Robotic Sandwich Assembly With Adaptive Bread Handling

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Solution Overview

Problem

The existing methods for assembling and packaging sandwiches, particularly hoagie style sandwiches, are inefficient and labor-intensive, leading to non-uniform results and increased labor costs due to the need for manual assembly and the difficulty in maintaining uniformity across different types of bread and toppings.

Innovation Solution

An automated system that uses robots and conveyors to slice, assemble, and package sandwiches, allowing for the selective addition of components and ensuring uniformity, with ultrasonic slicers and pick robots like the Weber PickRobot and SmartLoader, which handle different types of bread and toppings efficiently.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If manual assembly line is used for hoagie style sandwiches, then flexibility in handling different bread types is maintained, but labor costs increase and uniformity decreases

Engineering Contradiction:

Improveautomation of sandwich assemblyVSAvoidcomplexity of handling different bread geometries

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The system employs adjustable positioning mechanisms and reconfigurable fixtures that can dynamically adapt to different bread types and geometries. The assembly line includes adjustable guides and support structures that can be repositioned to accommodate various bread shapes, maintaining automation while handling diversity in product specifications.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system utilizes programmable control parameters that can be changed to accommodate different sandwich types. By modifying control settings, positioning coordinates, and assembly parameters through software rather than physical reconfiguration, the system maintains high automation levels while adapting to various bread types and topping combinations.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If automated assembly is implemented, then labor costs decrease and uniformity increases, but difficulty in handling hoagie style bread geometry increases

Engineering Contradiction:

Improveuniformity of sandwich assemblyVSAvoidease of adding inputs to hoagie bread

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The system introduces intermediary positioning fixtures and transfer mechanisms that mediate between the automated robotic components and the hoagie style bread. These intermediaries provide stable reference points and support structures that make it easier for automated systems to handle the challenging geometry of split-top bread, improving ease of manufacture while maintaining precision.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system replaces manual mechanical manipulation with automated robotic systems equipped with specialized end-effectors. These robotic components use controlled motion, force, and positioning algorithms to overcome the geometric challenges of hoagie bread, achieving uniform assembly precision that would be difficult with manual labor alone.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If bulk production is implemented, then productivity increases, but risk of cross-contamination increases

Engineering Contradiction:

Improvebulk production capacityVSAvoidcross-contamination risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The automated assembly line is divided into separate, dedicated stations for different sandwich types and topping categories. Each station is configured for specific product types, and the system uses automated changeover procedures that include cleaning and validation steps between production runs. This segmentation allows bulk production while minimizing cross-contamination risks through physical and procedural isolation of different product lines.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system incorporates sensors, vision systems, and control mechanisms that continuously monitor the assembly process for contamination risks. Automated cleaning systems are triggered based on product changeovers, and the control system tracks and validates that proper cleaning procedures have been completed before switching between different sandwich types, providing feedback-based contamination prevention.

Inventive Principle:

Principle #23Feedback

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 labor costs and increases efficiency while ensuring uniformity and safety in the assembly and packaging of sandwiches, enabling the production of variable sandwiches in bulk with reduced risk of cross-contamination.

Implementation Method 1

ultrasonic slicers

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Data Source

PatentUS20210169120A1Automated food preparation and packaging systems, methods, and apparatus

Publication Date: 2021.06.10 WEST LIBERTY FOODS LLC

AI summary

The automated assembly and manufacture of a submarine sandwich includes a number of robots that are used to slice, open, and add inputs to a roll of bread. The inputs may be sliced and portioned at individual stations and then the inputs can be delivered to the bread or the bread can be conveyed to the inputs. In either sense, the selected inputs are added to the bread, based on the type of sandwich to be assembled. The assembled sandwich is then conveyed to a packaging station, where the sandwich is packaged, labeled, and prepared for shipment.