FRYER INCLUDING AUTOMATIC BASKET SHAKER LIFT AND VISION-BASED CONTROLS OF COOKING CYCLES AND COOKING MEDIUM SERVICING

An automated cooking system includes a fryer with at least one fryer vat configured to hold a cooking medium, and at least one basket configured to receive and hold a food product for cooking in the cooking medium at the fryer. The cooking system further includes a basket movement device including a basket support for engaging the at least one basket. The basket movement device is configured to move the at least one basket into and out of the cooking medium. Further, the basket movement device includes a retention clip to releasably secure the at least one basket to the basket support. The cooking system includes a vision system and a visual indicator system to help, with the basket movement device, automate workflow decisions and management at the fryer. A method of cooking food products and a method for managing basket workflow with/at an automated cooking system are also provided.

TECHNICAL FIELD

This application generally relates to food product cooking systems such as fryers. More specifically, this application describes automated systems and controls for use with fryers having at least one cooking vat for receiving a basket of food product.

BACKGROUND

Cooking devices, such as fryers, are used to cook various food products, e.g., poultry, fish, potato products, and the like. Such cooking devices may include one or more cooking chambers, e.g., fryer pots or cooking vats, which may be filled with a cooking medium, e.g., an oil, a liquid shortening, or a meltable-solid shortening. Such cooking apparatus also may include a heating element, e.g., an electrical heating element, such as a heating coil, or a gas heating element, such as a gas burner and gas conveying tubes, which heats the cooking medium in the cooking chamber. After the cooking medium reaches a predetermined cooking temperature, the food products are placed into the cooking medium such that the food products are cooked in the cooking medium. For example, the food products may typically be positioned inside a basket, e.g., a wire basket, and submerged in the cooking medium for a predetermined amount of time sufficient to cook the food products.

Restaurants continually strive to increase production to satisfy customer demand. However, in many conventional kitchens, restaurant employees must complete or manage all the cooking and food preparation tasks to accomplish the increases in production and customer demand. For example, during a standard cooking cycle using a conventional open fryer with baskets for food products, an operator must fill the basket with frozen or fresh food product to be cooked; move the basket to an appropriate location (e.g., a cooking vat) within the fryer for cooking in the cooking medium; shake the basket at regular intervals to prevent certain food products from sticking or clumping together (also referred to as formation of product marriages) during frying; remove the basket from the fryer when a cooking cycle is completed; and transfer the cooked food products to a holding station or preparation station. It can become impossible for an operator to timely perform all these tasks associated with cooking cycles for a number of different cooking vats and a number of different food products if the expected production level or demand increases to a certain high level.

Restaurants also strive to provide the highest-quality cooked food product on a consistent basis. In the context of cooking food product with an open fryer, as described above, one significant factor for maintaining a consistent high quality of food product is regular filtration and level maintenance of the oil or other cooking medium used. Operators such as restaurant employees are also tasked with managing the cooking medium level and filtration cycles simultaneous with management of the various cooking cycles of food product noted above. The restaurant employee must monitor the level and color of the cooking medium to evaluate if the cooking medium in any of the cooking vats requires a filtration cycle, needs to be refilled (e.g., a top off), or needs to be changed, and this must often be done while cooking operations continue at other cooking vats in the fryer. It will be readily understood that this operator-based evaluation slows the cooking process because of the added demands placed on fryer operators, such as restaurant employees.

Furthermore, significant training is required for an operator to understand the appropriate times for all of these actions, both in cooking cycles for various food products and in filtration other and cooking medium maintenance cycles. To this end, the conventional fryer designs can necessitate operator intervention for each of product identification, filtration cycle starts, basket shaking and removal timing, cooking medium level verification, and more. With labor being a limiting constraint in present times for fields such as restaurant operations, such need for significant training and continual high demands on employees is generally undesirable. As a result, conventional fryers, operated manually in the traditional ways summarized above, cannot always achieve maximum product throughput or efficiency while maintaining consistent high quality cooked food product.

Therefore, it would be desirable to provide systems and methods for assisting an operator with the management of the various tasks associated with cooking cycles and cooking medium servicing (e.g., filtration cycles, refilling, changing out) at a fryer. Such systems and methods should help achieve the technical objectives of properly handling increased production demands in modern restaurant contexts, while also maintaining consistent high quality of cooked food product and limiting the labor-intensive nature of conventional fryer operations.

SUMMARY

The embodiments of the present invention provide a fryer including an automatic basket shaker lift and vision-based controls of cooking cycles and cooking medium maintenance and methods of use thereof that address known drawbacks in the fryer art. Certain exemplary aspects of the invention are set forth below. It should be understood that these aspects are presented merely to provide the reader with a brief summary of certain forms the invention might take and that these aspects are not intended to limit the scope of the invention

In a first aspect of the invention, an automated cooking system is provided. The automated cooking system includes a fryer including at least one fryer vat configured to hold a cooking medium. The automated cooking system further includes at least one basket configured to receive and hold a food product for cooking in the cooking medium at the fryer. The automated cooking system also includes a basket movement device located proximate to the at least one fryer vat. The basket movement device includes a basket support for engaging the at least one basket. The basket movement device is configured to move the at least one basket into and out of the cooking medium. Further, the basket movement device includes a retention clip to releasably secure the at least one basket to the basket support.

In one embodiment, the retention clip may engage at least a portion of the basket. The retention clip may be biased to lock the at least one basket in position on the basket support thereby preventing the at least one basket from being inadvertently removed from the basket support. Further, the bias may be applied by a torsion spring of the basket support. The retention clip may be disengaged by contact with a cam catch surface. More specifically, contact with the cam catch surface may cause the retention clip to pivot against the bias such that the at least one basket may be removed from the basket support. In an alternative embodiment, the retention clip may be disengaged by a pneumatic cylinder. More specifically, the pneumatic cylinder may cause the retention clip to pivot against the bias such that the at least one basket may be removed from the basket support.

