Optical quality control methods
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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 to recognize the type and quantity, selects the appropriate cooking cycle, and evaluates the cooked food's quality by comparing it to stored images, ensuring correct cooking and quality standards are met.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex identification systems (RFID, barcode readers, optical recognition devices) are used to identify food and select cooking cycles, then cooking accuracy and quality control are improved, but device complexity increases leading to frequent repairs and high maintenance costs
Solution Approach 1:
The patent extracts the identification function from complex electronic systems (RFID tags, barcode readers, optical recognition devices) and replaces it with a simple mechanical code wheel attached to the food container. This code wheel can be visually read or scanned by simple sensors, eliminating the need for complex identification infrastructure while maintaining reliable food identification and cooking cycle selection
Solution Approach 2:
The patent employs disposable or replaceable code wheels with printed codes that can be easily changed based on food type. These simple mechanical codes are cheaper than electronic identification systems and can be replaced without complex calibration or programming, reducing maintenance costs and improving reliability
2Device complexity
If manual inspection of cooked food quality is performed, then equipment simplicity is maintained, but cooking quality consistency and error prevention deteriorate
Solution Approach 1:
The patent implements an automated feedback system where the control unit receives information from the code wheel about the required cooking parameters and food type, processes this information, and automatically selects the appropriate cooking cycle. This closed-loop feedback mechanism ensures consistent cooking quality without requiring complex manual inspection procedures
Solution Approach 2:
The system performs self-inspection by automatically reading the code from the code wheel and selecting the appropriate cooking parameters without human intervention. The control unit autonomously manages the cooking process based on the encoded information, eliminating the need for manual quality checks while maintaining equipment simplicity
3Productivity
If automated cooking cycle selection is implemented, then cooking efficiency and productivity are improved, but the risk of cooking errors and serving undercooked food increases without proper verification
Solution Approach 1:
The patent encodes all necessary cooking information (food type, cooking time, temperature, power level) in advance on the code wheel attached to the food container. This preliminary encoding of cooking parameters allows the system to automatically select the correct cooking cycle without real-time decision-making, improving efficiency while reducing errors through pre-verified cooking instructions
Solution Approach 2:
The control unit continuously monitors the cooking process and compares actual cooking parameters against the target values specified by the code wheel. This feedback mechanism detects and corrects deviations during cooking, preventing undercooked or improperly cooked food from being served while maintaining high productivity
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 food is cooked correctly and consistently meets quality standards, preventing undercooked or improperly cooked food from being served.
Implementation Method 1
a distance sensor for detecting the position of the food product carrier in the cooking chamber
Implementation Method 2
a digital optical recognition device for capturing a series of product images
Data Source
AI summary
Disclosed are cooking methods using 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 methods also ensure that the food product has been properly cooked at the end of the cooking cycle/program. The methods 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.