Patent Publication Number: US-11041629-B2

Title: System and method for food preparation utilizing a multi-layer model

Description:
TECHNOLOGICAL FIELD 
     The present disclosure generally relates to a cooking system and related methods, and more particularly relates to systems and methods for modeling a food load. 
     SUMMARY 
     In at least one aspect, a cooking system is disclosed. The cooking system comprises a controller in communication with a heating apparatus and a user interface. The controller is configured to access a cooking model for a selected food. The cooking model comprises a first layer indicating a first heat absorption relationship and a second layer indicating a second heat absorption relationship. The controller is further configured to receive a first cooking parameter from the user interface for the first layer and a second cooking parameter from the user interface for the second layer. The controller may further calculate a heat exchange model based on the first heat absorption relationship and the second heat absorption relationship. 
     In at least another aspect, a method for heating a food load is disclosed. The method comprises receiving an indication of a selected food type and accessing a food load model for the selected food type. The model comprises a first layer indicating a first heat absorption relationship and a second layer indicating a second heat absorption relationship. The method may continue by receiving a first input indicating a first cooking parameter of the first layer and a second input indicating a second cooking parameter of the second layer. Based on the first heat absorption relationship and the second heat absorption relationship, the method may continue to calculate a heat exchange model. With the heat exchange model, the method may heat the food load by activating a plurality of heat sources. The heat sources are selectively activated to supply heat according to the heat exchange model thereby heating the food load such that the first layer conforms to the first cooking parameter and the second layer conforms to the second cooking parameter. 
     In at least another aspect, a cooking system configured heat each of a plurality of layers of a food load to a desired cooking parameter is disclosed. The system comprises a controller in communication with a heating apparatus and a user interface. The controller is configured to receive an indication of a selected food type from the user interface and access a food load model for the selected food type. The model comprises a first layer indicating a first heat absorption relationship, a second layer indicating a second heat absorption relationship, and a third layer indicating a third heat absorption relationship. The controller may further be configured to receive at least one cooking parameter for each of the first layer, the second layer, and the third layer and calculate a heat exchange model based on the cooking parameters. With the heat exchange model, the controller may calculate a cooking routine. The cooking routine may correspond to a control scheme indicating a selective activation of each of a plurality of heat sources to prepare the food load such that each of the first layer, the second layer, and the third layer conform to a corresponding cooking parameter. 
     These and other features, advantages, and objects of the present device will be further understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the drawings: 
         FIG. 1  is a schematic diagram of a cooking system; 
         FIG. 2  is a graphical model demonstrating a plurality of layers describing a food load; 
         FIG. 3A  is a flow chart demonstrating a method of operation of a cooking system; 
         FIG. 3B  is a flow chart demonstrating a method of operation of a cooking system continued from  FIG. 3A ; and 
         FIG. 4  is a block diagram of a cooking system in accordance with the disclosure. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     For purposes of description herein the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the device as oriented in  FIG. 1 . However, it is to be understood that the device may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. 
     Referring to  FIG. 1 , the disclosure may provide for a cooking system  10  and method of simulating the preparation of a food load  12 . The cooking system  10  may comprise a controller in communication with a user interface  14  and operable to access a model  16  of a food load  12 . The model  16  of the food load  12  may comprise a as a plurality of layers  20 . For example, the model  16  may comprise a first layer  22  (outside), a second layer  24  (intermediate), and a third layer  26  (interior). Each of the layers  20  may define properties of a food type that may be selected for preparation in a heating cavity  28  of the cooking system  10 . 
     The representation or model  16  of the food load  12  may provide for the estimation of a temperature of each of the layers in response to heat generated by at least one heat source  30  of a heating apparatus  32  of the cooking system  10 . In this configuration, the controller may calculate a control scheme for the at least one heat source  30  such that each of the layers  20  of the food load  12  may be prepared by the cooking system  10  to achieve a desired result. Such a result may be preconfigured by a variety of automated functions to control a variety of cooking characteristics of each of the layers  20 . Additionally, in some embodiments, the system  10  may provide for a customized setting wherein an operator can select cooking characteristics for each of the layers  20 . 
     The controller of the cooking system  10  may identify material and thermodynamic properties of each of the layers  20  of the food load  12  based on the user selection of the food type. The food type may correspond to a food category (e.g. meats, vegetables, grains, etc.), a food type (chicken, green beans, pasta, etc.), and/or a specific food portion (e.g. chicken breast, baked potato, pizza slice, etc.). Additionally, the controller may be configured to receive or identify a proportion of the food load  12  (e.g. weight, mass, volume, quantity, etc.) and various additional information to indicate a property of the food load  12  such as a starting temperature (e.g. frozen, chilled, room temperature, etc.). Though described as being input by a user, the information describing the food load  12  may also be identified by one or more sensors in communication with the controller (e.g. imagers, light sensors, scales, pressure sensors, and a variety of transducers). 