In another embodiment, the automated cooking system may further include a vision system. The vision system may include at least one camera and at least one image processor. The at least one camera may be mounted on a support. The support may be shared with the basket movement device. Further, the at least one camera may be configured to capture at least one visual image of the food product within the at least one basket. The at least one image processor may be configured to identify the food product from the at least one visual image. Furthermore, the at least one camera may be configured to capture at least one visual image of a color and/or a level of the cooking medium in the at least one fryer vat. The at least one image processor may be configured to identify a change in the color and/or the level of the cooking medium. Additionally, the automated cooking system may include a visual indicator system including at least one visual indicator configured to illuminate with different colors or different combinations of lights and/or colors to visually communicate information to an operator. The at least one series of lights may be mounted on the support shared with the basket movement device and shared with the at least one camera.

In a further embodiment, the automated cooking system may further include a visual indicator system. The visual indicator system may include at least one visual indicator to visually communicate information to an operator. The at least one visual indicator may be mounted on a support shared with the basket movement device. Further, the at least one visual indicator may illuminate in a color or in a combination/pattern to communicate that an associated fryer vat should next receive at the at least one basket. Additionally or alternatively, the at least one visual indicator may illuminate in a color or in a combination/pattern to communicate that the food product in the at least one basket of an associated fryer vat is fully cooked and that the at least one basket is ready to be removed from the fryer.

In another aspect of the invention, a method of cooking food products with an automated cooking system is provided. The method includes providing the automated cooking system. The automated cooking system includes a fryer including at least one fryer vat configured to hold a cooking medium. The automated cooking system further includes a basket movement device located proximate to the at least one fryer vat. The basket movement device includes a basket support. The method further includes attaching at least one basket of food product to the basket support. Additionally, the method includes releasably securing the at least one basket to the basket support with a retention clip. The retention clip is biased to lock the at least one basket in position on the basket support thereby preventing the at least one basket from being inadvertently removed from the basket support. The method further includes moving the at least one basket downwardly, by the basket movement device, to a lower position in which the at least one basket is substantially submerged in the cooking medium held within the at least one fryer vat, thereby beginning a cooking cycle for the food product. Additionally, the method includes moving the basket upwardly, by the basket movement device, to an upper position in which the at least one basket is located above the cooking medium in the at least one fryer vat, when the cooking cycle is completed.

In one embodiment, the retention clip may include a torsion spring and the step of releasably securing the at least one basket may further include applying a spring bias by the torsion spring to lock the at least one basket in position on the basket support. The method may further include disengaging the retention clip by contacting the retention clip with a cam catch surface to cause the retention clip to pivot against the spring bias of the torsion spring. In an alternative embodiment, the method may further include disengaging the retention clip using a pneumatic cylinder to cause the retention clip to pivot against the spring bias of the torsion spring.

In another embodiment, the automated cooking system may further include a vision system. The vision system may include at least one camera and at least one image processor. The method may further include capturing, by the at least one camera, at least one visual image of the food product within the at least one basket. Additionally, the method may include identifying, by the at least one image processor, the food product from the at least one visual image. Further, the method may include determining, by a fryer controller, the cooking cycle for the identified food product. Additionally, the method may include initiating, by the fryer controller, the cooking cycle. Furthermore, the method may include determining, by a fryer controller, that the identified food product requires shaking and then shaking, by the basket support, the at least one basket during the cooking cycle with rapid oscillation and/or vibration movements to break up any clumps or product marriages of the food product in the basket. The step of shaking may further include moving the basket upwardly during the cooking cycle prior to shaking, by the basket movement device, to an upper position in which the basket is located above the cooking medium in the fryer vat, thereby pausing the cooking cycle for the food product. The step of shaking may also include moving the at least one basket downwardly during the cooking cycle after shaking, by the basket movement device, to a lower position in which the at least one basket is substantially submerged in the cooking medium held within the fryer vat, thereby resuming the cooking cycle for the food product.

In a further embodiment, the automated cooking system may include a vision system. The vision system may include at least one camera and at least one image processor. The method may further include capturing, by the at least one camera, at least one visual image of a color of the cooking medium in the at least one fryer vat. The method may further include identifying, by the at least one image processor, a change in the color of the cooking medium from the at least one visual image. The method may further include determining, by a fryer controller, that the cooking medium requires filtration. The method may further include initiating, by the fryer controller, filtration of the cooking medium. Alternatively or additionally, the method may include capturing, by the at least one camera, at least one visual image of a level of the cooking medium in the at least one fryer vat. The method may further include identifying, by the at least one image processor, a change in the level of the cooking medium from the at least one visual image. The method may further include determining, by a fryer controller, that the cooking medium requires refilling. The method may further include initiating, by the fryer controller, refilling of the cooking medium. Alternatively or additionally, the method may include capturing, by the at least one camera, at least one visual image of a level of the cooking medium in the at least one fryer vat. The method may further include identifying, by the at least one image processor, a change in the level or a change in the color of the cooking medium from the at least one visual image. The method may further include determining, by a fryer controller, that the cooking medium requires replacement by changing out. The method may further include initiating, by the fryer controller, changing out of the cooking medium. Alternatively or additionally, the method may include capturing, by the at least one camera, at least one visual image of the at least one fryer vat. The method may further include identifying, by the at least one image processor, a status of the at least one fryer vat. The method may further include interpreting, by a fryer controller, the status of the at least one fryer vat. The method may further include communicating, by a visual indicator system, the status of the at least one fryer vat to an operator.

In yet another embodiment, the automated cooking system may further include a visual indicator system. The visual indicator system may include at least one visual indicator. The method may further include illuminating the at least one visual indicator in a color and/or in a combination/pattern to communicate information to an operator regarding cooking status or actions needed at one or more fryer vats. Alternatively or additionally, the method may include illuminating the at least one visual indicator in a color and/or in a combination/pattern to communicate to the operator that an associated fryer vat should next receive the at least one basket. Alternatively or additionally, the method may include illuminating the at least one visual indicator in in a color and/or in a combination/pattern to communicate to an operator that the food product in the at least one basket of an associated fryer vat is in the process of being cooked. Alternatively or additionally, the method may include illuminating the at least one visual indicator in a color and/or in a combination/pattern to communicate to an operator that the food product in the at least one basket of an associated fryer vat is fully cooked and that the at least one basket is ready to be removed from the fryer. Alternatively or additionally, the method may include illuminating the at least one visual indicator in a color and/or in a combination/pattern to communicate to an operator that an associated fryer vat is unavailable to be used.

