US20070006865A1 - Self-cleaning oven - Google Patents
Self-cleaning oven Download PDFInfo
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- US20070006865A1 US20070006865A1 US10/546,104 US54610404A US2007006865A1 US 20070006865 A1 US20070006865 A1 US 20070006865A1 US 54610404 A US54610404 A US 54610404A US 2007006865 A1 US2007006865 A1 US 2007006865A1
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- Prior art keywords
- oven
- conveyor
- air
- cooking
- cooking chamber
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- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24C—DOMESTIC STOVES OR RANGES ; DETAILS OF DOMESTIC STOVES OR RANGES, OF GENERAL APPLICATION
- F24C15/00—Details
- F24C15/32—Arrangements of ducts for hot gases, e.g. in or around baking ovens
- F24C15/322—Arrangements of ducts for hot gases, e.g. in or around baking ovens with forced circulation
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- A—HUMAN NECESSITIES
- A21—BAKING; EDIBLE DOUGHS
- A21B—BAKERS' OVENS; MACHINES OR EQUIPMENT FOR BAKING
- A21B1/00—Bakers' ovens
- A21B1/02—Bakers' ovens characterised by the heating arrangements
- A21B1/24—Ovens heated by media flowing therethrough
- A21B1/245—Ovens heated by media flowing therethrough with a plurality of air nozzles to obtain an impingement effect on the food
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- A—HUMAN NECESSITIES
- A21—BAKING; EDIBLE DOUGHS
- A21B—BAKERS' OVENS; MACHINES OR EQUIPMENT FOR BAKING
- A21B1/00—Bakers' ovens
- A21B1/42—Bakers' ovens characterised by the baking surfaces moving during the baking
- A21B1/48—Bakers' ovens characterised by the baking surfaces moving during the baking with surfaces in the form of an endless band
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24C—DOMESTIC STOVES OR RANGES ; DETAILS OF DOMESTIC STOVES OR RANGES, OF GENERAL APPLICATION
- F24C14/00—Stoves or ranges having self-cleaning provisions, e.g. continuous catalytic cleaning or electrostatic cleaning
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24C—DOMESTIC STOVES OR RANGES ; DETAILS OF DOMESTIC STOVES OR RANGES, OF GENERAL APPLICATION
- F24C14/00—Stoves or ranges having self-cleaning provisions, e.g. continuous catalytic cleaning or electrostatic cleaning
- F24C14/02—Stoves or ranges having self-cleaning provisions, e.g. continuous catalytic cleaning or electrostatic cleaning pyrolytic type
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24C—DOMESTIC STOVES OR RANGES ; DETAILS OF DOMESTIC STOVES OR RANGES, OF GENERAL APPLICATION
- F24C14/00—Stoves or ranges having self-cleaning provisions, e.g. continuous catalytic cleaning or electrostatic cleaning
- F24C14/02—Stoves or ranges having self-cleaning provisions, e.g. continuous catalytic cleaning or electrostatic cleaning pyrolytic type
- F24C14/025—Stoves or ranges having self-cleaning provisions, e.g. continuous catalytic cleaning or electrostatic cleaning pyrolytic type for gaseous fuels
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24C—DOMESTIC STOVES OR RANGES ; DETAILS OF DOMESTIC STOVES OR RANGES, OF GENERAL APPLICATION
- F24C3/00—Stoves or ranges for gaseous fuels
- F24C3/12—Arrangement or mounting of control or safety devices
- F24C3/122—Arrangement or mounting of control or safety devices on stoves
Definitions
- the present invention relates to a gas-fired tunnel oven, and particularly a gas-fired conveyor oven.
- Gas-fired tunnel ovens traditionally have been cleaned manually with detergent and acid solutions. The oven must be taken apart for cleaning by these methods. In addition to the oven walls, roof, and floor, the conveyor used with the tunnel oven must be cleaned, as well as any jet-impingement convection fingers, convection blowers, and fired burners. Cleaning by the traditional methods is tedious and expensive.
- a gas-fired, commercially-sized tunnel oven might be cleaned by installing electrical heaters at critical points to raise the internal temperature to a range that reduces virtually all contamination to ash.
- cleaning a gas-fired tunnel oven by raising the temperature with electrical heaters requires an estimated 50-100 amperes of electricity for each oven.
- Commercial bakers do not normally have access to this much electrical current, and the cost of installing high current electrical service is a significant financial barrier for most bakers.
- a self-cleaning, gas-fired tunnel oven that cleans by pyrolysis is provided.
- the oven is used with a conveyor for food products, which may be collapsed and placed inside the oven for pyrolitic cleaning.
- the oven includes a control system that regulates the oven temperature and duration of the self-cleaning operation and deters people from opening the oven during the self-cleaning operation.
- the control system also modulates combustion air and heating gas to one or more burners within the oven.
- a modulating control system regulates the flow of air or heating gas to the burner or burners.
- the ratio of airflow to heating gas flow is controlled directly so that the ratio of air to fuel gas flowing to the burner is approximately the same over a range of heating loads.
- the control system that proportionally coordinates the flow of air and fuel may be, for example, a mechanical linkage between the valves or one or more electric or pneumatic controllers that send positioning signals to the valves.
- the oven may be equipped with a plurality of convection blowers, each of the convection blowers being subject to individual speed control.
- the speed of one or more of the convection blowers is varied during start-up operation to optimize fuel consumption, during cooking operation to optimize the quality of food products cooked in the oven, and during the self-cleaning operation to control the rate of contaminant incineration, among other reasons.
- the oven includes a floating cooking chamber, which can withstand pyrolitic cleaning temperatures and repeated pyrolitic cleaning cycles without warping, cracking or developing metal fatigue.
- Various components of the floating cooking chamber are joined in a sliding fit that permits the floating cooking chamber to expand and contract in response to temperature changes without applying excessive mechanical stress to the components.
- the oven also includes a vacuum exhaust system for exhausting pyrolysis products.
- the convection blowers are situated to deliver convection air to the oven and, also, maintain the oven under a negative pressure with respect to the kitchen.
- an inducer blower extracts the exhaust air from the oven and delivers it to a disposal system. The negative pressure prevents combustion products produced during the self-cleaning process from escaping to the kitchen.
- the oven is equipped with an active cooling system in which air from the kitchen is passed through ducts that cool the exterior surfaces of the oven.
- the oven includes heat-slingers to protect the shafts of the convection blowers from overheating. Additionally, the oven includes self-cleaning fingers for a jet-impingement convection system that also clean the conveyor.
- FIG. 1 is a perspective view of a self-cleaning oven with both first and second conveyor extension sections extended, each of the conveyor sections being depicted without its mesh belt for clarity;
- FIG. 2 is a partial perspective view of the oven of FIG. 1 showing a drive shaft, a main conveyor section and the first and second conveyor extension sections, each of the conveyor sections being depicted without its mesh belt for clarity;
- FIG. 3 is a side view of the oven of FIG. 1 with one of the side walls removed, showing one of the blower and motor assemblies and two air-impingement fingers;
- FIG. 4 is a perspective view of the oven of FIG. 1 with the first conveyor extension section extended and the second conveyor extension section retracted, the first conveyor extension section being shown without its mesh belt for clarity;
- FIG. 5 is a view of the oven of FIG. 1 with the front access door removed, showing both conveyor extension sections in their retracted positions;
- FIG. 6 is a front elevation view of the oven of FIG. 1 with both conveyor extension sections retracted;
- FIG. 7 is an overhead perspective view of the oven of FIG. 1 with the ceiling and overhead insulation removed, showing a roof-mounted burner assembly, two blower and motor assemblies, and a vent arrangement;
- FIG. 8 is a close-up perspective view of the burner assembly of FIG. 3 showing a gas shut-off valve, a gas valve, an air valve, a valve link that coordinates the action of the gas valve with the action of the air valve, and a burner;
- FIG. 9 is a rear perspective view of the oven of FIG. 1 showing the two blowers and the vent arrangement.
- FIG. 10 is a perspective view of walls and a tubular frame support surrounding a cooking chamber of the oven of FIG. 1 .
- FIG. 11 is a partial perspective view of the oven of FIG. 1 showing a drive shaft, the main conveyor section and the first conveyor extension section, each of the conveyors depicted without its mesh belt for clarity.
- FIG. 12 is a an overhead view of the oven of FIG. 1 with the ceiling and overhead insulation removed, showing a roof-mounted flame tube assembly and two blower and motor assemblies.
- FIG. 13 is a view of the main conveyor section through an oven opening with one of the conveyor extension sections removed.
- FIG. 14 is a view of the main conveyor section and its connection to the front wall of the oven depicted in FIG. 1 .
- FIG. 15 is a view of one of the conveyor extension sections separated from the oven of FIG. 1 .
- FIG. 16 is a side view of the mesh belt of one of the conveyor extension sections.
- a pyrolytically self-cleaning, gas-fired, conveyor oven 10 as shown in FIG. 1 , includes an oven housing 12 supported on four legs 14 .
- the oven housing 12 surrounds a cooking chamber 16 through which food products are passed on a conveyor assembly 18 .