     Once the food type and proportion of the food load  12  are identified, the controller may access material properties for each of the layers  20  to simulate the food load  12  as the model  16 . Additionally, the controller may scale the model  16  based on the proportion to improve accuracy of a preparation routine for the heat source(s)  30  of the heating apparatus  32 . With the material properties of each of the layers  20  as defined by the model  16 , the controller may calculate a cooking routine based on an automated program or user defined characteristics of each of the layers  20 . The cooking routine may be based on a numerical model description of the food load  12 . With the numerical model, the controller may generate and control an actuation strategy of the at least one heat source  30  to prepare each of the layers  20  of the food load to a desired result. 
     For example, the controller may access a database in a memory or remote server to retrieve the model  16  corresponding to the selected or identified food type. The model  16  may comprise various characteristics of each of the layers  20  of the food load  12 . Such characteristics may include, but are not limited to a heat transfer coefficient, density, thermal capacity, thermal diffusivity as well as electromagnetic permittivity, reflection coefficient, IR absorption coefficient, and various additional properties and combinations thereof that may be applied to calculate a response of the food load to the at least one heat source  30  of the cooking device  20 . The characteristics of the food load  12  may be included as a numerical model and scaled to describe the food load  12  as a simplified lumped-elements model (e.g. the model  16 ). Accordingly, the disclosure may provide for a cooking system  10  and related methods of controlling the at least one heat source  30  to prepare each layer  20  of the food load  12  to a desired characteristic, quality, and/or temperature by numerically modeling the layers  20  to account for various heat exchange relationships among the layers  20  and the heating apparatus  32 . 
     The at least one heat source  30  may correspond to one or more of a microwave, convection heater, electrically resistive element, a gas heating element, inductive heating element, infrared element, etc. In operation, the controller of the cooking system  10  may control the at least one heating source  30  to achieve a user defined temperature and/or quality of each of the layers  22 ,  24 , and  26 . For example, an operator of the cooking system  10  may want to select specific finishing levels associated with each of the layers  22 ,  24 , and  26 . Such finishing levels may include different temperatures, moisture levels, browning levels, consistencies, and/or other various characteristics of each of the layers  20 . The temperatures or finishing levels of the layers  20  may be input by an operator of the cooking device  20  via a user interface  14 . 
     Referring now to  FIG. 2 , the model  16  of the food load  12  is shown demonstrating a relationship of the first layer  22 , the second layer  24 , and the third layer  26 . The model  16  may include a plurality of external heat exchange relationships  42  configured to model the interaction between each of the layers  20  and the at least one heat source  30 . Additionally, the model  16  may include a plurality of conductive relationships  44  configured to model the conductive heat transfer between the layers  20 . Based on the external heat exchange relationships  42  and the conduction relationships  44 , the cooking system  10  may generate a numeric model to simulate the response of each of the layers  20  to heating inputs generated by the at least one heat source  30 . 
     The external heat exchange relationships  42  may be referred to herein as a first external heat exchange relationship  42   a , a second external heat exchange relationship  42   b , and a third external heat exchange relationship  42   c . The first external heat exchange relationship  42   a  may describe an interaction between the at least one heat source  30  and the first layer  22  of the model  16 . The second external heat exchange relationship  42   b  may describe an interaction between the at least one heat source  30  and the second layer  24 . The third external heat exchange relationship  42   c  may describe an interaction between the at least one heat source  30  and the third layer  26 . 
     The conductive relationships  44  between the layers  20  may be described as a first conductive relationship  44   a  and second conductive relationship  44   b . The first conductive relationship  44   a  may describe a conductive interaction between the first layer  22  and the second layer  24 . The second conductive relationship  44   b  may describe a conductive relationship between the second layer  24  and the third layer  26 . In this way, the controller of the cooking system  10  may utilize the model  16  to simulate the behavior of each of the layers  20  based on the external heat relationships  42  and the conductive relationships  44 . Additionally, the controller may generate a control scheme for the at least one heat source  30  of the heating apparatus  32  in order to effectuate one or more heating inputs of the relationships  42  and  44 . 
     In some embodiments, the external heat exchange relationships  42  utilized for the model  16  may utilize the first external heat exchange relationship  42   a  and the second external heat exchange relationship  42   b  without the third external heat exchange relationship  42   c . For example, if the heat source  30  corresponds to a microwave heat source, the microwave energy may only penetrate to approximately less than 2 cm. In some embodiments, the microwave energy may only penetrate to approximately 1 cm. Under such circumstances, the heat generated by the heat source  30  may not penetrate into the third layer  26  and the heat delivered to the third layer may be modeled by the second conductive relationship  44   b . However, for some processes (e.g. thawing of ice), the third external heat exchange relationship  42   c  may be utilized to model an increased penetration through ice of microwave energy through ice. Accordingly, the model  16  may be adjusted to omit the third external heat exchange relationship  42   c  for specific embodiments or applications of the cooking system  10 . 
