Dough sheet forming device and dough sheet forming method
By using an intelligent control system and a multi-module collaborative sheet forming device, the shortcomings of traditional sheet forming equipment in terms of thickness consistency and automated production efficiency have been solved, achieving precise control of sheet thickness and efficient automated production.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-24
- Publication Date
- 2026-03-13
AI Technical Summary
Traditional dough sheet forming equipment cannot flexibly adjust to the differences in texture and thickness requirements of different batches of dough flakes, resulting in poor consistency in the thickness of the formed dough sheets. The operation is complicated and inefficient, and it lacks a real-time detection and feedback mechanism, making it difficult to achieve efficient automated production.
The sheet forming device employs a multi-module collaborative operation, including a primary sheet forming device, a composite device, an adjustable pressure roller assembly, a control device, and an intelligent detection device. Through the intelligent control system, the gap and thickness of the rollers are adjusted in real time, and combined with a PID adaptive adjustment algorithm and a multi-level alarm mechanism, precise control of the sheet thickness is achieved.
It improves the precision and stability of dough sheet forming, simplifies the operation process, reduces the need for manual intervention, ensures consistent product quality, and adapts to diverse production needs.
Smart Images
Figure CN121647285A_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of food processing machinery technology, specifically to a dough sheet forming device and a dough sheet forming method. Background Technology
[0002] In the field of dough sheet processing, dough sheet forming equipment is widely used in household and industrial production. Although traditional dough sheet forming equipment can accomplish basic dough sheet forming tasks, it still has some significant shortcomings and problems. First, the design of the pressure roller spacing cannot be automatically and flexibly adjusted according to the differences in texture and dough sheet thickness requirements of different batches of dough, resulting in poor consistency in the thickness of the formed dough sheets, affecting product quality and customer satisfaction. Second, traditional control methods rely on manual adjustment, which is complex and inefficient, making it difficult to achieve efficient automated production. Furthermore, traditional dough sheet forming equipment lacks real-time detection and feedback mechanisms, making it impossible to promptly detect and correct deviations in dough sheet thickness, leading to quality problems during production. Therefore, developing a dough sheet forming device that can adjust dough sheet thickness in real time, improving production efficiency and product quality, has become particularly urgent. Summary of the Invention
[0003] In view of this, this application provides a dough sheet forming device and a dough sheet forming method to solve the technical problems of traditional dough sheet forming equipment, which cannot flexibly adjust the spacing of the pressing rollers according to the differences in texture and dough sheet thickness requirements of different batches of dough flakes, the traditional control method relies on manual adjustment, which is complicated and inefficient, making it difficult to achieve efficient automated production, and the traditional dough sheet forming equipment lacks a real-time detection and feedback mechanism, which cannot detect and correct the deviation of dough sheet thickness in time, leading to quality problems that are prone to occur during the production process.
[0004] To achieve the above objectives, the present invention provides the following technical solution: This invention mainly consists of a sheet forming device and a sheet forming method. It achieves high-precision forming thickness control through multi-module collaboration and provides an intuitive interactive interface. The sheet forming device includes: a sheet initial forming device, a sheet composite device, an adjustable pressure roller assembly, a control device, and a sheet thickness intelligent detection device. The specific structure and functions are as follows: The dough sheet primary forming device includes a pair of symmetrically arranged first fixed-distance pressing roller assemblies, which are used to press dough flakes into primary dough sheets. During operation, dough flakes are conveyed between the two first fixed-distance pressing roller assemblies, and the loose dough flakes are pressed into primary dough sheets through a preset roller gap and roller rotation speed.
[0005] The dough sheet laminating device includes a second fixed-distance pressing roller assembly located directly below a pair of first fixed-distance pressing roller assemblies. This second fixed-distance pressing roller assembly is used to laminate two primary dough sheets into a single composite dough sheet. Two primary dough sheets from the primary dough sheet forming device are simultaneously guided by a conveyor guide plate into the roller-to-roll area of the second fixed-distance pressing roller assembly in this laminating device. The pressing action of the rollers achieves a tight bond between the two dough sheets, ultimately forming a single composite dough sheet. This process effectively improves the overall strength and texture of the dough sheet while ensuring its flatness after lamination, preventing defects such as bubbles and wrinkles.
[0006] Adjustable pressure roller assembly, used to shape composite sheets into shaped sheets with a defined thickness; The adjustable pressure roller assembly includes an active pressure roller, a driven pressure roller, and a roller gap adjustment mechanism. The roller gap adjustment mechanism can drive the driven pressure roller to move relative to the active pressure roller to adjust the roller gap and obtain a certain thickness for the formed sheet. The active and driven pressure rollers are arranged in parallel. The active pressure roller is driven by a drive motor to rotate, and the driven pressure roller rotates synchronously with the active pressure roller. The composite sheet is squeezed and shaped between the two rollers.
[0007] As a further aspect of the present invention: the roller gap adjustment mechanism includes: Electric actuator, mounted on the frame; The push plate is mounted on the extension rod of the electric push rod. Both ends of the push plate are equipped with push rods to achieve uniform power transmission. A pair of bearing seats are movably mounted on corresponding notches on the frame. The bearing seats are fixedly connected to the corresponding push rods, and the driven pressure roller is mounted on the pair of bearing seats. When the electric push rod drives the push plate to extend or retract, the push rod drives the bearing seats to move along the notches on the frame, thereby causing the driven pressure roller to move closer to or further away from the driving pressure roller, achieving precise adjustment of the roller gap.
