Toaster with input control
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Solution Overview
Problem
Conveyor toasters experience excessive wear and tear due to constant operation at a single speed, even when not actively toasting, leading to reduced lifespan and increased maintenance needs.
Innovation Solution
A conveyor toaster with an adjustable conveyor belt speed system, controlled by a processor and input sensors, that increases speed during high utilization periods and decreases speed during low utilization periods, minimizing unnecessary revolutions and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If the conveyor belt operates at a consistent high speed to maintain readiness for food products, then the toasting readiness and response time are improved, but the wear on conveyor belts and motive components increases
Solution Approach 1:
The conveyor belt speed is made dynamic rather than fixed. The system automatically adjusts between a first speed (higher wear rate) during active toasting and a second speed (lower wear rate) during idle periods. This dynamic adjustment resolves the contradiction by optimizing both response time and component lifespan based on actual operational needs.
Solution Approach 2:
The operational parameter (conveyor belt speed) is changed based on system state. The processor monitors whether the toaster is actively toasting or idle, and adjusts the speed parameter accordingly. This parameter change allows the system to maintain readiness when needed while reducing wear during non-productive periods.
2Manufacturing precision
If the conveyor belt operates continuously at calibrated speed to ensure consistent toasting quality, then the toasting performance is maintained, but energy consumption and component wear increase during idle periods
Solution Approach 1:
The conveyor belt operation transitions from continuous periodic action to intermittent periodic action. During idle periods, the belt operates at reduced speed or remains stationary, and only activates at full speed when food products are detected. This periodic adjustment maintains toasting quality when needed while reducing energy consumption during idle periods.
Solution Approach 2:
The system uses feedback from sensors that detect the presence of food products to control conveyor belt speed. When no food is detected, the system feedback indicates idle state and reduces speed. When food is detected, feedback triggers full-speed operation. This feedback mechanism ensures consistent toasting quality while minimizing energy waste.
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 adjustable speed system reduces wear on conveyor belts and motive components, extending the toaster's lifespan and reducing maintenance requirements while maintaining consistent toasting performance.
Implementation Method 1
The input sensor includes a photoemitter and a photodetector
Implementation Method 2
The input sensor includes a photoemitter and a photodetector arranged proximate the opening and configured to detect the food product
Implementation Method 3
The input sensor may further include at least one mirror assembly including at least one mirror. The photoemitter and the photodetector may be arranged on a same side of the opening and the mirror is positioned opposite the photoemitter and the photodetector across the opening
Implementation Method 4
a conveyor belt configured to be operated by a drive motor to transport the food product past a heating element
Implementation Method 5
a conveyor belt configured to be operated by a drive motor to transport the food product past a heating element
Data Source
AI summary
A conveyor toaster includes a toaster cabinet, an opening extending through the toaster cabinet and configured to receive a food product, and a conveyor assembly positioned in the toaster housing and associated with the feed opening. The conveyor assembly includes a conveyor belt configured to be operated by a drive motor to transport the food product past a heating element. The conveyor toaster further includes a an input sensor arranged proximate the opening and configured to detect the food product and a processor operably coupled to the input sensor and the conveyor assembly. The processor is configured to change between an operating condition with a first belt speed and an idle condition with a second belt speed based upon a signal from the input sensor.