In a further aspect of the invention, a method for managing basket workflow at an automated cooking system is provided. The automated cooking system includes a fryer including at least one fryer vat. The at least one fryer vat includes a basket movement device for receiving and moving a basket located proximate to the at least one fryer vat. The fryer also includes a vision system including at least one camera and at least one image processor and a visual indicator system including at least one visual indicator to visually communicate information to an operator. The method further includes illuminating the at least one visual indicator to communicate to the operator that the at least one fryer vat should receive the next basket. The method also includes placing the basket containing a food product on the basket movement device. The method also includes identifying, by the at least one camera and the at least one image processor, the food product in the basket and determining and initiating, by a fryer controller, the cooking cycle for the identified food product. The method also includes illuminating the at least one visual indicator to communicate to the operator that the food product in the basket is fully cooked and that the basket is ready to be removed from the fryer. The method also includes removing the basket containing fully cooked food product from the basket movement device.

It will be understood that various embodiments and aspects described above can be combined in any combination or sub-combination without departing from the scope of this disclosure.

DETAILED DESCRIPTION

With reference toFIGS.1through4, a fryer10is shown in accordance with one embodiment of the present invention. The fryer10generally includes at least one automatic basket movement device12and further equipment that allows for enhanced vision-based controls of several operations during cooking cycles and maintenance at the fryer10. As set forth in further detail below, the automatic basket movement device12is configured to move a basket14into and out of cooking medium16contained within a cooking vat18or other similar chamber for receiving basket14. The automatic basket movement device12also advantageously operates to move a basket14in a vibratory or shaking manner at certain intervals within a cooking cycle for food products20held in the fryer10by the basket14. These movements of the basket14with the automatic basket movement device12are properly timed and tailored for the specific food product20being cooked in the basket14, and this functionality is enabled by the vision-based controls operated by the fryer10.

To this end, the further equipment noted above may include a vision system22that communicates with a fryer controller24to provide various inputs for actuating the components of the fryer10and the basket movement device12. For example, the vision system22may include a camera26that can capture a visual image of the food product20in the basket14such that the specific cooking cycle parameters such as the cooking medium16temperature and/or cooking/shake times can be implemented for the correct food product20by the fryer10and the basket movement device12. Moreover, the camera26can also capture a visual image of the cooking medium16to provide input for the controller24to initiate a maintenance operation-such as a filtration cycle, refilling, or a wholesale change out (also referred to as replacement herein) of the cooking medium16when necessary.

The further equipment may also include a visual indicator system28that visually provides workflow updates to a fryer10operator, such as a restaurant employee. For example, the visual indicator system28may include one or more visual indicators30that can visually communicate to a fryer10operator the status of a cooking vat18or food product20within a basket14at the fryer10. This allows for the particular cooking cycle for a food product20to be closely adhered to or for workflow at the fryer10to be better managed, for example.

Consequently, the need for a fryer10operator, such as a restaurant employee, to fully manage such decisions and operational steps is eliminated, which frees up more time for the operator to perform other functions within the restaurant or kitchen. As a result, the fryer10according to these and other embodiments of the invention allows for increased production and demands to be handled with less labor needed, while also assuring more consistency in delivering high-quality food product20from the fryer10as well. The features of the fryer10, the automatic basket movement device12, the vision system22, and the visual indicator system28are set forth in further detail below to clarify each of these functional advantages and other benefits provided in this disclosure.

With reference toFIG.1(andFIG.4, described later), a fryer10in accordance with one embodiment of this invention is shown to include a plurality of cooking vats18along the length of a framework thereof. The fryer10may be just a portion of a larger fryer subsystem, but only a portion of such a subsystem is shown inFIG.1for better illustration clarity. The cooking medium16is shown in one of the vats18for clarity. The vats18are supported by the fryer housing32in this embodiment, the housing32enclosing a space beneath the vats18for control and recirculation/filtration equipment such as drain pan(s) and pump(s), as will be readily understood in the field of fryers. The fryer10illustrated inFIG.1also includes a user interface34along a front side of the housing32, but it will be understood that additional interface elements (e.g., the vision system22and the visual indicator system28) have been added to enhance communications to human operators as set forth in further detail below. The user interface34may include one or more touchscreens. The specific elements of the exemplary fryer10shown inFIG.1are not described in further detail herein, as the focus is on the newly-added elements which can be retrofitted and added to almost any known fryer design. However, a couple commercially-available designs of such fryers and their further details can be reviewed at the “F5™ Series” of fryers and at the “Evolution Elite®” series of fryers from Henny Penny Corporation, of Eaton, Ohio.

Each of the cooking vats18in this embodiment includes a heating element36, one of which is shown on the left ofFIG.1. The heating element36extends downwardly into the vat18, so as to be submerged in cooking medium16. In the depicted embodiment, the heating element36is an electric heating element. In an alternative embodiment, the heating element36could be a gas powered heating element-typically located outside the cooking vat18- or another kind of heating element. Some of the vats18may be sized to receive multiple baskets14of food product20(as exemplified by the leftmost cooking vat18inFIG.1), while others may be sized to receive a single basket14(as exemplified by the two rightmost cooking vats18inFIG.1). It will be understood that variations from the particular vat layout in the fryer10may be made in other embodiments without departing from the scope of the present invention. Likewise, while all the vats18are shown as conventional open fryer vats18in this embodiment, it will be understood that modifications such as inclusion of one or more pressure fryer vats in this regard are also possible within the scope of the invention, and furthermore, different types and combinations of heating elements may be used in other embodiments. To this end, the movement device12and the further equipment for vision-based controls (e.g., vision system22and visual indicator system28) can be implemented using many different types of fryers10, and the fryers10shown in these Figures are merely examples of such.

Referring now toFIGS.2and3, the automatic basket shaker lift defined by the movement device12is shown in further detail. The movement device12is configured to transport the basket14upwardly and downwardly relative to the cooking vat18, and thereby automatically control all basket14movements during cooking cycles at the fryer10. In the depicted embodiment, the movement device12is mounted to a rear wall of fryer housing32that extends behind and above the back of each cooking vat18, e.g., the wall where the top end of the support mounts38for heating elements36are typically mounted. It should be understood that the movement device12could, alternatively, be mounted to a different portion of the fryer housing32. For example, the movement device12could be mounted to the framework of the fryer10. As such, the movement device12is configured for retrofitting/adding onto many existing types of open fryers. One of the movement devices12now described can be added at each cooking vat18or each area where a basket14would normally enter a cooking vat18-though it is not necessary for each cooking vat18to include a movement device12. For example, one or more cooking vats18may be reserved for wholly manual operation by an operator.

