Gas Conveyor Oven Flame Modulator and Air Distribution
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Solution Overview
Problem
Gas-heated conveyor ovens with single burner and fan struggle to achieve adjustable and uniform cooking due to temperature regulation challenges, resulting in inefficient and non-homogeneous cooking compared to electric models.
Innovation Solution
A gas conveyor oven design incorporating a continuous flame modulator with a Venturi air intake tube and electronically adjustable fan for automatic regulation of gas flow, combined with a labyrinthine forced air structure and differential air feeders to optimize air-gas mixing and heat distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single gas burner and fan are used in a gas-heated conveyor oven, then the device complexity is reduced, but the temperature regulation capability and cooking uniformity deteriorate
Solution Approach 1:
The patent divides the single air flow from the fan into multiple separate air feeds (upper air feed and lower air feed) that are directed to different locations in the baking chamber. This segmentation allows each air feed to be independently controlled and directed to specific heating zones, enabling temperature regulation capability comparable to systems with multiple burners and fans while maintaining device simplicity.
Solution Approach 2:
The patent creates different air flow characteristics and temperatures at different locations within the baking chamber by directing heated air through separate upper and lower feeds. The upper air feed provides different thermal conditions than the lower air feed, allowing local optimization of cooking conditions for different product surfaces (top vs. bottom) without adding multiple burners.
2Device complexity
If a single gas burner is used, then the device complexity is reduced, but the cooking uniformity and adjustability deteriorate
Solution Approach 1:
The single burner's heated air is segmented into multiple independent air feeds that can be directed to different locations. This allows the system to achieve uniform cooking across the product by distributing heat through multiple pathways rather than relying on a single heat source, improving cooking uniformity without increasing the number of burners.
Solution Approach 2:
The patent employs variable speed fans that can be electronically adjusted to control air flow rates dynamically. This allows the system to adapt air flow characteristics to match different cooking requirements and product types, providing the adjustability normally associated with multiple independent heating elements while maintaining a simpler single-burner configuration.
3Device complexity
If on-off burner regulation is used, then the device complexity is reduced, but the temperature homogeneity and cooking efficiency deteriorate
Solution Approach 1:
The patent replaces on-off burner regulation with continuously variable speed fan control. The fans can be electronically adjusted to any speed within their range, providing continuous adjustment of air flow and heat distribution. This dynamic control eliminates the temperature peaks and valleys associated with on-off cycling, achieving homogeneous cooking temperatures without increasing burner complexity.
Solution Approach 2:
The patent incorporates temperature sensors that provide feedback to the control system. This feedback mechanism allows the variable speed fans to be automatically adjusted based on actual temperature conditions in the baking chamber, maintaining consistent temperature homogeneity and preventing the peaks and valleys characteristic of on-off regulation systems.
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 adjustable and uniform cooking comparable to electric models, maintaining optimal temperature without flame shut-off, reducing gas waste and enhancing cooking efficiency and flexibility.
Implementation Method 1
a gas supply valve connected to a Venturi air intake tube serving a variable speed electronically adjustable electric fan, for automatic regulation of the gas flow based on the incoming flow of air, adjusted by the variable speed fan and consequent mixing of the two fluids in order to optimize the stoichiometric combustion ratios
Implementation Method 2
The heating of the baking chamber 2 is done by one gas burner 5 with a flame column 6
Implementation Method 3
a left rotating centrifugal fan (8) located on the opposite side of the baking chamber 2, which centrally draws in air from and evenly expels it peripherally into a ventilation chamber 10
Implementation Method 4
a forced air circulation device in the form of a labyrinthian structure, which directs the flow of air in such a way as to minimize dispersive turbulence
Data Source
Figure 1
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AI summary
System to optimize the operation of gas conveyor ovens for food, including the continuous flame supply modulator for the burner (5), deflectors (14, 15, 16) for the preferential differentiated channelling of hot air inside a forced air labyrinthian structure (17, 18, 19, 20) and selective shielding (26) of the return air flow over the burner's flame column for reheating.