They say the best things in life are the simplest, and few things speak truer to this than the quesadilla. At its purest form it is two heated tortillas full of melted cheese in the middle. The quesadilla originated in Mexico and can be modified to include a variety of meats and vegetables. But at the end of the day, you can’t beat the winning combination of cheese and bread. Quesadillas are commonly made using frying pans, but this method includes the obvious hassles of watching the quesadilla to make sure it doesn’t burn while also flipping it to cook both sides evenly. It was these predicaments that gave birth to the quesadilla maker. A quesadilla maker is essentially the cousin to the panini press: a machine that uses two heated plates to cook both sides of a sandwich. Panini presses have been modified into waffle makers and breakfast sandwich makers, but quesadilla makers are specifically designed with circular-shaped heating plates to perfectly fit tortillas.
Creating a Quesadilla Maker may seem simple in theory, but there are several variables that need to be accounted for. Anyone that has enjoyed a quesadilla knows that the biggest tragedy is finding out that your cheese didn’t fully melt while cooking. A close second tragedy is having a quesadilla that is too crunchy or burnt on the outside. This suggests that the variable that needs controlling in this process is the temperature of the heated plates of the quesadilla maker. Although this control is not necessarily essential to the device’s operation, avoiding both aforementioned tragedies would spare many a quesadilla lover a lot of heartache. So, we have the task at hand: we want to design a two-plated heating system that will both heat up the quesadilla high enough to melt the cheese fully, while not too high that will burn the tortillas. As time is of the essence for all quesadilla-lovers, we also must make sure that the quesadilla maker finishes in a timely fashion in order to have little wait time for cheesy-goodness. Our God-challenging machine will be fittingly named: the Queso-Roboto. While our task may seem impossible for some, we are chemical engineers. We live for the challenge, and more importantly, for the quesadilla.
According to Sargento, a global cheese superpower, cheddar cheese begins melting at approximately 66 oC. Cheddar cheese is undeniably one of the best cheeses for use in quesadillas, and is included in the recipes of many great chefs like superstar Paula Deen. We will use this melting temperature as the lower limit of our possible control range.
The upper limit of the possible temperature range is capped by the temperature at which the tortillas burn. Fun Fact: burning actually occurs when all of the water in a food has evaporated. This does not occur at a particular temperature, so an experiment to find the temperature that cooks the best quesadilla would have to be performed. This experiment would not only provide us with a set point for temperature, but it would also provide us with an ample amount of quesadillas. While some would burn during the experiment, we believe that a burnt quesadilla is better than no quesadilla.
In the experiment, our quesadilla research and development mavens would make quesadillas at temperatures increasing from 66 to 100 oC. Each trial would be run in triplicate to have an assessment of reproducibility, and panelists of a double blind study would rate the quesadillas. Rated attributes would be evenness of cooking, crispness of tortillas, cheese stretch length, perfect bite, overall beauty, Bue-No or Bue-Yes, and “wow” factor. The cook temperature determined to yield the most perfect quesadilla would be used as the set point temperature of our quesadilla making device. As with any self-respecting experiment, a randomized DOE run order will be developed. This will later be analyzed to note trends, reoccurring errors, outliers, and all the fixins.
A trial example and scoring is as follows-
- Trial #5
- Evenness of Cooking: 5/5
- Crispness of Tortilla: 4.5/5
- Cheese Stretch Length: 12.3 cm
- Perfect Bite: Si
- Overall Beauty: Eva Longoria
- Bue-No or Bue-Yes: Bue-Yes
- “Wow” Factor: Ah Dios Mio!
In order to control the temperature of the plates, the variable that needs to be manipulated is the amount of current flowing into the quesadilla maker from the source of electricity. This can be practically done, by implementing a feedback loop that uses a temperature sensor to measure the temperature of the sizzling quesadilla, and compare it a set point. The controller will use any difference between the actual temperature and the experimentally determined set point to adjust the amount of current to either increase or decrease the temperature of the plates.