[0008] As a further embodiment of the present invention, it also includes a control device for controlling the movement of an electric push rod to adjust the movement of the driven pressure roller relative to the active pressure roller, thereby adjusting the gap between the face rollers so that the formed sheet obtains a certain thickness. A pressure sensor is provided at the electric push rod, and the pressure sensor is used to detect the reaction force of the sheet on the driven pressure roller and transmit the detection data to the core processor.
[0009] As a further embodiment of the present invention: the control device includes a core processor, a display module, a driver module, and an alarm reminder module; The core processor acquires parameter data from legitimate user input via the input module. This parameter data includes the standard thickness of the sheet and the rotation speed of the pressure rollers. It then controls the display module to visualize the sheet thickness data, adjustment parameters, and abnormal alarm status. Furthermore, it uses a PID adaptive adjustment algorithm to generate dynamic adjustment signals based on thickness detection data and pressure sensor feedback. These signals are output to the drive module, which receives the dynamic adjustment signals from the core processor, converts them into drive commands, and controls the extension and retraction speed of the electric push rods, thereby adjusting the gap between the sheet rollers. Simultaneously, it controls the rotation speed of the drive motors for each pressure roller assembly, achieving speed adaptation. Alarm functions are also included. The alert module is connected to the core processor. It is used to analyze alarm information, perform multi-mode audible and visual alarms, and remote alarms. Specifically, it collects three thickness error data points within a preset period and compares them with preset error alarm thresholds, such as ±0.1mm for level 1 and ±0.3mm for level 2, to match the corresponding alarm level. Different warning methods are triggered according to the alarm level, including local audible and visual alarms on the device. For example, a level 1 alarm will light up a yellow light and sound a buzzer, while a level 2 alarm will light up a red light, sound a continuous alarm, send an SMS notification to the management personnel (for level 2 and above alarms), and upload an alarm to the remote monitoring platform (in case of serious anomalies). At the same time, the alarm details are displayed in a pop-up window on the display module to facilitate quick troubleshooting.
[0010] As a further embodiment of the present invention, it also includes a sheet thickness intelligent detection device, which is used to detect the thickness of the formed sheet and feed the detection result back to the control device to form a closed loop of thickness control, thereby realizing real-time control of sheet thickness. The intelligent sheet thickness detection device includes a laser displacement sensor group and a sheet thickness calculation module. The laser displacement sensor group is installed below the adjustable pressure roller assembly, located on the conveying path of the formed sheet. The laser displacement sensor group includes a first laser displacement sensor located in front of the formed sheet and a second laser displacement sensor located behind the formed sheet. The emitting ends of both sensors are perpendicular to the surface of the formed sheet, and the central axes of the two sensors are on the same straight line to ensure detection accuracy. The sheet thickness calculation module receives the detection information from the laser displacement sensor group and calculates the actual thickness of the formed sheet according to the formula: T=D-d1-d2. The sheet thickness calculation module compares the actual thickness T with the preset standard thickness and calculates the thickness error value, which is: error value = actual thickness T - standard thickness. The error information is sent to the core controller. The distance from the first laser displacement sensor to the surface of the formed sheet is d1, the distance from the second laser displacement sensor to the surface of the formed sheet is d2, and the fixed distance between the emitting ends of the two sensors is D.
[0011] A method for forming a dough sheet based on the above-mentioned dough sheet forming apparatus includes the following steps: S1, Initial Forming: A pair of first fixed-distance pressing roller assemblies press the dough into initial sheets according to the control signal output by the control device. The operator sets the preset thickness, roller speed and other processing parameters of the corresponding sheet through the input module of the control device. After receiving the parameters, the core processor sends a control signal to the drive module, and the pair of first fixed-distance pressing roller assemblies start to rotate under the action of the drive control signal. S2, Composite Forming: A second fixed-distance pressing roller assembly presses two primary sheets into a composite sheet according to the control signal output by the control device. The second fixed-distance pressing roller assembly of the sheet composite device starts to rotate under the synchronous control signal of the control device. The two primary sheets enter the space between the second fixed-distance pressing roller assembly of the sheet composite device under the guidance of the conveying guide plate. Through the squeezing action of the rollers, the two primary sheets are tightly bonded to form a composite sheet.
[0012] S3, Sheet Shaping: The adjustable pressure roller assembly presses and shapes the composite sheet into a shaped sheet with a defined thickness; The control device controls the movement of the electric push rod, adjusts the movement of the driven pressure roller relative to the driving pressure roller, thereby adjusting the gap between the rollers of the adjustable pressure roller assembly to achieve a certain thickness of the formed sheet. A pressure sensor is installed at the electric push rod to detect the reaction force of the sheet on the driven pressure roller and transmits the detection data to the core processor of the control device. The intelligent sheet thickness detection device detects the thickness of the formed sheet and feeds the detection result back to the core processor to achieve real-time control of the sheet thickness.
[0013] As a further aspect of the present invention, it also includes the following steps: After the formed sheet is output from the adjustable pressure roller assembly, it enters the detection area of the sheet thickness intelligent detection device; the laser displacement sensor group starts working.
