Automatic broiler for variable batch cooking
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Solution Overview
Problem
Conventional conveyorized chain cooking devices are inflexible and inefficient in changing cooking profiles to accommodate different food products and sizes, leading to thermal energy wastage, maintenance challenges, and lack of uniform cooking, especially when broiling is required.
Innovation Solution
An automatic broiler with a stationary conveyorized cooking surface and adjustable infrared heating elements, allowing for varying infrared energy radiation based on food type and batch size, combined with a gas burner for flame broiling, and an enclosed design to enhance thermal efficiency and ease of use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conveyorized chain cooking devices are used for continuous sequential cooking, then productivity is improved, but adaptability deteriorates due to inability to quickly change cooking profiles for different food products
Solution Approach 1:
The patent applies dynamics by making the cooking system adjustable and adaptable through variable speed conveyor mechanisms and controllable heating elements. The conveyor speed can be dynamically changed to match different cooking requirements for various food products, while the heating elements can be independently controlled to create different cooking profiles. This dynamic capability allows the system to maintain high productivity through continuous operation while adapting to different food types and cooking requirements.
2Manufacturing precision
If heating elements continuously radiate heat in conveyorized devices, then cooking uniformity is improved, but energy efficiency deteriorates due to thermal energy wastage
Solution Approach 1:
The patent applies periodic action by implementing cyclic heating patterns where heating elements are activated and deactivated in sequence rather than continuously. The controller systematically activates specific heating elements based on the position of food products on the conveyor belt, providing heat only when and where needed. This periodic heating approach maintains cooking uniformity by ensuring all products receive appropriate heat exposure while dramatically reducing energy waste from continuous radiation.
Solution Approach 2:
The system applies self-service through automated control mechanisms that monitor conveyor position and food product location, then automatically activate heating elements as needed. The controller system manages the heating process without continuous human intervention, systematically determining which heating elements should be active based on real-time conditions, thereby optimizing both cooking uniformity and energy efficiency.
3Productivity
If conveyor cooking surfaces are in constant motion, then cooking efficiency is improved, but device complexity and maintenance difficulty increase due to drive train components
Solution Approach 1:
The patent applies the extraction principle by removing the complex continuous drive train mechanism from the conveyor system. Instead of using a complex continuous motion drive, the invention uses a simpler intermittent motion mechanism with individual positioning capabilities. This extraction of the complex continuous drive reduces mechanical complexity, decreases maintenance requirements, and eliminates many drive train components while still achieving efficient cooking throughput through controlled intermittent movement.
4Ease of operation
If open cooking areas are used in conveyorized devices, then ease of cleaning is improved, but thermal efficiency deteriorates due to heat loss
Solution Approach 1:
The patent applies flexible shells and thin films by using removable panels, shields, or covers that can be easily installed and removed. These flexible thermal barriers provide insulation and reduce heat loss during cooking operations, yet can be quickly removed or accessed for cleaning purposes. This approach maintains ease of cleaning while significantly improving thermal efficiency by preventing heat escape to the surrounding environment.
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
Enables quick and efficient cooking of diverse food batches with uniformity and reduced thermal losses, improving kitchen operations and maintenance by optimizing cooking profiles and maintaining high thermal efficiency.
Implementation Method 1
a radiant burner below the broiled food product
Implementation Method 2
by altering the infrared energy radiated from a heat source above the broiled food product
Data Source
Figure 1
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AI summary
A flexible automatic broiler and method of use for variable batch cooking for particular use in quick serve and fast food service restaurants. The automatic cooking devices include a conveyorized cooking surface for alignment and discharge of food products, an altering/pulsating infrared energy radiation heat sources, and a control system. The arrangement and method facilitate a combination of batch preparation and made-to-order assembly of fast-food sandwiches.