Automatic Broiler Control for Variable Batch Cooking Profiles
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Solution Overview
Problem
Conventional conveyorized cooking devices are inflexible in changing cooking profiles to accommodate different food products and sizes, leading to inefficient thermal output, waste of thermal energy, and poor cooking quality due to inaccurate temperature control and lack of enclosed cooking areas.
Innovation Solution
A flexible automatic broiler with a conveyorized cooking surface, a lower gas burner, and a pulsing upper infrared heat source, controlled by a system that adjusts infrared energy intensity and cooking time to match specific food products, allowing for easy loading and discharge, and featuring a control unit for pre-programmed cooking profiles, fault detection, and statistical data tracking.
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 implements a programmable microprocessor-based control system that dynamically adjusts cooking parameters (temperature, time, heat source intensity) based on selected cooking profiles. This allows the same physical cooking chamber to adapt to different food products by changing control parameters rather than physical configuration, resolving the contradiction between continuous operation and profile flexibility.
Solution Approach 2:
The system stores multiple pre-programmed cooking profiles with different temperature, time, and heat source combinations for various food products. The microprocessor changes operational parameters electronically to match the selected profile, enabling quick adaptation between different cooking requirements while maintaining continuous productivity.
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 waste from conveying motion and lack of enclosed cooking area
Solution Approach 1:
The patent divides the heating function into multiple independent heat sources (upper and lower heating elements) that can be independently controlled. This segmentation allows selective activation of only the heat sources needed for the current cooking task, reducing energy waste compared to a single variable-load heater that must continuously operate.
Solution Approach 2:
The patent extracts the cooking surface from continuous motion by using a stationary cooking chamber with manual or batch loading. This eliminates the energy waste associated with conveyor motion while maintaining adaptability through programmable heat source control and multiple cooking profiles.
Solution Approach 3:
The enclosed cooking chamber creates a controlled thermal environment that retains heat and prevents energy loss to the surrounding atmosphere. This enclosure maintains thermal efficiency while allowing flexible programming of different cooking profiles for various food products.
3Device complexity
If conventional thermostat control is 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 a microprocessor-based control system with temperature sensors that continuously monitor actual cooking temperatures and provide feedback to the control algorithm. This closed-loop feedback enables precise temperature control and compensation for gradients, achieving high cooking precision without excessive system complexity.
Solution Approach 2:
The patent replaces conventional mechanical thermostat control with an electronic microprocessor-based system. This substitution enables more accurate temperature regulation through digital control algorithms while maintaining relatively simple overall device complexity.
4Productivity
If conveyorized cooking surfaces with drive train components are used, then productivity is improved, but ease of repair deteriorates due to difficulty and expense of maintenance
Solution Approach 1:
The patent removes the conveyor drive train and continuous motion mechanism from the cooking system, replacing it with a stationary cooking chamber. This extraction eliminates the complex mechanical components that require maintenance while maintaining productivity through efficient batch cooking and programmable control.
Solution Approach 2:
The simplified stationary design with fewer moving parts reduces maintenance requirements. The system is easier to clean, inspect, and repair due to the absence of conveyor belts, motors, and drive train components, allowing for simpler self-maintenance and reduced service costs.
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 thermal output and cooking times, reducing energy waste, improving cooking quality, and simplifying operation and maintenance with precise temperature control and data management.
Implementation Method 1
by 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.