[0014] S4, the laser displacement sensor group detects the distance information from the laser displacement sensor to the forming sheet. The sheet thickness calculation module calculates the thickness of the forming sheet based on the detected distance information according to the formula: T=D-d1-d2, and compares the sheet thickness calculation information with the preset standard thickness, and sends the error information to the core controller. S5, the core controller uses a PID adaptive adjustment algorithm to generate a dynamic adjustment signal based on error information and pressure feedback information from the pressure sensor. If the actual thickness T is greater than the standard thickness, the error value is positive, and the adjustment amount of the face roller gap needs to be reduced; if the actual thickness T is less than the standard thickness, the error value is negative, and the adjustment amount of the face roller gap needs to be increased. After the calculation is completed, the core processor generates a dynamic adjustment signal and outputs it to the drive module. The drive module converts the adjustment signal into a drive command, controls the extension and retraction of the electric push rod, and drives the driven pressure roller to move relative to the active pressure roller to the target position, thereby achieving precise adjustment of the face roller gap and ensuring that the actual thickness of the subsequently formed sheet always approaches the standard thickness, forming a closed loop of thickness control.
[0015] As a further aspect of the present invention, it also includes the following steps: S6, the alarm reminder module collects three thickness errors within a preset period, compares them with the error alarm threshold, matches the alarm level, and triggers audible and visual alarms, SMS notifications or remote platform alarms according to the level. The real-time pressure curve, thickness error value, production parameters, alarm information and adjustment parameters are displayed through the display module.
[0016] Throughout the processing, the alarm module collects thickness error data transmitted by the core processor in real time. It records the thickness error value at a preset interval, such as every 10 seconds. After three consecutive thickness error data collections, it compares them with preset error alarm thresholds, such as a first-level threshold of ±0.1mm and a second-level threshold of ±0.3mm. If all three error values are within the first-level threshold, it is considered "normal" and no alarm is triggered. If one of the three error values exceeds the first-level threshold but not the second-level threshold, it is considered a "first-level alarm," triggering a flashing yellow light and a buzzer alarm on the device. If one of the three error values exceeds the second-level threshold, it is considered a "second-level alarm," triggering a continuous red light and a continuous buzzer alarm on the device, and simultaneously sending an SMS notification to a preset management personnel's mobile phone number. If all three error values exceed the second-level threshold, it is considered a "serious anomaly," triggering all measures for a second-level alarm, and also uploading the alarm information to a remote monitoring platform to alert maintenance personnel for emergency handling.
[0017] As can be seen from the above technical solution, the advantages of the present invention are: 1. This application utilizes an intelligent control device and a dough roller gap adjustment mechanism to adjust the gap between the active and driven pressure rollers in real time. This adapts to the differences in texture and dough sheet thickness requirements of different batches of dough, improving the precision and stability of dough sheet forming. The intelligent control device, through algorithmic control of the electric push rod, automatically adjusts the dough roller gap, reducing manual intervention and increasing production efficiency. Simultaneously, an intelligent dough sheet thickness detection device is installed to detect the actual thickness of the formed dough sheet in real time and feeds the detection results back to the intelligent control device, ensuring that the thickness of the formed dough sheet always remains near the target value, thus improving product quality.
[0018] 2. The entire dough sheet forming process is automatically managed by an intelligent control device, simplifying operation, reducing operational difficulty and production costs, and meeting the demands of modern production and high-quality products. (See attached diagram.) The accompanying drawings, which form part of this application, are used to provide a further understanding of this application. The illustrative embodiments of this application and their descriptions are used to explain this application and do not constitute an undue limitation of this application.
[0019] Figure 1 This is a schematic diagram of the overall structure of this application.
[0020] Figure 2 This is a schematic diagram showing the connection relationship between the adjustable pressure face roller assembly, the face roller gap adjustment mechanism, and the frame of this application.
[0021] Figure 3 This is a schematic diagram of the control device structure of this application.
[0022] Figure 4 The diagram shows the specific steps of the sheet forming method of this application.
[0023] Figure 5 This is a front view showing the connection relationship of the first fixed-distance pressure roller assembly in this application.
[0024] Figure 6 This is a front view showing the connection relationship of the adjustable pressure roller assembly in this application.
[0025] Figure 7 This is a top view showing the connection between the roller gap adjustment mechanism and the frame in this application.
[0026] Figure 8 for Figure 7 A partial structural cross-sectional view.
[0027] Figure 9 This is a schematic diagram showing the connection relationship between the roller gap adjustment mechanism and the connecting plate in this application.
[0028] Explanation of reference numerals in the attached drawings: 1. Hopper; 2. First fixed-distance pressing roller assembly; 21. First pressure roller; 22. Second pressure roller; 23. First electric motor; 24. First driving gear; 25. First driven gear; 3. Flour flakes; 4. Initial sheet; 5. Guide plate; 6. Adjustable pressing roller assembly; 61. Driving pressure roller; 62. Driven pressure roller; 63. Second electric motor; 64. Second driving gear; 65. Second driven gear; 7. Roller gap adjustment mechanism; 71. Electric push rod; 711. Extending rod; 72. Push plate; 73. Push rod; 74. Bearing seat; 8. Composite sheet; 9. Formed sheet; 10. Connecting plate; 11. Side plate; 12. Notch; 121. Guide groove; 200. Second fixed-distance pressing roller assembly. Detailed Implementation
[0029] To make the objectives, technical solutions, and advantages of this application clearer, the application will be further described in detail below with reference to the embodiments and accompanying drawings. Here, the illustrative embodiments and their descriptions are used to explain this application, but are not intended to limit it.
