Optical quality control system
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cooking devices for commercial use are complex and prone to frequent repairs, and lack a reliable method to ensure that food is cooked according to the correct cycle and meets quality standards, often resulting in undercooked or improperly cooked food being served.
Innovation Solution
A cooking device equipped with a distance sensor and digital optical recognition system that captures images of the food for recognition and quality analysis, ensuring the correct cooking cycle is selected and completed, and that the food meets quality standards by comparing images to a database of properly cooked food.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complex identification systems (RFID, bar code readers, digital optical recognition) are used to identify food and select cooking cycles, then cooking cycle selection accuracy is improved, but device complexity increases
Solution Approach 1:
The system divides the cooking device into distinct functional modules: an identification module (with RFID, bar code reader, or digital optical recognition) and a control module. Each module performs a specific function, allowing the system to achieve accurate cooking cycle selection while maintaining manageable complexity through modular design.
Solution Approach 2:
The control module is designed to work with multiple types of identification systems (RFID tags, bar codes, digital images) through a unified interface. This multi-functionality allows the system to achieve accurate food identification and cooking cycle selection without requiring separate dedicated systems for each identification method, thereby reducing overall device complexity.
2Reliability
If multiple sensors and recognition devices are added to monitor cooking quality, then food quality control is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple monitoring functions (visual inspection, temperature sensing, quality analysis) into an integrated inspection system that operates within the existing cooking device architecture. By merging these functions into a unified system rather than adding separate independent systems, the patent achieves reliable food quality control while minimizing the increase in device complexity.
Solution Approach 2:
The inspection system continuously monitors cooking progress and provides feedback to the control module, which automatically adjusts cooking parameters to maintain quality standards. This closed-loop feedback mechanism ensures reliable quality control without requiring complex manual intervention systems.
3Reliability
If automated inspection systems are implemented to verify cooked food quality, then cooking error reduction is improved, but ease of operation deteriorates
Solution Approach 1:
The inspection system is designed to automatically perform quality verification and provide pass/fail indications without requiring operators to manually inspect each item. The system serves itself by automatically comparing actual cooking results against predefined quality standards, thereby reducing cooking errors while maintaining ease of operation through automated decision-making.
4Manufacturing precision
If distance sensors and optical recognition devices are used to track food placement, then cooking precision is improved, but ease of repair deteriorates
Solution Approach 1:
The system separates the precision measurement functions (distance sensing, optical recognition) into distinct modular components that can be independently accessed and maintained. This segmentation allows technicians to repair or replace individual sensor modules without affecting the entire cooking device, thereby maintaining high food placement precision while improving ease of repair.
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 significantly reduces cooking errors, ensuring that food is consistently cooked to the correct standard, eliminating the risk of serving undercooked food and simplifying the cooking process for operators.
Implementation Method 1
a distance sensor that detects the position of the food product carrier in the cooking chamber
Implementation Method 2
a digital optical recognition device that captures a series of product images for the purpose(s) of food product recognition and of quality analysis of the state of the food product having been cooked
Data Source
AI summary
Disclosed are cooking devices having inspection systems including: a distance sensor and a digital optical recognition device. The distance sensor detects the position of the food product placed in the cooking device and the digital optical recognition device captures a series of images for the purpose of food product recognition. Once the food product is recognized, the operator is provided with the correct cooking cycle/program for the position and type of food product placed in the cooking device. The inspection systems also ensure that the food product has been properly cooked at the end of the cooking cycle/program. The inspection systems ensure: (1) the food product is correctly recognized; (2) the cooking cycle/program is correctly selected; (3) the correct cooking cycle/program is followed to completion and (4) the quality of the cooked food product meets expected standards.