- the oven 10 also includes a front access door 40 that can be opened using a front access door handle 41 .
- the conveyor assembly 18 includes powered rollers 20 that drive a wire mesh conveyor belt (not shown in the Figures) that conveys. food through the cooling chamber 16 .
- the powered rollers 20 can be driven in either direction so that, as viewed in FIG. 2 , the conveyor belt can convey food through the cooking chamber 16 from left-to-right or right-to-left.
- Food products can be transported by the conveyor assembly 18 into a first oven opening 37 and out of a second oven opening 38 or, alternatively, into the second oven opening 38 and out of the first oven opening 37 .
- the motion of the conveyor drive motor (not shown) and, consequently, the motions of the conveyor assembly 18 are precisely and continuously controlled in order to provide the optimum cooking time for the food products.
- the speed and direction of the conveyor assembly 18 are input by an operator through a control station (not shown).
- the conveyor assembly 18 extends out of the cooking chamber 16 at both ends. Food is placed on the conveyor assembly 18 at either end of the oven 10 and is carried through the cooking chamber 16 to the other end of the oven 10 .
- the conveyor assembly 18 includes a main conveyor section 30 and first and second conveyor extension sections 32 , 34 extending out of the cooking chamber 16 . Over time, as food products travel back and forth over the conveyor assembly 18 , the various sections 30 , 32 , 34 of the conveyor assembly 18 clog with food debris and otherwise become dirty. Additionally, food particles that drop onto various surfaces and components within the cooking chamber 16 become dirty. To clean the oven 10 , the first and second conveyor extension sections 32 , 34 can be disconnected from the main conveyor section 30 and inserted into the cooking chamber 16 .
- the main conveyor 30 is driven by a direct current electric motor operating through a gear reducer.
- a pulse-controlled conveyor drive motor (not shown) turns a drive shaft 86 which is rigidly attached to a drive gear 88 , which are depicted in FIG. 11 .
- the drive motor sends well-defined pulses of electrical energy to move the drive shaft 86 in either a clockwise or counterclockwise direction.
- Each electrical pulse of the motor moves the drive shaft 86 a reproducible increment. For example, a single pulse may be adjusted to advance the drive shaft 86 by a predetermined number of angular degrees.
- the frequency of electrical pules determines the speed of the drive shaft 86 , and consequently the speed of the conveyor assembly 18 , in either direction.
- the drive gear 88 turns the main conveyor section 30 and the first and second conveyor extension sections 32 , 34 by means of follower gears 90 , 92 (only one is shown for the first conveyor extension section 32 ).
- the follower gears 90 , 92 cause conveyor axles 110 to turn, which creates the conveyor motion.
- the speed of all the conveyor sections, and ultimately, the cooking time of food products traveling through the oven 10 is regulated by the drive motor.
- the drive motor for oven 10 is controlled by a digital control unit (not shown).
- FIGS. 1 and 2 depict both the first conveyor extension section 32 and the second conveyor extension section 34 in an extended and locked position, the conveyor extension sections 32 , 34 being both collapsible and extendable.
- the first conveyor extension section 32 is accompanied by a first insulated door 35 and the second conveyor extension section 34 is accompanied by a second insulated door 36 .
- Both the first and second conveyor extension sections 32 , 34 can be separated from the oven housing 12 and inserted into a first oven opening 37 and a second oven opening 38 , respectively.
- the first insulated door 35 can be shut to close the first oven opening 37 and the second insulated door 36 can be shut to close the second oven opening 38 .
- FIG. 11 is a partial perspective view of oven 10 in which only selected components are shown in order to better communicate the invention.
- FIG. 11 shows the relationship of the main conveyor section 30 to the first conveyor extension section 32 when the first conveyor extension section 32 is in the extended position.
- the first and second conveyor extension sections 32 , 34 (only one is shown in FIG. 11 ) each include an upper notch 78 , sized and shaped to receive an upper peg 80 , which is attached to an inside wall of the oven (not shown in FIG. 11 ).
- the first and second conveyor extension sections 32 , 34 also each include a lower notch 82 for receiving a lower peg 84 , which is also attached to the inside wall (not shown). Lifting the first and second conveyor extension sections 32 , 34 causes them to rotate about the upper pegs 80 until the lower pegs 84 disengage from the lower notches 82 .
- the first and second conveyor extension sections 32 , 34 can be separated from oven 10 and inserted into the first and second oven openings 37 , 38 so that the first and second insulated doors 35 , 36 close the first and second oven openings 36 , 38 , as shown in FIG. 6 .
- the first conveyor section 32 is partially inserted into the first oven opening 37 and locked in an extended position with respect to the main conveyor section 30 .
- the first conveyor section 32 is locked by inserting the pair of upper notches 78 formed by the sides of the first conveyor section 32 under a pair of upper pegs 80 mounted in the oven 10 .
- a pair of lower notches 82 also formed by the sides of the first conveyor extension 32 are then rotated onto a pair of lower pegs 84 mounted in the oven 10 .
- the second conveyor extension section 34 is similarly inserted into the second oven opening 38 and locked in an extended position with respect to the main conveyor section 30 .
- the first conveyor extension section 32 is separated from the oven 10 in FIG. 13 , providing a close-up view of the first oven opening 37 and the main conveyor section 30 .
- the drive shaft 86 of the main conveyor section 30 extends between two side plates 96 , although only one of the side plates 96 is visible in FIG. 13 .
- FIG. 13 also depicts five of the six drive sprocket wheels 100 attached to the conveyor axle 110 of the main conveyor section 30 .
- a mesh belt 102 is shown as an endless chain engaged with the drive sprocket wheels 100 .
- One of the upper pegs 80 and one of the lower pegs 84 which cooperate for locking the first conveyor section 32 (not shown in FIG. 13 ) in an extended position, are also visible in FIG. 13 .
- the sixth of the six drive sprocket wheels 100 of the main conveyor section 30 is shown in FIG. 14 along with one of the two side plates 96 .
- a bracket 106 extends from one of the side plates 96 and is fastened to the front wall 66 for supporting the main conveyor section 30 .
- the front wall 66 also supports one of the upper pegs 80 and one of the lower pegs 84 .
- FIG. 15 A close-up, partial perspective view of the first conveyor extension section 32 is presented in FIG. 15 .
- the mesh belt 102 of the first conveyor extension section 32 tends to sag if not supported, as illustrated in FIG. 16 .
- FIG. 15 depicts four guides 108 , which are provided to support the mesh belt 102 .
- the guides 108 are in turn supported by guide supports 98 , which extend the width of the first conveyor extension section 32 .
- FIG. 15 also shows the conveyor axle 110 and the six drive sprocket wheels 100 for the first conveyor section, which are used to facilitate the progress of the mesh belt 102 .
- FIG. 4 shows the second conveyor extension section 34 inserted into the cooling chamber 16 and a second insulated door 36 closed to seal off the second oven opening 38 through which the second conveyor extension section 34 previously extended.
- FIG. 5 further illustrates that the main conveyor section 30 supports the first conveyor extension section 32 when the first conveyor extension section 32 is inserted into the first oven opening 37 . Inserting the first conveyor extension section 32 into first oven opening 37 allows the first insulated door 35 to close the first oven opening 37 .
- the main conveyor section 30 supports the second conveyor extension section 34 , when the second conveyor extension section 34 is inserted into the second oven opening 38 so that the second insulated door 36 can close the second oven opening 38 .
- the cooling chamber 16 of the oven 10 is completely sealed, as shown in FIG. 6 .
- the cooking chamber 16 can then be superheated to approximately 900°, turning all food debris in the oven 10 to ash.
- the front access door 40 can be opened using the front access door handle 41 and the ash can be cleaned from the oven 10 .
- each of conveyors includes endless stainless steel mesh belts 102 capable of travelling in either direction and at variable speeds.
- Crumb trays (not shown) are removably installed underneath the first and second conveyor extension sections 32 , 34 .
- the depicted conveyor oven 10 includes two fingers 24 , a lower finger having nozzles 22 directing air upward at the bottom of the conveyor assembly 18 and an upper finger having nozzles 22 (not seen in FIG. 2 ) directing air downward at the top of the main conveyor section 30 .
- the fingers 24 contain an inner distributor plate (not shown) and a perforated outer plate containing the nozzles 22 that collimate the heated air and evenly distribute the heated air across the main conveyor section 30 on which the food products ride.
- the oven 10 depicted in FIG. 3 includes two fingers 24 (one above the conveyor and one below), however, the oven 10 can accommodate a number of bottom fingers 24 and top fingers 24 . Any combination or deletion of fingers may be employed.
- the hot air directed through the fingers 24 is heated by a burner assembly 42 (best seen in FIGS. 7 and 8 ) located under an instrument panel 39 ( FIG. 1 ) on the front of the oven 10 .
- the burner assembly 42 creates the heat used by the oven 10 during both cooking (baking) and self-cleaning.
- the burner assembly 42 heats the hot air that flows through the fingers 24 to cook food products passing along the conveyor assembly 18 .
