INDUSTRIAL BAKING SAFETY AUDITOR AND BAKING SYSTEM USING SAME

Abstract

A safety auditor is designed to perform opening and closing of every safety switch that is used in an industrial bakery oven. Every pressure sensor can be tested for on and off states. The low gas pressure switch can be vented and the high gas pressure switch pressurized. All thermocouples associated with the high temperature circuits are tripped. Fans are started and stopped over a communications signal or via the hard-wired interface as required to generate the safety testing. Once the safety testing is complete, the results along with time, date, name of tester, pass or fail will be printed out via a small kiosk printer. This ticket can then be filed in an office. As the operation is easy to do and requires little effort, it is much more likely to be performed and therefore safer for the host bakery.

Claims

1. A safety auditing system comprising: an oven, the oven comprising: an oven chamber; an oven chamber inlet; an oven chamber outlet; and a plurality of oven chamber zones through which product passes from the inlet to the outlet; at least one zone baking device within each one of the plurality of chamber zones, wherein: all of the zone baking devices are electronically connected to a programmable master control panel, wherein the master control panel further comprises a user interface; and each zone baking device is electronically and/or electromechanically actuated in accordance with a preprogrammed scheme by the master control panel; an array of zone safety devices, wherein each zone safety device in the array of zone safety devices is electronically connected to the master control panel; and each zone safety device is electronically and/or electromechanically actuated by the master control panel; a safety auditor connected to the zone safety devices via the master control panel for safety testing the zone baking devices via the zone safety devices, the safety auditor being programmable and having a user interface and further allowing a user to generate a safety test report via a printer.

2. The system of claim 1, wherein the safety auditor and master control panel connection comprises hard wiring of the safety auditor to the master control panel.

3. The system of claim 1, wherein the master control panel is configured for wireless connectivity; the safety auditor is configured for wireless connectivity; and the safety auditor and master control connection is wireless.

4. The system of claim 1, wherein the at least one zone baking device comprises a top and/or bottom heating device and/or an air flow device.

5. The system of claim 1, wherein the zone baking devices are configured to produce a desired baking profile within a corresponding oven chamber zone in accordance with a preprogrammed scheme by the master control panel.

6. The system of claim 1, wherein each zone baking device further comprises a plurality of gas pressure switches, wherein: each gas pressure switch of the plurality of gas pressure switches includes a safety switch; and the plurality of gas pressure switches is coupled to the master control panel such that the master control panel is able to selectively open or close each safety switch; and a plurality of fans, wherein the plurality of fans is coupled to the master control panel such that the master control panel is able to selectively start or stop each fan.

7. The system of claim 6, further comprising low pressure gas switches and high pressure gas switches, wherein each low gas pressure switch can be vented and each high pressure gas switch pressurized.

8. The system of claim 6, further comprising thermocouples associated with high temperature circuits and such thermocouples can be tripped.

9. The system of claim 1, wherein the safety auditor is configured to the exact number of zone baking devices and zone safety devices included in a particular oven.

10. The system of claim 1, wherein the safety auditor is configured to interface with multiple oven configurations, together with the zone baking devices and the zone safety devices, all as required by the output requirements of each oven configuration.

11. The system of claim 1, wherein the safety auditor is configured to be tamper proof.

12. The system of claim 1, wherein the safety auditor is programmed to log unusual oven performance.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] FIG. 1 is a first schematic view of a representative bakery oven shown with its essential features relative to the present invention.

[0012] FIG. 2 is a second schematic view of the safety features for the bakery oven show in FIG. 1 and showing the essential features relative to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0013] Referring now to the drawings in detail, wherein like-numbered elements refer to like elements throughout, FIG. 1 illustrates a generic oven, generally identified 10. The oven 10 comprises a tunnel-type oven chamber 20 for baking food product 2, 4. The chamber 20 comprises a food product input end 21 and a food product output end 23. A continuous belt 30 moves food product 2 through different zones 31, 33, 35, 37 within the chamber 20, with each zone of the chamber 20 providing a different baking profile depending on the food product 2 to be cooked. The belt 30 is driven by rollers 22, 24 or like structure. Within each zone 31, 33, 35, 37 is a corresponding top and/or bottom heating and/or air flow devices 32, 34, 36, 38 (or zone baking devices). The zone baking devices are configured to produce the desired baking profile that is required within each zone. The zone baking devices are electrically and/or electromechanically actuated. As shown, four chambers are shown but the present invention is not so limited. In operation, the uncooked food product 2 enters the chamber 20 at the input end 21, is moved through each of the required zones and the cooked food product 4 exits the chamber 20 at the output end 23 for further processing and/or packaging. It is to be understood that operation of the oven 10 and its component parts is accomplished via conventional electronic circuitry (not shown) that comprises processors programmed in accordance with preprogrammed schemes, interfaces and memory elements of the type known to those skilled in the art.

[0014] As shown in FIG. 2, the oven 10 further comprises a safety device array, generally identified 40. The array 40 comprises a plurality of zone safety devices that may run in series 41, 43, 45, 47 with the zone baking devices 32, 34, 36, 38 or in parallel 42, 44, 46, 48 with them. All zone baking devices and zone safety devices are connected to a master control panel, generally identified 50, the panel 50 comprising a fixed panel female jack 52. A safety auditor, generally identified 100, in accordance with the present invention is provided with a housing 102 and a movable male plug 104 that is configured to be received by the female jack 52. In ovens 10 where the auditor 100 is built into the oven 10, that interface would instead comprise permanent connections between the master control panel 50 and the auditor 100.

[0015] As stated at the outset, OSHA mandates that All safety devices on ovens shall be inspected at intervals of not less than twice a month by an especially appointed, properly instructed bakery employee, and not less than once a year by representatives of the oven manufacturers. Normally to do this, a maintenance engineer will have to manually start and stop fans each time checking that the pressure switch or auxiliary contact is both opening and closing. This manual step typically does not happen. The maintenance engineer also checks that, when the fan is running, the switch is on. This is time consuming activity and, when it comes to the gas pressure switches, this requires further work, and/or disconnecting electrically the switches, which often ends up being skipped. The safety auditor 100 is designed to perform opening and closing of every safety switch that is used. Every pressure sensor is tested for on and off states. The low gas pressure switch is vented and the high gas pressure switch pressurized. All thermocouples associated with the high temperature circuits are tripped. Fans are started and stopped over the communications or via the hard-wired interface as required to generate the test. Once the test is complete, the results along with time, date, name of tester, pass or fail will be printed out via a small kiosk printer. This ticket can then be filed in an office. As the operation is easy to do and requires little effort, it is much more likely to be performed, thereby making the oven 10 safer for users, which are typically a host bakery.

[0016] As alluded to previously, the safety auditor 100 can be configured in multiple configurations and customized to suit different types of ovens. It is tamper proof and possibly log unusual oven performance. Further, it is to be understood that operation of the safety auditor 100 and its diagnostic components is accomplished via conventional electronic circuitry (not shown) that comprises processors programmed in accordance with preprogrammed schemes, interfaces and memory elements of the type known to those skilled in the art.

[0017] Lastly, it is to be understood that the electronic circuitry (not shown) of the safety auditor 100 and the electronic circuitry (also not shown) of the oven 10 can be configured to communicate via wireless connectivity, such as Bluetooth short range radio linking, the electronic circuitry of each being modified to provide such wireless connectivity.

[0018] In view of the foregoing, it will be apparent that the present invention provides a unique and novel solution for compliance testing and safety concerns related to direct gas fired ovens.