A possible disturbance hindering one from achieving quesadilla perfection is the fact that the press is not completely closed when it is operating. Because of this, heat is able to be exchanged with the air around the open edges of the press. Since the temperature of the air is cooler than the temperature of the inside of the quesadilla maker, heat is exchanged between the quesadilla and the ambient air. This creates a difference in temperature between the edges and the middle of the quesadilla. To account for this, the apparatus could be designed to have two separate heating mechanisms, and two different control systems. Each heater would have its own temperature sensor and set point, and would report back to its own controller. This would allow the temperature of the outside of the quesadilla maker to be slightly hotter than the inner temperature to allow for more even cooking despite heat exchange with the environment.
Another possible disturbance would be the blessing, and curse, of endless human creativity. The trials we are performing, consisting of purely tortillas and cheddar cheese, do no account for the free-thinkers and rebels of the quesadilla world. Our current model only works assuming that the quesadilla in question is in its most basic form. In world full of meats, vegetables, sauces, and guac, we will never be able to predict and prepare for every combination the Queso-Roboto will encounter. Instead, we will create a set time length and timer for the quesadilla models used in our trials, and leave it up to the discretion of the user to keep it in for longer periods of time. Though the insides will change, our original controller for the temperature limit and outside air effects should still be viable for these potential quesa-monstrosities.
Sources:
Cheese melting temp: http://www.sargentofoodservice.com/trends-innovation/cheese-melt-meter/
Paula Deen recipe: http://www.foodnetwork.com/recipes/paula-deen/cheese-quesadillas-recipe.html
As a quesadilla lover, I like this idea. There are many people that enjoy their quesadillas and, as far as I know, there isn’t a specific machine that is designed to cook a quesadilla. That’s where the Queso-Roboto comes into play. When I first started reading this, I thought that your product might be too similar to a panini press. However, you made it clear that there were specific details that set your product apart from the commonly used panini press. I like that you had fun with the project and added humor into your blog. It made it easy and fun to read your post. I could see myself using this product and potentially being a major success.
The controlled variable would be the temperature of the circular hot plate, which makes sense because the main purpose is to heat and cook the quesadilla to the perfect temperature. The manipulated variable is stated to be the current that is flowing from the source of electricity to the quesadilla maker. This variable also makes logical sense. The disturbance variable is the variable that I am questioning. It’s stated that the quesadilla maker would be partially open, similar to a panini press. This would cause a disturbance variable of heat being lost to the surroundings. Might I make a suggestion… What if you made the quesadilla maker completely closed. This is would eliminate the loss of heat to the surrounding, as well as, separate the Queso-Roboto even more from the traditional panini press. The two heating systems that are proposed in the blog may be too difficult to implement. Another possible disturbance variable (and maybe a silly one) could be the amount of cheese put in the quesadilla. The more cheese that is added to the quesadilla, the longer it takes to fully melt the cheese and cook the quesadilla. This disturbance variable might be taken into consideration when talking about the endless human creativity, but I think it should be explicitly stated somewhere in the blog.
The setup of the Queso-Roboto is briefly mentioned when talking about the disturbance variables. It’s stated that, “Each heater would have its own temperature sensor and set point, and would report back to its own controller”. In my opinion, I think you should elaborate more on the setup. The controller that you would probably want to use it a PID controller. The PID controller responses fast to sudden changes that could occur in the temperature. It also eliminates oscillations and increases control and stability.
Overall, I thought this was a factual and fun blog. The product is new and could be very successful in the food industry or in homes. With the few things suggested and a bit more explanation, I think this could be a great blog!!
The novel Queso-Roboto can effectively solve those issues existed in the present quesadilla maker. By applying two-plate heating system and controlling the temperature of the plate, the two tragedies mentioned in the article can be effectively avoided. The present quesadilla makers work similarly with the microwave, so the implement of a feedback loop would be really helpful the system to automatically control the plate temperature in order to make the quesadilla more delicious. I would expect the general public to purchase this product if commercializing the advanced quesadilla maker because the technology needed to make the machine is fully developed and the novel machine improve food quality and simplify the cooking process.