- the burner assembly 42 burns a gas and air mixture at a burner 44 , which shoots a flame down a flame tube 46 .
- the flame heats the air contained in the flame tube 46 , and the heated air exits the flame tube through an outlet 47 and into a plenum 94 , as seen in FIG. 12 .
- the open space of the plenum 94 located in front of the back wall 70 of the oven 10 , provides the hot air with a directed passageway toward a blower housing 74 where it will be circulated throughout the cooking chamber 16 .
- the burner 44 is called upon to satisfy a wide range of heat output requirements, it is necessary to control the flow of gas and air supplied to the burner 44 . While the burner 44 is operating, the flow of both air and heating gas to the burner 44 is modulated by a combined control system. With this combined modulating control system for combustion air and heating gas, optimum combustion conditions within the burner 44 can be maintained approximately constant over a range of heat outputs. With this combined modulating control system, the ratio of combustion air flow to heating gas flow can be optimized and maintained so that combustion is thermally efficient and environmentally sound, producing a minimum of objectionable byproducts.
- the ratio of combustion air to heating gas can be optimized to produce, for example, environmentally clean burning and the ratio will remain close to the optimum value whether the programmable controller (not shown) calls for high heat or low heat.
- the ratio may be optimized for optimal fuel consumption, optimal heat-up time or any other results that the operator desires and the ratio will not vary substantially with heat output.
- This modulating control system for combustion air and heating gas over a range of heat output is especially advantageous for a self-cleaning oven, such as the oven 10 , where a range of heat outputs is required.
- the burner assembly 42 includes an actuator 48 that operates an air valve 50 that regulates the amount of air entering the burner 44 from a combustion air blower 52 .
- the actuator 48 controls the position of the air valve 50 based on signals received from other control instruments and sensors (not shown) included in oven 10 .
- a valve link 54 coordinates the movement of the gas valve 56 with that of the air valve 50 .
- the gas valve 56 receives gas from an automatic gas shut-off valve 57 and modulates the flow of this gas so that the ratio of heating gas to combustion air is relatively constant for a wide range of heating loads.
- the valve link 54 connects the air valve 50 to the gas valve 56 so that as the actuator 48 opens and closes the air valve 50 , the gas valve 56 is correspondingly opened and closed, proportionally mixing the air and gas as they enter the burner 44 . The air and gas mixture is then ignited inside the burner 44 and a flame shoots down the flame tube 46 .
- valve link 54 One of the advantages of modulating air and gas control, as provided by the valve link 54 , is that the amount of excess air in the flame tube 46 remains substantially the same during high and low heating load periods. This advantage is particularly important in a self-cleaning, pyrolitic oven, which exhibits a significantly higher heating load during self-cleaning than conventional cooling heating loads.
- valve link 54 depicted in FIGS. 6, 7 and 8 is mechanical, it is also contemplated that the positions of an air valve and a gas valve in modulating air and gas control systems may alternatively be coordinated by, for example, utilizing electronically-controlled actuators for each of the valves and coordinating their positions by means of one or more electronic controllers.
- the burner 44 may be mounted anywhere in the oven.
- the burner 44 is roof-mounted as shown and sends its flame along the inside of the flame tube 46 mounted adjacent the ceiling of the oven 10 .
- contaminants tend to accumulate most heavily on and near the oven floors.
- the roof-mounted burner system is more likely to progressively incinerate and less likely to ignite the floor accumulation as compared to conventional floor-mounted and wall-mounted burner configurations.
- the flame tube 46 becomes very hot and radiates heat energy throughout the inventive oven 10 . It is contemplated that a diffusing tube (not shown) may be employed around the burner for processing food products that tend to discolor or otherwise deteriorate when subjected to intense radiant heat.
- the oven 10 has two relatively large blowers 26 , 27 (see FIG. . 7 ) to move the heated air created by the burner 44 through the fingers 24 and onto the product so that the most efficient bake is achieved for each food product processed in the oven 10 . More specifically, the oven 10 employs collimated, vertical air streams to give uniform and intensive heating. The collimated, vertical streams of air that emerge from the fingers 24 provide an exceptional heat transfer rate and generally bake foods faster and at lower temperatures than in conventional convection hot air or infrared heating ovens.
- the hot air is circulated through the oven 10 by the two blowers 26 , 27 located at the back of the oven 10 (see FIG. 9 ).
- the two convection blowers 26 , 27 are located in the blower housing 74 (see FIG. 10 ).
- the blowers 26 , 27 are each powered by a blower motor 75 (only one is shown in FIG. 9 ), which is mounted on the back wall 70 , and connected to the blowers 26 , 27 by a shaft (not shown).
- the shafts may be fitted with heat-slingers (not shown) or other cooling apparatuses.
- a heat slinger is a type of fan arrangement mounted on the shaft.
- Each blower motor 75 may be equipped with a dedicated speed controller (not shown), preferably including an electrical power inverter. With the benefit of individual speed control, the blowers 26 , 27 can be individually accelerated and decelerated to optimize electrical current inrush, the burner 44 firing or convective heat loss. The speed of the blowers 26 , 27 may also be individually controlled in order to create distinguishable heating zones within the oven 10 to optimize the baking of particular food products.
- blowers 26 , 27 may be variable speed blowers that are controlled together so that their speeds, while variable, are always the same as each other.
- cooling fans 13 , 15 located on the front of oven 10 as depicted in FIGS. 1, 4 , 6 , and 7 . These fans blow cool air in through the machinery compartment and out the side walls.
- the cooling fans 13 , 15 draw air from the surroundings through the instrument panel 39 for cooling the instruments located behind the instrument panel 39 .
- a portion of the discharge air from the cooling fans 13 , 15 may enter the combustion air blower 52 and be delivered to the burner 44 as combustion air.
- the remainder of the discharge air from cooling fans 13 , 15 enters passages that extend between the external sheeting of the oven 10 and an inside wall, which supports insulation. The flow of air in these passages serves to cool the external sheeting of the oven 10 below preferably about 125 degrees F.
- a vent arrangement 58 is located at the back of the oven 10 .
- the vent arrangement 58 includes a vent valve 60 that is positioned between a vent tube 62 and a T-shaped tube 64 that communicates with the high-pressure sides of the blowers 26 .
- the vent valve 60 is closed so that no air passes through the vent valve 60 into the vent tube 62 . In this way, during cooking, air that is heated is directed solely into the cooking chamber 16 for efficient cooking of food in the cooking chamber 16 .
- the vent valve 60 is opened and the oven openings 37 , 38 are closed, as discussed above.
- vent valve 60 By opening the vent valve 60 , enough heated air is exhausted through the vent tube 62 to maintain a slight negative pressure within the cooking chamber 16 . In this way, the smoke and soot that develops during a self-cleaning cycle is exhausted through the vent tube 62 and the passage of smoke and soot through small openings and cracks in the oven housing 12 is prevented.
- the cooking chamber 16 is bounded by a front wall 66 and two side walls 68 that are connected to a back wall 70 .
- the front wall 66 , two side walls 68 , and back wall 70 are all screwed together to form a box surrounding the cooking chamber 16 .
- the back wall 70 of this box is fixed to a tubular frame 71 , which is connected to a platform 72 .
- the front wall 66 , and two side walls 68 are free-floating. That is, the front wall 66 and two side walls 68 are connected to the back wall 70 , but are not connected to the tubular frame 71 .
- the perimeters of the front wall 66 and the two side walls 68 include lips 73 that sit on the various members that make up the tubular frame 71 , but are not fixedly connected to those members. In this way, the front wall 66 and two side walls 68 are free to move relative to the tubular frame 71 so that during cooking, and particularly during self-cleaning when the temperatures in the cooking chamber 16 are relatively high, the front wall 66 and side walls 68 of the cooking chamber 16 are free to expand and slide on the members of the tubular frame 71 , thereby preventing buckling and warping of the walls of the cooking chamber 16 .
- a unified display control station (not shown) for the oven 10 can include a blower selector, a heat selector, a conveyor selector, two or more conveyor speed controllers and a digital temperature controller. Additionally, a machinery compartment access panel safety switch disconnects electrical power to the controls and the blowers when the machinery compartment access panel is opened.
- an operator confirms that the front access door 40 is closed. The operator then turns the blower and conveyor selectors to the “on” position. If necessary, the operator adjusts the conveyor speed setting by pushing appropriate selectors on the conveyor speed controller. The operator adjusts the temperature controller to a desired temperature and selects normal operation.
- a heat switch on a control station (not shown) of the oven 10 activates the combustion air blower 52 .
- the burner 44 is a direct ignition burner.
- the main gas valve 57 is opened while starting. a spark in the burner 44 .
- a sensor then monitors whether a flame is present within the burner 44 . If a flame is not detected within 6 seconds, the main gas valve 57 is shut down, the burner 44 is purged, and the ignition cycle is repeated. Referring to FIGS. 7 and 8 , a gas bypass tube 76 provides enough gas to the burner 44 to maintain a minimum flame even when the gas modulation valve 56 is closed.
