Dough Sheeter Docker Speed and Gap Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing dough sheeters with integral dockers face issues of inconsistent deaeration due to fixed speed and inconvenient gap adjustments, leading to non-uniform dough processing, especially when handling doughs of different thicknesses and consistencies.
Innovation Solution
A dough sheeter with a separate docker drive mechanism and a removable docker assembly that allows independent speed adjustment of the docker and convenient gap adjustment, enabling uniform deaeration and easy operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the docker is driven by the same belt that drives the sheeter system, then the docker operates at a fixed speed relative to the sheeter, but this causes inconsistent deaeration when handling doughs of different thicknesses and consistencies
Solution Approach 1:
The drive system is segmented into two independent parts: the sheeter drive mechanism (belt-driven rollers) and the docker drive mechanism (separate motor driving the docker roller). This segmentation allows each component to be controlled independently, enabling the docker speed to be adjusted separately from the sheeter speed to accommodate different dough types and thicknesses.
Solution Approach 2:
The docker roller is equipped with an adjustable speed mechanism that allows its rotational speed to be dynamically changed relative to the sheeter rollers. This dynamic adjustment capability enables the system to adapt to varying dough characteristics, ensuring consistent deaeration performance across different dough types.
2Ease of operation
If the gap adjustment mechanism is integrated into the housing, then the gap can be adjusted, but the adjustment is very inconvenient
Solution Approach 1:
The gap adjustment mechanism is extracted from the fixed housing structure and implemented as a movable backer assembly that can be independently positioned. The backer is mounted on a rod that can be adjusted along the length of the housing, allowing the gap between the docker roller and backer to be easily changed by moving the backer assembly rather than disassembling the housing.
Solution Approach 2:
The backer assembly includes an integrated adjustment mechanism with a knob or handle that allows the operator to directly control the gap size through a simple rotational motion. This self-service design eliminates the need for complex tool-based adjustments or housing disassembly, making gap adjustment a quick and convenient operation.
3Device complexity
If a manually operated rolling pin-type docker is used, then the device is simple, but inconsistencies in the deaerating process occur due to non-uniform rolling
Solution Approach 1:
The manual mechanical rolling pin operation is replaced with a motor-driven docker roller system. The motor provides consistent rotational force, and the roller is supported by bearings to ensure uniform rotation. This mechanical substitution eliminates the variability introduced by manual operation, resulting in consistent deaeration across the entire dough surface.
Solution Approach 2:
The docker roller system incorporates a drive mechanism that maintains constant rotational speed through motor control. This feedback-controlled speed regulation ensures that the docker roller rotates at a uniform rate, preventing the speed variations that cause non-uniform deaeration in manual systems.
Data Source
AI summary
The present invention is a dough sheeter with integral dough docker. The dough docker is a removable assembly with a docker subassembly and a scraper subassembly. The docker subassembly includes the docker roller and grate. The docker sprocket, driven by the sheeter motor, has a disk that meshes with a complimentary disk on the docker roller. The scraper subassembly includes the scraper, the backer attached to the scraper, and the gap adjuster, which includes a semicircular shaft that abuts the backer, a rectangular shaft attached to the scraper, and a threaded rod extending from the semicircular shaft through a hole in the scraper and a threaded hole in the rectangular shaft. The gap is adjusted by turning the rod in or out of the threaded hole.