I think it would be more accurate to define the heat flow rate as the manipulate variable. The control system cannot manipulate the amount of current, which is supplied by the electricity company, flowing into the quesadilla maker but can control the amount of heat transferred into the system by using a thermal panel. If the temperature of the plate is lower than set point, the controller in the maker will adjust the thermal panel to release more heat into the system.
Similarly, one possible variable is the unsteady current flowing into the system. Ideally, the current supplied to a quesadilla maker is stable and constant. As a result, the cooker can have a stable rate to transfer electrical energy into heat in order to allow its internal system to determine how much heat is needed and how long it will take to achieve the set point. In this case, any changes or disruption on the electric current can negatively affect the efficiency of the cooker and disturb the system. For example, if the amount of electric energy supplied into the maker is less than the steady state value, it will make the system take longer to achieve the desired temperature.
A PI controller may be appropriated in the control system. Since the process is highly temperature sensitive, overshoot should be avoided in this process and fast response is not required. Although PI controller still may introduce overshoot, it can eliminate the offset caused by proportional controller. As a result, it would be an appropriate choice for developer. The controller parameter can be calculated by using the developed methods for a closed loop. A PID controller may be another option when facing a sudden change which may occurs in the internal control system.
The Queso-Roboto is a groundbreaking instrument soon to be found in all American-cheese-loving-non-Spanish-speaking households! As a current cheese enthusiast (more specifically quesadilla enthusiast) this product will revolutionize the quesadilla making industry and surely (hopefully) put taco bell out of business. However, for those who are afraid to let automation replace the authenticity of home-cooking this product needs a genuine-factor. Make sure not to market just efficiency and perfection. Overall, the product is wonderful and would make life more delicious.
The control system within the Queso-Roboto takes into account the temperature the quesadilla is at, and makes sure the product is cooked to perfection. However, like stated in the article, quesadilla pioneers such as myself are not limited to cheddar cheese. Maybe the instrument should have many different settings (controller parameters) based upon the different melting points of a wide variety of cheeses. More experimental testing will have to be done will cheeses such as pepper jack, sharp cheddar, gouda, swiss, american, brie, blue cheese, goat cheese, gorgonzola, mozzarella, parmesan, etc.
It makes sense to control the circular hotplate by manipulating the electrical current/power provided to it. However, you may want to think about measuring the temperature of the actual quesadilla in addition to the plates it sits on. Based upon the heftiness of the quesadilla, more heat is necessary for cooking. You need to make sure the tortillas are not burning, but also the middle of the quesadilla is being cooking sufficiently. For example, you do not cook a cake at 500 F for ten minutes, you need to cook it at 350F for a longer period of time. How fast the quesadilla is changing temperature (derivative control) may affect the cook time of the quesadilla!
The last point states that the Queso-Roboto does not account for the amount of cheese between the two tortillas. A possible factor to take into account is the weight of the quesadilla. You want to make sure to account for hefty thicknesses so the cheese is thoroughly melted to the exact consistently specified within the article. If the cheese is too cold and physically heterogeneous, the quesadilla remains unsatisfactory.
The controller used may want to be a PID controller instead of the commonly used PI controller seen throughout chemical engineering processes. The derivative control will account for how fast the temperature of the quesadilla and plates are changing. The integral control and proportional control will level the disturbances such as the ambient temperature which causes a temperature gradient and further heat losses. Lastly, it is necessary that the controller parameters are configured so the process is quick, and it explicitly does NOT cause and OVERSHOOT. An overshoot in temperature of the hotplates may cause severe burning of the tortilla or burning the ingredients used inside. The IMC method may give the controller the most accurate and stable conditions for the explicit cooking process.
I am excitet about the Queso-Roboto and hope to be the first one to use it! Good luck with your adventures.