[0030] refer to Figures 1 to 9 This embodiment provides a dough sheet forming device and method capable of precisely controlling the dough sheet forming thickness. It enables automated, high-precision monitoring and adjustment of the dough sheet forming thickness, improving production efficiency and dough sheet quality, and adapting to diverse production needs. Figure 1 , Figure 2 , Figure 3 , Figure 4 As shown, the sheet forming device includes: a sheet primary forming device, a sheet composite device, an adjustable pressure roller assembly 6, a control device, and a sheet thickness intelligent detection device. The sheet primary forming device includes a pair of symmetrically arranged first fixed-distance pressure roller assemblies 2, which are used to press dough flakes 3 into primary sheets 4. The first fixed-distance pressure roller assembly 2 includes a first pressure roller 21 and a second pressure roller 22, both of which are movably mounted on the frame. The gap between the first pressure roller 21 and the second pressure roller 22 is fixed. The rear end of the first pressure roller 21 is connected to a first motor 23 on the frame. A first driving gear 24 is installed at the front end of the first pressure roller 21, and a first driven gear 25 is installed at the front end of the second pressure roller 22. The first driven gear 25 meshes with the first driving gear 24. The first motor 23 drives the first pressure roller 21 to rotate, which in turn drives the first driven gear 25 to rotate, thereby causing the second pressure roller 22 to rotate. A hopper 1 is provided at the upper end of the first fixed-distance pressing roller assembly 2 at the top. The hopper 1 is fixed on the frame. The dough flakes 3 in the hopper 1 enter the gap between the first pressing roller 21 and the second pressing roller 22 through the lower opening of the hopper 1. Driven by the first motor 23, the first pressing roller 21 and the second pressing roller 22 rotate, pressing the dough flakes 3 into the initial dough sheet 4.
[0031] Two initial dough sheets 4 are guided by guide plates 5 into the dough sheet composite device for forming. The guide plates 5 are installed on the frame. The guide plate 5 at the left end is located between the second pressure roller 22 of the first fixed-distance pressing roller assembly 2 at the upper left end and the second pressure roller 22 of the second fixed-distance pressing roller assembly 200 at the lower end; the guide plate 5 at the right end is located between the first pressure roller 21 of the first fixed-distance pressing roller assembly 2 at the upper right end and the first pressure roller 21 of the second fixed-distance pressing roller assembly 200 at the lower end.
[0032] The sheet laminating device includes a second fixed-distance pressing roller assembly 200, which is located below a pair of first fixed-distance pressing roller assemblies 2 at the upper end. The second fixed-distance pressing roller assembly 200 is used to laminate two primary sheets 4 into a composite sheet 8.
[0033] The second fixed-distance pressing roller assembly 200 of the sheet composite device has the same structure as the first fixed-distance pressing roller assembly 2 of the sheet primary forming device.
[0034] Specifically, the primary sheet 4 on the left is guided by the corresponding guide plate 5, and the primary sheet 4 on the right is guided by the corresponding guide plate 5. The two primary sheets 4 are bonded together and enter between the first pressure roller 21 and the second pressure roller 22 below to form a composite sheet 8.
[0035] The adjustable pressure roller assembly 6 is used to shape the composite sheet 8 into a shaped sheet 9; wherein, the adjustable pressure roller assembly 6 includes an active pressure roller 61, a driven pressure roller 62 and a roller gap adjustment mechanism 7, the roller gap adjustment mechanism 7 can drive the driven pressure roller 62 to move relative to the active pressure roller 61 to adjust the roller gap so that the shaped sheet 9 obtains a certain thickness.
[0036] The adjustable pressure roller assembly 6 also includes a second motor 63, a second drive gear 64, and a second driven gear 65. The second motor 63 is mounted on the frame and is connected to the rear end of the drive roller 61, which is rotatably mounted on the frame. The front end of the drive roller 61 is fitted with the second drive gear 64. The front end of the driven roller 62 is mounted on a front bearing seat 74, and the rear end is mounted on a rear bearing seat 74. The front end of the driven roller 62 is fitted with the second driven gear 65, which is connected to the second drive gear 64. When engaged, the second motor 63 rotates, driving the active pressure roller 61 and the second active gear 64 to rotate, which in turn drives the second driven gear 65 and the driven pressure roller 62 to rotate. The rotation of the active pressure roller 61 and the driven pressure roller 62 shapes the composite sheet 8 into a shaped sheet 9. The gap between the active pressure roller 61 and the driven pressure roller 62 can be adjusted by the sheet roller gap adjustment mechanism 7, which will allow the shaped sheet 9 to obtain a certain thickness. The gear meshing gap between the second driven gear 65 and the second active gear 64 is relatively large, which facilitates the adjustment of the gap between the active pressure roller 61 and the driven pressure roller 62.