The movement device12of this embodiment more generally includes a support bracket40, a drive mechanism42, a basket support44, and a retention clip46. In the depicted embodiment, the support bracket40is generally L-shaped and is mounted in a stationary manner on the fryer10. It should be understood that the support bracket40may take on other forms. The support bracket40may be mounted on the rear end of the fryer10just above the support mount(s)38of the heating elements36. It should be understood that the support bracket40may be mounted to a different portion of the fryer10. A free end of the support bracket40(i.e., the end of the support bracket40not mounted to the fryer10) extends outwardly from the fryer10(e.g., in the direction of the vat18) and angles downwardly in the direction of the basket support44to define a cam catch surface48, the function of which is described further below. The drive mechanism42includes a housing49, as shown inFIGS.1-4, that may sit on a portion of the support bracket40. The drive mechanism42internal elements are not shown in detail in the figures, but typical drive mechanism42internal elements may include electric or rodless pneumatic drives configured to generate a linear movement upwardly and downwardly of the basket support44connected to a front of the drive mechanism42, as would be understood by one of ordinary skill in the art.

With continued reference toFIGS.2and3, the basket support44, in the depicted embodiment, is defined by a loop-shaped elongate rod member that extends between an upper end52(in the form of a support crossbar) and a lower end54. It should be understood that the basket support44may take on other forms. The upper end52of the basket support44engages with a mounting hook50extending from a front of the drive mechanism42. The lower end54of the basket support44is configured to engage with the basket14. More particularly, the lower end54of basket support44in this embodiment includes a support crossbar56and a clamp mounting bracket60. The support crossbar56is configured to receive hanger hook(s)58located at the back end of the basket14. It should be understood that, in alternative embodiments, the basket14may interface with the basket support44in a different way. In the depicted embodiment, the clamp mounting bracket60is connected to a rear-facing (i.e., fryer facing) side of the basket support44-opposite where the basket14is located when mounted on the basket support44, as shown in these views. The retention clip46is pivotally mounted on the clamp mounting bracket60so as to be positioned behind the basket support44(i.e., between the basket support44and the support bracket40). It is to be understood that the retention clip46could be alternatively located and/or alternatively connected to the basket support44.

A first operational position of the movement device12is shown inFIG.2, this operational position being an initial position where the basket14is locked in engagement with the basket support44by the retention clip46. In this position, an upper end62of the retention clip46is pivoted into engagement with an opening in the hanger hook(s)58on the rear end of basket14. A spring bias applied by a torsion spring64, for example, at the clamp mounting bracket60biases the retention clip46to this engaged position. With the retention clip46in the engaged position, the hanger hook58is prevented from moving upwardly past the upper end62of the retention clip46. Thus, the retention clip46, when engaged, prevents the hanger hook58from upward movement that would disengage the basket14from the support crossbar56at the basket support44. In this regard, the retention clip46locks the basket14in position on the basket support44to prevent accidental/unintended removal of the basket14during a cooking cycle. It is to be understood that the retention clip46could be biased into engagement with the hanger hook(s)58in an alternative way. The first operational position is a top position at which the basket14is held during a cooking operation at the fryer10(but as will be described above, further upward movements are possible to unlock the basket14after a cooking operation is completed).

From this first operational position inFIG.2, the drive mechanism42can move the basket support44and the basket14vertically downward and then upward without worry of the basket14disengaging from the support bracket40. For example, after the basket14is initially placed and locked in position as described, the fryer controller24can initiate a cooking cycle when the cooking medium16is at the correct cooking temperature by actuating the drive mechanism42to move the basket support44downward such that the basket14filled with food product20is submersed in the cooking medium16. At specific time intervals during the cooking cycle, it may be desired to shake the basket14to break up any product marriages that may have formed during cooking. The basket14may be shaken by the drive mechanism42one or more times during the cooking cycle as necessary to prevent food product marriages and to ensure a high-quality cooked food product20.

In such a situation, the fryer controller24may actuate the drive mechanism42to rapidly oscillate the basket support44upward and downward to perform this shaking. In one example, the small upward and downward movements may extend through about 0.2 inches of total movement and may cycle up-and-down once per second. The shaking movement may apply approximately 5 g's of force when accelerating the basket14in the upward and downward movements. The intensity of the shaking may vary depending on the specific food product20. The shaking movement may be performed while the basket14is submerged in the cooking medium16or, alternatively, the basket14may be lifted from the cooking medium16prior to performing the shaking movement and subsequently returned to the cooking medium16after the shaking movement is performed. Alternatively or additionally, the shaking movement may be performed in a horizontal direction as opposed to a vertical direction. How frequently (if at all) the food product20is shaken during the cooking cycle may depend on the specific food product20.

With continued reference toFIG.2, once a cooking cycle is completed, the fryer controller24actuates the drive mechanism42to move the basket support44back towards the first operational position. This removes the basket14from submersion in the cooking medium16and allows excess cooking medium16(e.g., oil) to drip off back into the cooking vat18. All of these steps are automated by use of the fryer controller24and the movement device12. It will be understood that the retention clip46prevents the basket14from inadvertently falling off the basket support44during the rapid shaking movements or before the cooking cycle is properly completed. Such functions keep a human operator from needing to manage these particular steps of a cooking cycle, while assuring improved and consistent cook quality for each cooking cycle.

If the drive mechanism42moves the basket support44further upwardly from the first operational position, the basket support44moves to a second operational position shown inFIG.3. As a result of this small amount of upward movement, a lower end66of the retention clip46is brought into engagement with an underside of the cam catch surface48on the free end of the support bracket40. This engagement coupled with continued upward movement of the basket support44(and the retention clip46, which is mounted on the clamp mounting bracket60carried by basket support44) forces a cam-like action of the lower end66of the retention clip46(as shown by movement arrow A1inFIG.3). The cam-like action of the lower end66of the retention clip46forces a pivotal movement of the retention clip46(as shown by movement arrow A2inFIG.3) against the spring bias of the torsion spring64to thereby move the retention clip46to the position shown inFIG.3(i.e., disengaged from the hanger hooks(s)58of the basket14). It should be understood that alternative mechanisms may be used to disengage the retention clip46. For example, in an alternative embodiment, the retention clip46may be released by a pneumatic cylinder to thereby move to an unlocked state.