     In operation, a selection of a food type may be received by the cooking system  10  via the user interface  14 . With the food type selected, the controller may access a specific model (e.g. the model  16 ) for the selected food type. The model  16  may include each of the layers  20  incorporated in a numeric model. The numeric model may include various food characteristics (e.g. thermal diffusivity, density, thermal capacity, etc.) of the food type. The numeric model therefore may represent each of the external heat exchange relationships  42  and a conductive relationship  44  for the separately modeled layers  20  based on the specific characteristics related to the selected food type. With this information, the controller may calculate a specific heating procedure or routine to selectively activate the at least one heat source  30  over time to reach a desired result as specified by a user or a preconfigured recipe for each of the layers  20 . 
     In an exemplary embodiment, the controller of the cooking system  10  may prompt an operator via the user interface  14  to input one or more desired characteristics of each of the plurality of layers  20 . For example, the controller may receive various selections via the user interface  14  to indicate an internal level of doneness or temperature, a level of moisture content or dehydration, a crusting or a brownness level, and/or various properties of each of the layers  20 . The level of doneness may also be described utilizing typical cooking terms as they may apply to a selected food type. For example, for a steak the controller may cross-reference the meaning of particular terms (e.g. well done, medium, rare, etc.) for a particular type of meat (e.g. beef, pork, etc.) by cross-referencing the internal temperature for the particular type of meat to achieve the requested result. In this way, the controller may gather information describing a desired result for each of the layers  20  and incorporate the results into the numerical model. 
     The numerical model may correspond to a lumped sum elements model comprising each of the layers  20  modeled as non-overlapping elements. Thus, the numerical model may be generated based on the model  16  in order to generate the control scheme for the at least one heat source  30 . The various embodiments of the cooking system  10  may utilize a numerical representation of the model  16  to control the at least one heat source  30  of the heating apparatus  32  to prepare the food load  12  to meet the desired quality results requested for each of the layers  20 . In some embodiments, a plurality of heat sources may be independently activated by the controller to provide various intensities and methods of heat delivery to the food load  12  to provide the desired results for each of the layers  20 . 
     Referring now to  FIGS. 3A and 3B , a flow chart of a cooking method  50  utilizing the model  16  is shown. The method  50  may begin by initiating a setup for a cooking routine ( 52 ). In response to the initiation of the setup for the cooking routine, the controller of the cooking system  10  may request and/or receive an entry of a food type for the food load  12  ( 54 ). Additionally, the method  50  may request and/or receive a proportion (e.g. weight, mass, volume, quantity, etc.) for the food load  12  ( 56 ). Based on this information, the controller may utilize the food type selected in step  54  to retrieve a model  16  including characteristics of the plurality of layers  20  for the selected food type. Additionally, the controller may scale the model based on the proportion of the food load  12  received in step  56 . 
     With the model  16 , the method  50  may continue by receiving a cooking parameter for an outer shell for the first layer  22  of the model  16  ( 58 ). The controller may also receive one or more cooking parameters for an intermediate layer for the second layer  24  of model  16  ( 60 ). Finally, the controller may receive one or more cooking parameters for an inner layer for the third layer  26  of the model  16  ( 62 ). Each of the cooking parameters may be receive via the user interface  14 , which may comprise a screen configured to prompt an operator of the cooking system  10  to input the cooking parameters. 
     Once the one or more parameters are received for each of the layers  20 , the controller may initiate an automated cooking process for the food load  12 . The automated cooking process may comprise a control routine for the at least heat source  30  to achieve the desired results defined as the cooking parameters for each of the layers  20 . Though specifically described as receiving the individual parameters for each of the plurality of layers  20 , the cooking system  10  may similarly be configured to automatically provide recipes incorporating parameters for each of the plurality of layers  20 . In this way, the cooking system  10  may provide for a balance of flexibility and ease of use to achieve a desired result for each of the layers  20 . 
     Continuing now in reference to  FIG. 3B , the method  50  may continue by initiating the automated cooking process ( 64 ). As previously described in reference to  FIG. 3A , the controller may generate a numerical representation of the model  16  by accessing properties of each of the layers  20  of the food load  12  ( 66 ). As further described in reference to  FIG. 4 , the controller may access the properties for each of the layers  20  via local storage in the form of a memory and/or a communication circuit configured to communicate with a remote server. With the numerical representation of the model  16  populated with the properties of the food type and the desired results of each of the layers  20 , the controller may resolve the numerical representation of the model  16  to determine a cooking time, cooking power, and cooking method to achieve the received parameters ( 68 ). 
