Coffee Roaster Calibration Using Temporary Chamber Temperature Probes
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Solution Overview
Problem
Existing coffee bean roasting apparatuses struggle to consistently reproduce the same roasting profile across different units due to the absence of temperature sensors inside the roasting chamber, leading to variations in color and aroma, even when using identical roasting profiles defined by a master apparatus.
Innovation Solution
A calibration process is introduced, involving a temporary temperature probe inside the roasting chamber or a temporary calibration chamber with a second temperature probe, to measure and compare temperatures with a reference curve from a master apparatus, allowing for corrections in the feedback loop regulation to ensure consistent roasting across different apparatuses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a temperature sensor is introduced inside the roasting chamber to measure temperature inside the bed of coffee beans, then temperature measurement precision is improved, but device complexity and maintenance requirements increase due to sensor contamination and frequent cleaning needs
Solution Approach 1:
The patent introduces an intermediary calibration chamber that temporarily replaces the roasting chamber during calibration operations. This calibration chamber contains a temperature sensor that does not contact coffee beans, thereby avoiding contamination while still enabling accurate temperature measurements for calibration purposes. The sensor in the calibration chamber serves as a mediator to obtain reference temperature data without the drawbacks of placing sensors directly in the roasting chamber.
Solution Approach 2:
The patent performs calibration operations before actual roasting operations. By temporarily installing the temperature sensor in the calibration chamber prior to roasting, the system establishes reference temperature profiles in advance. This preliminary calibration allows the roasting process to proceed without requiring the sensor to be present during roasting, thus avoiding contamination issues while maintaining measurement accuracy for process control.
2Ease of operation
If the roasting chamber is designed to be removable for bean introduction and emptying, then ease of operation is improved, but reliability deteriorates because temperature sensors would need to be disconnected at each roasting operation
Solution Approach 1:
The calibration chamber serves as an intermediary structure that remains permanently installed in the roasting apparatus while the actual roasting chamber is removable. The temperature sensor is mounted in this fixed calibration chamber, which stays in place during all roasting operations. This allows the roasting chamber to be freely removed and reinstalled for bean loading while the sensor remains undisturbed, maintaining continuous reliability without requiring disconnection.
Solution Approach 2:
The patent segments the roasting system into a removable roasting chamber and a fixed calibration chamber. The temperature measurement function is separated from the removable roasting chamber and placed in the permanent calibration chamber structure. This segmentation allows the roasting chamber to be easily removed and reinstalled while the temperature sensor in the fixed calibration chamber maintains reliable continuous operation.
3Device complexity
If temperature is regulated using a fixed sensor outside the chamber close to the heating device, then device complexity is reduced, but manufacturing precision deteriorates due to inconsistent temperature reproduction across different apparatuses
Solution Approach 1:
The patent performs preliminary calibration operations before actual roasting to establish apparatus-specific temperature profiles. During calibration, the system measures actual temperature profiles in the calibration chamber and compares them to reference profiles. Correction factors are calculated and stored in advance, allowing the simple external temperature sensor to be compensated for apparatus-specific variations during subsequent roasting operations, thereby achieving consistent manufacturing precision across different units.
Solution Approach 2:
The patent implements a feedback mechanism where temperature measurements from the calibration chamber are used to calculate correction factors that are applied to the roasting control. The external temperature sensor provides feedback on actual heating performance, and this feedback is processed to determine apparatus-specific calibration parameters. These correction factors are then applied in the control algorithm to compensate for manufacturing variations, enabling consistent temperature reproduction despite using simple external sensors.
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
The calibration process ensures that coffee bean roasting apparatuses reproduce the same roasting profile as the master apparatus, maintaining consistency in color and aroma, even without temperature sensors inside the chamber.
Implementation Method 1
a heating device to heat air supplied to the chamber
Implementation Method 2
at least one first temperature probe to regulate the temperature supplied by the heating device
Data Source
AI summary
The invention concerns process of calibration of a coffee beans roasting apparatus in order to reproduce coffee beans roasting recipes defined with one specific master roasting apparatus, said calibration process comprising the steps of: a—introducing at least one second temporary temperature probe inside the chamber of the roasting apparatus, b—controlling the heating device to reproduce a preset curve R said control being based on the temperature Treg regulated by the at least one first temperature probe, c—during the reproduction of the preset curve Rset, measuring the temperature Tcal in function of time inside the chamber, d—comparing the temperature Tcal@ti with the temperature Tref@ti of a pre-determined calibration curve Rref obtained with the master roasting apparatus (M), said calibration curve Rref representing the temperature Tref measured in the chamber of the specific master apparatus (M) while controlling the heating device of the master apparatus to reproduce said preset curve Rset, e—based on this comparison, calibrating the roasting apparatus by applying a correction, to the temperature Treg regulated by the first temperature probe inside the control system of the roasting apparatus.