- the oven 10 will typically heat to a desired heating set-point temperature within a matter of minutes. While the oven 10 is heating, the control station (not shown) displays the actual temperature. One or more thermocouples (not shown) in the interior of the oven 10 send signals to a programmable controller (not shown) that controls the actuator 48 . If the programmable controller (not shown) calls for more heat, the actuator 48 rotates to open the air valve 50 and more combustion air is permitted to pass from the combustion air blower 52 to the burner 44 . Simultaneously, the valve link 54 moves under the influence of the actuator 48 to further open the gas valve 56 , permitting more heating gas to pass from gas line 55 to the burner 44 .
- valve link 54 causes the air valve 50 and the gas valve 56 to close simultaneously and proportionally. Consequently, the ratio of combustion air flow to heating gas flow entering the burner 44 remains approximately constant over a range of heat output.
- the speed of the blowers 26 , 27 can be varied.
- the speed of the blowers may be two-thirds full speed during start-up and self-cleaning cycles and full speed during a cooking cycle to promote heating efficiency during each of the cycles.
- one or both of the blower motors 75 start and routinely ramp up to a desired operating speed in a programmable period of time. Programming the start-up time of convection blower motors 75 makes firing of the burner 44 more reliable and promotes better combustion, among other things.
- the burner 44 is initially fired with a minimum heat output and ramped up to the baking or self-cleaning heat output over a period of time by, for example, a programmable controller (not shown).
- a programmable controller not shown
- the blower motors 75 are accelerated to operating speed in a programmable period of time.
- the start-up procedure (i.e., ramping up the speed of one or both of the blowers 26 , 27 ) prevents an objectionable current inrush situation that is observed in conventional ovens, which commonly start two or more blower motors at full speed simultaneously.
- This startup procedure is also quieter, and requires less electricity and heating gas, than the startup of conventional ovens.
- the blowers 26 , 27 draw more electrical current when the oven is cold and the air in the oven is relatively dense, operating both blowers at low speed during heat-up (start-up) saves electricity. Also, because increased convection on the inside surfaces of the oven walls promotes heat loss to the kitchen, operating only one of the convection blowers during heat-up saves heating gas.
- each of the blowers 26 , 27 is equipped with an electrical power inverter (not shown), which alters the frequency and/or voltage of the electrical current to control the speed of the blower 26 or 27 .
- the blower motor 75 can be either ramped up to operating speed over a programmable period such as, for example, about thirty minutes, or held at an optimal intermediate speed until the oven 10 reaches baling or cleaning temperature and then accelerated. These variations conserve still more energy by providing appropriate programmable blower speeds depending on the current operation of the oven 10 .
- the oven 10 is, for example, baking (cooking), self-cleaning, warning up, or cooling down
- the blowers 26 , 27 can operate at specific speeds best suited for each individual activity.
- the speed of the blower motors 75 may be separately adjusted to create two or more different heating zones (not shown) within the oven 10 .
- These heating zones (not shown) can be created at will and utilized to optimize the baking process and, consequently, the finished quality of a particular food product.
- the oven 10 may be equipped with two or more thermocouples (not shown) or other temperature sensors to individually monitor and adjust these heating zones (not shown). The manner in which the signals from these thermocouples (not shown) are averaged or otherwise interpreted by the programmable controller can be varied to suit the food product.
- blowers 26 , 27 In order to shut down the blowers 26 , 27 , the operator selects standby on the control station. The blowers 26 , 27 will remain in operation until the oven 10 has cooled to below 200 degrees F. and then cease turning.
- the oven 10 When it is determined that the oven 10 should be cleaned, it is cooled to a temperature below about 140 degrees F. The operator then disengages the first conveyor extension section 32 and withdraws the first conveyor extension section 32 from the first oven opening 37 . The first conveyor extension section 32 is then inserted into the first oven opening 37 so that the first conveyor extension section 32 is supported by the main conveyor section 30 and the first insulated door 35 closes the first oven opening 37 . The second conveyor extension section 34 is similarly separated from the oven 10 and inserted into the second oven opening 38 and the second insulated door 36 is closed. Because the first and second conveyor extension sections 32 , 34 are inserted into the interior of the oven I 0 , they are cleaned by pyrolitic heat during the self-cleaning cycle.
- the vent valve 60 (best seen in FIG.
- oven 10 operates under the control of temperature sensors and controllers (not shown) that are specifically designed to operate in the range of about 650-1000 degrees F. These may be the same sensors and controllers used for baling (not shown) or a separate set.
- the programmable control system actuates a set of safety interlocks adapted for cleaning temperature operation.
- the oven overrides the baling cycle high temperature shutdown limits, which are typically set at values less than 600 degrees F.
- the programmable control system actuates door locks that deter people from opening the oven doors during the pyrolitic self-cleaning cycle.
- the programmable controller also initiates corrective action if unsafe or undesirable conditions are detected. For example, upon detecting excessively high temperatures, high smoke levels or low oxygen levels within the oven, the programmable controller shuts down the burner 44 and the blowers 26 , 27 .
- the interior of the oven 10 is kept under a negative pressure compared to the surrounding atmospheric pressure.
- the opening of the vent valve 60 and the operation of the blowers 26 , 27 create the negative pressure in the interior of the oven 10 .
- an inducer blower (not shown) maintains the interior of the oven 10 under a negative pressure during cleaning as compared to the surrounding atmospheric pressure. The inducer blower creates this negative pressure by drawing air from the blower housing 74 .
- the blowers 26 , 27 actually assist the inducer blower in creating this negative pressure because the discharge flow from the blowers 26 , 27 is impelled directly into the inducer blower.
- the combined effect is similar to that of a two-stage blower.
- the discharge flow from the inducer blower is sent to the vent arrangement 58 .
- the inducer blower could also take suction from the interior of the oven 10 during normal baking.
- the entry of the inducer blower opens directly into the blower housing 74 .
- the inducer blower may be positioned directly in the path of the discharge air flow from each of the blowers 26 , 27 so that the two sets of blowers work in tandem to reduce the pressure in the interior of the oven 10 .
- the inducer blower may be mounted anywhere in the interior of the oven 10 .
- the discharge flow of air from the inducer blower is sent to the vent arrangement 58 for disposal.
- Maintaining negative pressure in the interior of the oven 10 during both cooking and self-cleaning enhances energy efficiency and safety. Maintaining negative pressure in the interior of the oven 10 during the cooking and self-cleaning operations insures that little or no heated air escapes to the kitchen. Minimizing heated air loss makes the oven 10 more energy efficient. Any loss or discharge of heated air from the interior of the oven 10 necessitates the combustion of additional heating gas. By directing all exhaust flows from the oven 10 to the vent arrangement 58 and ultimately the vent tube 62 , the loss or discharge of heated air can be better controlled and minimized. Also, the negative pressure system promotes safety because negative pressure retains burning gases in the interior of the oven 10 rather than permitting them to escape into the kitchen.
- maintaining negative pressure in the oven 10 tends to prevent any smoky residue from building up on the exterior of the oven 10 during normal cooking and self-cleaning operations.
- the exterior surfaces of the oven 10 remain clean longer because they are not subjected to smoke, which commonly escapes from the atmospheric cooking chambers of conventional ovens.
- the blowers 26 , 27 turn at a relatively low speed during a first incineration period of the cleaning cycle. This low speed uniformly distributes heat throughout the interior of the oven 10 while minimizing convective heat loss through the walls of the oven 10 .
- the first incineration period generally continues for about one hour, although it may be longer or shorter based on factors such as the cleaning temperature and the amount and type of contamination in the oven 10 .
- the blowers 26 , 27 operate at a relatively higher speed to promote complete incineration of the contamination or debris accumulation.
- the temperature of the oven 10 is increased to a peak temperature at least once during the second incineration period.
- the programmable controller cools the oven, disengages the safety interlocks and arranges the control system for cooling operation. Due to the combination of high temperature and convective air flow in the inventive oven during the self-cleaning cycle, any contamination accumulation that is in the oven is reduced to harmless and sterile ash.
- This ash may be collected on drip pans provided for that purpose, which can be accessed through the front access door 40 and carried away to disposal. Alternatively, the ash may be collected in a vacuum cleaner system that is built into or independent of the inventive oven.
- collection of the ash from the lower fingers may be facilitated by constructing the mesh belt 102 of the main conveyor section 30 so that it is close to or touching the perforated plates of the lower fingers 24 .
- the mesh belt 102 thus pushes or scrapes the ash from the lower fingers 24 for collection by a drip pan or vacuum system.
- the perforations are formed so that the lower fingers 24 present a nonabrasive surface to the mesh belt 102 .
