Cooking Oven Software Power Modulation for Multi-Rating Adaptability
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Solution Overview
Problem
Existing oven configurations require physical changes to burners or gas supply adjustments to accommodate different power ratings, leading to manufacturing and installation inefficiencies due to varying electrical and gas power requirements across countries.
Innovation Solution
A method and system that allows for setting a peak operating power level through a user interface and controller, enabling adjustment of power levels without physical changes to burners or components, using a modulating valve for gas ovens and relay control for electric ovens, allowing operation within specified power limits without replacing parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If burners with different orifice sizes are provided or gas pressure is adjusted to match different power ratings, then the oven can operate at different power levels, but physical changes to burners or assistance of utility employee is required
Solution Approach 1:
The patent changes the control parameter from physical burner configuration to software-controlled power modulation. The controller adjusts the power level by modulating the heating elements or gas valve opening degree, allowing the same physical hardware to operate at different power ratings (e.g., 20kW, 30kW, 50kW) without any physical modifications.
Solution Approach 2:
The patent replaces the mechanical approach of changing burner orifices or adjusting gas pressure manually with an electronic control system. The controller uses electronic signals to modulate the power delivery to heating elements or gas valves, eliminating the need for physical burner changes or utility employee assistance.
2Adaptability or versatility
If multiple oven configurations are manufactured to match different power sources, then the oven can be adapted to various electrical ratings (30 amps or 50 amps), but numerous different oven configurations must be manufactured and installed
Solution Approach 1:
The patent makes a single oven configuration universal by equipping it with a controller that can adapt to different power sources. The controller reads the power rating from the power source and automatically adjusts its operation accordingly, allowing one oven design to serve multiple power ratings (30 amps, 50 amps, or other variations) without requiring multiple specialized configurations.
Solution Approach 2:
The patent introduces dynamic adaptability where the oven's operating parameters are not fixed but can change based on the detected power source characteristics. The controller dynamically adjusts heating power, temperature profiles, and operational modes according to the available power rating, enabling a single static physical configuration to deliver multiple operational states.
3Loss of energy
If the maximum power rating is set for an oven, then the oven can operate within power limits, but additional fees are charged for operation above the rated power (e.g., $7,000 for each KW above 20 KW)
Solution Approach 1:
The patent implements partial power delivery as the standard operating mode. Instead of always operating at maximum capacity, the controller deliberately delivers only the portion of power that matches the rated capacity (e.g., 20kW out of a 50kW capability), preventing excessive power consumption and associated fees while maintaining adequate cooking performance through optimized heating control.
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
Enables ovens to operate within set power limits, reducing the need for multiple configurations and physical adjustments, facilitating installation and operation across different power rating scenarios, such as from 20 kW to 50 kW electrically or 75,000 BTU/hr to 160,000 BTU/hr gas-wise, with software-controlled adjustments.
Implementation Method 1
a modulating valve for modulating a quantity of fuel gas conveyed to the burner to control a maximum peak operating power level of heat output by the burner
Implementation Method 2
a first heating element... selectively provide a power control signal to generate heat
Implementation Method 3
at least one burner disposed in the oven compartment... ignites the burner to heat the oven
Data Source
AI summary
A method and arrangement is provided for setting a peak operating power level for an oven having an oven compartment, a user interface, and a controller having a memory with a maximum peak operating power level stored therein. The method includes the steps of displaying an oven set-up user interface window on the user interface during an initial start-up of the oven; in response to an input for selecting a maximum output for the oven, displaying a maximum output user interface window on the user interface. Further, after input of a peak operating power level, the method stores the peak operating power level in the memory and selectively provides a power control signal to generate heat that corresponds to the peak operating power level. The oven is either an electric oven or gas oven. In operation, the oven heats at the peak operating power level, which is less than the maximum peak operating power level.