Optical Sorting and Robotic Pairing for Sandwich Production
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Solution Overview
Problem
The industrial production of filled sandwiches is time-consuming and expensive due to the significant amount of manual work involved, which hampers efficiency and increases costs.
Innovation Solution
A fully automated system utilizing optical detectors to sort and align sandwich discs, robotic grippers to pair and fold the discs, and a pressure roasting station to seal the sandwiches with a food-grade bonding agent, ensuring precise alignment and a secure, leak-proof seal for efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual work is used for placing and aligning sandwich slices, then flexibility and simplicity are maintained, but productivity is low and labor costs are high
Solution Approach 1:
The system uses optical detectors to automatically detect and sort sandwich slices based on their geometric properties, and robotic grippers to automatically place and align them, eliminating the need for manual intervention while maintaining high productivity
Solution Approach 2:
Manual mechanical operations are replaced with an automated system combining optical detection, robotic manipulation, and controlled mechanical pressing, transitioning from labor-intensive to automation-intensive processes
2Reliability
If sandwich slices are not pre-toasted and sealed, then preparation is simpler, but ingredients escape during toasting causing fire hazards and damage
Solution Approach 1:
The sandwich slices are pre-toasted and sealed with a bonding agent before final assembly, creating a secure closure that prevents ingredient escape during subsequent toasting in consumer toasters
Solution Approach 2:
The pressing operation applies controlled heat and pressure to activate the bonding agent and seal the sandwich edges, transforming the physical state of the bread and adhesive to create a permanent seal
3Manufacturing precision
If optical detectors and robotic grippers are used for automatic sorting and alignment, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
Visual inspection and manual alignment are replaced with optical detection systems that automatically measure sandwich slice geometry and robotic grippers that precisely position them, achieving high precision through automation
Solution Approach 2:
The optical detectors create a digital representation of the sandwich slice geometry, which is then used by the control system to guide the robotic gripper in precise alignment operations
4Reliability
If pressure and heat are applied to seal sandwich edges, then reliability is improved, but energy consumption increases
Solution Approach 1:
The pressing operation applies controlled heat and pressure for a brief duration to activate the bonding agent and seal the sandwich edges, using minimal energy to achieve the required seal integrity
Solution Approach 2:
A food-grade bonding agent is applied to the sandwich edges before pressing, creating a composite structure that bonds the bread slices together and seals the filling, reducing the need for excessive heat and pressure
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
The automated system significantly reduces manual labor, increases production speed, and ensures high-quality, leak-proof filled sandwiches that can be toasted without ingredient escape, enhancing both efficiency and cost-effectiveness.
Implementation Method 1
The conveyor belt is now screened according to the invention for sorting out and aligning the sandwich disks in such a way that the light which penetrates the conveyor belt is detected by optical detectors.
Implementation Method 2
the sandwich slices, after they have been assembled to form a sandwich of the type mentioned above, are connected to one another in a firm and liquid-tight manner in their edge regions by applying pressure and heat
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
Method and plant for the industrial production of filled sandwiches (34, 80, 80') comprising two sandwich discs (14, 14', 14'', 14b', 14b'', 14c', 14c') and at least one value-determining ingredient (26), wherein, in addition to many other work steps in a processing station (60), the method sorts out unusable sandwich discs (14a) in a work step (B) and aligns the remaining sandwich discs (14, 14', 14'', 14b', 14b'', 14c', 14c") for further processing. For this purpose, a conveyor belt (16) on which the sandwich discs lie is illuminated such that the light is detected by optical detectors (64) and unusable sandwich discs (14a) are identified and automatically sorted out based on differences in brightness and/or color and their spatial distribution, and sandwich discs (14b', 14b'', 14c', 14c'') of similar geometry are recognized and placed in pairs on a conveyor belt (16, 16').