Automatic Grill Gap Calibration With Motor Current Feedback
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Solution Overview
Problem
Existing grills require manual calibration and labor-intensive maintenance to ensure the upper grilling surface is level, leading to increased costs and inefficiencies in cooking processes.
Innovation Solution
A grill with a pivotally attached upper platen assembly and a leveling mechanism using three independently controlled motors, which automatically calibrates the gap between the upper and lower grilling surfaces by detecting changes in motor current to maintain a level surface and adjust accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual calibration is used to level the upper grilling surface, then the grill can be adjusted to a level position, but additional cost and labor are required
Solution Approach 1:
The system performs automatic calibration without requiring external manual intervention. The microprocessor controls the motors to adjust the upper platen assembly's position, and the level sensor detects when the surface is level, eliminating the need for service technicians to manually calibrate the grill
Solution Approach 2:
The level sensor provides continuous feedback to the microprocessor about the upper grilling surface's levelness. This feedback loop allows the system to automatically detect when calibration is complete and adjust the position accordingly, resolving the contradiction between achieving precision and reducing manual labor
2Manufacturing precision
If service technicians manually calibrate the grill at the site, then the upper grilling surface can be leveled, but travel time and additional labor costs are incurred
Solution Approach 1:
The grill calibrates itself automatically using the integrated level sensor and motor system controlled by the microprocessor. This eliminates the need for service technicians to travel to the site for calibration, saving time and reducing operational costs while maintaining the required levelness precision
3Productivity
If the upper platen assembly is manually flipped to cook both sides of food, then both sides can be grilled, but the process is labor-intensive
Solution Approach 1:
The upper platen assembly is made dynamically movable through the motorized lifting mechanism. The microprocessor controls the motors to automatically lower and raise the upper platen, enabling the system to adapt its position for cooking different food configurations without manual intervention, thereby increasing productivity while reducing operational complexity
4Reliability
If the upper grilling surface is not level, then cooking uniformity is compromised, but manual calibration is required to fix this
Solution Approach 1:
The level sensor provides real-time feedback to the microprocessor about the upper grilling surface's levelness. This feedback mechanism enables automatic detection and correction of levelness issues, ensuring cooking uniformity while managing device complexity through automated control rather than manual adjustment mechanisms
Solution Approach 2:
The manual mechanical calibration process is replaced with an automated electromechanical system. The microprocessor controls the motors based on level sensor feedback, substituting the need for manual mechanical adjustment with an automated control system that maintains cooking uniformity
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 automatic calibration ensures consistent and efficient cooking by maintaining a uniform gap, reducing the need for manual intervention and minimizing labor costs, while also allowing for automatic recognition and adjustment of food item size for optimized cooking parameters.
Implementation Method 1
A current sensor detects the current in the motor. When the upper grilling surface is slightly lifted from the lower grilling surface, the current of the motor changes.
Implementation Method 2
The motors each operate independently to rotate a shaft including a disc.
Data Source
AI summary
A grill includes a lower platen assembly having a lower grilling surface and a pivotally attached upper platen assembly having an upper grilling surface. The upper platen assembly includes three motors encased in a shell. A cable attached to each motor suspends the upper grilling surface. The grill is automatically calibrated to ensure that the upper grilling surface is level. Each motor independently and sequentially raises the upper grilling surface from the lower grilling surface. When the upper grilling surface lifts from the lower grilling surface, the current in the motor changes. The settings of each motor at this instant are stored in a control to determine the calibration point when the upper grilling surface is level. The grill also automatically recognizes a food item placed on the lower grilling surface to determine the cooking parameters of the grill.