Infrared Toaster Feedback Control for Uniform Browning
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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 overtoasting or undertoasting due to surface irregularities and varying distances from the heat source.
Innovation Solution
A toaster system that uses an infrared source, a camera for image analysis, and a processor to monitor the toasting process, adjusting the IR energy based on digital images of the food product's color and brightness to achieve a predetermined toasting level, while also considering initial color and surface properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If infrared energy input is increased to shorten toasting time, then productivity is improved, but manufacturing precision deteriorates resulting in burned bread products
Solution Approach 1:
The system employs a camera to capture real-time images of the bread surface during toasting and uses image processing algorithms to analyze color changes and toasting uniformity. This feedback loop allows the control system to monitor the toasting process dynamically and adjust infrared energy delivery to maintain uniform browning while achieving faster toasting times.
Solution Approach 2:
The patent implements dynamic control of the infrared heating elements based on real-time image analysis. The system adjusts the intensity and distribution of infrared energy during the toasting process according to the actual state of the bread surface, transitioning from static pre-set timing to adaptive dynamic control that responds to actual toasting conditions.
2Manufacturing precision
If toasting time is extended to achieve uniform browning, then manufacturing precision is improved, but productivity deteriorates due to longer processing time
Solution Approach 1:
The system applies different infrared energy levels to different regions of the bread surface based on real-time image analysis. Areas that are browning faster receive reduced energy while slower-browning areas receive increased energy, creating a localized adaptive heating strategy that achieves uniform results more quickly than uniform heating approaches.
Solution Approach 2:
The patent dynamically changes multiple parameters including infrared energy intensity, exposure time, and spatial distribution based on real-time monitoring of bread surface color and texture. This multi-parameter adjustment allows the system to optimize the toasting process for both speed and uniformity simultaneously.
3Device complexity
If pre-set fixed time toasting is used, then device complexity is reduced, but manufacturing precision deteriorates due to inability to accommodate surface irregularities
Solution Approach 1:
The system enables the toasting process to self-regulate through automated image capture and analysis. The camera and processing algorithms allow the system to monitor and adjust its own operation in real-time, eliminating the need for complex manual control while achieving superior uniformity compared to simple timer-based 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
Ensures consistent and uniform toasting across various bread products by dynamically adjusting the IR energy, preventing overtoasting and undertoasting, and accommodating different types and initial colors.
Implementation Method 1
An infrared (IR) source is arranged relative to the support. The IR source is operable to direct IR energy to the food product on the support.
Implementation Method 2
Toasting food products like sliced bread, English muffins, bagels, pizza crust and other baked goods is usually accomplished using radiant or conductive energy transfer into the baked good from one or more heat sources.
Implementation Method 3
A light source is arranged relative to the support. The light source is operable to illuminate the food product on the support while the IR source operates to direct IR energy.
Data Source
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AI summary
An infrared toaster and a method of toasting use a support configured to hold a food product relative to an infrared source. A light source and a camera are arranged relative to the support to illuminate the food product and capture digital images of the food product. A processor receives and analyzes successive images from the camera. The processor operates the IR source to achieve a predetermined toasting level of the food product. The processor operates the IR source to terminate operation directing IR energy when the predetermined toasting level is reached.