IR Toaster Image-Based Heating Control for Consistent Toasting
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Solution Overview
Problem
Toasters face challenges in consistently toasting bread products with uniform surface color and texture due to variations in density and starting temperature, often resulting in inconsistent toasting outcomes and potential over-toasting.
Innovation Solution
Mechanical thermal management components, including heat retention lids and a shutter for the camera aperture, along with a controller that analyzes image data from an external camera to adjust heating element operation, ensuring precise toasting control and uniformity across different bread types and temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional heating elements are used without thermal management, then toasting speed is reduced, but heat distribution uniformity deteriorates leading to inconsistent toasting results
Solution Approach 1:
The patent employs dynamically adjustable thermal management components including movable lids that can open/close and shutters that can adjust positioning during the toasting cycle. These dynamic elements allow real-time modification of heat distribution to accommodate variations in bread density and starting temperature, achieving both fast and consistent toasting results
Solution Approach 2:
The system changes thermal parameters by controlling lid positioning and shutter angles to modify heat retention and distribution characteristics. The controller adjusts these parameters based on image analysis feedback, optimizing heat conditions for different bread types and achieving consistent toasting outcomes while maintaining high productivity
2Productivity
If heating intensity is increased to improve toasting speed, then toasting time is reduced, but risk of over-toasting and burning increases
Solution Approach 1:
The patent incorporates image capture devices that continuously monitor the toasting process and provide feedback to the controller. The controller uses this visual feedback to detect early signs of over-toasting and automatically adjusts heating intensity or extends the toasting cycle, enabling fast toasting while preventing burning through real-time monitoring and adaptive control
Solution Approach 2:
The system uses periodic imaging during the toasting cycle to assess progress at multiple time points. This periodic monitoring allows the controller to adjust heating parameters in stages, maintaining high temperature for speed while preventing overheating through intermittent verification and adaptive timing adjustments
3Manufacturing precision
If thermal management components are added to improve heat control, then toasting precision is improved, but device complexity increases
Solution Approach 1:
The patent designs thermal management components that serve multiple functions: lids provide both structural enclosure and adjustable heat retention, shutters offer both mechanical adjustment capability and heat blocking function, and image capture devices serve both monitoring and control guidance purposes. This multi-functionality reduces the need for separate dedicated components, managing device complexity while achieving precise toasting control
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 solution enables faster, more consistent toasting of bread products by maintaining optimal heat conditions and using image analysis for precise timing, reducing the risk of over-toasting and improving user safety.
Implementation Method 1
A heating element is arranged within the toasting chamber interior of the housing and relative to the rack. The heating element is operable to direct IR energy to the bread product on the rack.
Implementation Method 2
A lid is movable with the rack between an open condition and a closed condition. In the closed condition the lid occludes an opening into the toasting chamber.
Implementation Method 3
The mechanical thermal management components may further include a shutter that selectively occludes a camera aperture. The shutter blocks the camera from being exposed to a portion of the heat energy generated by the toaster during operation.
Data Source
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AI summary
A toaster (10) includes a rack (16) within a toasting chamber (32). A lid (22) is movable with the rack (16) to selectively occlude an opening to the toasting chamber (32). A heating element (20) within the toasting chamber (32) is operable to direct IR energy to the bread product on the rack (16). An image capture device (30) operates to acquire image data of the bread product on the rack (16). A controller (42) receives the image data. The controller (42) processor analyzes successive image data received from the image capture device (30). Based upon the analysis of the image data, the controller (42) operates the heating element (20) to achieve a predetermined toasting level of the bread product and then turn off the heating element (20).