[0037] like Figure 2 , Figure 7 , Figure 8 and Figure 9 As shown, the roller gap adjustment mechanism 7 includes an electric push rod 71, a push plate 72, and a pair of bearing seats 74. The electric push rod 71 is installed on the inner side of the connecting plate 10 of the frame, and the connecting plate 10 is fixedly installed at the end of the frame. The push plate 72 is installed on the extension rod 711 of the electric push rod 71, and push rods 73 are installed at both ends of the push plate 72. The pair of bearing seats 74 are respectively movably installed at the corresponding notches 12 on the frame, and the bearing seats 74 are fixedly connected to the corresponding push rods 73. The driven pressure roller 62 is movably installed on the pair of bearing seats 74.
[0038] Specifically, the frame is provided with two side plates 11, and the side plates 11 have corresponding notches 12, and the bearing seat 74 is slidably installed in the corresponding notches 12.
[0039] Furthermore, guide grooves 121 are provided on both the upper and lower inner walls of the notch 12. The upper end of the bearing seat 74 is slidably engaged with the guide groove 121 on the upper inner wall, and the lower end of the bearing seat 74 is slidably engaged with the guide groove 121 on the lower inner wall.
[0040] During production, the extension rod 711 of the electric push rod 71 extends, driving the push plate 72 to move the two push rods 73, thereby driving the two bearing seats 74 to move, which in turn brings the driven pressure roller 62 closer to the driving pressure roller 61. When the gap between the driving pressure roller 61 and the driven pressure roller 62 is too large, the extension rod 711 continues to extend. When the gap between the driving pressure roller 61 and the driven pressure roller 62 is too small, the extension rod 711 retracts.
[0041] This application also includes a control device for controlling the extension and retraction of the extension rod of the electric push rod 71 to adjust the movement of the driven pressure roller 62 relative to the driving pressure roller 61, thereby adjusting the gap between the two rollers to achieve a certain thickness for the formed sheet 9. A pressure sensor is provided at the electric push rod 71 to detect the reaction force of the sheet on the driven pressure roller 62 and transmit the detection data to the core processor of the control device. Specifically, as Figure 3 As shown, the control device includes a core processor, a display module, a drive module, and an alarm reminder module. The core processor is used to acquire parameter data input by authorized users through the input module. The parameter data includes the standard thickness of the sheet and the speed of the pressure roller, etc. It also controls the display module to visualize the thickness data, adjustment parameters, and abnormal alarm status of the sheet. Furthermore, it is used to generate a dynamic adjustment signal based on the thickness detection data and the pressure feedback information from the pressure sensor using a PID adaptive adjustment algorithm, and output the dynamic adjustment signal to the drive module. The drive module controls the movement of the electric push rod 71. The drive module includes three sets of motors for driving the first fixed-distance pressure roller assembly 2 and the second fixed-distance pressure roller assembly 200, a second motor 63 for driving the active pressure roller 61, and a servo motor for driving the electric push rod. The alarm notification module is connected to the core processor. It is used to analyze alarm information, perform multi-mode audible and visual alarms, and remote alarms. Specifically, it collects three thickness error data points within a preset period and compares them with preset error alarm thresholds, such as ±0.1mm for level 1 and ±0.3mm for level 2, to match the corresponding alarm level. Different warning methods are triggered according to the alarm level, including local audible and visual alarms on the device. For example, a level 1 alarm will light up a yellow light and sound a buzzer, a level 2 alarm will light up a red light and sound a continuous alarm, and a text message notification will be sent to the management personnel (level 2 and above alarms). In case of serious abnormalities, the alarm will be uploaded to the remote monitoring platform, and alarm details will be displayed in a pop-up window on the display module for quick troubleshooting.
[0042] In this embodiment, the control device further includes a user identification module and an input module. The user identification module compares the user's input identity information with the user registration information in the basic information database. Based on the comparison result, it determines whether the user is legitimate. If the user is legitimate, parameter input can be performed, avoiding accidental operations. In this embodiment, facial data features and password data information are used as identity features. The input module is used for legitimate users to input target thickness parameters, corresponding roller spacing, and rotational speed parameters. The display module can display real-time pressure curves, thickness error values, alarm information, and adjustment action logs.
[0043] In this embodiment, the specific process of generating a dynamic adjustment signal using the PID adaptive adjustment algorithm based on thickness detection data and pressure feedback information from the pressure sensor includes: Step A: The actual thickness Ta of the formed sheet is measured in real time by the laser displacement sensor group. At the same time, the pressure sensor collects the actual pressure feedback value P of the driven pressure roller 62 in real time. Step B: The core processor compares the actual thickness Ta collected with the target thickness Tt set by the user, and calculates the instantaneous error e(t) = Tt - Ta. Here, the error e(t) is the direct input of the PID calculation. e(t) > 0 indicates that the sheet is too thick and the pressure needs to be increased; e(t) < 0 indicates that the sheet is too thin and the pressure needs to be reduced. Step C: Adaptively adjust PID parameters based on fuzzy logic rules, and dynamically adjust kp, ki, and kd based on e(t). For example, when the absolute value of the error e(t) is large and the error change rate is small, increase Kp to speed up the adjustment; when the absolute value of the error e(t) is small and the error change rate is large, decrease Kd to avoid overshoot. Step D: The core processor uses the adaptively adjusted PID parameters Kp', Ki', Kd' to calculate the control quantity u(t). u(t)=Kp'•e(t)+Ki'•∫e(t)dt+Kd'•de(t) / dt, The calculated control quantity u(t) is converted into a specific dynamic adjustment signal, such as a PWM signal, and output to the electric push rod 71 through the drive module. The electric push rod 71 extends and retracts according to the signal, thereby precisely adjusting the gap or pressure of the pressure roller.
