Conveyor Oven Tunnel Segmentation and Dynamic Control
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Solution Overview
Problem
Conveyor ovens face challenges in achieving uniform heating throughout the tunnel, leading to energy wastage and inefficient baking times due to variations in the physical and thermal configuration caused by food products, and they lack effective energy-saving modes for intermittent cooking.
Innovation Solution
The implementation of a conveyor oven with a tunnel segmented into independent heating zones, each with its own temperature sensing and air delivery system, controlled by a microprocessor-driven controller that adjusts heat and airflow based on the presence and position of food products, and an energy-saving mode activated by remote input devices to reduce energy consumption during idle periods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conveyor ovens operate continuously in full production mode, then they can meet high cooking demand, but energy is wasted during idle periods when no food is being cooked
Solution Approach 1:
The oven system dynamically adjusts its operational state between full production mode and energy-saving mode based on real-time cooking demand. The microprocessor controller monitors whether food products are present on the conveyor and automatically transitions the heating elements and conveyor motor between active and standby states, optimizing energy consumption while maintaining cooking capability when needed.
Solution Approach 2:
This principle is not applicable to this patent as the solution does not involve chemical oxidation processes.
2Loss of energy
If the oven is turned off completely during idle periods, then energy consumption is reduced, but it requires unacceptably long shut-down and start-up times when cooking is needed
Solution Approach 1:
The system implements dynamic operational states rather than simple on/off switching. During idle periods, the oven enters a partial standby mode where the conveyor motor is stopped and heating elements are deactivated, but the control system remains active and pre-heating components are maintained at reduced power levels, enabling rapid transition to full operation when cooking demand arises.
3Temperature
If temperature sensors near inlet and outlet ends control heating to maintain average temperature, then overall temperature balance is achieved, but uniform heating throughout the tunnel cannot be achieved
Solution Approach 1:
The oven tunnel is divided into multiple independent heating zones along its length, with each zone equipped with its own heating elements and controlled by temperature sensors positioned within that specific zone. The microprocessor controller independently regulates each zone's heating output, ensuring uniform temperature distribution throughout the entire tunnel rather than relying on average temperature control from only inlet and outlet sensors.
Solution Approach 2:
Each heating zone is optimized with localized temperature control, where temperature sensors and heating elements are positioned within individual zones to maintain precise temperature uniformity in each segment. This local quality approach ensures that every portion of the tunnel maintains consistent temperature, addressing the non-uniform heating problem that arises from centralized average temperature control.
4Manufacturing precision
If the conveyor speed is reduced to allow more baking time, then uniform heating can be achieved, but baking time increases beyond optimal efficiency
Solution Approach 1:
By segmenting the tunnel into multiple independently controlled heating zones, the system can maintain uniform temperature distribution across all zones simultaneously at optimal conveyor speeds. This eliminates the need to reduce conveyor speed for uniform heating, as each zone's temperature is independently regulated to ensure even heating throughout the tunnel at full production velocity.
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
This solution ensures more uniform heating across the tunnel, reducing baking times and energy wastage, while allowing for efficient operation during intermittent cooking by dynamically adjusting heating and airflow, and implementing energy-saving modes to lower energy consumption when not in use.
Implementation Method 1
a heating element operable to generate heat to be provided to the tunnel
Implementation Method 2
a fan operable to move air in the tunnel
Implementation Method 3
a fan operable to move air in the tunnel
Implementation Method 4
a sensor positioned to detect at least one of a temperature within the oven
Data Source
Figure 1~2
Figure 3
Figure 3A
AI summary
An oven according to some embodiments includes an oven chamber in which food is cooked, a heating element, a fan, a sensor for sensing the temperature of the oven chamber, a remote input device, and a controller configured to receive a signal from the remote input device and to change the fan or heating element based at least in part upon the signal received from the remote input device. In a method of operating the oven according to some embodiments, the oven enters an operating mode from an energy-savings mode responsive to receiving an signal from a remote device.