Conveyor Speed Control for Radiant Toaster Heat Transition States
Solution Overview
Problem
Existing toasters struggle to efficiently transition between different operational states to accommodate varying bread products and demand fluctuations, leading to inefficiencies in energy consumption and mechanical wear.
Innovation Solution
A radiant toaster with a controller that adjusts conveyor speed based on empirically derived transition state models, using polynomial equations to maintain consistent toasting quality during changes in heat source output, allowing for efficient operation and power management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the toaster operates at high heat output for all bread products, then toasting quality is maintained, but energy consumption increases
Solution Approach 1:
The system dynamically adjusts heat output levels based on the specific bread product being toasted. Different heat output levels are selected from multiple available levels according to the bread product type, allowing the toaster to operate at the minimum necessary heat level for each product rather than maintaining constant high heat output.
Solution Approach 2:
The system changes the heat output parameter based on the bread product being processed. By selecting from multiple heat output levels (first, second, third levels) corresponding to different bread products, the system optimizes energy consumption while maintaining toasting quality for each specific product type.
2Reliability
If the conveyor speed is adjusted during transition states, then toasting quality is maintained, but control complexity increases
Solution Approach 1:
The system pre-calculates and stores transition state conveyor speeds for different scenarios in memory. When a heat output change is initiated, the controller retrieves the appropriate transition state conveyor speed from stored data based on the current and target heat output levels, eliminating the need for complex real-time calculations during transitions.
Solution Approach 2:
The system replaces complex real-time control calculations with pre-computed lookup tables stored in memory. The controller simply retrieves appropriate transition state parameters from storage based on current operating conditions, substituting complex computational mechanics with simpler data retrieval operations.
3Use of energy by moving object
If the toaster enters low heat output state for energy saving, then energy consumption decreases, but toasting quality deteriorates
Solution Approach 1:
The system dynamically selects from multiple heat output levels (first, second, third levels) based on the specific bread product type. Each bread product is associated with an optimal heat output level that maintains toasting quality while minimizing energy consumption, allowing the system to operate at the lowest necessary heat level for each product.
Solution Approach 2:
The system changes the heat output parameter according to the bread product being toasted. By selecting from multiple discrete heat output levels corresponding to different bread types, the system achieves energy savings by operating at lower heat levels appropriate for each product rather than using a single high heat level for all products.
4Productivity
If the conveyor operates continuously at high speed, then productivity increases, but toasting quality decreases during heat transitions
Solution Approach 1:
The system pre-calculates and stores appropriate transition state conveyor speeds for different heat output transition scenarios. During actual transitions, the controller retrieves the pre-determined conveyor speed from memory, allowing the conveyor to be properly adjusted without delaying the toasting process or requiring complex real-time calculations.
Solution Approach 2:
The system replaces complex real-time conveyor speed calculations during heat transitions with pre-computed lookup tables. The controller simply retrieves the appropriate transition state conveyor speed from stored data based on current and target heat output levels, maintaining productivity while ensuring toasting quality during transitions.
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 solution ensures accurate and efficient toasting of different bread products by adjusting conveyor speed during transitions, reducing energy consumption and mechanical wear, while maintaining consistent toasting quality.
Implementation Method 1
radiant or conductive energy transfer into the baked good from one or more heat sources
Implementation Method 2
radiant or conductive energy transfer into the baked good from one or more heat sources
Implementation Method 3
The Maillard reaction is the reaction between carbohydrates and proteins that occurs upon heating and which produces browning
Data Source
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AI summary
Systems and methods of conveyor speed control in a radiant toaster includes a toaster (10) with a conveyor (12) and a heat source (20). A controller (34) is configured to receive a transition state model and a toasting recipe that includes a standard operation toasting time. Upon receipt of an instruction to change the heat source from a first heat output to a second heat output, the controller operates the heat source to the new output and measures an elapsed time since the change to the new output. The controller calculates a current transition state toast time by applying the standard operation toasting time and the elapsed time to the transition state model. The controller is configured to operate the conveyor to a conveyor speed associated to the current transition state toast time.