Abstract
A self-cleaning, gas-fired tunnel oven is provided. One embodiment of the oven provides a self-cleaning, gas-fired tunnel oven for cooking food products. The oven includes a control system that regulates oven temperature during a pyrolitic, self-cleaning procedure for incinerating contaminants that accumulate inside; a burner for cooking food products and incinerating contaminants; a modulating air and fuel control system arranged for proportionally delivering air and fuel to the burner; a plurality of convection air fingers for directing heated air toward the food products; a collapsible conveyor, capable of fitting into the oven when collapsed, for passing the food products through the oven; a plurality of blowers, each having a dedicated speed controller; a floating cooking chamber; and a vent system that maintains a negative pressure in the oven during the self-cleaning procedure
Description
- The present patent application claims the benefit of prior filed U.S. provisional patent application Ser. No. 60/449,545, filed on Feb. 21, 2003, the entire contents of which are hereby incorporated by reference.
- The present invention relates to a gas-fired tunnel oven, and particularly a gas-fired conveyor oven.
- Commercial, gas-fired tunnel ovens equipped with conveyors produce, among other things, pizzas, cookies, bread, cakes and donuts. Each oven routinely processes a large volume of food products and, as a result, becomes rather dirty. Bits of the food products themselves, burned food products, and soot from the burners are typical sources of contamination that accumulate during use.
- Gas-fired tunnel ovens traditionally have been cleaned manually with detergent and acid solutions. The oven must be taken apart for cleaning by these methods. In addition to the oven walls, roof, and floor, the conveyor used with the tunnel oven must be cleaned, as well as any jet-impingement convection fingers, convection blowers, and fired burners. Cleaning by the traditional methods is tedious and expensive.
- In theory, a gas-fired, commercially-sized tunnel oven might be cleaned by installing electrical heaters at critical points to raise the internal temperature to a range that reduces virtually all contamination to ash. In practice, cleaning a gas-fired tunnel oven by raising the temperature with electrical heaters requires an estimated 50-100 amperes of electricity for each oven. Commercial bakers do not normally have access to this much electrical current, and the cost of installing high current electrical service is a significant financial barrier for most bakers.
- Accordingly, there is a need for a self-cleaning, gas-fired tunnel oven suitable for use with a conveyor that can be cleaned without need of disassembly, manual cleaning, or detergents. Commercial bakers would welcome a self-cleaning, gas-fired tunnel oven.
- A self-cleaning, gas-fired tunnel oven that cleans by pyrolysis is provided. The oven is used with a conveyor for food products, which may be collapsed and placed inside the oven for pyrolitic cleaning. The oven includes a control system that regulates the oven temperature and duration of the self-cleaning operation and deters people from opening the oven during the self-cleaning operation.
- The control system also modulates combustion air and heating gas to one or more burners within the oven. A modulating control system regulates the flow of air or heating gas to the burner or burners. The ratio of airflow to heating gas flow is controlled directly so that the ratio of air to fuel gas flowing to the burner is approximately the same over a range of heating loads. The control system that proportionally coordinates the flow of air and fuel may be, for example, a mechanical linkage between the valves or one or more electric or pneumatic controllers that send positioning signals to the valves. With modulating control of combustion air and heating gas, the oven operates cleanly and efficiently over a wide range of heating loads.
- The oven may be equipped with a plurality of convection blowers, each of the convection blowers being subject to individual speed control. The speed of one or more of the convection blowers is varied during start-up operation to optimize fuel consumption, during cooking operation to optimize the quality of food products cooked in the oven, and during the self-cleaning operation to control the rate of contaminant incineration, among other reasons.
- The oven includes a floating cooking chamber, which can withstand pyrolitic cleaning temperatures and repeated pyrolitic cleaning cycles without warping, cracking or developing metal fatigue. Various components of the floating cooking chamber are joined in a sliding fit that permits the floating cooking chamber to expand and contract in response to temperature changes without applying excessive mechanical stress to the components.
- The oven also includes a vacuum exhaust system for exhausting pyrolysis products. In one version, the convection blowers are situated to deliver convection air to the oven and, also, maintain the oven under a negative pressure with respect to the kitchen. In another version, an inducer blower extracts the exhaust air from the oven and delivers it to a disposal system. The negative pressure prevents combustion products produced during the self-cleaning process from escaping to the kitchen.
- The oven is equipped with an active cooling system in which air from the kitchen is passed through ducts that cool the exterior surfaces of the oven. The oven includes heat-slingers to protect the shafts of the convection blowers from overheating. Additionally, the oven includes self-cleaning fingers for a jet-impingement convection system that also clean the conveyor.
-
FIG. 1 is a perspective view of a self-cleaning oven with both first and second conveyor extension sections extended, each of the conveyor sections being depicted without its mesh belt for clarity; -
FIG. 2 is a partial perspective view of the oven ofFIG. 1 showing a drive shaft, a main conveyor section and the first and second conveyor extension sections, each of the conveyor sections being depicted without its mesh belt for clarity; -
FIG. 3 is a side view of the oven ofFIG. 1 with one of the side walls removed, showing one of the blower and motor assemblies and two air-impingement fingers; -
FIG. 4 is a perspective view of the oven ofFIG. 1 with the first conveyor extension section extended and the second conveyor extension section retracted, the first conveyor extension section being shown without its mesh belt for clarity; -
FIG. 5 is a view of the oven ofFIG. 1 with the front access door removed, showing both conveyor extension sections in their retracted positions; -
FIG. 6 is a front elevation view of the oven ofFIG. 1 with both conveyor extension sections retracted; -
FIG. 7 is an overhead perspective view of the oven ofFIG. 1 with the ceiling and overhead insulation removed, showing a roof-mounted burner assembly, two blower and motor assemblies, and a vent arrangement; -
FIG. 8 is a close-up perspective view of the burner assembly ofFIG. 3 showing a gas shut-off valve, a gas valve, an air valve, a valve link that coordinates the action of the gas valve with the action of the air valve, and a burner; -
FIG. 9 is a rear perspective view of the oven ofFIG. 1 showing the two blowers and the vent arrangement; and -
FIG. 10 is a perspective view of walls and a tubular frame support surrounding a cooking chamber of the oven ofFIG. 1 . -
FIG. 11 is a partial perspective view of the oven ofFIG. 1 showing a drive shaft, the main conveyor section and the first conveyor extension section, each of the conveyors depicted without its mesh belt for clarity. -
FIG. 12 is a an overhead view of the oven ofFIG. 1 with the ceiling and overhead insulation removed, showing a roof-mounted flame tube assembly and two blower and motor assemblies. -
FIG. 13 is a view of the main conveyor section through an oven opening with one of the conveyor extension sections removed. -
FIG. 14 is a view of the main conveyor section and its connection to the front wall of the oven depicted inFIG. 1 . -
FIG. 15 is a view of one of the conveyor extension sections separated from the oven ofFIG. 1 . -
FIG. 16 is a side view of the mesh belt of one of the conveyor extension sections. - According to one embodiment, a pyrolytically self-cleaning, gas-fired,
conveyor oven 10, as shown inFIG. 1 , includes anoven housing 12 supported on fourlegs 14. The oven housing 12 surrounds acooking chamber 16 through which food products are passed on aconveyor assembly 18. Theoven 10 also includes afront access door 40 that can be opened using a frontaccess door handle 41. - As best seen in
FIG. 2 , theconveyor assembly 18 includes poweredrollers 20 that drive a wire mesh conveyor belt (not shown in the Figures) that conveys. food through thecooling chamber 16. The poweredrollers 20 can be driven in either direction so that, as viewed inFIG. 2 , the conveyor belt can convey food through thecooking chamber 16 from left-to-right or right-to-left. Food products can be transported by theconveyor assembly 18 into a first oven opening 37 and out of a second oven opening 38 or, alternatively, into the second oven opening 38 and out of the first oven opening 37. In either case, the motion of the conveyor drive motor (not shown) and, consequently, the motions of theconveyor assembly 18 are precisely and continuously controlled in order to provide the optimum cooking time for the food products. The speed and direction of theconveyor assembly 18 are input by an operator through a control station (not shown). - As the