[0044] This application also includes a sheet thickness intelligent detection device, which is used to detect the thickness of the formed sheet 9 and feed the detection result back to the control device, thereby realizing real-time control of the sheet thickness.
[0045] Specifically, the intelligent sheet thickness detection device includes a laser displacement sensor group and a sheet thickness calculation module. The laser displacement sensor group is installed below the adjustable pressure roller assembly 6 and adopts a dual-sensor collaborative detection design. It is located on the conveying path of the formed sheet. The laser displacement sensor group includes a first laser displacement sensor located in front of the formed sheet 9 and a second laser displacement sensor located behind the formed sheet 9. The emitting ends of both sensors are perpendicular to the surface of the formed sheet, and the central axes of the two sensors are on the same straight line to ensure detection accuracy. The sheet thickness calculation module establishes a real-time data transmission channel with the laser displacement sensor group, receives the detection information from the laser displacement sensor group, and calculates the actual thickness of the formed sheet 9 according to the formula: T=D-d1-d2. The sheet thickness calculation module compares the actual thickness T with the preset standard thickness and calculates the thickness error value: error value = actual thickness T - standard thickness. The error information is sent to the core controller. The distance from the first laser displacement sensor to the surface of the formed sheet 9 is d1, the distance from the second laser displacement sensor to the surface of the formed sheet 9 is d2, and the fixed distance between the emitting ends of the two sensors is D.
[0046] In this embodiment, the first and second laser displacement sensors are installed at the top of the U-shaped support rod, and the formed sheet passes through the U-shaped opening. Thickness detection and data feedback are mainly completed through the following process: The sheet thickness calculation module receives the detection data from the two laser displacement sensors in real time, where d1 is the vertical distance from the first laser displacement sensor to the sheet surface, and d2 is the vertical distance from the second laser displacement sensor to the sheet surface; based on preset sensor installation parameters, the fixed vertical distance between the two laser displacement sensors is D, and the actual thickness T of the formed sheet is calculated using the formula T=D-d1-d2; the calculated actual sheet thickness T is compared with the system's preset standard thickness range. If there is a deviation, i.e., T exceeds the standard range, the error information is immediately transmitted to the core processor, providing data for subsequent parameter adjustments.
[0047] This application also discloses a sheet forming method based on the above-mentioned sheet forming apparatus, including the following steps: S1, Initial Forming: A pair of first fixed-distance pressing roller assemblies 2 press the dough flakes 3 into initial dough sheets 4 according to the control signal output by the control device.
[0048] Before the initial sheet is prepared, the authorized user, after being authenticated by the control device, enters the parameter setting interface, sets parameters such as the preset sheet thickness and the motor speed of the drive module, and inputs the start command; the core processor sends a control signal to the drive module, the first motor 23 starts, and drives the first pressure roller 21 and the second pressure roller 22 to rotate synchronously in opposite directions. The dough flakes 3 in the hopper 1 fall between the two pressure rollers through the bottom opening, and under the extrusion action, form the initial sheet 4 of the preset thickness. The initial sheet 4 is conveyed to the sheet composite device along the guide plate 5.
[0049] S2, Composite molding: A second fixed-distance pressing roller assembly 200 presses two primary sheets 4 together into a composite sheet 8 according to the control signal output by the control device.
[0050] Specifically, the core processor synchronously sends a control signal to the first motor 23 of the sheet laminating device, and the second fixed-distance pressure roller assembly 200 of the laminating device is started. The primary sheets 4 on the left and right sides are guided by the corresponding guide plates 5 and then synchronously enter the pressure rollers of the sheet laminating device. Under the action of extrusion, they are bonded to form a composite sheet 8, which is then conveyed to the adjustable pressure roller assembly 6.
[0051] S3, Sheet Shaping: The adjustable pressure roller assembly 6 presses and shapes the composite sheet 8 into a shaped sheet 9 with a defined thickness.
[0052] In step S3, the core processor controls the second motor 63 to start, driving the active pressure roller 61 to rotate, which in turn drives the driven pressure roller 62 to rotate synchronously through gear meshing. The composite sheet 8 enters between the active pressure roller 61 and the driven pressure roller 62. The core processor sends an initial signal to the drive module according to the preset standard thickness, and the electric push rod 71 actuates to adjust the gap between the rollers to the initial position, initially pressing and forming the sheet 9.
[0053] In this embodiment, the following thickness detection and dynamic adjustment steps are also included: Specifically, the formed sheet 9 enters the U-shaped detection area of the sheet thickness intelligent detection device. Two laser displacement sensors detect distance information d1 and d2 respectively and transmit it to the sheet thickness calculation module. The sheet calculation module calculates the actual thickness T using the formula T=D-d1-d2, compares it with the standard thickness to obtain the error value, and transmits the error information to the core processor in real time.
