Rotating Stacker for Uniform Flatbread Stack Formation
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Solution Overview
Problem
The existing methods for creating stacks of flatbreads result in inconsistent thickness due to manufacturing processes, leading to curved stacks that are difficult to handle and display, requiring manual correction which increases costs and human contact.
Innovation Solution
A rotating stacker apparatus and method that uses a stack support that rotates as each object is added, distributing the rotational orientation of the objects to avoid cumulative thickness inconsistencies, allowing for a more uniform and straight stack formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If flatbreads are stacked without rotating the stack support, then the stacking process is simple and fast, but the thicker portions align cumulatively causing the stack to curve
Solution Approach 1:
The stack support is made rotatable rather than fixed, allowing dynamic adjustment of orientation during the stacking process. As each flatbread is placed on the stack support, the support can be rotated to a different angular position, distributing the thicker portions of consecutive flatbreads around the circumference rather than allowing them to align in a single direction, thereby preventing cumulative curvature of the stack
2Shape
If manual shuffling is used to correct curved stacks, then stack straightness is improved, but labor costs increase and human contact with flatbread increases
Solution Approach 1:
The rotation of the stack support during the stacking process performs the straightening function proactively as the stack is being formed, rather than requiring corrective action after the stack is complete. By distributing thicker portions evenly around the circumference during stacking, the stack emerges straight from the process itself, eliminating the need for subsequent manual shuffling operations
3Shape
If the stack support rotates as each object is added, then thickness irregularities are distributed evenly, but the stacking mechanism becomes more complex
Solution Approach 1:
The stack support serves multiple functions: it provides the structural base for stacking flatbreads, enables rotation to distribute thickness irregularities, and facilitates the transfer of the completed stack to the output conveyor. By making the stack support itself rotatable rather than adding a separate rotation mechanism, the design achieves the desired distribution effect with minimal additional complexity
Data Source
AI summary
Some manufacturing processes include forming stacks of manufactured objects for handling and/or processing. While some such manufactured objects are consistent in thickness, other are more irregular. Some manufactured objects are generally flat, but are also generally thicker along one edge. When objects having these characteristics are stacked, the cumulative effect of such inconsistent thickness results in an unbalanced stack. The disclosed apparatus and method utilize a novel rotating stacker that rotates the stack of manufactured objects as each new object is added to the stack, thereby distributing the thickness inconsistency of individual objects throughout the stack, producing a more uniform stack without manual intervention.