In this second operational position of the movement device12, the upper end62of the retention clip46has pivoted away from engagement with the opening in the hanger hook(s)58(as shown by movement arrow A3inFIG.3). This releases the lock that previously prevented upward movement and removal of the basket14(as shown by movement arrow A4inFIG.3) from the support crossbar56of the basket support44. As readily understood inFIG.3, this second operational position is an uppermost extent of the vertical movement caused by the movement device12. When the movement device12is in the second operational position (and thus the retention clip46is disengaged), the basket14is free to be removed and replaced by a human operator or by a robotic basket movement system. However, the basket14does not automatically fall off or disengage when the retention clip46is unlocked. The total movement between the first and second operational positions shown inFIGS.2and3may be about one inch, whereas the total translation movement of the basket support44betweenFIG.3and the fully submerged position (as shown inFIG.4) may be 10 inches or more. It should be understood that these movement values may vary depending on the particular fryer the movement device12is attached to.

With reference toFIGS.2and3, it will be understood that the retention clip46of the movement device12defines a roller latch or cam latch type of mechanism for locking the basket14into engagement with the basket support44. Though, it should be understood that alternative mechanisms may be used. For example, in an alternative embodiment, the retention clip46may be released by a pneumatic cylinder. It can also be seen clearly inFIGS.2and3that the various movements of the basket support44do not interfere with the preexisting structure of the fryer10such as the heating elements36of the fryer10, which allows for retrofitting of the movement device12onto fryers of varying designs. The drive mechanism42and basket support44shape and specifics may be modified in further embodiments, and it will be understood that operational parameters such as total translation length vertically and the amplitude and frequency of the shaking vibrational movements are adjustable to meet the needs of different fryers, end users, and use cases.

As initially described above, the fryer10of the embodiments of this invention is further improved by adding further equipment to enable vision-based controls of various fryer operations-such as cooking medium16maintenance operations. To that end, an embodiment of the fryer10includes a vision system22. The vision system22includes at least one camera26or other similar imaging device and, typically, at least one camera26at each of the cooking locations defined at the cooking vats18as shown inFIG.4, for example. One such camera26is also schematically shown inFIGS.1-3. Generally, the camera(s)26are directed downwardly towards the cooking vat18and the basket14when present at the cooking vat18. Thus, each camera26captures visual images of any food product20contained within the basket14that the camera26is aimed towards. Additionally, each camera26can also detect a color and height/level of the cooking medium16within the cooking vat18. The camera(s)26may be mounted on the same support68as the drive mechanism42of the movement device12, for example. In some embodiments, the support68may be the housing49of the drive mechanism42. That is to say that the camera26could be mounted to the housing49of the drive mechanism42. The shared support68further facilitates retrofitting an existing fryer with the movement device12and vision system22. It should be understood that one camera26could be used monitor more than one cooking vat18. In other words, it is not necessary for each cooking vat18to have a dedicated camera26for monitoring. One camera26could monitor one more cooking vats18at the fryer10.

The one or more cameras26are connected operationally to an image processor70. The image processor70may be integrated software algorithms or programming loaded on a microprocessor as well understood in the fields of digital imaging and controls. Although shown as a separate block element inFIG.1, for example, the image processor70may be integrated with the fryer controller24in some embodiments. The camera26provides input in the form of still images or continuous video that can be processed by the image processor70into detected statuses to determine appropriate control inputs that help the fryer controller24determine what actions to automatically perform in accordance with the invention.

With continued reference toFIG.4, for example, the camera26and image processor70(e.g., microcontroller) equipment combination can detect when food product20is placed in a basket14at the fryer10, and furthermore, can identify specifically what type of food product20is in the basket14. The fryer controller24may be programmed with different series of time periods for starting and ending cooking (e.g., the cooking cycle) and for shaking food product20during the cooking cycle depending on the type of food product20. Typically, the selection of the food product20has to be entered manually by an operator at the user interface34to allow for any automation or automated notification signals to be provided for such actions of the cooking cycle. But, the vision-based controls provided by the equipment-specifically, the vision system22-in this embodiment fully automates that food product20determination process and associated input to the fryer controller24. When combined with the movement device12described herein, the fryer controller24can start and complete an appropriate cooking cycle for any known food product20that is detected by the camera26and image processor70by actuating appropriate operations of the movement device12accordingly. Overcooking or undercooking of the food product20is therefore avoided, and the consistent timing and execution of shaking movements assures that each cooking cycle generates high quality food product20with minimal operator intervention.

The additional equipment of the vision system22also allows for automated prompting and operation of filtration cycles for, refilling of, and/or replacement of the cooking medium16. To this end, the camera26and image processor70equipment combination can detect when a cooking medium16(e.g., oil) level in the cooking vat18is too low, or a coloration of the cooking medium16has changed sufficiently to indicate that filtration, refilling, and/or replacement is desired to maintain a high quality of future cooked food product20. These inputs are provided as signals to the fryer controller24, and appropriate remediation actions are then taken. For the cooking medium 16 level being too low, the pumps of the fryer10can be actuated by the fryer controller24to refill (e.g., top off) the cooking medium16by adding an additional amount of new cooking medium16into the cooking vat18. For discoloration of the cooking medium16indicating that filtration or changing out of the cooking medium16is needed, the recirculation and filtration system within the fryer10can be actuated by the fryer controller24at a convenient time (e.g., between cooking cycles or when the cooked food product20is not in high demand) at the cooking vat18to remove and replace the cooking medium16after filtration thereof.

With continued reference toFIG.4, as the camera26and image processor70are capable of detecting cooking medium 16 level changes and cooking medium16color changes to a more precise degree than most human operators, the decisions of when to refill, filter, or replace the cooking medium16are made more reliably at the time when such operations are needed, thereby better assuring a better cooking medium16quality over time and a consistent high quality cook of food products20at the fryer10. Thus, the vision system22of the fryer10of the embodiments of this invention improves consistency and quality while minimizing human or robot operator interaction and inputs needed, with this automation allowing for higher quantities of food product20to be reliably cooked at high quality to meet the increasing demands in industries such as restaurants.