     Resolving the numerical representation of the model  16  may comprise simulating and generating a cooking routine configured to control the at least one heat source  30  to supply inputs to each of the external heat exchange relationships  42  and the resulting conductive relationships  44 . In some embodiments, the at least one heat source  30  may comprise a plurality of heat sources, each of which may be configured to deliver heat energy to the food load  12  via different heat delivery methods. For example, the at least one heat source  30  may correspond to a plurality of heat sources including one or more of a gas burner, an electrically resistive heating element, and induction heating element, a browning or ferritic heating element, a microwave apparatus, or any other suitable heating device. Accordingly, the method  50  may continue to configure or optimize the heating routine utilizing one more heat delivery methods available by controlling the at least one heat source  30  ( 70 ). With the heating routine, the method  50  may then continue by controlling the heating apparatus  32  to achieve the heating routine thus providing for the desired results for the layers  20  ( 72 ). 
     During the heating routine, the controller may continue by monitoring the status of the heating apparatus  32  and recording a cooking time to identify cooking interruptions ( 74 ). An interruption may include opening a door or access hatch during the heating routine, pausing a cooking operation, etc. In step  76 , if an interruption is detected, the method  50  may update a cooking time, cooking power, and various other characteristics of the heating routine ( 78 ). Following step  78 , the method may return to step  70 . 
     If in step  76  no interruption is detected, the controller may continue to monitor the heating routine to determine if the cooking process is complete ( 80 ). If the cooking process is not complete in step  80 , the controller may return to step  74  to continue monitoring and recording the operation of the heating apparatus  32  for interruptions. Once the cooking process is identified as being complete, the controller may continue to finish the cooking process, which may include outputting a message or alert to communicate that the process is complete. 
     Referring now to  FIG. 4 , a block diagram of the cooking system  10  is shown. As previously discussed, the cooking system  10  may comprise a controller  92 , which may be configured to control the cooking apparatus  12 . The controller may comprise a processor  94  and a memory  96 . The processor  94  may correspond to one or more circuits and/or processors configured to communicate with the user interface  14  and access the properties of a selected food type via the memory  96  such that a numerical model may be generated for the model  16 . In this configuration, the controller  92  may be operable to generate the heating or cooking routine for the at least one heat source  30  of the heating apparatus  32 . The properties of the each of the layers  20  for the food types stored in the memory  96  may include a wide variety of properties including a heat transfer coefficient, density, thermal capacity, thermal diffusivity as well as electromagnetic permittivity, reflection coefficient, IR absorption coefficient, and various additional properties. Additionally, the memory  96  may comprise instructions for a variety of scaling and/or arithmetic operations that may be configured to resolve the numerical model of the food load  12  based on a proportion of a specified food type. 
     The controller  92  may be supplied electrical current by a power supply  98  and may further comprise a communication circuit  100 . The communication circuit  100  may correspond to various wired and/or wireless communication devices through which the controller  92  may communicate and/or access information stored in a remote server or location. For example, the communication circuit  100  may correspond to a local area network interface and/or a wireless communication interface. The wireless communication interface may be configured to communicate through various communication protocols including but not limited to wireless 3G, 4G, Wi-Fi®, Wi-Max®, CDMA, GSM, and/or any suitable wireless communication protocol. In this configuration, the controller  92  of the cooking system  10  may be configured to access information (e.g. properties of the layers  20 ) for a wide variety of food types. 
     The heating apparatus  32  may comprise various forms of heat sources  30  including, but not limited to a browning or heating element  102 , a microwave element  104 , a convection fan  106 , or any mechanism suitable to heat food as discussed herein. The browning or heating element  102  may correspond to a gas burner, an electrically resistive heating element, an induction heating element, a browning or ferritic heating element or any other suitable heating device. Depending on the specific parameters of the layers  20 , the controller  92  may selectively and independently control one or more of the heat sources  30  such that each of the layers  20  of the food load  12  is prepared to a desired parameter. 
     It will be understood by one having ordinary skill in the art that construction of the described device and other components is not limited to any specific material. Other exemplary embodiments of the device disclosed herein may be formed from a wide variety of materials, unless described otherwise herein. 
     For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated. 
     It is also important to note that the construction and arrangement of the elements of the device as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations. 
     It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present device. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting. 
     It is also to be understood that variations and modifications can be made on the aforementioned structures and methods without departing from the concepts of the present device, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise. 
     The above description is considered that of the illustrated embodiments only. Modifications of the device will occur to those skilled in the art and to those who make or use the device. Therefore, it is understood that the embodiments shown in the drawings and described above is merely for illustrative purposes and not intended to limit the scope of the device, which is defined by the following claims as interpreted according to the principles of patent law, including the Doctrine of Equivalents.