oven 10 is shown inFIGS. 1 and 2 , it is configured for cooking food products. That is, theconveyor assembly 18 extends out of thecooking chamber 16 at both ends. Food is placed on theconveyor assembly 18 at either end of theoven 10 and is carried through thecooking chamber 16 to the other end of theoven 10. As best seen inFIG. 2 , theconveyor assembly 18 includes amain conveyor section 30 and first and secondconveyor extension sections cooking chamber 16. Over time, as food products travel back and forth over theconveyor assembly 18, thevarious sections conveyor assembly 18 clog with food debris and otherwise become dirty. Additionally, food particles that drop onto various surfaces and components within thecooking chamber 16 become dirty. To clean theoven 10, the first and secondconveyor extension sections main conveyor section 30 and inserted into thecooking chamber 16. - The
main conveyor 30 is driven by a direct current electric motor operating through a gear reducer. A pulse-controlled conveyor drive motor (not shown) turns adrive shaft 86 which is rigidly attached to adrive gear 88, which are depicted inFIG. 11 . The drive motor sends well-defined pulses of electrical energy to move thedrive shaft 86 in either a clockwise or counterclockwise direction. Each electrical pulse of the motor moves the drive shaft 86 a reproducible increment. For example, a single pulse may be adjusted to advance thedrive shaft 86 by a predetermined number of angular degrees. The frequency of electrical pules determines the speed of thedrive shaft 86, and consequently the speed of theconveyor assembly 18, in either direction. Thedrive gear 88 turns themain conveyor section 30 and the first and secondconveyor extension sections cause conveyor axles 110 to turn, which creates the conveyor motion. The speed of all the conveyor sections, and ultimately, the cooking time of food products traveling through theoven 10, is regulated by the drive motor. The drive motor foroven 10 is controlled by a digital control unit (not shown). -
FIGS. 1 and 2 depict both the firstconveyor extension section 32 and the secondconveyor extension section 34 in an extended and locked position, theconveyor extension sections conveyor extension section 32 is accompanied by a firstinsulated door 35 and the secondconveyor extension section 34 is accompanied by a secondinsulated door 36. Both the first and secondconveyor extension sections oven housing 12 and inserted into afirst oven opening 37 and a second oven opening 38, respectively. After theconveyor extension sections oven housing 12, the firstinsulated door 35 can be shut to close thefirst oven opening 37 and the secondinsulated door 36 can be shut to close thesecond oven opening 38. -
FIG. 11 is a partial perspective view ofoven 10 in which only selected components are shown in order to better communicate the invention.FIG. 11 shows the relationship of themain conveyor section 30 to the firstconveyor extension section 32 when the firstconveyor extension section 32 is in the extended position. The first and secondconveyor extension sections 32, 34 (only one is shown inFIG. 11 ) each include an upper notch 78, sized and shaped to receive anupper peg 80, which is attached to an inside wall of the oven (not shown inFIG. 11 ). The first and secondconveyor extension sections lower notch 82 for receiving alower peg 84, which is also attached to the inside wall (not shown). Lifting the first and secondconveyor extension sections upper pegs 80 until thelower pegs 84 disengage from thelower notches 82. - With the
lower notches 82 disengaged, the first and secondconveyor extension sections oven 10 and inserted into the first andsecond oven openings insulated doors second oven openings FIG. 6 . - In order to assemble the
conveyor assembly 18 for baking, thefirst conveyor section 32 is partially inserted into thefirst oven opening 37 and locked in an extended position with respect to themain conveyor section 30. Thefirst conveyor section 32 is locked by inserting the pair of upper notches 78 formed by the sides of thefirst conveyor section 32 under a pair ofupper pegs 80 mounted in theoven 10. A pair oflower notches 82 also formed by the sides of thefirst conveyor extension 32 are then rotated onto a pair oflower pegs 84 mounted in theoven 10. The secondconveyor extension section 34 is similarly inserted into the second oven opening 38 and locked in an extended position with respect to themain conveyor section 30. - The first
conveyor extension section 32 is separated from theoven 10 inFIG. 13 , providing a close-up view of thefirst oven opening 37 and themain conveyor section 30. Thedrive shaft 86 of themain conveyor section 30 extends between twoside plates 96, although only one of theside plates 96 is visible inFIG. 13 .FIG. 13 also depicts five of the sixdrive sprocket wheels 100 attached to theconveyor axle 110 of themain conveyor section 30. Amesh belt 102 is shown as an endless chain engaged with thedrive sprocket wheels 100. One of theupper pegs 80 and one of the lower pegs 84, which cooperate for locking the first conveyor section 32 (not shown inFIG. 13 ) in an extended position, are also visible inFIG. 13 . - The sixth of the six
drive sprocket wheels 100 of themain conveyor section 30 is shown inFIG. 14 along with one of the twoside plates 96. Abracket 106 extends from one of theside plates 96 and is fastened to thefront wall 66 for supporting themain conveyor section 30. Thefront wall 66 also supports one of theupper pegs 80 and one of the lower pegs 84. - A close-up, partial perspective view of the first
conveyor extension section 32 is presented inFIG. 15 . Themesh belt 102 of the firstconveyor extension section 32 tends to sag if not supported, as illustrated inFIG. 16 .FIG. 15 depicts fourguides 108, which are provided to support themesh belt 102. Theguides 108 are in turn supported by guide supports 98, which extend the width of the firstconveyor extension section 32.FIG. 15 also shows theconveyor axle 110 and the sixdrive sprocket wheels 100 for the first conveyor section, which are used to facilitate the progress of themesh belt 102. -
FIG. 4 shows the secondconveyor extension section 34 inserted into the coolingchamber 16 and a secondinsulated door 36 closed to seal off the second oven opening 38 through which the secondconveyor extension section 34 previously extended. -
FIG. 5 further illustrates that themain conveyor section 30 supports the firstconveyor extension section 32 when the firstconveyor extension section 32 is inserted into thefirst oven opening 37. Inserting the firstconveyor extension section 32 intofirst oven opening 37 allows the firstinsulated door 35 to close thefirst oven opening 37. Similarly, themain conveyor section 30 supports the secondconveyor extension section 34, when the secondconveyor extension section 34 is inserted into the second oven opening 38 so that the secondinsulated door 36 can close thesecond oven opening 38. With theinsulated doors chamber 16 of theoven 10 is completely sealed, as shown inFIG. 6 . Thecooking chamber 16 can then be superheated to approximately 900°, turning all food debris in theoven 10 to ash. When the food debris has been burned and turned to ash, thefront access door 40 can be opened using the frontaccess door handle 41 and the ash can be cleaned from theoven 10. - As seen in
FIGS. 13-16 each of conveyors includes endless stainlesssteel mesh belts 102 capable of travelling in either direction and at variable speeds. Crumb trays (not shown) are removably installed underneath the first and secondconveyor extension sections - As food travels through the
cooking chamber 16, it is cooked by the impingement of hot air that is directed at themain conveyor section 30 throughnozzles 22 located onfingers 24. As shown inFIGS. 2 and 3 , the depictedconveyor oven 10 includes twofingers 24, a lowerfinger having nozzles 22 directing air upward at the bottom of theconveyor assembly 18 and an upper finger having nozzles 22 (not seen inFIG. 2 ) directing air downward at the top of themain conveyor section 30. Thefingers 24 contain an inner distributor plate (not shown) and a perforated outer plate containing thenozzles 22 that collimate the heated air and evenly distribute the heated air across themain conveyor section 30 on which the food products ride. Theoven 10 depicted inFIG. 3 includes two fingers 24 (one above the conveyor and one below), however, theoven 10 can accommodate a number ofbottom fingers 24 andtop fingers 24. Any combination or deletion of fingers may be employed. - The hot air directed through the
fingers 24 is heated by a burner assembly 42 (best seen inFIGS. 7 and 8 ) located under an instrument panel 39 (FIG. 1 ) on the front of theoven 10. Theburner assembly 42 creates the heat used by theoven 10 during both cooking (baking) and self-cleaning. Theburner assembly 42 heats the hot air that flows through thefingers 24 to cook food products passing along theconveyor assembly 18. Theburner assembly 42 burns a gas and air mixture at a burner 44, which shoots a flame down aflame tube 46. The flame heats the air contained in theflame tube 46, and the heated air exits the flame tube through anoutlet 47 and into aplenum 94, as seen inFIG. 12 . The open space of theplenum 94, located in front of theback wall 70 of theoven 10, provides the hot air with a directed passageway toward ablower housing 74 where it will be circulated throughout thecooking chamber 16. - Because the burner 44 is called upon to satisfy a wide range of heat output requirements, it is necessary to control the flow of gas and air supplied to the burner 44. While the burner 44 is operating, the flow of both air and heating gas to the burner 44 is modulated by a combined control system. With this combined modulating control system for combustion air and heating gas, optimum combustion conditions within the burner 44 can be maintained approximately constant over a range of heat outputs. With this combined modulating control system, the ratio of combustion air flow to heating gas flow can be optimized and maintained so that combustion is thermally efficient and environmentally sound, producing a minimum of objectionable byproducts.