The added vision-based equipment for the fryer10of this invention may also include a visual indicator system28for providing feedback on aspects of the operational status of the fryer10. The visual indicator system28includes at least one visual indicator30and typically at least one visual indicator30at each of the cooking locations defined at the cooking vats18as shown inFIG.4, for example. Generally, the visual indicator(s)30are located roughly at operator eye height above the cooking vats18. The visual indicator(s)30may be mounted on the same support68as the drive mechanism42of the movement device12, for example, as shown inFIGS.1-4. The same support68may also be shared by a camera26of the vision system22. As previously mentioned, in some embodiments the shared support68may be the housing49of the drive mechanism42. This shared support68further facilitates retrofitting an existing fryer with the movement device12and vision system22.

With continued reference toFIG.4, in one embodiment, the visual indicator30may be a series or row of LED lights72affixed to or located within a housing74. It is to be understood that the visual indicator30could take on other forms. The housing74may be mounted on the same support68as the camera26and as the drive mechanism42of the movement device12, for example. As shown in the drawings, the visual indicators30are conveniently located on the movement device12to keep the visual indicator30and the operator focus at the same location as where actions in the basket14workflow will then need to be taken at the cooking vat18of fryer10. The LED lights72of the visual indicator30may be configured to illuminate with different colors or different combinations or patterns of lights to provide information on operational states to the operator of the fryer10. Specifically, the LED lights72are operatively connected to the fryer controller24to receive signals that determine how to illuminate, which again is dependent on the current operational state of the cooking vat18(and/or the movement device12) associated with the particular visual indicator30.

In embodiments where the baskets14are manually moved by a human operator to and from the cooking vats18of fryer10, the visual indicator(s)30of the visual indicator system28may illuminate in different colors or patterns to communicate which cooking vat18and associated movement device12should be the next one to receive a basket14containing food product20to be cooked. For example, the a visual indicator30may illuminate in a first color, combination, or pattern to communicate to an operator of the fryer10that the cooking vat18associated with the visual indicator30is ready to (or should) receive a basket14of food product20. Thus, with a quick glance at all of the visual indicators30, an operator is instructed where to put incoming basket(s)14of food product20and the operator does not have to manage this workflow processing mentally on their own.

With continued reference toFIG.4, similarly, the illumination of the visual indicator(s)30may change when a basket14is ready with cooked food product20to be removed from the fryer10. For example, a visual indicator30may illuminate in a second color, combination, or pattern to communicate to an operator of the fryer10that the food product20is fully cooked and the basket14is ready to be removed from the fryer10. This avoids having the human operator try to remove baskets14before a cooking cycle is totally completed, which may include the drip time after the cooking (e.g., the visual indicator30does not change to indicate completion of the cooking cycle until the movement device12actually moves to the unlocked configuration shown inFIG.3and described above).

Further, the visual indicator(s)30may be utilized to convey to an operator that a cooking vat18is unavailable for a new basket14of food product20. For example, a visual indicator30may illuminate in a third color, combination, or pattern to communicate to an operator of the fryer10that the cooking vat18associated with the visual indicator30is currently in use (e.g., a basket14of food product20is actively submerged in the cooking vat18). Additionally, a visual indicator30may illuminate in a fourth color, combination, or pattern to communicate to an operator of the fryer10that the cooking vat18associated with the visual indicator30is undergoing maintenance. Such may occur if the cooking medium16in the cooking vat18is being filtered, refilled, or changed out, for example—which may be initiated by the vision system22and/or the fryer controller24.

With continued reference toFIG.4, the visual indicator system28, based on instructions from the fryer controller24, therefore illuminates the visual indicator(s)30to, among other things, balance cooking workload at each of the cooking vats18while also allowing for a cooking vat18to be skipped when a filtration cycle, refilling, or replacement is needed or actively underway (including a recovery heating time after a filtration cycle). Thus, the visual indicators30provided by the LED lights72, for example, help achieve workload balancing of the cooking vats18simultaneous to work flow management and/or the providing of instructions to an operator for most efficient work flow- and it will be understood that further functions can be assisted by use of the visual indicators30beyond this stated combination as well in further embodiments.

When a robotic or automated basket movement system such as a robotic arm or an automated gantry system is used, the fryer controller24can also or alternatively provide signals for all of these statuses (i.e., statuses that would be displayed on one or more visual indicators30) directly to the automated basket movement system, such that new baskets14are added in the most optimal sequence at the available cooking vats18of the fryer10. Likewise, signals are provided to cause the automated basket movement system to promptly retrieve baskets14when a cooking cycle is completed, while avoiding basket movements to any cooking vats18currently inactive due to filtration or the like.

With continued reference toFIG.4, thus, when putting all of the added equipment together from these embodiments with operational links via the controller24, a more automated and desirable operation of the fryer10is enabled. The status of any single cooking vat18(e.g., cooking, ready for cook, not available, ideal for next basket placement) is continuously communicated via one or more visual indicators30of the visual indicator system28to an operator of the fryer10. The movement devices12ensure consistent quality of food product20(of various types) by visually identifying the type of food product20using the cameras26and image processor70of the vision system22and then actuating movements of the basket14into and out of the cooking medium16and actuating shaking movements tailored to the specific ideal cooking cycle for that type of food product20. Food product20is thus not overcooked, undercooked, or subjected to undesirable clumping or product marriages during cooking cycles.

Moreover, when cooking medium 16 level or quality indicates a filtration, refilling, or replacement is necessary (which can be caused by a number of cooking cycles completed since last filtration as well as the coloration detected with this vision-based control), the controller24, as prompted by inputs from the camera(s)26and image processor70, initiates and performs filtration, refilling, and/or changing out of the cooking medium16at the particular cooking vat18, while also avoiding placement of new baskets14of food product20at that cooking vat18until the filtration cycle process is completed. The fryer controller24can also plan for filtration, refilling, or replacement cycles to be performed at convenient times when demand is not so high and a cooking vat18is not needed for cooking operations for the requisite time period (e.g., 4-5 minutes) needed for a normal filtration, refilling, or replacement cycle. Thus, cooking medium16quality and level is improved as compared to conventional designs relying on human operator intervention to manage such parameters.

