Paper Interleaver Shuttle Plate Vacuum Suction
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Solution Overview
Problem
Existing systems for inserting paper underneath food patties during processing and packaging are limited in efficiency and flexibility, particularly when integrated with food patty molding machines, as they often restrict the ability to apply paper after top and bottom perforations and are not compatible with double row forming technology, leading to reduced production speeds and increased maintenance needs.
Innovation Solution
A separate paper interleaver system comprising a hopper with a tear pin design, vacuum ports, and a shuttle plate with mechanical or pneumatic controls, allowing for precise placement of paper underneath food patties, which can be transported and aligned using a conveyor system, enabling efficient paper application independent of the molding machine and supporting higher production speeds and reduced maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If paper interleaving is integrated with the food patty molding machine, then the paper insertion process is automated, but the production speed is reduced and maintenance needs increase
Solution Approach 1:
The paper interleaving function is separated from the food patty molding machine into an independent interleaver device. This segmentation allows each machine to operate independently at optimal speeds, with the interleaver专门负责 paper insertion without constraining the molding machine's production speed, thereby resolving the contradiction between automation and productivity.
Solution Approach 2:
An independent interleaver device acts as an intermediary between the food patty molding machine and the final packaging process. This intermediary device handles paper insertion separately, allowing the molding machine to maintain high production speeds while still achieving automated paper insertion through the coordinated operation of the interleaver.
2Extent of automation
If paper interleaving is integrated with the food patty molding machine, then paper insertion is automated, but maintenance needs increase
Solution Approach 1:
By segmenting the paper interleaving function into a separate, dedicated device, the complexity and maintenance burden are isolated to the interleaver rather than affecting the entire molding system. This allows for easier maintenance and repair of the interleaver component without disrupting the food patty molding operation.
Solution Approach 2:
The paper insertion mechanism is extracted from the molding machine, removing the maintenance complexity associated with integrated systems. The standalone interleaver can be maintained and repaired independently, reducing the overall maintenance needs of the production line.
3Loss of time
If paper is applied before top and bottom perforations, then paper placement is early in the process, but the ability to apply paper after perforations is lost
Solution Approach 1:
The interleaver is positioned and paper is prepared in advance before the perforation process, but the actual paper application occurs after perforation is complete. This preliminary positioning enables the system to maintain flexibility in the sequence of operations, allowing paper to be applied after both top and bottom perforations while still achieving efficient placement.
Solution Approach 2:
The interleaver system is designed with dynamic positioning capabilities that allow it to operate at different stages of the processing sequence. This dynamic design enables the system to adapt to different process requirements, including applying paper after perforation, thereby maintaining versatility while optimizing timing.
4Productivity
If a separate interleaver is used, then production speed increases and maintenance decreases, but device complexity increases
Solution Approach 1:
The independent interleaver is designed as a universal device that can handle various paper types and integrate with different molding machine configurations. This multi-functionality reduces the need for multiple specialized devices, thereby managing system complexity while maintaining high production speeds and low maintenance requirements.
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 system enhances production efficiency by allowing paper application after both top and bottom perforations, supports double row forming technology, and reduces maintenance needs by minimizing wear on parts, thereby extending equipment lifespan and lowering operational costs.
Implementation Method 1
The shuttle plate contains one or more holes (ports) which draw air into the ports creating a suction or vacuum to hold the paper in place
Data Source
AI summary
A paper interleaver that is separate from the food patty molding machine for inserting a sheet of paper underneath a meat patty.