- The ratio of combustion air to heating gas can be optimized to produce, for example, environmentally clean burning and the ratio will remain close to the optimum value whether the programmable controller (not shown) calls for high heat or low heat. Alternatively, the ratio may be optimized for optimal fuel consumption, optimal heat-up time or any other results that the operator desires and the ratio will not vary substantially with heat output. This modulating control system for combustion air and heating gas over a range of heat output is especially advantageous for a self-cleaning oven, such as the
oven 10, where a range of heat outputs is required. - The
burner assembly 42 includes anactuator 48 that operates anair valve 50 that regulates the amount of air entering the burner 44 from acombustion air blower 52. Theactuator 48 controls the position of theair valve 50 based on signals received from other control instruments and sensors (not shown) included inoven 10. Avalve link 54 coordinates the movement of thegas valve 56 with that of theair valve 50. Thegas valve 56 receives gas from an automatic gas shut-offvalve 57 and modulates the flow of this gas so that the ratio of heating gas to combustion air is relatively constant for a wide range of heating loads. Thevalve link 54 connects theair valve 50 to thegas valve 56 so that as theactuator 48 opens and closes theair valve 50, thegas valve 56 is correspondingly opened and closed, proportionally mixing the air and gas as they enter the burner 44. The air and gas mixture is then ignited inside the burner 44 and a flame shoots down theflame tube 46. - One of the advantages of modulating air and gas control, as provided by the
valve link 54, is that the amount of excess air in theflame tube 46 remains substantially the same during high and low heating load periods. This advantage is particularly important in a self-cleaning, pyrolitic oven, which exhibits a significantly higher heating load during self-cleaning than conventional cooling heating loads. Although thevalve link 54 depicted inFIGS. 6, 7 and 8 is mechanical, it is also contemplated that the positions of an air valve and a gas valve in modulating air and gas control systems may alternatively be coordinated by, for example, utilizing electronically-controlled actuators for each of the valves and coordinating their positions by means of one or more electronic controllers. - The burner 44 may be mounted anywhere in the oven. Preferably, the burner 44. is roof-mounted as shown and sends its flame along the inside of the
flame tube 46 mounted adjacent the ceiling of theoven 10. During operation of theoven 10, contaminants tend to accumulate most heavily on and near the oven floors. Thus, the roof-mounted burner system is more likely to progressively incinerate and less likely to ignite the floor accumulation as compared to conventional floor-mounted and wall-mounted burner configurations. - During baking and self-cleaning operations, the
flame tube 46 becomes very hot and radiates heat energy throughout theinventive oven 10. It is contemplated that a diffusing tube (not shown) may be employed around the burner for processing food products that tend to discolor or otherwise deteriorate when subjected to intense radiant heat. - The
oven 10 has two relativelylarge blowers 26, 27 (see FIG. .7) to move the heated air created by the burner 44 through thefingers 24 and onto the product so that the most efficient bake is achieved for each food product processed in theoven 10. More specifically, theoven 10 employs collimated, vertical air streams to give uniform and intensive heating. The collimated, vertical streams of air that emerge from thefingers 24 provide an exceptional heat transfer rate and generally bake foods faster and at lower temperatures than in conventional convection hot air or infrared heating ovens. - The hot air is circulated through the
oven 10 by the twoblowers FIG. 9 ). The twoconvection blowers FIG. 10 ). Theblowers FIG. 9 ), which is mounted on theback wall 70, and connected to theblowers blower motor 75 may be equipped with a dedicated speed controller (not shown), preferably including an electrical power inverter. With the benefit of individual speed control, theblowers blowers oven 10 to optimize the baking of particular food products. - In another embodiment, the
blowers - There are also two cooling
fans oven 10 as depicted inFIGS. 1, 4 , 6, and 7. These fans blow cool air in through the machinery compartment and out the side walls. The coolingfans instrument panel 39 for cooling the instruments located behind theinstrument panel 39. A portion of the discharge air from the coolingfans combustion air blower 52 and be delivered to the burner 44 as combustion air. The remainder of the discharge air from coolingfans oven 10 and an inside wall, which supports insulation. The flow of air in these passages serves to cool the external sheeting of theoven 10 below preferably about 125 degrees F. - Referring to
FIG. 9 , avent arrangement 58 is located at the back of theoven 10. Thevent arrangement 58 includes avent valve 60 that is positioned between avent tube 62 and a T-shapedtube 64 that communicates with the high-pressure sides of theblowers 26. During a normal cooking cycle, thevent valve 60 is closed so that no air passes through thevent valve 60 into thevent tube 62. In this way, during cooking, air that is heated is directed solely into thecooking chamber 16 for efficient cooking of food in thecooking chamber 16. However, when it is desired to clean theoven 10, thevent valve 60 is opened and theoven openings vent valve 60, enough heated air is exhausted through thevent tube 62 to maintain a slight negative pressure within thecooking chamber 16. In this way, the smoke and soot that develops during a self-cleaning cycle is exhausted through thevent tube 62 and the passage of smoke and soot through small openings and cracks in theoven housing 12 is prevented. - As shown in
FIG. 10 , thecooking chamber 16 is bounded by afront wall 66 and twoside walls 68 that are connected to aback wall 70. Thefront wall 66, twoside walls 68, andback wall 70 are all screwed together to form a box surrounding thecooking chamber 16. Theback wall 70 of this box is fixed to atubular frame 71, which is connected to aplatform 72. However, while theback wall 70 of the box is fixed to thetubular frame 71, thefront wall 66, and twoside walls 68 are free-floating. That is, thefront wall 66 and twoside walls 68 are connected to theback wall 70, but are not connected to thetubular frame 71. The perimeters of thefront wall 66 and the twoside walls 68 includelips 73 that sit on the various members that make up thetubular frame 71, but are not fixedly connected to those members. In this way, thefront wall 66 and twoside walls 68 are free to move relative to thetubular frame 71 so that during cooking, and particularly during self-cleaning when the temperatures in thecooking chamber 16 are relatively high, thefront wall 66 andside walls 68 of thecooking chamber 16 are free to expand and slide on the members of thetubular frame 71, thereby preventing buckling and warping of the walls of thecooking chamber 16. - A unified display control station (not shown) for the
oven 10 can include a blower selector, a heat selector, a conveyor selector, two or more conveyor speed controllers and a digital temperature controller. Additionally, a machinery compartment access panel safety switch disconnects electrical power to the controls and the blowers when the machinery compartment access panel is opened. - In order to start up the
oven 10, an operator confirms that thefront access door 40 is closed. The operator then turns the blower and conveyor selectors to the “on” position. If necessary, the operator adjusts the conveyor speed setting by pushing appropriate selectors on the conveyor speed controller. The operator adjusts the temperature controller to a desired temperature and selects normal operation. A heat switch on a control station (not shown) of theoven 10 activates thecombustion air blower 52. The burner 44 is a direct ignition burner. Themain gas valve 57 is opened while starting. a spark in the burner 44. A sensor then monitors whether a flame is present within the burner 44. If a flame is not detected within 6 seconds, themain gas valve 57 is shut down, the burner 44 is purged, and the ignition cycle is repeated. Referring toFIGS. 7 and 8 , agas bypass tube 76 provides enough gas to the burner 44 to maintain a minimum flame even when thegas modulation valve 56 is closed. - The
oven 10 will typically heat to a desired heating set-point temperature within a matter of minutes. While theoven 10 is heating, the control station (not shown) displays the actual temperature. One or more thermocouples (not shown) in the interior of theoven 10 send signals to a programmable controller (not shown) that controls theactuator 48. If the programmable controller (not shown) calls for more heat, theactuator 48 rotates to open theair valve 50 and more combustion air is permitted to pass from thecombustion air blower 52 to the burner 44. Simultaneously, thevalve link 54 moves under the influence of theactuator 48 to further open thegas valve 56, permitting more heating gas to pass fromgas line 55 to the burner 44. If the programmable controller (not shown) calls for less heat, thevalve link 54 causes theair valve 50 and thegas valve 56 to close simultaneously and proportionally. Consequently, the ratio of combustion air flow to heating gas flow entering the burner 44 remains approximately constant over a range of heat output. - As mentioned, the speed of the
blowers oven 10 to baking or self-cleaning temperatures, one or both of the blower motors 75 (only one is shown inFIG. 9 ) start and routinely ramp up to a desired operating speed in a programmable period of time. Programming the start-up time ofconvection blower motors 75 makes firing of the burner 44 more reliable and promotes better combustion, among other things. When theblowers blower motors 75 are accelerated to operating speed in a programmable period of time. - The start-up procedure (i.e., ramping up the speed of one or both of the
blowers 26, 27) prevents an objectionable current inrush situation that is observed in conventional ovens, which commonly start two or more blower motors at full speed simultaneously. This startup procedure is also quieter, and requires less electricity and heating gas, than the startup of conventional ovens. Because theblowers - Preferably, each of the
blowers blower blower motor 75 can be either ramped up to operating speed over a programmable period such as, for example, about thirty minutes, or held at an optimal intermediate speed until theoven 10 reaches baling or cleaning temperature and then accelerated. These variations conserve still more energy by providing appropriate programmable blower speeds depending on the current operation of theoven 10. When theoven 10 is, for example, baking (cooking), self-cleaning, warning up, or cooling down, theblowers - Furthermore, for baking, the speed of the blower motors 75 (only one is shown in
FIG. 9 ) may be separately adjusted to create two or more different heating zones (not shown) within theoven 10. These heating zones (not shown) can be created at will and utilized to optimize the baking process and, consequently, the finished quality of a particular food product. Theoven 10 may be equipped with two or more thermocouples (not shown) or other temperature sensors to individually monitor and adjust these heating zones (not shown). The manner in which the signals from these thermocouples (not shown) are averaged or otherwise interpreted by the programmable controller can be varied to suit the food product. - In order to shut down the
blowers blowers oven 10 has cooled to below 200 degrees F. and then cease turning. - When it is determined that the
oven 10 should be cleaned, it is cooled to a temperature below about 140 degrees F. The operator then disengages the firstconveyor extension section 32 and withdraws the firstconveyor extension section 32 from thefirst oven opening 37. The firstconveyor extension section 32 is then inserted into thefirst oven opening 37 so that the firstconveyor extension section 32 is supported by themain conveyor section 30 and the firstinsulated door 35 closes thefirst oven opening 37. The secondconveyor extension section 34 is similarly separated from theoven 10 and inserted into the second oven opening 38 and the secondinsulated door 36 is closed. Because the first and secondconveyor extension sections FIG. 9 ) is opened and theblowers oven 10 to self-cleaning temperature. During the self-cleaning cycle,oven 10 operates under the control of temperature sensors and controllers (not shown) that are specifically designed to operate in the range of about 650-1000 degrees F. These may be the same sensors and controllers used for baling (not shown) or a separate set. - In either case, the programmable control system actuates a set of safety interlocks adapted for cleaning temperature operation. For example, the oven overrides the baling cycle high temperature shutdown limits, which are typically set at values less than 600 degrees F. As another example, the programmable control system actuates door locks that deter people from opening the oven doors during the pyrolitic self-cleaning cycle.
