Automated Burrito Maker Air Blast Folding
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Solution Overview
Problem
Manual on-site assembly of burritos leads to labor and quality control issues, with a need for an automated process that can produce consistent products efficiently without sacrificing quality.
Innovation Solution
An automated burrito maker system that includes a tortilla dispensing station, filling station, air blast station, front and side fold stations with rollers and crimping rails, and a freezing station to form and package burritos, allowing for precise deposition and folding of tortillas around burrito filling ingredients.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual on-site assembly is used, then flexibility in handling different ingredients is maintained, but labor demands increase and quality consistency deteriorates
Solution Approach 1:
The automated burrito assembly system is divided into distinct functional stations: a filling station that deposits filling onto tortillas, an air blast station that lifts the tortilla leading edge, and fold stations with rails that guide folding. This segmentation allows each component to perform a specific function, reducing overall system complexity while achieving high automation.
Solution Approach 2:
An air blast is used as an intermediary mechanism to lift the tortilla leading edge without direct mechanical contact. This pneumatic intermediary simplifies the lifting operation compared to mechanical grippers or actuators, reducing device complexity while maintaining automation.
2Productivity
If manual folding is performed, then adaptability to different burrito types is maintained, but productivity decreases and quality consistency worsens
Solution Approach 1:
The tortilla leading edge is lifted using an air blast that acts on the tortilla itself, causing it to fold under its own weight and the guidance of the folding rails. This self-service mechanism eliminates the need for complex mechanical folding actuators, maintaining ease of operation while dramatically increasing productivity to approximately 700 burritos per minute.
3Productivity
If rapid automated production is implemented, then productivity increases to 700 burritos per minute, but manufacturing precision may deteriorate
Solution Approach 1:
The filling is deposited onto the tortilla at a controlled filling station before the tortilla enters the high-speed folding and production sequence. This preliminary action allows precise filling placement to be established early in the process, ensuring manufacturing precision is maintained even as the tortilla moves rapidly through subsequent stations at 700 burritos per minute production rate.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the production of high-quality burritos at high speeds, approximately 700 per minute, with consistent filling and folding, reducing labor demands and improving product quality.
Implementation Method 1
an air supply positioned below the gap for delivering an air blast to lift the leading edge of each tortilla as each tortilla is conveyed in the machine direction from the first horizontal belt toward the second horizontal belt and over the gap
Data Source
AI summary
An automated burrito maker is described, including a filling station for providing a quantity of burrito filling on an upper surface of tortillas on a first belt, an air supply positioned below a gap between the first belt and a second belt for delivering an air blast to lift a leading edge of each tortilla moving over the gap, a front fold station for crimping the leading edge of the tortilla toward the upper tortilla surface and around at least a portion of the burrito filling, a first side fold station having a first folding rail for wrapping the first tortilla side over at least a portion of the burrito filling, and a second side fold station having a second folding rail for wrapping the second tortilla side over at least a portion of the burrito filling and at least a portion of the first side of the tortilla.