Ah all these wild promises! The cheese! The salsa! The quesadilla! A riveting read for all those interested in Mexican delights and the fine art of quesadilla making. The control system in the quesoroboto takes the temperature of the quesadilla into account when accounting for the timed automation and creation of the prefect quesadilla. I think there is novelty to adding different buttons, or choices, to make the quesadilla so that the user is not just limited to one type of cheese when creating and consuming their delicious meal. I agree with sean when he says there should be more settings to the quesoroboto, however… what about the meats??? What about chicken? Beef? Tofu? FAJITA VEGETABLES??? The possibilities for the settings of this great device are endless.
The controlled variable in this fabulous invention is the temperature of the hot plate. This is totally correct because its major function is to cook the quesadilla by making the four tortillas hot. The disturbance variable here could be the addition of great different flavor packed insides to the quesadilla (see comment on meats and veggies), and I think that different settings on your creation could minimize this disturbance but also adding a little knife-like temperature gauge to the center of the quesadilla that could potentially pierce your food and – depending on the setting – would then be able to know what temperature the inside of the quesadilla should reach and therefore, you would get the best cheesy, delicious, and amazing creation possible.
This invention is super temperature sensitive, so overshoot cant happen honestly. I totally agree with pervious posts here. PID controllers could help this, but I think my little additional sensor would be better, considering I’m usually right and I like more than just cheese in my dilla. Overall, stellar performance, I give u mila kunis on a scale of 1-10.
After recently getting a poorly cooked quesadilla at Wawa, I do believe there is a need for an invention like the Queso-Roboto. Quesadillas are a very popular food for people of all ages and all cooking levels. Although some people might argue that making quesadillas is easy, it is hard to make a perfect quesadilla, which is way I could see this product selling well. I like the idea of having the a different sensor and controller for the outer edges of the quesadilla since the loss of heat to the environment on the edges is a big issue. Many times the cheese on the outside of my quesadilla is not melted, which makes me sad. The multiple sensors and control system would keep me from being sad. However, I do think it might be an issue if the Queso-Roboto only works for cheese and tortilla quesadillas. I know very few people who eat a plain quesadilla. It might be beneficial to, instead, determine what the most common quesadilla is and use that quesadilla to chose your set points. In addition, it might be cool to have more than one setting, like the microwave has multiple buttons for different commonly microwaved items. Because what goes into the quesadilla besides cheese is a disturbance, having the different settings would lower to amount of disturbances, and thus lead to better quesadillas. It would be cool if there was a window of some sort so you could see the progress of the cooking quesadilla. Each time you open Queso-Roboto to check on your loaded chicken quesadilla, heat is lost to the environment and it takes longer for your cheese to melt. By having a window you would not need to open it up to check the status of your quesadilla. One thing to note is that if the temperature jumps real high and overshoots the set point, the quesadilla could potentially burn, which would be no bueno. A PI or PID controller could be used for this device. The parameters could be found using closed loop tuning like the Ziegler-Nicholas method. You could start at a arbitrary low controller gain, Kc, and increase it until sustained oscillation is observed. The tables could be used to calculate the Kc, tau I, and tau D.
