preventing over- or under-flipping. This ensures that the dough receives optimal gravity assistance during demolding and also ensures the stability of the equipment operation.

[0057] The oven 2 is provided with an opening rail 5 and a closing rail 6 at its outlet and inlet, respectively. When the free end of the opening and closing rod 36 is inserted into the opening rail 5, the second long side 322 of the flip plate 32 is disengaged from the fixing rod 35. When the free end of the opening and closing rod 36 is inserted into the closing rail 6, the second long side 322 of the flip plate 32 is engaged with the fixing rod 35.

[0058] Both the opening rail 5 and the closing rail 6 are two spaced-apart curved rods, which are fixedly connected by an arc-shaped connecting piece. The opening rail 5 has an opening section 51 with gradually increasing height at the end near the oven, and the closing rail 6 has a closing section 61 with gradually decreasing height at the end near the oven.

[0059] It also includes a demolding component 7 located at one end of the conveyor belt 1 in the conveying direction. The demolding component 7 includes two symmetrically arranged mounting plates 71, a demolding cylinder 72 located on the mounting plate 71, a mounting rod 73 connected to the drive end of each demolding cylinder 72, a vibration generator 74 spaced on the mounting rod 73, a support plate 75 connected to both sides below the mounting rod 73, and a pancake receiving conveyor belt 76 located between each support plate 75.

[0060] The top of each of the support plates 75 is sloping. The sloping design can guide and position the support plate 75 when it comes into contact with the flip plate 32, ensuring that the support plate 75 and the flip plate 32 make stable contact, avoiding rigid collisions, and helping to compensate for minor alignment errors that may occur during equipment operation. The vibration generator is an electromagnetic vibrator.

[0061] The plywood rail 6 is provided with a cleaning component 8 on the side away from the oven 2. The cleaning component 8 includes two cleaning rods 81 spaced apart, a sliding block 82 slidably disposed on each of the cleaning rods 81, a cleaning cylinder 83 connected to one side of the sliding block 82, and a cleaning block 84 disposed at the driving end of the cleaning cylinder 83.

[0062] The sliding block 82 is driven by the drive cylinder 85 to reciprocate on each of the cleaning rods 81. The cleaning block 84 is made of high-temperature resistant, food-grade dense sponge or non-woven fabric. During operation, when the conveyor belt 1 is stopped, the cleaning cylinder 83 pushes the cleaning block 84 to contact the surface of the baking plate 3, and the drive cylinder 85 drives the sliding block 82 to slide from one end of each of the cleaning rods 81 to the other end. Then the cleaning cylinder 83 and the drive cylinder 85 reset. After demolding, the baking plate 3 can be automatically cleaned without leaving the production line to remove residues and prepare for the next production cycle.

[0063] Specifically, the drive connection between the drive cylinder 85 and the sliding block 82 is achieved by the cooperation of a gear set and a rack 86. The gear set includes a drive gear 88 and a driven gear 89 mounted on a fixed plate 87. The rack 86 is mounted on the outside of the drive gear 88 and the driven gear 89 and is fixedly connected to the sliding block 82. The top of the drive gear 88 protrudes from the bottom of the fixed plate 87 and is provided with teeth. The drive end of the drive cylinder 85 is provided with a toothed rod 851 that matches the teeth at the bottom of the drive gear 88.

[0064] Example 2: A dorayaki production process using the one-piece molding equipment described in Example 1, comprising the following steps:

[0065] S1. Grouting: The prepared dough paste is precisely injected into the grooves 31 of each baking plate 3 using a quantitative grouting machine.

[0066] S2. Baking and shaping: The conveyor belt 1 is started, and the baking plate 3 carrying the batter enters and passes through the oven 2 in an intermittent "movement-pause" motion. The fan 44 delivers the circulating hot air that has reached the working temperature, collected by the hot air collection hood 43 in the oven 2, to each air blowing pipe 41. Finally, it blows vertically downward from the air blowing head 42 onto the stationary batter. This blowing action can effectively suppress the upward bulging tendency of the center of the batter due to thermal expansion and accelerate its surface solidification. As a result, during the shaping process, a flat depression is formed in the center of the batter, which is conducive to the subsequent filling. By adjusting the valve, the blowing pressure is increased with the process, which can ensure that the shape can still be effectively shaped in the later stage of the dough's gradual shaping, making the shaping effect more uniform and thorough.

[0067] S3. Opening and flipping: The baking plate 3, which has completed baking and shaping, continues to be conveyed by the conveyor belt 1. When the opening and closing rods 36 at both ends of the plate are inserted into the opening rail 5, the sliding hook 33 slides against the pre-tightening force of the elastic element 34 under the guidance of the rail. Its wedge-shaped end disengages from the matching inclined surface of the fixing rod 35, and the flipping plate 32 is unlocked. It flips with its first long side 321 as the axis, and the limiting block 37 ensures that it is accurately flipped 180° so that the opening of the groove 31 faces downward.

[0068] S4. Vibration demolding: When the flipping plate 32 flips at the end of the conveyor belt 1 so that the opening of the groove 31 faces downward, the demolding component 7 is activated. The demolding cylinder 72 pushes the mounting rod 73 and the vibration generator 74 close to the flipping plate 32, so that the support plate 75 supports the bottom of the flipping plate 32, and at the same time, the vibration generator 74 contacts the top of the flipping plate 32. The vibration generator 74 is activated, and the bottom layer of the pancake is shaken from the groove 31 onto the pancake receiving conveyor belt 76 through high-frequency vibration.