[0054] S4, the distance information from the laser displacement sensor to the forming sheet 9 is detected by the laser displacement sensor group. The sheet thickness calculation module calculates the thickness of the forming sheet 9 based on the detected distance information according to the formula: T=D-d1-d2, and compares the sheet thickness calculation information with the preset standard thickness to calculate the thickness error value. The error value = actual thickness T - standard thickness, and sends the error information to the core controller.
[0055] S5, the core controller uses a PID adaptive adjustment algorithm to generate a dynamic adjustment signal based on error information and pressure feedback information from the pressure sensor, and outputs the dynamic adjustment signal to the drive module. The drive module converts the adjustment signal into a drive command, controls the extension and retraction of the electric push rod 71, adjusts the movement of the driven pressure roller 62 relative to the active pressure roller 61, and realizes the adjustment of the gap between the face rollers.
[0056] S6, the alarm reminder module collects three thickness errors within a preset period, compares them with the error alarm threshold, matches the alarm level, and triggers audible and visual alarms, SMS notifications or remote platform alarms according to the level. The real-time pressure curve, thickness error value, production parameters, alarm information and adjustment parameters are displayed through the display module. Throughout the processing, the alarm module collects thickness error data transmitted by the core processor in real time. It records the thickness error value at a preset interval, such as every 10 seconds. After three consecutive thickness error data collections, it compares them with preset error alarm thresholds, such as a first-level threshold of ±0.1mm and a second-level threshold of ±0.3mm. If all three error values are within the first-level threshold, it is considered "normal" and no alarm is triggered. If one of the three error values exceeds the first-level threshold but not the second-level threshold, it is considered a "first-level alarm," triggering a flashing yellow light and a buzzer alarm on the device. If one of the three error values exceeds the second-level threshold, it is considered a "second-level alarm," triggering a continuous red light and a continuous buzzer alarm on the device, and simultaneously sending an SMS notification to a preset management personnel's mobile phone number. If all three error values exceed the second-level threshold, it is considered a "serious anomaly," triggering all measures for a second-level alarm, and also uploading the alarm information to a remote monitoring platform to alert maintenance personnel for emergency handling.
[0057] This embodiment, applied in a food processing plant, targets a thickness error of 0.15mm for the production of 2.5mm thick dough sheets. During operation, the system dynamically adjusts the roller spacing to control the actual thickness error within the range of 0.10-0.15mm, significantly improving product quality consistency. Simultaneously, the adaptive adjustment function allows the system to quickly adapt to differences in flour characteristics between different batches, reducing the need for manual intervention.
[0058] As shown in Table 1, compared with traditional dough pressing equipment, this device has a smaller thickness error range and faster pressure response, in addition to having a detection and alarm function. Moreover, in the face of differences in different batches of flour and different dough moisture content, the system can automatically adjust the pressure and gap of the pressing rollers without manual intervention, and the adjustment accuracy is higher.
[0059] Table 1
[0060] The test conditions were as follows: dough thickness: 2.5mm±0.1mm, flour protein content: 12±0.5%, and dough moisture content: 50±5%RH.
[0061] This invention achieves precise control of the formed sheet thickness through real-time detection by an intelligent sheet thickness detection device and dynamic adjustment using a PID adaptive adjustment algorithm. The error can be controlled within ±0.15mm, far exceeding traditional manual adjustment methods. Furthermore, from initial forming and composite forming to final shaping, detection, adjustment, and alarm, the entire process requires no manual intervention, significantly reducing the labor intensity of operators and avoiding human error. In addition, a multi-level alarm mechanism, combined with local audible and visual alarms, SMS notifications, and remote platform alarms, ensures that abnormal situations can be quickly detected and handled, reducing the production of defective products. By adjusting the preset parameters of the control device, it can adapt to the processing needs of sheets with different thicknesses and moisture levels (such as dumpling wrappers, noodle sheets, and bun wrappers), making it flexible in application scenarios.
[0062] It should be noted that the order of the embodiments described above is merely for descriptive purposes and does not represent the superiority or inferiority of the embodiments. In some cases, the actions or steps recorded in the specification and claims can be performed in a different order than that shown in the embodiments, and the desired result can still be achieved. In addition, the processes depicted in the drawings do not necessarily require a specific or sequential order to achieve the desired result; in some embodiments, multitasking and parallel processing are also feasible or advantageous.
[0063] Those skilled in the art will understand that all or part of the steps of the above embodiments can be implemented by hardware or by a program instructing the relevant hardware to implement them. The program can be stored in a computer-readable storage medium, such as a read-only memory, a disk, or an optical disk.
[0064] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to the embodiments of this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.
Claims
1. A sheet forming apparatus, characterized in that, include: The dough sheet primary forming device includes a pair of symmetrically arranged first fixed-distance pressing roller assemblies (2), which are used to press dough flakes (3) into primary dough sheets (4). A sheet composite device, the sheet composite device including a second fixed-distance pressing roller assembly (200) located below the pair of first fixed-distance pressing roller assemblies (2), the second fixed-distance pressing roller assembly (200) being used to composite two primary sheets (4) into a composite sheet (8). Adjustable pressure roller assembly (6), which is used to shape the composite sheet (8) into a shaped sheet (9). The adjustable pressure roller assembly (6) includes an active pressure roller (61), a driven pressure roller (62), and a roller gap adjustment mechanism (7). The roller gap adjustment mechanism (7) can drive the driven pressure roller (62) to move relative to the active pressure roller (61) to adjust the roller gap so that the formed sheet (9) obtains a certain thickness.
