Toaster with controlled conveyor speed
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Solution Overview
Problem
Conveyor toasters face challenges in efficiently controlling the cooking degree of food products due to limitations in temperature and product load management, leading to inconsistent cooking results and energy inefficiency.
Innovation Solution
A controller is programmed to adjust cook time and conveyor speed based on estimated temperature and product load, using sensors to detect food presence and calculate heat power input, allowing for precise control of cooking parameters and energy conservation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the conveyor speed is reduced to allow food product to cook to the desired level, then the cooking degree is improved, but the productivity decreases
Solution Approach 1:
The conveyor speed is made dynamically adjustable rather than fixed. The system continuously monitors the actual temperature in the cook chamber and automatically adjusts the conveyor speed to match the cooking requirements, enabling both precise cooking control and maintained productivity
Solution Approach 2:
A temperature sensor provides real-time feedback on the actual temperature in the cook chamber. This feedback is fed back to the controller which adjusts the conveyor speed accordingly, creating a closed-loop control system that ensures consistent cooking quality while optimizing throughput
2Loss of energy
If the conveyor is stopped and heat is reduced in standby mode, then energy consumption is reduced, but the response time to resume cooking increases
Solution Approach 1:
Instead of completely stopping the conveyor and shutting off heat in standby mode, the system uses periodic or reduced-level heating and conveyor movement. This maintains the cook chamber at a lower but sustained temperature, allowing rapid resumption of full cooking operations without long warm-up delays
Solution Approach 2:
The system performs preliminary actions by maintaining minimal heat and conveyor operation during standby mode. This preliminary maintenance of thermal conditions prepares the system for quick transition back to full cooking mode, reducing the time penalty associated with energy conservation
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 enables precise control of cooking time and temperature, ensuring consistent food cooking and reducing energy consumption by optimizing conveyor speed and heating element usage.
Implementation Method 1
heating elements for cooking the food product
Implementation Method 2
a conveyor positioned to move food product through the cook chamber
Data Source
AI summary
A method of operating an oven to cook a food product that includes changing a heat setting of a heating element of the oven, selecting a cook time for the food product in the oven, driving a heating element of the oven at a heat power input based on the heat setting, predicting a cooking ability of the oven by calculating an estimated temperature in the oven using a formula that is a function of a heat power input during a previous time period, and modifying the cook time to a modified cook time based on the estimated temperature that was calculated using the formula.