Gyoza Wrapper Molding Machine with Pendulum Direction Change
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Solution Overview
Problem
Existing methods for manufacturing gyoza wrappers require professional skill and large apparatuses, making it difficult for small kitchens or restaurants to produce a large number of gyoza wrappers efficiently, and the wrappers often adhere to each other, making advance manufacturing undesirable.
Innovation Solution
A molding machine that rolls a gyoza wrapper material lump using a first roller and a direction changing device with a pendulum to form a semi-finished product, which is then rolled by a second roller to create a uniform thickness and circular shape, along with a gyoza wrapper material lump having a notch for easy alignment and storage to prevent adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If stamping molding is used to form gyoza wrappers from a band-shaped sheet, then gyoza wrappers can be mass produced, but a large amount of material is required and a collection mechanism is needed
Solution Approach 1:
The band-shaped sheet is divided into individual gyoza wrapper portions by the cutting member, which cuts the continuous sheet into separate circular wrappers. This segmentation eliminates the need for large material preparation and simplifies the collection mechanism by processing one portion at a time.
2Manufacturing precision
If a die with a circular cavity is used to mold gyoza wrappers, then wrappers can be formed with proper shape, but it is difficult to remove the wrappers from the die
Solution Approach 1:
The gyoza wrapper portion is extracted from the die cavity by the lifting member, which lifts the formed wrapper out of the die. This extraction mechanism solves the removal difficulty by providing a dedicated lifting action that separates the wrapper from the die cavity without requiring complex release mechanisms.
3Productivity
If a large-size apparatus is used to continuously manufacture gyoza wrappers, then high production rate is achieved, but it is difficult for small kitchens to introduce and the wrappers adhere to each other
Solution Approach 1:
The apparatus is segmented into separate functional modules: a sheet feeding section, a molding section with die, a cutting member, and a lifting member. This modular segmentation allows the device to be compact while maintaining continuous manufacturing capability, making it suitable for small kitchens.
Solution Approach 2:
The gyoza wrappers are formed and immediately lifted out of the die by the lifting member, preventing them from remaining in contact with each other or the die surface. This preliminary action of immediate removal prevents adhesion and allows wrappers to be stacked without sticking together.
4Manufacturing precision
If professional skill is required to form gyoza wrappers manually, then wrappers can be formed with proper shape and uniform thickness, but it is difficult to maintain constant production rate
Solution Approach 1:
The apparatus performs self-service by automatically forming, cutting, and lifting gyoza wrappers without requiring manual skill. The die cavity automatically forms the wrapper shape, the cutting member automatically cuts the sheet, and the lifting member automatically removes the formed wrappers, eliminating the need for professional skill while maintaining constant 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 efficient production of gyoza wrappers with high uniformity and simplicity, reducing the need for professional skill and large apparatuses, and prevents adhesion during storage and use.
Implementation Method 1
a direction changing device comprising a pendulum, and arranged on the lower side of the first roller in the vertical direction, wherein the pendulum comprises a fulcrum portion thereof and an edge receiving portion arranged at a position on the lower side of the fulcrum portion of the pendulum in the vertical direction
Data Source
AI summary
A molding machine 1 is provided, which molds a gyoza wrapper by rolling a gyoza wrapper material lump. A first roller 12 rolls the gyoza wrapper material lump vertically downward to form an approximately elliptical semi-finished product. A direction changing device 30 including a pendulum 31 is positioned vertically below the first roller 12. The pendulum 31 includes a fulcrum portion 314 and an edge receiving portion 311 positioned closer to the central portion side of the first roller 12 than a position immediately below the fulcrum portion 31, which receives the front edge of the semi-finished product. When the semi-finished product is received by the edge receiving portion 311, the pendulum 31 changes the direction of the semi-finished product. A second roller 22 positioned vertically below the first roller 12 then rolls the semi-finished product vertically downward, so as to form a gyoza wrapper.