- The programmable controller also initiates corrective action if unsafe or undesirable conditions are detected. For example, upon detecting excessively high temperatures, high smoke levels or low oxygen levels within the oven, the programmable controller shuts down the burner 44 and the
blowers - As mentioned, during cleaning, the interior of the
oven 10 is kept under a negative pressure compared to the surrounding atmospheric pressure. In the illustrated embodiment the opening of thevent valve 60 and the operation of theblowers oven 10. As mentioned earlier, when thevent valve 60 is opened and theblowers vent valve 60 to create the negative pressure inside thecooking chamber 16 necessary to force the smoke and soot created during the cleaning cycle through thevent tube 62. In another embodiment, an inducer blower (not shown) maintains the interior of theoven 10 under a negative pressure during cleaning as compared to the surrounding atmospheric pressure. The inducer blower creates this negative pressure by drawing air from theblower housing 74. Theblowers blowers vent arrangement 58. - The inducer blower could also take suction from the interior of the
oven 10 during normal baking. The entry of the inducer blower opens directly into theblower housing 74. The inducer blower may be positioned directly in the path of the discharge air flow from each of theblowers oven 10. Alternatively, the inducer blower may be mounted anywhere in the interior of theoven 10. The discharge flow of air from the inducer blower is sent to thevent arrangement 58 for disposal. - Maintaining negative pressure in the interior of the
oven 10 during both cooking and self-cleaning enhances energy efficiency and safety. Maintaining negative pressure in the interior of theoven 10 during the cooking and self-cleaning operations insures that little or no heated air escapes to the kitchen. Minimizing heated air loss makes theoven 10 more energy efficient. Any loss or discharge of heated air from the interior of theoven 10 necessitates the combustion of additional heating gas. By directing all exhaust flows from theoven 10 to thevent arrangement 58 and ultimately thevent tube 62, the loss or discharge of heated air can be better controlled and minimized. Also, the negative pressure system promotes safety because negative pressure retains burning gases in the interior of theoven 10 rather than permitting them to escape into the kitchen. Additionally, maintaining negative pressure in theoven 10 tends to prevent any smoky residue from building up on the exterior of theoven 10 during normal cooking and self-cleaning operations. The exterior surfaces of theoven 10 remain clean longer because they are not subjected to smoke, which commonly escapes from the atmospheric cooking chambers of conventional ovens. - The
blowers oven 10 while minimizing convective heat loss through the walls of theoven 10. The first incineration period generally continues for about one hour, although it may be longer or shorter based on factors such as the cleaning temperature and the amount and type of contamination in theoven 10. - During a second incineration period, which is generally about one to three hours in duration, the
blowers oven 10 is increased to a peak temperature at least once during the second incineration period. - After the incineration periods, the programmable controller cools the oven, disengages the safety interlocks and arranges the control system for cooling operation. Due to the combination of high temperature and convective air flow in the inventive oven during the self-cleaning cycle, any contamination accumulation that is in the oven is reduced to harmless and sterile ash. This ash may be collected on drip pans provided for that purpose, which can be accessed through the
front access door 40 and carried away to disposal. Alternatively, the ash may be collected in a vacuum cleaner system that is built into or independent of the inventive oven. - It is contemplated that collection of the ash from the lower fingers may be facilitated by constructing the
mesh belt 102 of themain conveyor section 30 so that it is close to or touching the perforated plates of thelower fingers 24. Themesh belt 102 thus pushes or scrapes the ash from thelower fingers 24 for collection by a drip pan or vacuum system. Preferably, the perforations are formed so that thelower fingers 24 present a nonabrasive surface to themesh belt 102. - Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of the invention as described and defined in the following claims.
Claims (17)
1. A conveyor oven comprising:
a housing defining a cooking chamber therein; and
a conveyor having a main conveyor section positioned substantially within the cooking chamber and first and second conveyor extension sections releasably connected to the main conveyor section at opposite ends of the main conveyor section, the first and second conveyor extension sections extending at least partially outside the cooking chamber during a cooking cycle of the oven, wherein the first and second conveyor extension sections are disconnected from the main conveyor section and placed substantially within the cooking chamber during a self-cleaning cycle of the conveyor oven.
2. The conveyor oven of claim 1 , further comprising oven openings on opposite sides of the housing through which the conveyor extension sections extend during the cooling cycle and doors that close the oven openings during the self-cleaning cycle.
3. A conveyor oven comprising:
a housing defining a cooling chamber therein;
a blower having a high pressure side and a low pressure side, the blower propelling air on the high pressure side into the cooking chamber and drawing air from the cooking chamber into the low pressure side;
a vent tube in fluid communication with the high pressure side, the vent tube providing a bypass route for air from the high pressure side to the outside of the housing without entering the cooking chamber; and
a vent valve positioned within the vent tube, the vent valve being closed during a cooking cycle of the oven so that air from the high pressure side is substantially directed into the cooking chamber and being opened during a self-cleaning cycle of the oven so that at least some air from the high pressure side is directed through the vent tube and outside the oven housing.
4. The conveyor oven of claim 3 , further comprising an inducer blower in the venttube.
5. A conveyor oven comprising:
a platform;
an outer housing fixed to the platform; and
a cooking housing defining a cooking chamber and positioned within the outer housing, the cooking housing being supported by the platform and moveable with respect to the platform to permit contraction and expansion of the cooking housing.
6. The conveyor oven of claim 5 , wherein the cooking housing includes a front wall, back wall, and two side walls, the back wall being fixed with respect to the platform and the front wall and side walls being permitted to move with respect to the platform.
7. The conveyor of claim 5 , further comprising insulation between the outer housing and the cooking housing.
8. A conveyor oven comprising:
a housing defining a cooking chamber;
an opening in a wall of the housing providing a passageway from the exterior of the oven to the cooking chamber;
a conveyor positioned adjacent the opening; and
a door moveable between a first and second position, the door closing the opening in the second position.
9. The conveyor oven of claim 8 , wherein the conveyor includes a main conveyor section and a conveyor extension section separable from the main conveyor section, the conveyor extension section at least partially extending outside the housing.
10. A conveyor oven comprising:
a housing defining a cooking chamber;
a conveyor moveable through the cooking chamber;
a burner providing heat to the cooking chamber;
a gas line providing gas to the burner;
a gas valve moveable to regulate the flow of gas through the gas line;
an air line providing air to the burner; and
an air valve moveable to regulate the flow of air through the air line, wherein the movements of the gas and air valves are dependent on each other.
11. The conveyor oven of claim 10 , further including a valve link connecting the gas valve to the air valve, thereby moving the gas valve and air valve together.
12. A conveyor oven comprising:
a housing defining a cooling chamber;
a burner in fluid communication with the cooking chamber; and
a variable speed blower blowing air into the cooking chamber, wherein the blower operates at a first speed during a cooking cycle of the oven and at a second speed during a self-cleaning cycle of the oven.
13. The conveyor oven of claim 12 , wherein the speed of the blower is controlled by a computer.
14. The conveyor oven of claim 12 , wherein the first speed is slower than the second speed.
15. A conveyor oven comprising:
a housing defining a cooling chamber;
a burner in fluid communication with the cooking chamber; and
a variable speed blower blowing air into the cooling chamber, wherein the blower operates at a first speed during a cooking cycle of the oven and at a second speed during a start-up cycle of the oven.
16. The conveyor oven of claim 15 , wherein the speed of the blower is controlled by a computer.
17. The conveyor oven of claim 15 , wherein the first speed is faster than the second speed.
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US13/612,522 US10024548B2 (en) | 2003-02-21 | 2012-09-12 | Self-cleaning oven |
US13/793,679 US10036558B2 (en) | 2003-02-21 | 2013-03-11 | Self-cleaning oven |
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Also Published As
Publication number | Publication date |
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US8413646B2 (en) | 2013-04-09 |
US10036558B2 (en) | 2018-07-31 |
US20090223503A1 (en) | 2009-09-10 |
US20130186387A1 (en) | 2013-07-25 |
US20130000628A1 (en) | 2013-01-03 |
US10024548B2 (en) | 2018-07-17 |
WO2004076928A2 (en) | 2004-09-10 |
WO2004076928A3 (en) | 2004-12-16 |
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