Transition state toasting control
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Solution Overview
Problem
Existing toasters face challenges in accurately adjusting toasting times and conveyor speeds during transitions between operational states, particularly when handling different bread products with varying moisture and density, leading to inconsistent toasting results and increased energy consumption.
Innovation Solution
A radiant toaster system with a controller that uses transition state models, such as polynomial equations, to adjust conveyor speed based on elapsed time and standard toasting time, allowing for efficient transitions between operational states and maintaining consistent toasting quality across different bread products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the conveyor speed is adjusted during transitions between operational states, then the toasting quality consistency is improved, but the control system complexity increases
Solution Approach 1:
The system pre-calculates transition state toasting times using polynomial equations before actual transitions occur. The controller stores multiple polynomial equations representing different transition scenarios (heating up, cooling down, steady state) and selects the appropriate equation in advance based on the current operational state, eliminating the need for complex real-time calculations during transitions.
Solution Approach 2:
Polynomial equations serve as mathematical intermediaries between the operational state changes and the conveyor speed control. Instead of directly controlling conveyor speed based on complex thermal dynamics, the system uses polynomial equations to translate operational state (temperature, time) into appropriate toasting times, simplifying the control logic while maintaining precision.
2Use of energy by moving object
If the toaster operates in steady state mode, then the energy consumption is reduced, but the adaptability to different bread products decreases
Solution Approach 1:
The system dynamically transitions between steady state and transition states based on operational requirements. When bread products are loaded, the system enters transition states with adjusted conveyor speeds calculated via polynomial equations to accommodate different product characteristics. When no products are present, the system returns to steady state for energy efficiency, creating a dynamic balance between adaptability and energy consumption.
Solution Approach 2:
The system changes operational parameters (conveyor speed, heating power) based on the phase of operation. During transition states, polynomial equations determine optimized parameter settings for different bread products. During steady state, parameters are maintained at energy-efficient levels. This parameter switching allows the system to be both energy-efficient and adaptable.
3Manufacturing precision
If polynomial equations are used to calculate transition state toasting times, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
Multiple polynomial equations are pre-calculated and stored in the controller's memory during system setup or manufacturing. These equations represent different transition scenarios (heating rates, cooling rates, power level changes). During operation, the controller simply selects and applies the appropriate pre-stored equation based on current conditions, avoiding complex real-time calculations while maintaining high precision.
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 system ensures accurate and efficient toasting by adjusting conveyor speed in real-time, reducing mechanical wear and energy consumption, while maintaining consistent toasting quality across various bread products and operational states.
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
AI summary
Systems and methods of conveyor speed control in a radiant toaster includes a toaster with a conveyor and a heat source. A controller 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.