Design Project: Dual Heat Charcoal Grill

Justin Acevedo, Chandler Dove

Powdersville High School
Mr. McCullough
EDD B-Day Afternoon
5/12/15

Abstract
The process of engineering and innovating the outdoor charcoal grills used to day
produced several design flaws that need addressing. Using a charcoal grill is time consuming,
high maintenance, produces unevenly cooked products, and potentially hazardous. With the
recent numbers of grilling injuries high and the shipment numbers of charcoal grills falling
behind gas grills, these flaws are forcing consumers to sacrifice quality for functionality. This
report identifies the flaws of traditional charcoal grill designs and provide an improved solution
for the problems faced. Through testing and careful designing, this solution proves to be a
promising alternative to traditional measures of grilling using charcoal.

Table of Contents
Abstract..................................................................................................................................... pg. 1
Table of Contents...................................................................................................................... pg. 2
Introduction............................................................................................................................... pg. 3
Background.............................................................................................................................pg. 4-5
Materials List............................................................................................................................ pg. 6
Procedure.................................................................................................................................. pg. 7
Results....................................................................................................................................... pg. 8
Conclusion................................................................................................................................ pg. 9
Concept Sketches.................................................................................................................... pg. 10
Technical Drawings........................................................................................................... pg. 11-13
Appendix........................................................................................................................... pg. 14-15
Citations................................................................................................................................. pg. 16

Introduction
Subject:
During the preliminary brainstorming stages of this project, the research conducted
yielded several issues with traditional charcoal grills being discussed. With these safety issues
and inefficiencies receiving consumer disapproval, the issue has caused the consumption
numbers of charcoal grills to fall behind gas grills. The number of users receiving injuries and
charcoal grilling being time consuming, inefficient in cooking food evenly, and requiring the user
to be attentive. All this makes charcoal grilling to be a hassle and potentially dangerous.
Purpose:
With the problems of injuries, slow grill time, uneven grilling, and extra manual control
all appearing in various reports, charcoal grills are becoming less reasonable for grilling. The
user reaching over the open flame of the grill poses a burn risk, the use of one heat source slows
cook time and cooks unevenly, and the need to flip the food for full cooking makes grilling more
of a burden. This report proposes several design changes that will make grilling with charcoal
easier and less of a injury risk.
Scope:
This report summarizes production and testing methods, material choices, and testing
results for the dual heat charcoal grill design. Also discussed is the thermodynamics behind the
design, the background information and history, and the concept and technical drawings for this
charcoal grill design.

Background
Grill History:
Grilling dates back to as far as the Stone Age, after man's domestication of fire. The first
functioning barbequing method was developed in the America's during the 1660's which lead to a
more improved method developed by arriving colonists in the early 1700's. The next major
innovation to grilling was charcoal briskets invented in 1897. In the 1960's the propane gas grill
became the new favorite method to grilling, which was then met with the less popular electric
George Foreman grill in 1994.
Thermodynamics Behind Grilling:
The burning charcoals produce radiant heat and convection heat which rises and is
absorbed by the grill grate where the food lays on. The grill grate absorbs the heat and produces
conduction heat to the surface of the food which makes it way from the surface to the center of
the food, cooking it. The radiant and convection heat not absorbed by the grill grate is deflected
by the dome covering and further warms the space inside the grill.
Thermodynamic Concept Behind the Dual Heat Grill:
In order to more evenly and quickly cook the food without overheating, this design
redistributes the heat sources rather than increasing the heat source. The charcoal will be at the
bottom and top of the grill, both an even amount. The top charcoal pile will be held by an heat
absorbing aluminum plate that heats and cools quickly. This plate will be lowered so that it is
touching the food as to transfer the heat properly. This cooks two opposite sides of the food,
allowing it to transfer the conduction heat to the center of the food quicker.

Background

Current and Past Solutions:

The George Foreman Grill is an electric, indoor grill that is used as an alternative for
outdoor traditional grilling. The food is cooked on both the top and bottom side so that there is
no flipping required. There have been several other models made and each is advertised to make
foods healthier by eliminating fat. This grill was designed for easy grilling and easy clean up.
However, comments have been made that this product does not provide the same great quality as
traditional grills. The food cooked on them do not taste as good which is why it is not a full
solution. Rotisserie grills are grills that props up food by a pole that spins the food as it is
exposed to indirect heat. These grills can be gas or charcoal, however they take a longer time to
cook and it cooks the food differently than a traditional grill. These grills are not ideal for some
types of cooking and some types of meat, so they are not a great solution for this problem.

Materials List

Aluminum Angle 4'

Barrel Charcoal Grill
5-40 x 1/2 screws x 8
5-40 Hex nuts x 8
Drawer Handle
Hinges x 1
12" x 17" x 3/8" Aluminum Sheet
Cobalt Drill bits
Power Drill
Table saw

Testing Procedure
Initial Conditions:

Grill will be cleaned as if lightly used and will be empty of all charcoal and food substances.
Preparation for testing would include loading the bottom and top of grill with charcoal and then
preheating to a controlled temperature.
Potential Hazards:
During testing, there is a risk of handlers being burned, grill tipping over, parts breaking under
heat, and sickness from poorly cooked food.
Safety Precautions:
Safety glasses will be worn during testing, lighters will be held with care, there will be no horse
play while testing, and the food being tested will not be consumed by anyone.
Test Criteria:
There will be six separate tests performed using the same amount of charcoal, same heat level,
same type of food. Three of the tests will be testing for even cooking and the other three will test
for how fast the food fully cooks. The goal is to cook the food fast, but evenly on top and bottom
while also checking to make sure the additional safety features work under normal, less
controlled circumstances. In order to know if the test is a success is by grilling the food and after
letting it cool down, cut it in half to see if the inside is cooked and if the top and bottom are
cooked to the same degree. All tests will be timed, however three will be at a fixed time and the
others will be looking for the minimum amount of time needed to fully grill the food.
Results
The prototype performed to a lower quality than intended as the presence of several
issues was discovered following the testing. The test was a success as it met most of the

objectives, however the others were not accomplished to the efficiency desired. The objectives
put in place included grilling faster than traditional grills, grilling the meat without having to flip
the food, and to be safer to use. The test showed that the grill performed faster, grilled both sides
without flipping, however the safety features were problematic. The meat was not as evenly
grilled as intended and the materials used to construct the safety features were poorly chosen.
The tests however showed that the overall concept would work with improvements to the design.
These improvements would include better building materials for the pull-out grill grate, the
handle, and the thermometer, and more carefully planned measurements. With these
improvements and a slight budget increase, this product would be market ready.

Conclusion
Through tests, re-design and research involved in the construction and preliminary design
work, the results yield that the concept behind this product is valid and effective. The grill

innovation uses charcoal on both the top and bottom of the grill, simultaneously cooking the top
and the bottom of the food, cutting down on time, removing the need to flip the food, which
solves several safety issues, and cooks the meat more evenly making charcoal grilling more
feasible for consumers. This product, with minor modifications and further detailing will prove a
realistic contender in creating a new age in outdoor grilling.

Concept Sketches

Technical Drawings

Technical Drawings

Technical Drawings

Appendix

Test Results:

Gantt Chart:

Appendix

Decision Matrix:

Citations

Huntley, C. (2011, June 28). Principles of Grilling - Conduction, Convection, etc. Retrieved May
11, 2015.
Goldwyn, M. (n.d.). Amazingribs.com. Retrieved May 11, 2015.
Thermal Conductivity of Metals. (n.d.). Retrieved May 11, 2015.