Conveyor Toaster Speed Control Using Real-Time Load Detection
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Solution Overview
Problem
Conveyor toasters lack efficient control mechanisms for cooking food products, as existing technologies rely on conveyor speed adjustments based on temperature and pre-programmed options, which do not account for real-time product load and cooking ability variations, leading to suboptimal cooking results and energy inefficiencies.
Innovation Solution
A controller that calculates cooking time and conveyor speed based on estimated temperature and product load, using formulas to adjust heat power input and speed modifiers, with sensors to detect food presence and adjust cooking parameters dynamically.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conveyor speed is controlled based on pre-programmed options and temperature, then cooking time can be adjusted, but cooking quality consistency deteriorates due to lack of real-time product load adaptation
Solution Approach 1:
The system uses presence sensors to detect food items on the conveyor and provides feedback to the controller. The controller calculates product load based on sensor signals and adjusts conveyor speed dynamically. This closed-loop feedback mechanism enables real-time adaptation to varying product loads, ensuring consistent cooking quality across different operating conditions.
Solution Approach 2:
The conveyor speed is transformed from a static pre-programmed value to a dynamic parameter that changes in real-time based on detected product load. The controller continuously calculates the number of food items and adjusts the speed modifier accordingly, allowing the system to adapt its cooking parameters dynamically to maintain optimal cooking quality.
2Manufacturing precision
If conveyor speed is reduced to improve cooking quality, then cooking precision improves, but energy consumption increases
Solution Approach 1:
The system dynamically changes the conveyor speed parameter based on the detected product load. When fewer food items are detected, the conveyor speed increases, reducing energy consumption. When more items are detected, the speed decreases to maintain cooking precision. This parameter adaptation resolves the contradiction by optimizing both precision and energy efficiency based on actual operating conditions.
Solution Approach 2:
The system applies partial heating and speed reduction only when necessary based on product load detection. Instead of continuously operating at high precision settings that consume more energy, the system adjusts its action level to match the actual cooking demand, achieving efficient energy utilization while maintaining required cooking quality.
3Use of energy by moving object
If standby mode is used to reduce energy consumption, then energy efficiency improves, but cooking response time deteriorates when food is placed
Solution Approach 1:
The system performs preliminary detection of food items using presence sensors before full cooking operation begins. When food is detected on the conveyor, the controller immediately calculates the product load and prepares to adjust cooking parameters. This preliminary detection and rapid response mechanism minimizes the time penalty associated with exiting standby mode while maintaining energy efficiency during idle periods.
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 conveyor speed, ensuring consistent cooking quality and energy efficiency by adapting to real-time conditions, such as food presence and temperature changes, thereby improving cooking performance and reducing energy consumption.
Implementation Method 1
heating elements for cooking the food product
Implementation Method 2
a conveyor for moving food product through the cook chamber, and a motor coupled to the conveyor
Data Source
Figure 1
Figure 2
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AI summary
A conveyor oven comprising a housing defining a cook chamber and a heating element adjacent the cook chamber. A controller is programmed to control a cook time based upon a current estimated temperature in the oven, wherein the current estimated temperature is a function of a heat power input during a previous time period and can also be a function of a previous estimated temperature. In one embodiment, the oven further includes a conveyor and a motor coupled to the conveyor, wherein the controller is programmed to control a cook time of the conveyor. The controller can also be programmed to control the cook time based upon a product loading condition (e.g., a calculation that is a function of a presence of food in the oven). The oven can further include a presence sensor for detecting the presence of food in the oven and for providing a corresponding signal to the controller. Preferably, the calculation is an eye calculation that is a function of a previous eye calculation.