2. The sheet forming apparatus according to claim 1, characterized in that, The roller gap adjustment mechanism (7) includes: Electric push rod (71), mounted on the frame; Push plate (72), the push plate (72) is mounted on the extension rod (711) of the electric push rod (71), and push rods (73) are installed at both ends of the push plate (72); A pair of bearing seats (74) are movably installed at the corresponding notches (12) on the frame. The bearing seats (74) are fixedly connected to the corresponding push rods (73). The driven pressure roller (62) is installed on the pair of bearing seats (74).
3. The sheet forming apparatus according to claim 2, characterized in that, It also includes a control device for controlling the movement of the electric push rod (71) to adjust the movement of the driven pressure roller (62) relative to the driving pressure roller (61), thereby adjusting the gap between the face rollers so that the formed face sheet (9) obtains a certain thickness. A pressure sensor is provided at the electric push rod (71) for detecting the reaction force of the face sheet on the driven pressure roller (62) and feeding back the detection data to the control device.
4. The sheet forming apparatus according to claim 3, characterized in that, The control device includes a core processor, a display module, a driver module, and an alarm reminder module; The core processor is used to acquire parameter data input by legitimate users and control the display module to visualize the thickness data, adjustment parameters and abnormal alarm status of the sheet. It is also used to generate a dynamic adjustment signal based on the thickness detection data and pressure feedback information from the pressure sensor using a PID adaptive adjustment algorithm, and output the dynamic adjustment signal to the drive module, which controls the movement of the electric push rod (71). The alarm reminder module is connected to the core processor and is used to analyze alarm information, perform multi-mode audible and visual alarms and remote alarms.
5. The sheet forming apparatus according to claim 4, characterized in that, It also includes a sheet thickness intelligent detection device, which is used to detect the thickness of the formed sheet (9) and feed the detection result back to the core controller, thereby realizing real-time control of the sheet thickness; The intelligent sheet thickness detection device includes a laser displacement sensor group and a sheet thickness calculation module. The laser displacement sensor group is installed below the adjustable pressure sheet roller assembly (6). The laser displacement sensor group includes a first laser displacement sensor set in front of the formed sheet (9) and a second laser displacement sensor set behind the formed sheet (9). The sheet thickness calculation module receives the detection information from the laser displacement sensor group, calculates the thickness of the formed sheet (9) according to the formula: T=D-d1-d2, compares the sheet thickness calculation information with the preset standard thickness, and sends the error information to the core controller. The distance from the first laser displacement sensor to the surface of the formed sheet (9) is d1, the distance from the second laser displacement sensor to the surface of the formed sheet (9) is d2, and the fixed distance between the two sensors is D.
6. A method for forming a dough sheet based on the dough sheet forming apparatus according to any one of claims 1 to 5, characterized in that, Includes the following steps: S1, Initial forming: A pair of first fixed-distance pressing roller assemblies (2) press the dough flakes (3) into initial dough sheets (4) according to the control signal output by the control device. S2, Composite molding: A second fixed-distance pressing roller assembly (200) presses two primary sheets (4) into a composite sheet (8) according to the control signal output by the control device. S3, sheet shaping: The adjustable pressure roller assembly (6) presses and shapes the composite sheet (8) into a shaped sheet (9) with a defined thickness. The control device is used to control the movement of the electric push rod (71) and adjust the movement of the driven pressure roller (62) relative to the active pressure roller (61), thereby adjusting the gap between the rollers of the adjustable pressure roller assembly (6) so that the formed sheet (9) obtains a certain thickness. A pressure sensor is provided at the electric push rod (71). The pressure sensor is used to detect the reaction force of the sheet on the driven pressure roller (62) and transmit the detection data to the core processor of the control device. The sheet thickness intelligent detection device is used to detect the thickness of the formed sheet (9) and feed the detection result back to the core processor to realize real-time control of the sheet thickness.
7. The sheet forming method according to claim 6, characterized in that, It also includes the following steps: S4, the distance information from the laser displacement sensor to the forming sheet (9) is detected by the laser displacement sensor group. The sheet thickness calculation module calculates the thickness of the forming sheet (9) based on the detected distance information according to the formula: T=D-d1-d2, and compares the sheet thickness calculation information with the preset standard thickness, and sends the error information to the core controller. S5, the core controller uses a PID adaptive adjustment algorithm to generate a dynamic adjustment signal based on error information and pressure feedback information from the pressure sensor, and outputs the dynamic adjustment signal to the drive module. The drive module controls the electric push rod (71) to move, and adjusts the movement of the driven pressure roller (62) relative to the active pressure roller (61).
8. The sheet forming method according to claim 7, characterized in that, It also includes the following steps: S6, the alarm reminder module collects three thickness errors within a preset period, compares them with the error alarm threshold, matches the alarm level, and triggers audible and visual alarms, SMS notifications or remote platform alarms according to the level. The real-time pressure curve, thickness error value, production parameters, alarm information and adjustment parameters are displayed through the display module.