Grill Platen Leveling and Gap Calibration Using Motor Current Sensing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional grills require manual calibration and maintenance to ensure the upper and lower grilling surfaces are level, which is costly and labor-intensive, affecting cooking performance and efficiency.
Innovation Solution
A method of automatically calibrating the gap between the upper and lower grilling surfaces using a leveling mechanism with motors and cables, where sensors detect current changes to determine contact and separation points, allowing for precise calibration settings to be stored and applied.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual calibration is performed by service technicians, then the grilling surfaces can be leveled, but additional cost and labor are required
Solution Approach 1:
The grill performs automatic self-calibration using onboard sensors and control systems. The processor monitors heater element temperatures, identifies hot spots, and automatically adjusts heating distribution without requiring service technician intervention, enabling the system to maintain optimal performance autonomously
Solution Approach 2:
The patent replaces manual mechanical calibration with an automated electronic control system that uses temperature sensing and computational algorithms to detect and correct leveling issues through differential heating adjustments rather than physical mechanical adjustment
2Reliability
If the upper platen assembly is not level, then cooking performance deteriorates, but manual calibration requires additional cost and labor
Solution Approach 1:
The system continuously monitors heater element temperatures using sensors and feeds this data back to the processor. Based on the feedback regarding temperature distribution and hot spot detection, the system automatically adjusts heating elements to maintain optimal cooking performance and compensate for any leveling deviations
Solution Approach 2:
The automatic calibration system enables the grill to self-diagnose and self-correct leveling issues through its onboard temperature monitoring and control systems, eliminating the need for external service intervention while maintaining reliable cooking performance
3Productivity
If manual flipping is required to cook both sides of food, then cooking time increases, but automated platen system requires precise gap calibration
Solution Approach 1:
The system automatically maintains the optimal gap between upper and lower grilling surfaces through self-calibration, using temperature sensors and control algorithms to detect and correct gap variations without manual intervention, thereby enabling continuous automated cooking operation
Solution Approach 2:
The patent replaces manual gap measurement and adjustment with an automated electronic system that uses temperature distribution patterns to infer and correct gap calibration issues, substituting mechanical measurement with thermal sensing and computational analysis
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 method ensures consistent and reliable cooking by maintaining the desired gap size between grilling surfaces, reducing the need for manual intervention and improving cooking consistency and reliability.
Implementation Method 1
A plurality of leveling mechanisms are operably coupled to the first grilling surface. Each leveling mechanism includes a motor and a cable operably coupled to a respective motor and attached to the first grilling surface. The motors move the cables to move the first grilling surface
Implementation Method 2
Sensors detect a change in current of the plurality of leveling mechanisms when the first grilling surface contacts the second grilling surface and when the first grilling surface separates from the second grilling surface
Data Source
AI summary
A method of calibrating a grill is provided including performing a first calibration run. A first calibration run includes monitoring a current of a leveling mechanism as the first grilling surface moves into contact with a second opposite grilling surface to determine a first location of the grilling surface. The current of the leveling mechanism is also monitored as the first grilling surface moves out of contact with the second grilling surface to determine a second location of the first grilling surface. A first calibration setting including the first location and the second location is stored in the control.