Referring now toFIG.5, a series of exemplary operational steps taken by the fryer10of the embodiments of this invention and/or operator of the fryer10are shown in the schematic flowchart ofFIG.5. It will be understood that more or fewer operational steps may be performed, as these are just some of the operations enabled with more automation by the embodiments described herein. At step100, a basket14containing fresh or frozen food product20to be cooked is placed on the basket support44of the movement device12at a particular cooking vat18. This placement of the basket14may be done by a human operator and guided by visual indicators30of the next vat18to use by the visual indicator system28(as described in greater detail below), or it may be done by a robot (e.g., a robotic arm or gantry) moving the basket14and communicating with the fryer controller24to know which cooking vat18to use next. At step102, the vision system22detects the type of food product20in the basket14such as by capturing images of the food product20with the camera26and using the integrated image processor70to correctly identify what the food product20type is. This identification of the food product20in the basket14is communicated as an input to the fryer controller24, which then outputs control signals to the movement device12in accordance with temperatures, timers, and time periods for the cooking cycle of that particular food product20.

At step104, the movement device12is actuated by the fryer controller24to lower the basket14and submerge the food product20and the basket14in the cooking medium16thus beginning the cooking cycle of the food product20. At this time, as shown in step106, the visual indicator30located above the vat18in which the food product20is being cooked may communicate (e.g., to an operator) that the cooking vat18is in use. Such may be accomplished by illuminating the visual indicator30(e.g., one or more LED lights72) associated with the cooking vat18in a particular color, combination, or pattern understood to mean that the cooking vat18is currently in use.

With continued reference toFIG.5, at step108, at a midpoint or other desirable designated time during the cooking cycle, the fryer controller24may also cause the movement device12to (optionally) lift and shake the basket14with rapid oscillation/vibration movements to break up any clumps or product marriages that developed during the cooking process. A particular cooking cycle could call for no shaking or one or more shakes of the basket14during the cooking cycle. Such would depend on the particular food product20as identified by the vision system22and as understood by the controller24. At step110, the movement device12is actuated by the fryer controller24to raise the basket14out of the cooking medium16and allow for a drip time such that excess cooking medium16can fall off (i.e., drip from) the cooked food product20in the basket14. At step112, after the cooking cycle is complete and adequate drip time has passed, the movement device12may unlock the retention clip46and signal (via the visual indicators30or by sending a control signal to a robotic arm or gantry) that the basket14is ready for removal. At step114, the basket14may be removed from the support44by a human operator, robotic arm, or gantry, for example.

At the same time as all of these operations, the fryer controller24is detecting incoming/upcoming cooking demands and is preferably planning the workflow of the fryer10to most optimally handle all demands. As a part of this workflow management, at step116, the vision system22communicates signals to the fryer controller24when the cooking medium16(e.g., oil) level or quality (as can be visually detected by camera(s)26and image processor70based on coloration or relative level of the cooking medium16in the cooking vat18) is determined to require a filtration cycle or other service, such as refilling (e.g., top off) or replacement. Alternatively, the fryer controller24may also queue up a next filtration, refilling, or replacement based on how many vats18are currently in use and the number of cooking cycles for a vat18since the most recent filtration, refilling service, or replacement was performed. At step118, while the cooking vat18is undergoing service, the visual indicator system28may communicate to an operator of the fryer10that the particular cooking vat18is unavailable for use and undergoing maintenance. For example, the visual indicator30(e.g., one or more LED lights72) associated with the cooking vat18may illuminate in a particular color, combination, or pattern understood to mean that the cooking vat18is unavailable for use. In any event, at step120, the fryer controller24activates the recirculation and filtration system of the fryer10to automatically perform filtration and replacement of the cooking medium16for a cooking vat18that is not actively in use.

With continued reference toFIG.5, at step122, after the maintenance operation (e.g., filtration, refilling, replacement) is completed, the fryer controller24uses the visual indicator system28to communicate to an operator of the fryer10that the particular cooking vat18is once again available for use and ready to receive a new basket14of food product20. For example, the visual indicator30(e.g., one or more LED lights72) associated with the cooking vat18may illuminate in a particular color, combination, or pattern understood to mean that the cooking vat18is ready to receive a new basket14of food product20. As with prior steps, the visual indicator30can be replaced by a direct control signal to a basket movement robot (e.g., robotic arm or gantry arm) when those are used at the fryer10. As will be understood from these operational steps inFIG.5, the fryer controller24interacting with the new equipment at the fryer10automates much of the cooking and cooking medium16management steps so that high quality is maintained with less operator input required.

The program code embodied in any of the applications/modules described herein is capable of being individually or collectively distributed as a computer program product in a variety of different forms. In particular, the program code may be distributed using a computer-readable storage medium having computer-readable program instructions thereon for causing a processor to carry out aspects of the embodiments of the invention.

Computer-readable storage media, which is inherently non-transitory, may include volatile and non-volatile, and removable and non-removable tangible media implemented in any method or technology for storage of data, such as computer-readable instructions, data structures, program modules, or other data. Computer-readable storage media may further include RAM, ROM, erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other solid state memory technology, portable compact disc read-only memory (CD-ROM), or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to store data and which can be read by a computer. A computer-readable storage medium should not be construed as transitory signals per se (e.g., radio waves or other propagating electromagnetic waves, electromagnetic waves propagating through a transmission media such as a waveguide, or electrical signals transmitted through a wire). Computer-readable program instructions may be downloaded to a computer, another type of programmable data processing apparatus, or another device from a computer-readable storage medium or to an external computer or external storage device via a network.

Computer-readable program instructions stored in a computer-readable medium may be used to direct a computer, other types of programmable data processing apparatuses, or other devices to function in a particular manner, such that the instructions stored in the computer-readable medium produce an article of manufacture including instructions that implement the functions, acts, or operations specified in the flowcharts, sequence diagrams, or block diagrams. The computer program instructions may be provided to one or more processors of a general purpose computer, a special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the one or more processors, cause a series of computations to be performed to implement the functions, acts, or operations specified in the flowcharts, sequence diagrams, or block diagrams.

