Automatic Broiler Infrared Heating for Variable Batch Cooking
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Solution Overview
Problem
Conventional conveyorized cooking devices are inflexible in changing cooking profiles for different food products, leading to inefficient thermal output, waste of energy, and poor cooking quality due to lack of uniform heat distribution and inadequate control systems, especially when transitioning between cooking stages or handling varying batch sizes and types of meat.
Innovation Solution
An automatic broiler with a radiant burner below and infrared heat source above the cooking surface, allowing for adjustable infrared energy emission and a stationary conveyor system that aligns heating elements with food products for uniform cooking, combined with an enclosed design and advanced control mechanism for precise temperature control and batch-specific cooking profiles.
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 heating elements adjustable in intensity and the conveyor speed variable, allowing the cooking system to adapt to different food products while maintaining continuous operation. The control system dynamically modifies heating parameters based on the specific cooking requirements of different products.
Solution Approach 2:
The invention changes physical parameters by allowing independent adjustment of heating element intensity, conveyor speed, and cooking time for different food products. This enables the same equipment to handle various products with different cooking requirements without physical modification.
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 wasted thermal energy from non-uniform radiation
Solution Approach 1:
The patent applies local quality by positioning multiple heating elements at specific locations (above, below, and at sides of cooking chambers) to create localized heating zones. Each heating element can be independently controlled to provide precise heat distribution exactly where needed, eliminating wasted thermal energy.
Solution Approach 2:
The invention replaces conventional less-efficient heating mechanisms with infrared heating elements that directly radiate energy to the food surface, improving thermal efficiency by reducing heat loss to the surrounding environment.
3Device complexity
If conventional thermostat control systems are used for temperature regulation, then device complexity is reduced, but manufacturing precision deteriorates due to inaccurate cooking temperature and temperature gradients
Solution Approach 1:
The patent implements feedback control by using temperature sensors to continuously monitor the cooking environment and automatically adjusting heating element output to maintain precise temperature control. This eliminates temperature gradients and ensures uniform cooking across all products.
Solution Approach 2:
The control system performs multiple functions including temperature monitoring, heating control, timing, and coordination of multiple heating elements, providing precise temperature uniformity without requiring overly complex specialized components for each function.
4Productivity
If conveyorized cooking surfaces with drive train components are used for continuous cooking, then productivity is improved, but ease of repair deteriorates due to difficulty and cost of maintenance
Solution Approach 1:
The patent extracts the drive train components from the cooking chamber area, positioning them externally where they are easily accessible for maintenance. This allows continuous operation to be maintained while simplifying repair access without compromising productivity.
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 efficient and uniform cooking of various food products by adjusting infrared energy and thermal output, reducing energy waste and improving cooking quality by maintaining precise temperature control and facilitating easy cleaning and maintenance.
Implementation Method 1
by utilizing a radiant burner below the broiled food product and by altering the infrared energy radiated from a heat source above the broiled food product
Implementation Method 2
altering the infrared energy radiated from a heat source above the broiled food product
Data Source
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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 source, and a control system. The arrangement and method facilitate a combination of batch preparation and made-to-order assembly of fast-food sandwiches.