Dough Line Automated Property Tracking and Control
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Solution Overview
Problem
Existing dough lines face challenges in controlling settings changes along the processing line, requiring manual adjustment by a controller as the dough moves through various devices, which is inefficient and difficult to manage.
Innovation Solution
A dough line with multiple processing devices and conveyors equipped with measurement devices and a digital controller that records and calculates physical properties of the dough sheet at predetermined positions, allowing for automated adjustment of settings based on expected changes and conveyor speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual control of dough processing settings is used, then the controller can adjust settings as dough arrives at each device, but the process is difficult to control and requires continuous manual intervention
Solution Approach 1:
The system performs preliminary actions by measuring dough properties at upstream positions and calculating expected properties at downstream positions before the dough actually arrives. This allows the controller to pre-adjust settings of processing devices based on predicted dough characteristics, eliminating the need for continuous manual intervention while maintaining ease of control.
Solution Approach 2:
The system implements feedback by using measurement devices to continuously monitor dough properties (width, position, thickness) and using this information to automatically adjust processing device settings. The controller receives feedback from measurements and automatically modifies parameters, reducing control complexity while improving ease of operation.
2Productivity
If settings are changed at the beginning of the dough line, then production can start for another product, but the controller must follow the dough throughout the line to adapt settings
Solution Approach 1:
The system calculates expected dough properties at various positions along the processing line in advance, before the dough actually reaches those positions. This preliminary calculation allows settings to be automatically adjusted without requiring the controller to track and manually adjust settings as dough moves through the line, saving time and improving productivity during product transitions.
Solution Approach 2:
The system performs self-service by automatically adjusting processing device settings based on calculated expected dough properties, without requiring continuous human intervention. The controller autonomously manages setting changes throughout the dough line, reducing the time loss associated with manual setting adjustments and improving overall production efficiency.
3Measurement precision
If measurement devices are placed along the conveyors, then physical dough properties can be determined at specific positions, but the system must calculate properties for future positions based on expected conveyor speeds and processing changes
Solution Approach 1:
The system performs preliminary calculations of dough properties at downstream positions based on measured properties at upstream positions, using expected conveyor speeds and known processing device characteristics. This allows the system to determine future dough properties in advance, maintaining measurement precision while managing system complexity through systematic calculation approaches.
Data Source
AI summary
Dough line for processing a dough sheet, comprising a plurality of subsequent dough processing devices, each for performing a dough processing step on the dough sheet; the dough processing step changing at least one physical property of the dough sheet, one or more conveyors for transporting the dough sheet along each of the subsequently dough processing devices, each with a predetermined speed, at least one device for measuring said physical dough sheet property at said position, a processing device, comprising a register, comprising records corresponding with multiple predetermined positions along the dough line wherein the processing device is configured for recording at least one physical dough sheet property in a record for a first predetermined position and calculating physical dough sheet properties for further predetermined positions, based on expected speeds of the one or more conveyors or dough processing devices.