Automatic Broiler with Pulsed Infrared Control 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 types of food products and batch sizes, leading to thermal energy wastage, maintenance challenges, and lack of uniform cooking, especially when broiling is required.
Innovation Solution
A flexible automatic broiler with a conveyorized cooking surface, a lower heat source, a pulsing upper heat source, and a control system that varies infrared energy intensity and cooking time to establish specific profiles for different food products, along with a loading and discharge system to maintain thermal efficiency and facilitate easy cleaning.
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 heating elements are designed with variable thermal mass and can be dynamically adjusted in intensity and positioning. The system transitions from static heating to dynamic control where heating element intensity, position, and activation timing are continuously adjustable to match different cooking requirements for various food products.
Solution Approach 2:
The system changes multiple parameters simultaneously including heating element intensity, thermal mass configuration, element positioning, and activation timing. This multi-parameter control enables the same conveyorized system to adapt to different cooking profiles for various food products while maintaining continuous operation.
2Adaptability or versatility
If variable-load heating elements are used to accommodate different food products, then adaptability is improved, but energy efficiency deteriorates due to thermal energy wastage
Solution Approach 1:
Instead of uniformly heating the entire conveyorized cooking surface, the system applies heating locally and selectively. Individual heating elements can be independently controlled to provide heat only where and when needed for specific food products, reducing thermal energy wastage while maintaining adaptability.
Solution Approach 2:
The heating elements operate in periodic cycles rather than continuously, activating only during periods when food products are present and requiring heat. This periodic operation reduces energy consumption while maintaining the ability to handle variable loads of different food products.
3Productivity
If conveyorized cooking surface is in constant motion, then productivity is improved, but ease of operation deteriorates due to difficulty in loading and cleaning
Solution Approach 1:
Food products are pre-loaded onto trays or carriers before entering the cooking zone. This preliminary loading action simplifies the continuous operation by allowing batch loading while maintaining continuous conveyor motion, improving both productivity and ease of operation.
Solution Approach 2:
The conveyorized cooking surface is segmented into discrete zones with independent heating elements and control sections. This segmentation allows different sections to be cleaned or maintained without stopping the entire system, improving ease of operation while maintaining continuous productivity.
4Ease of operation
If open cooking area is used for conveyorized cooking, then ease of operation is improved, but energy efficiency deteriorates due to thermal energy loss
Solution Approach 1:
The system uses reflective barriers or thermal shielding films positioned strategically in the cooking area. These flexible barriers reduce thermal energy loss while maintaining an open, accessible cooking area for easy loading and unloading of food products.
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 various food products with improved thermal efficiency, reduced maintenance costs, and uniform cooking results by allowing precise control of infrared energy and cooking cycles, enhancing the overall operational efficiency in fast-food settings.
Implementation Method 1
utilizing 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
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.