System and method of broiler heating element control
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Solution Overview
Problem
Existing cooking appliances lack efficient control systems for maintaining consistent temperature and energy usage during the cooking and holding processes, particularly in conveyor-based systems, leading to inefficiencies and potential temperature fluctuations.
Innovation Solution
A controller-based system that adjusts heat sources between high and low fire conditions based on temperature sensors, ensuring consistent cooking temperatures and efficient energy use by monitoring and responding to the introduction of food products, with features like automatic loading and indicator lights for cycle completion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heat sources operate continuously at high power to maintain temperature, then temperature consistency is improved, but energy consumption increases
Solution Approach 1:
The controller implements periodic cycling of the heating element between on and off states based on temperature feedback from the sensor. This allows the system to maintain average temperature consistency while reducing overall energy consumption compared to continuous high-power operation.
Solution Approach 2:
A temperature sensor provides continuous feedback to the controller, which adjusts heating element operation accordingly. This closed-loop control ensures temperature consistency is maintained only when necessary, reducing energy waste during periods when temperature targets are already met.
2Measurement precision
If heat sources are rapidly adjusted in response to temperature changes, then temperature control precision is improved, but temperature fluctuations increase
Solution Approach 1:
The controller incorporates a delay period after temperature threshold detection before activating the heating element. This cushioning approach prevents over-reactive cycling that would cause fluctuations, while still achieving adequate temperature control precision for the cooking application.
Solution Approach 2:
The system dynamically adjusts heating element operation based on real-time temperature conditions, transitioning between off, delayed activation, and on states. This dynamic response optimizes the balance between control precision and temperature stability throughout the cooking cycle.
3Device complexity
If manual intervention is required for temperature monitoring and adjustment, then system complexity is reduced, but productivity decreases
Solution Approach 1:
The system performs self-monitoring and self-adjustment of heating parameters through the controller and temperature sensor. This automation eliminates the need for manual temperature monitoring and adjustment, significantly improving cooking productivity while adding only moderate system complexity.
Solution Approach 2:
Manual temperature monitoring and adjustment operations are replaced by an automated electronic control system comprising a sensor and controller. This substitution of mechanical/manual processes with automated systems increases productivity while keeping the added complexity manageable through simple on/off control logic.
4Speed
If heat sources operate at high power throughout the cooking cycle, then cooking speed is improved, but energy efficiency deteriorates
Solution Approach 1:
The heating element operates in periodic cycles rather than continuously, providing high power only when temperature targets are not met. This approach maintains adequate cooking speed during critical phases while eliminating energy waste during sufficient-temperature periods, improving overall energy efficiency.
Solution Approach 2:
The system dynamically changes the power parameter of the heating element based on temperature conditions, transitioning between high power (when heating is needed) and zero power (when temperature targets are met). This parameter modulation maintains cooking speed when necessary while improving energy efficiency overall.
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
Ensures precise temperature control and energy efficiency by dynamically adjusting heat sources, reducing the need for manual intervention and enhancing food quality by maintaining consistent cooking conditions.
Implementation Method 1
At least one temperature sensor is arranged at the food product inlet relative to the at least one conveyor
Implementation Method 2
A plurality of heat sources are arranged about the at least one conveyor. The plurality of heat sources configured to output heat towards the at least one conveyor
Data Source
AI summary
A plurality of heat sources are arranged about at least one conveyor. The plurality of heat sources are configured to output heat towards the at least one conveyor. At least one temperature sensor is arranged at a food product inlet relative to the at least one conveyor. A controller is configured to receive temperature measurements from the at least one temperature sensor and to operate at least one heat source of the plurality of heat sources between a high fire condition and a low fire condition in an idle mode operation and a cooking mode operation.