Layered Grill Heater Control for Fast Surface Temperature Response
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Solution Overview
Problem
Commercial cooking grills face challenges with slow temperature response and energy inefficiency due to their large mass, which limits precise control over temperature variations and waste energy when not all surfaces are in use, and existing systems cannot accurately sense or respond to loads on the grill surface.
Innovation Solution
A layered heater system with resistive heating layers and nodes connected via lead wires and a multiplexer, controlled by a controller to adjust power based on resistance differences, allowing for precise temperature control and energy efficiency by reducing the mass to be heated and improving contact with the cooking surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a large mass grill is used to reduce temperature variations, then temperature stability is improved, but response time to load changes deteriorates and equipment becomes heavy and bulky
Solution Approach 1:
The grill heating system is divided into multiple independent heating zones, each with its own heating elements and temperature control. This allows different sections to respond independently to load changes, improving overall response time while maintaining temperature stability in each zone through localized control.
Solution Approach 2:
The system dynamically adjusts heating power in response to detected load changes by monitoring temperature variations and automatically modifying heating element output. This dynamic response capability allows the grill to quickly adapt to changing thermal conditions without requiring excessive mass for stability.
2Stability of the object's composition
If a large mass grill is used to maintain temperature, then temperature consistency is improved, but energy consumption increases
Solution Approach 1:
By segmenting the grill into controlled zones, energy is applied only where and when needed rather than heating the entire large mass uniformly. This reduces overall energy consumption while maintaining temperature consistency in active cooking areas through precise localized control.
Solution Approach 2:
The system continuously monitors temperature in multiple zones and uses this feedback to automatically adjust heating element power levels. This closed-loop control prevents energy waste by applying heat only to the extent necessary to maintain desired temperatures, eliminating the need to overheat large masses for safety margins.
3Reliability
If thermocouples are placed away from the surface for temperature sensing, then sensor safety is improved, but temperature measurement accuracy and response time deteriorate
Solution Approach 1:
The system uses the grill structure itself as an intermediary thermal conduction path. Temperature sensors positioned away from the cooking surface measure temperature in the grill body, which serves as a thermal intermediary that quickly equilibrates with surface temperature. This provides accurate indirect measurement while keeping sensors protected from direct exposure to cooking conditions.
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 enables rapid and accurate temperature control, reducing thermal inertia, conserving energy, and allowing for real-time verification of surface temperatures and tailored cooking profiles, enhancing cooking efficiency and safety.
Implementation Method 1
a layered heater formed on the heating surface, the layered heater defining at least one resistive heating layer
Implementation Method 2
The resistive heating material defines a positive temperature coefficient material such that when a load is placed on the upper substrate, the resistive heating material provides for an increase in power proximate the load
Data Source
AI summary
A heater system and related methods of heating a surface are provided by the present disclosure that includes, in one form, a substrate defining a heating surface and a layered heater formed on the heating surface. A plurality of nodes are disposed along the heating surface and are in electrical contact with a resistive heating layer of the layered heater, along with a plurality of lead wires connected to the plurality of nodes. In one form, a multiplexer is in communication with the plurality of nodes through the plurality of lead wires, and a controller is in communication with the multiplexer, wherein the multiplexer sequences and transmits resistances from the plurality of nodes to the controller, and the controller controls an amount of power provided to each of the plurality of nodes based on the differences in resistances between the nodes.