The flowcharts and block diagrams depicted in the figures illustrate the architecture, functionality, or operation of possible implementations of systems, methods, or computer program products according to various embodiments of the invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of instructions, which comprises one or more executable instructions for implementing the specified logical function or functions.

In certain alternative embodiments, the functions, acts, or operations specified in the flowcharts, sequence diagrams, or block diagrams may be re-ordered, processed serially, or processed concurrently consistent with embodiments of the invention. Moreover, any of the flowcharts, sequence diagrams, or block diagrams may include more or fewer blocks than those illustrated consistent with embodiments of the invention. It should also be understood that each block of the block diagrams or flowcharts, or any combination of blocks in the block diagrams or flowcharts, may be implemented by a special purpose hardware-based system configured to perform the specified functions or acts, or carried out by a combination of special purpose hardware and computer instructions.

The automatic basket movement device12, vision system22including one or more cameras26and image processor70, and visual indicator system28including one or more visual indicators30(e.g., one or more LED lights72in a housing74) of the embodiments of this invention improve the field of cooking devices such as fryers10. To this end, less human operator interaction is needed to achieve consistent high quality of cooked food product20(e.g., fried products without clumps/product marriages of food stuck together following the cooking cycle and without overcooking or undercooking) as conventional fully manual methods used with fryers. Moreover, the integration of the shaking movement or functionality into the same drive as the primary movement all caused by movement device12reduces manufacturing cost and complexity of the fryer10, while also reducing the number of components that may be subject to failure and/or need regular maintenance. Automation of various tasks associated with cooking cycles and filtration cycles and/or cooking medium16management eliminates opportunities for operator error or in optimal timing of actions taken at or by the fryer10. The net result is more consistent cooked food product20from the fryer10with less labor demand. Therefore, the fryer10and operations described herein are cost-effective and functionally improved from fryers and cooking methods of known designs. These concepts can be modified and tailored to many different types of fryers as well as the added equipment is designed as a retrofit applicable to almost any known fryer, thereby allowing for improvements in restaurants of many different designs.

Alternative Aspects of the Invention

In an alternative aspect of the invention, a method for managing basket workflow at an automated cooking system is disclosed. The automated cooking system includes a fryer including at least one fryer vat. The at least one fryer vat includes a basket movement device for receiving and moving a basket located proximate to the at least one fryer vat. The automated cooking system also includes a vision system including at least one camera and at least one image processor. The automated cooking system also includes a visual indicator system including at least one visual indicator to visually communicate information to an operator. The method includes illuminating the at least one visual indicator to communicate to the operator that the at least one fryer vat should receive the next basket. The method further includes placing the basket containing a food product on the basket movement device. The method further includes identifying, by the at least one camera and the at least one image processor, the food product in the basket. The method further includes determining and initiating, by a fryer controller, the cooking cycle for the identified food product. The method further includes illuminating the at least one visual indicator to communicate to the operator that the food product in the basket is fully cooked and that the basket is ready to be removed from the fryer. The method further includes removing the basket containing fully cooked food product from the basket movement device.

In one embodiment, the method may further include determining, by a fryer controller, that the identified food product requires shaking and shaking, by the basket support, the at least one basket during the cooking cycle with rapid oscillation and/or vibration movements to break up any clumps or product marriages of the food product in the basket. The method may further include, after the food product is fully cooked, suspending the basket above a cooking medium for a predetermined period of time to allow excess cooking medium to drip from the food product and illuminating the at least one visual indicator to communicate to the operator that the food product in the basket is fully cooked, but that the basket is not ready to be removed from the fryer.

In one embodiment, the method may further include illuminating the at least one visual indicator to communicate to the operator that an associated fryer vat is unavailable to be used. The fryer vat may be unavailable because the fryer vat is being used to cook food product. Alternatively, the fryer vat may be unavailable because the fryer vat is undergoing a maintenance operation. The maintenance operation may be filtering of a cooking medium. Alternatively, the maintenance operation may be refilling or changing out of a cooking medium. The method may further include placing the basket containing a food product on a basket movement device of an alternative fryer vat. The alternative fryer vat may be different than the unavailable fryer vat.

In a further alternative aspect of the invention, a method for managing basket workflow at an automated cooking system is provided. The automated cooking system includes a fryer including at least one fryer vat. The at least one fryer vat includes a basket movement device for receiving and moving a basket located proximate to the at least one fryer vat. The automated cooking system also includes a vision system including at least one camera and at least one image processor. The automated cooking system also includes a visual indicator system including at least one visual indicator to visually communicate information to an operator. The method includes detecting, by the at least one camera and the at least one image processor, that a maintenance operation is required in the at least one fryer vat. The method further includes illuminating the at least one visual indicator to communicate to the operator that the at least one fryer vat is unavailable to be used due to the maintenance operation. The method further includes initiating, by a fryer controller, the maintenance operation. The method further includes illuminating the at least one visual indicator to communicate to the operator that the at least one fryer vat is available to be used after completion of the maintenance operation.

In one embodiment, the method may further include placing the basket containing a food product on a basket movement device of an alternative fryer vat. The alternative fryer vat may be different than the unavailable fryer vat. The maintenance operation may be filtration of a cooking medium in the at least one fryer vat, and the method may further include identifying, by the at least one camera and the at least one image processor, a color of the cooking medium within the at least one fryer vat and examining, by the fryer controller, the color of the cooking medium to determine if the cooking medium requires filtration. Alternatively, the maintenance operation may be refilling or replacement of a cooking medium in the at least one fryer vat, and the method may further include identifying, by the at least one camera and the at least one image processor, a surface level of the cooking medium within the at least one fryer vat and examining, by the fryer controller, the surface level of the cooking medium to determine if the at least one fryer vat requires refilling or replacement of the cooking medium.

In one embodiment, the method may further include scheduling, by the fryer controller, the maintenance operation for a time in the future. The maintenance operation may be scheduled for the time when demand for food product output of the fryer is low. Alternatively, the maintenance operation may be scheduled for the time when less than all of the fryer vats at the fryer will be in use. Alternatively, the maintenance operation may be scheduled for a predetermined time measured from a time of the last maintenance operation.