Thermal measurement and process control
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Solution Overview
Problem
Current food processing systems face challenges in accurately determining the thermal treatment of food products due to variations in food thickness and the reliance on manual temperature measurement, leading to inefficiencies and safety risks, as well as overcooking, which results in economic losses and potential health hazards.
Innovation Solution
A system comprising a conveyor, scanner, computing device, and temperature measurement system that automatically selects and characterizes food products, adjusts thermal processing parameters based on real-time data, and ensures consistent temperature monitoring to prevent undercooking or overcooking by modeling the thermal processing dynamics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual temperature measurement is used with small sample sizes, then labor costs are reduced, but measurement precision and reliability of thermal processing control deteriorate
Solution Approach 1:
The system enables self-service through automated temperature measurement where the food product itself guides the probe placement. The probe automatically inserts at the location of maximum thickness detected by the optical sensor, eliminating the need for manual operator intervention and achieving consistent, accurate measurements without labor costs.
Solution Approach 2:
Manual mechanical probe insertion is replaced with an automated system combining optical sensing and automated probe actuation. The optical sensor detects food geometry and the automated probe system executes precise insertion based on detected characteristics, substituting human judgment and manual operation with automated sensing and actuation.
2Reliability
If thermal processing is adjusted to ensure the thickest workpieces reach desired temperature, then food safety is improved, but productivity and product quality deteriorate due to overcooking
Solution Approach 1:
The system applies local quality by measuring and controlling temperature specifically at the location of maximum thickness in each individual food product. Rather than uniformly processing all products to the same temperature, the system identifies and targets the critical thermal zone in each product, ensuring safety without unnecessary overcooking of thinner areas.
Solution Approach 2:
The system dynamically changes processing parameters based on real-time measurement of each food product's actual thickness and temperature characteristics. By adjusting thermal processing parameters to match the specific geometry detected by the optical sensor, the system optimizes cooking time and temperature for each product, preventing overcooking while ensuring safety.
3Device complexity
If manual temperature probe insertion is used, then device complexity is reduced, but measurement precision deteriorates due to positioning errors and void detection difficulties
Solution Approach 1:
An optical sensor acts as an intermediary between the manual operator and the food product. The optical sensor detects the food's geometry, thickness, and internal structure characteristics, providing information that guides automated probe insertion to the optimal location, eliminating the need for manual judgment while maintaining system simplicity.
Solution Approach 2:
The optical sensor performs preliminary detection of the food product's characteristics before temperature measurement. By pre-identifying the location of maximum thickness and potential voids through optical scanning, the system prepares the optimal measurement location in advance, ensuring accurate temperature measurement when the probe inserts.
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
This system enhances food safety and efficiency by ensuring precise thermal treatment, reducing waste, and minimizing labor and sanitation costs, while maintaining product quality and safety standards.
Implementation Method 1
a scanner to scan all of the food products to be processed to model the physical features of the scanned food products
Implementation Method 2
The temperature of the food product leaving the thermal processing station is typically measured manually by inserting a thermal couple probe into the processed food product
Implementation Method 3
the thermal processing of a food product can be significantly impacted by physical attributes of the food product
Implementation Method 4
oven, fryer, steamer, roaster
Data Source
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AI summary
A thermal processing and control system (300) includes a thermal processing station (312) for receiving food products (14) being carried on a conveyor system (316). A first scanning station (318) is located upstream from the thermal processing station (312) for scanning the food products being carried by the conveyor (316). An actuator (420) automatically connects temperature measuring devices (402) with selected food products (14). A diverter conveyor (324) diverts selected food products (14) from the conveyor (316) to a transverse conveyor (326) for either further processing or alternative processing, depending on how system (300) is configured. The temperature measuring devices (402) are automatically removed from the food products at station (329).