Infrared Toaster with Camera Feedback for Uniform Browning Control
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Solution Overview
Problem
Existing toasters fail to consistently achieve uniform toasting across bread products like English muffins in a short time period, often resulting in burning due to surface irregularities and varying distances from the infrared source, making it difficult to balance toasting time and quality.
Innovation Solution
A toaster system that uses an infrared source, a camera for image capture and analysis, and a processor to monitor the toasting process, adjusting the IR energy application based on pixel values and predetermined toasting levels to ensure uniform browning, with supplemental light and forced gas to enhance image clarity and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the toasting time is extended to achieve uniform browning, then the toasting uniformity is improved, but the productivity decreases
Solution Approach 1:
The patent employs a camera to capture images of the bread product during toasting and a processor to analyze the images for color uniformity. Based on the analysis results, the system provides feedback by adjusting the infrared energy distribution or toasting time, ensuring uniform browning while optimizing the toasting duration for high productivity.
2Productivity
If the infrared energy intensity is increased to reduce toasting time, then the productivity is improved, but the bread product is burned
Solution Approach 1:
The patent uses multiple infrared sources positioned at different locations to provide localized heating zones. The system independently controls the intensity of each infrared source based on real-time image analysis, allowing different regions of the bread product to receive appropriate energy levels, thus preventing burning while maintaining fast toasting speed.
Solution Approach 2:
The system dynamically adjusts the infrared energy intensity during the toasting process based on real-time monitoring of bread color changes. The processor continuously analyzes captured images and modifies the energy distribution from multiple infrared sources to prevent over-toasting and burning, enabling high-speed toasting without quality degradation.
3Manufacturing precision
If multiple infrared sources are added to improve toasting uniformity, then the toasting quality is improved, but the device complexity increases
Solution Approach 1:
The patent makes the camera serve multiple functions: it monitors the toasting process, analyzes color uniformity, and provides data for controlling the infrared sources. This multi-functionality reduces the need for additional dedicated sensors or control devices, thereby limiting the increase in device complexity despite using multiple infrared sources for uniform toasting.
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 system achieves consistent and uniform toasting by precisely controlling IR energy application, reducing the risk of over- or under-toasting, and ensures that all surfaces reach the desired level of doneness without burning, improving the efficiency and quality of the toasting process.
Implementation Method 1
infrared energy emitted from one or more electrically-heated wires in a toaster or broiler
Implementation Method 2
The process of toasting, is the result of a chemical reaction known as the Maillard reaction. The Maillard reaction is considered to be the reaction between carbohydrates and proteins that occurs upon heating and which produces toasting.
Implementation Method 3
A light source is arranged relative to the support and operates to illuminate the bread product on the support while the IR source operates to direct the IR energy
Implementation Method 4
Carbon absorbs light. The surface of a burned bread product therefore appears black.
Data Source
AI summary
An infrared source is arranged relative to support for bread product and operates to direct IR energy to the bread product. A light source is arranged relative to the support and operates to illuminate the bread product and a camera operates to capture images of the bread product. A processor receives the images from the camera. The processor compares successive images received from the camera. Based upon the comparison, the processor operates the IR source to achieve a predetermined toasting level of the bread product.