[0069] S5. Reset: After demolding is completed, the demolding cylinder 72 resets, causing the vibration generator 74 and the support plate 75 to separate from the baking plate 3. The unloaded baking plate 3 continues to run with the conveyor belt 1. When its opening and closing rod 36 enters the closing plate rail 6, the flipping plate 32 is locked back to the horizontal state.

[0070] Although the invention has been specifically shown and described in conjunction with preferred embodiments, those skilled in the art should understand that various changes in form and detail may be made to the invention without departing from the spirit and scope of the invention as defined in the appended claims, all of which shall be within the scope of protection of the invention.

Claims

1. A one-piece molding equipment for dorayaki, characterized in that, include: The conveyor belt and the oven mounted on the conveyor belt, the conveyor belt comprising two spaced-apart conveyor chains, the conveyor belt being provided with a plurality of baking plates, the baking plates being provided with a plurality of grooves spaced apart for receiving pastry batter; The oven is equipped with an air blowing assembly, which includes a number of air blowing pipes spaced apart. Each air blowing pipe has a number of air blowing heads spaced apart at its bottom, and each air blowing head is arranged corresponding to a groove. Each of the baking plates includes a flip plate, a sliding hook, at least one elastic element, a fixing rod, and an opening and closing rod. The two ends of the first long side of the flip plate are rotatably connected to each of the conveyor chains. The sliding hook is slidably connected to the flip plate. One end of the elastic element is connected to the bottom of the flip plate, and the other end of the elastic element is connected to the sliding hook. The second long side of the flip plate is fastened to the fixing rod by the sliding hook. The opening and closing rod is provided at both ends of the second long side of the flip plate. The oven is provided with an opening rail and a closing rail at both ends. When the free end of the opening and closing rod is inserted into the opening rail, the second long side of the flip plate is disengaged from the fixing rod. When the free end of the opening and closing rod is inserted into the closing rail, the second long side of the flip plate is engaged with the fixing rod. It also includes a demolding component located at one end of the conveyor belt in the conveying direction. The demolding component includes two symmetrically arranged mounting plates, a demolding cylinder on the mounting plate, a mounting rod connected to the drive end of each demolding cylinder, a vibration generator spaced apart on the mounting rod, a support plate connected to both sides below the mounting rod, and a disc receiving conveyor belt located between each support plate.

2. The one-piece molding equipment for dorayaki according to claim 1, characterized in that: The flip plate has limit blocks at both ends of the first long side to limit the flip angle.

3. The one-piece molding equipment for dorayaki according to claim 1, characterized in that: The side of the plywood rail away from the oven is provided with a cleaning component. The cleaning component includes two cleaning rods spaced apart, a sliding block slidably disposed on each of the cleaning rods, a cleaning cylinder connected to one side of the sliding block, and a cleaning block disposed at the drive end of the cleaning cylinder.

4. The one-piece molding equipment for dorayaki according to claim 1, characterized in that: The air blowing assembly also includes a hot air collecting hood inside the oven and a fan on the top of the oven. One side of the fan is connected to the hot air collecting hood, and the other end of the fan is connected to each of the air blowing pipes.

5. The one-piece molding equipment for dorayaki according to claim 1, characterized in that: The blowing pressure of each of the air blowing pipes increases with the conveying direction of the conveyor belt.

6. The one-piece molding equipment for dorayaki according to claim 1, characterized in that: The snap-fit ​​end of the sliding hook is wedge-shaped, and the corresponding snap-fit ​​surface of the fixing rod is a matching inclined surface.

7. The one-piece molding equipment for dorayaki according to claim 1, characterized in that: The sliding hook is elongated, and its length is the same as that of the baking plate.

8. The one-piece molding equipment for dorayaki according to claim 1, characterized in that: The elastic element is a contraction spring or a wave-shaped spring sheet, which always provides a preload force to the sliding hook in the direction of the fixed rod.

9. The one-piece molding equipment for dorayaki according to claim 1, characterized in that: Each of the aforementioned support plates has a sloping surface at the top.

10. A dorayaki production process using the dorayaki one-piece molding equipment described in any one of claims 1-9, characterized in that, Includes the following steps: S1. Injection: A measured amount of dough batter is injected into the grooves of each baking plate. S2. Baking and shaping: Start the conveyor belt and intermittently transport the baking plate carrying the crust batter through the oven. During the set time of each pause of the conveyor belt, the air blowing component blows air into the batter in the groove of the baking plate below it, so that the batter forms a depression in the middle during the heating and shaping process. S3. Opening and flipping: The baking plate that has completed baking and shaping continues to be conveyed by the conveyor belt. When the opening and closing rods at both ends of the plate are inserted into the opening rail, the sliding hook is disengaged from the fixing rod under the action of the opening rail, and the flipping plate flips with its first long side as the axis. S4. Vibration demolding: When the flipping plate flips at the end of the conveyor belt until the groove opening faces downward, the demolding component is activated. The demolding cylinder pushes the mounting rod and vibration generator close to the flipping plate, so that the support plate supports the bottom of the flipping plate. At the same time, the vibration generator contacts the top of the flipping plate and is activated. Through high-frequency vibration, the bottom layer of dough is shaken from the groove onto the dough receiving conveyor belt. S5. Reset: After demolding is completed, the demolding cylinder resets, causing the vibration generator and support plate to separate from the baking plate. The unloaded baking plate continues to run with the conveyor belt. When its opening and closing rod enters the plate rail, the flipping plate is locked back to the horizontal state.

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