It baffles me that I have never heard or thought about a quesadilla maker before this moment. It is just such an ingenious idea that it is surprising that a Panini press is more popular than this. The controlled variable was made clear that it was heat and it was easy to see why this was the most important variable to control. Obviously none of us want our cheese to be hard or our quesadilla to be burnt. I like that there is a possible control range instead of just saying that it has to be one temperature because I personally like my cheese to be extra melted while others might just want it a little less melty. The experiment was a great way to test what the best way to cook a quesadilla was. I personally really enjoyed the rating system, evenness, crispness, cheese stretch, perfect bite, overall beauty, and wow factor. It seemed extremely sophisticated! With a feedback loop, I also agree that this is the best way to control the system. This is better because if the temperature gets too hot suddenly, it can correct itself. A PID controller is probably best because it can report fast changes which are always important in cooking. I like that they took into account the fact that the quesadilla maker does not close all the way though I am slightly confused on where the two separate heaters would be. Would one be in the top plate and one in the bottom? I think that having a set point for a quesadilla filled with other things besides cheese would be important because I don’t know a lot of people who put the exact same amount of cheese on the quesadilla every time or who never switch it up a little. Also what was the final decision for the maker? They did not tell us what the ideal temperature was supposed to be. However, besides this I really enjoyed this post. I feel as though this application would do extremely well in the market. People can never get enough of cheese and while a Panini press has been engineered to near perfection, a quesadilla maker with some updates like they suggested could really thrive. The blog post itself was extremely nice to read because it had humor and some great photos. I only wish that they would have provided the results of the experiment because then I would have been really committed to the project.
As a fan of fun kitchen gadgets, I am very much interested in this quesadilla maker. I too, love a perfect quesadilla and would be willing to test this product. I also liked the humor in the article because it made it much more enjoyable to read. I was just a little confused on the rating scale what a “blue-yes” and “blue-no” are but other than that I was a big fan of the writing style. By providing the consumer with the opportunity to make restaurant quality quesadilla, one does not have to go to a restaurant or any other establishment to buy it, thus saving the consumer money. I think it would be interesting to later have a quesadilla maker that has different setting based on what does in the quesadilla. That would make the product even more versatile.
In terms of the description of the control aspect, I agree with everything that was said. The controlled variables are the temperature of the inside of the quesadilla maker with an upper bound being the temperature before the tortilla will burn and the lower limit being the melting point of cheese. The manipulated variables is the amount of electricity that is given to the electric heaters and the disturbance is that the quesadilla maker is open to the air. A possible solution for the disturbance would be to make it fully close but have holes where the steam could escape. This would create a more even cooking environment while also letting the steam escape to avoid a soggy quesadilla. Also, some Panini presses require you to grease them to avoid sticking, would this be the case for the quesadilla maker, and if so, how would that change the max temperature?
Because the quesadilla maker’s goal is to be efficient and have good temperature control, I would suggest a PID controller. It is important that the temperature does not go about the 100 degrees Celsius so temperature oscillation should be avoided at all costs. The advantages of a PID controller are that it has the quick response of proportional and integral but the derivative control helps counteract the oscillatory aspect of the integral control. Overall, I think this is a great product and I look forward to seeing it come out so I can purchase one of my own!
I’m glad someone looked into this. As an International Student, I’m a novice in the world of Mexican-American food, and I know very little about the numerous variations of quesadillas mentioned in this blog post. However, like most Americans, I’m in love with unauthentic versions of Mexican classics and Queso-Roboto seeks to make them even easier to make! Like all home appliances that make cooking convenient, Queso-roboto has tremendous potential in a marketplace increasingly drooling over quesadillas. I also have to appreciate the humorous tone of the blog, which made the reading less bland.
Controlling the hot plate temperature by manipulating the electrical current in seems like a reasonable way to control the process. However, a little more intuitive control variable would be the internal temperature of the quesadilla, as the final product is quesadilla and controlling its quality, in this case the cheese quality, is our prime purpose. Adding a needle thermometer right in the middle of the plate could do the job. This could also be beneficial given we are considering the weight (or the addition of extra ingredients) a disturbance variable. Types of ingredients will also matter when looking at disturbance variables, heating cheese is much easier than heating minced beef, and thus a sensor that could provide information to that effect to the controller would be beneficial too.
A PID controller should be deemed suitable for this process, as the existence of Proportional and Integral control results in quick response times to sudden ambient temperature changes, and the derivative control would reduce oscillations, which could prove disastrous when you’re looking for that perfectly cooked quesadilla.
As a college student who loves cooking food, and with appliances ranging from a Keurig to a dough kneader, I would like to add a Queso-Roboto to my kitchen. Please tell me you all are planning on making these once you leave Lafayette.