Robotic Sandwich Assembly With Bread Orientation Feedback
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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 ideal bread orientation for adding 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 features like ultrasonic slicers, PickRobots, and SmartLoaders to manage inputs and packaging efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual assembly line is used for sandwich preparation, then flexibility in handling different bread types is maintained, but labor costs increase and uniformity decreases
Solution Approach 1:
The patent implements a universal automated assembly system that can handle multiple bread types (sliced bread, hoagie rolls, sub rolls) through programmable control. The system uses adjustable components including variable blade positions, adjustable conveyor speeds, and reconfigurable input hoppers that can accommodate different bread geometries and sizes, allowing one machine to perform multiple sandwich preparation functions without requiring manual intervention for each bread type
Solution Approach 2:
The patent replaces manual mechanical assembly with an automated mechanical system featuring robotic arms, automated slicers, and computer-controlled conveyor systems. The mechanical system uses programmable logic to automatically adjust parameters such as blade depth, conveyor speed, and component placement positions, eliminating the need for human workers to manually handle different bread types while maintaining adaptability through software control
2Productivity
If automated system is used for sandwich assembly, then labor costs decrease and uniformity increases, but difficulty in accommodating different bread orientations increases
Solution Approach 1:
The patent employs dynamic adjustment mechanisms that allow the system to adapt to different bread orientations in real-time. The conveyor system features variable speed zones and adjustable positioning mechanisms that can reorient bread products as they move through the assembly line. The automated slicer includes adjustable blade angles and depths that can be programmed based on the detected bread orientation, enabling the system to handle various bread types without requiring complex manual reconfiguration
Solution Approach 2:
The patent incorporates sensors and detection systems that monitor bread orientation, size, and type as they enter the assembly line. This feedback information is used by the control system to automatically adjust subsequent processing parameters including slicing depth, conveyor speed, and component placement positions. The feedback loop ensures that the automated system can accommodate variations in bread orientation while maintaining uniform assembly quality
3Adaptability or versatility
If multiple inputs are used for different sandwich types, then product variety increases, but risk of cross-contamination increases
Solution Approach 1:
The patent implements separate, dedicated input hoppers and delivery mechanisms for each sandwich component type (meats, cheeses, vegetables, condiments). Each input station is physically separated and can be independently controlled, allowing the system to extract and deliver only the specific components needed for the current sandwich type. This physical separation eliminates cross-contamination risks while maintaining the ability to quickly switch between different sandwich formulations by simply changing the input configuration through programmable control
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 sandwich assembly and packaging, enabling the bulk production of various sandwich types with reduced risk of cross-contamination.
Implementation Method 1
an ultrasonic slicer
Data Source
AI summary
The automated assembly and manufacture of a 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.