Grill Surface Temperature Control Using Embedded RTD Sensor Feedback
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Solution Overview
Problem
Existing grill temperature control systems are not capable of accurately maintaining a set grill surface temperature due to unpredictable heat transfer rates influenced by environmental conditions and lack of direct surface temperature measurement, requiring users to adjust knobs manually and rely on air temperature gauges.
Innovation Solution
A temperature controller system for grills that includes a selector for setting desired temperatures, a heat source with adjustable output, and a resistance thermal detector (RTD) sensor embedded in the cooking element, allowing for precise temperature maintenance and automatic adjustment of heat output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a temperature gauge measures air temperature inside the grill, then the user can see temperature readings, but the grill surface temperature cannot be accurately controlled or predicted
Solution Approach 1:
A thermocouple sensor is introduced as an intermediary element that directly contacts the grill cooking surface to accurately measure its temperature. This sensor works with a controller to form a feedback loop, enabling precise temperature control. The intermediary sensor bridges the gap between the heat source and the control system, allowing the controller to adjust power output based on actual surface temperature readings rather than relying on indirect air temperature measurements.
2Adaptability or versatility
If manual knob adjustment is used to control grill temperature, then the user can adjust power settings, but the actual grill surface temperature becomes unpredictable due to environmental conditions
Solution Approach 1:
The system implements automatic feedback control where the controller continuously monitors the grill surface temperature via the thermocouple sensor and automatically adjusts the power output to maintain the desired temperature. This closed-loop feedback mechanism eliminates the need for manual knob adjustment and compensates for environmental variations automatically, ensuring consistent temperature control regardless of external conditions.
3Measurement precision
If the temperature sensor is embedded in the cooking element, then direct surface temperature measurement is achieved, but the cooking element becomes harder to remove for cleaning
Solution Approach 1:
The system is segmented into separate functional components: the thermocouple sensor is integrated into the cooking element for accurate temperature measurement, while the controller housing and wiring are separated into a fixed base unit. This segmentation allows the cooking element with the embedded sensor to be easily removed for cleaning, as the sensor is small and integrated without creating mechanical interlocks that would prevent removal.
Solution Approach 2:
A flexible connector or wire acts as an intermediary between the thermocouple sensor in the removable cooking element and the controller in the fixed base. This intermediary connection allows the cooking element to be freely removed and reattached while maintaining electrical connectivity for temperature sensing.
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 users to set and maintain a consistent grill surface temperature, improving cooking precision and ease of use by directly measuring and regulating the cooking element's temperature, while allowing for easy cleaning and removable components.
Implementation Method 1
the temperature sensor is a resistance thermal detector (RTD) embedded in a housing, the housing directly in contact with said cooking surface
Data Source
AI summary
A grill having a control system that monitors the temperature of the grill grate and adjusts heat output to the grill according to a temperature selected by the user. The grill grate includes channels on the rear face thereof, one channel contains the electrically powered heat source and the other channel contains the temperature sensor. A drip pan is located below the grill grate. The grill grate is removable from the grill and removable from the two channels for cleaning. Multiple zones are provided, each with a controller that allows the user to set the desired temperature of the grill grate/grilling surface.