Inline Transport Device for Buffering Flat Baked Products
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Solution Overview
Problem
Existing production systems for flat baked products, such as waffles, face challenges in maintaining a continuous process flow due to downstream machine failures, leading to high product rejects and the need for costly and space-consuming intermediate storage solutions.
Innovation Solution
A production plant with an inline transport device featuring conveyor belts and manipulators that allow for stacking and unstacking of products, enabling temporary buffering and storage within the transport route, which can adjust speed and direction to compensate for downstream system failures, thus avoiding the need for external intermediate storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If parallel wafer block intermediate stores are provided to buffer products during downstream failures, then product rejects are reduced, but investment costs increase, space requirements increase, and production process complexity increases
Solution Approach 1:
The patent combines the transport function and intermediate storage function into a single inline transport device. The transport device can operate in two modes: conveying products individually during normal operation, and forming stacks of products to create intermediate storage capacity when downstream systems fail. This merging eliminates the need for separate parallel intermediate stores while maintaining the ability to buffer products during disruptions.
Solution Approach 2:
The inline transport device is designed with multi-functionality, serving both as a continuous transport route and as an intermediate storage system. By incorporating stacking capability through manipulators, the same hardware infrastructure can dynamically switch between conveying mode and storage mode, providing universal functionality that addresses both transport and buffering requirements without adding separate dedicated systems.
2Reliability
If conventional intermediate storage solutions are implemented, then continuous product flow is maintained during downstream failures, but space requirements and investment costs increase significantly
Solution Approach 1:
The patent merges the transport route and intermediate storage into a single inline transport device. During normal operation, the device conveys products continuously. When downstream failures occur, the device forms stacks of products along the transport route, utilizing the same physical space for both transport and storage purposes, thereby eliminating the need for separate dedicated storage areas.
Solution Approach 2:
The transport device incorporates dynamic functionality through manipulators that can stack and unstack products on demand. This dynamic capability allows the system to adapt its configuration based on operational needs - conveying individually during normal operation and forming stacks during disruptions - maximizing the utilization of available space without requiring additional fixed infrastructure.
3Quantity of substance
If the transport device forms stacks of products for buffering, then intermediate storage is achieved within the transport route, but device complexity increases
Solution Approach 1:
The patent integrates the stacking function directly into the inline transport device by incorporating manipulators at transfer stations. This merging allows the transport device to provide intermediate storage capacity by forming stacks of products along the transport route, utilizing the same hardware infrastructure for both transport and storage operations without requiring separate dedicated storage systems.
Solution Approach 2:
The manipulators integrated into the transport device perform stacking and unstacking operations autonomously based on system needs. During downstream failures, the manipulators automatically form stacks to buffer products; during normal operation, they convey products individually. This self-service capability allows the transport device to dynamically adjust its own configuration to provide intermediate storage without external intervention or complex external control systems.
Data Source
Figure 1~2
Figure 3a~3c
Figure 4
AI summary
The invention relates to a production system for producing flat, stackable products of the food industry, particularly preferably flat baked products, comprising a pre-treatment system (2), particularly preferably a baking device for baking raw dough products, a subsequent transport device (3) for the further transport of the baked products, and a post-treatment system (4) arranged after the transport apparatus. The transport device (3) has a first transfer station (5) at the entrance of the transport device, at least two conveyor belts (9) after the first transfer station, and, after the at least two conveyor belts, a second transfer station (6) at the exit of the transport device. The first transfer station (5) has a first manipulator (10), by means of which the baked products can be stacked one over the other and/or unstacked, and the second transfer station (6) has a second manipulator (11), by means of which the baked products can be stacked one over the other and/or unstacked, such that the baked products can be stored in the transport device by forming a stack of the baked products. The individual conveyor belts of the at least two conveyor belts can be individually controlled, such that the conveying direction and/or conveying speed of each conveyor belt can be changed.