Sandwich Former for Multi-Layer Wafer Production
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Solution Overview
Problem
Existing systems for producing multi-layer wafer products face challenges in achieving high throughput while maintaining cost-effectiveness, as they require complex and expensive control and regulation components.
Innovation Solution
A method and system utilizing a sandwich former, pressing station, and conveying devices with stopper-free positioning and adjustable speeds to form multi-layer wafer products, enabling increased throughput with simpler and more affordable components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If complex control and regulation components are used to increase throughput, then productivity is improved, but device complexity and cost increase
Solution Approach 1:
The system uses the natural flow and positioning of wafer sheets on conveyor surfaces to automatically achieve correct stacking positions without mechanical stoppers or complex positioning mechanisms. The process self-regulates through the inherent properties of the material flow and simple guiding structures.
Solution Approach 2:
The invention removes complex positioning mechanisms (stoppers) from the system entirely, relying instead on the natural behavior of conveyed materials and simplified guiding structures to achieve precise positioning, thereby reducing device complexity while maintaining productivity.
2Manufacturing precision
If mechanical stoppers are used for positioning wafer sheets, then positioning precision is improved, but device complexity and cost increase
Solution Approach 1:
Wafer sheets automatically position themselves on the conveyor surfaces through the natural flow and alignment of the material stream, eliminating the need for mechanical stoppers. The system utilizes the inherent properties of continuous material flow to achieve precise positioning.
Solution Approach 2:
The invention completely removes mechanical stoppers from the positioning system, replacing them with simplified guiding structures that allow wafer sheets to self-align and position themselves during conveyance, thereby reducing mechanical complexity while maintaining positioning accuracy.
3Productivity
If continuous production processes are implemented to increase throughput, then productivity is improved, but control and regulation costs increase
Solution Approach 1:
The continuous production process self-regulates through the natural flow of materials on conveyor surfaces, with automatic positioning and stacking occurring without complex control systems. The process inherently maintains continuity and precision through material flow dynamics rather than active regulation.
Solution Approach 2:
The system maintains continuous production by keeping wafer sheets in constant motion on conveyor surfaces, eliminating idle time and interruptions. The continuous flow of materials naturally ensures uninterrupted production while simplifying control requirements compared to batch processes with frequent start-stop cycles.
Data Source
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AI summary
The invention relates to a method and a system for forming a multi-layered waffle intermediate product (1), with a sandwich former (4) for forming a waffle sandwich (20) by covering a first waffle base sheet (2') provided with an edible filling layer with a waffle top sheet (6).