SYSTEM AND METHOD OF BROILER HEATING ELEMENT CONTROL

A plurality of heat sources are arranged about at least one conveyor. The plurality of heat sources are configured to output heat towards the at least one conveyor. At least one temperature sensor is arranged at a food product inlet relative to the at least one conveyor. A controller is configured to receive temperature measurements from the at least one temperature sensor and to operate at least one heat source of the plurality of heat sources between a high fire condition and a low fire condition in an idle mode operation and a cooking mode operation.

BACKGROUND

The present disclosure relates to heat treatment of food. More specifically, the present disclosure relates to a warming and holding device for cooked food product in a cooking appliance. In various embodiments, the cooking appliance may be a broiler, oven, toaster, or the like for cooking, baking, or toasting a plurality of food items.

Heat transfer systems may be used to provide thermal energy to a broiler, oven, toaster, or the like for use in the heat treatment of food items to achieve cooking, baking, or toasting of the food item. Conveyor systems move the food item in relation to one or more heat sources to achieve a continuous cooking, baking, or toasting process.

U.S. Patent Application Publication No. 2018/0289209 discloses a conveyor toaster which includes a conveyor assembly with a bracket and a conveyor belt. The conveyor belt rotates about the first and second gears. A drive motor operates to move the conveyor belt about the first and second gears. A platen is configured to be heated and is positioned relative to the conveyor belt. A mounting bracket is connected to the bracket of the conveyor assembly. Movement of the mounting bracket changes the position of the conveyor assembly relative to the platen. This application is incorporated by reference herein in its entirety.

U.S. Patent Application Publication No. 2019/0290063 is incorporated by reference herein in its entirety and relates to a heat transfer system. The heat transfer system includes a mixing chamber that surrounds the heat source. An air inlet provides a flow of pressurized air into the mixing chamber. The mixing chamber directs the flow of air past the heat source or direct heating of the flow of air by the heat source. The flow of air is further directed out of the mixing chamber through an outlet to impinge upon a food product.

U.S. Patent Application Publication No. 2014/0199446 relates to a conveyor toaster with a housing and a split-conveyor; International Publication Number WO2020/091840 discloses a belted warmer assembly with a heated rotating drum, a belt roller, and a belt; U.S. Pat. No. 6,595,117 discloses a high-speed variable size toaster; and U.S. Pat. No. 9,585,400 discloses a conveyor oven with a sensor positioned to detect an event that will cause a decrease in the internal temperature of a tunnel, each of these references is incorporated herein by reference in their entireties.

U.S. Patent Application Publication No. 2021/0127688, entitled Dynamic Cooking with Limited Control Authority Conveyor Compensation and U.S. Patent Application Publication No. 2021/0127898, entitled Cooking Appliance with Cooked Food Holding Apparatus both disclose heat transfer systems for cooking a food product. Both of these references are incorporated herein by reference in their entireties.

BRIEF DISCLOSURE

An example of a heat transfer system for cooking a food product includes an enclosure comprising a food product inlet, a food product outlet, and a plurality of walls. At least one conveyor extends into the enclosure from the food product inlet. A plurality of heat sources are arranged about the at least one conveyor. The plurality of heat sources configured to output heat towards the at least one conveyor. At least one temperature sensor is arranged at the food product inlet relative to the at least one conveyor. A controller is configured to receive temperature measurements from the at least one temperature sensor and to operate at least one heat source of the plurality of heat sources between a high fire condition and a low fire condition in an idle mode operation and a cooking mode operation.

In further examples, the controller, in the idle mode operation, is configured to maintain the temperature measurements between a cooking temperature setpoint and an upper temperature setpoint, the upper temperature setpoint being above the cooking temperature setpoint. The controller, in the idle mode operation, operates at least one of the plurality of heat sources in the high fire condition until the temperature measurements reach the upper temperature setpoint, and the controller operates at least one of the plurality of heat sources in the low fire condition until the temperature measurements reach the cooking temperature setpoint. The controller operates in the cooking mode operation when the temperature measurements fall below a lower temperature setpoint below the cooking temperature setpoint. The controller, in the cooking mode operation, is configured to operate at least one heat source of the plurality of heat sources in the high fire condition for a predetermined time period. The predetermined time period begins after the temperature measurements rise above the lower temperature setpoint. A plurality of temperature sensors are arranged at the food product inlet relative to lanes on the food product conveyor. The controller is configured such that when the temperature measurements from a temperature sensor of the plurality of temperature sensors falls below the lower temperature threshold, the predetermined time starts after the temperature measurements from the temperature sensor rise above the lower temperature setpoint.

In still further examples, a discharge ramp is positioned below the conveyor at an end of the conveyor opposite the food product inlet. A food product tray is positioned below the conveyor and configured to receive food product from the conveyor directed into the tray by the discharge ramp. A drip tray is positioned below the conveyor and angled in the direction of the discharge ramp, wherein the drip tray is configured to collect grease and direct the grease onto the discharge ramp for collection in the food product tray. In the low fire condition the plurality of heat sources output energy that is less than an energy output required to maintain the cooking temperature setpoint at the at least one temperature sensor. In the high fire condition the plurality of heat sources output energy that is greater than an energy output required to exceed the upper temperature setpoint at the at least one temperature sensor. The plurality of heat sources include a first heat source positioned above the conveyor and configured to remain in a low fire condition and a second heat source configured to operate at the low fire condition and the high fire condition. The second heat source is positioned above the conveyor towards the food product inlet and wherein the first heat source is internal the enclosure from the second heat source. The third heat source positioned below the conveyor and configured to operate at the low fire condition and the high fire condition.

An example of a method of cooking a food product includes providing a heat transfer system comprising an enclosure comprising a food product inlet, a food product outlet, and a plurality of walls, a conveyor, a plurality of heat sources arranged about the conveyor the plurality of heat sources configured to output heat towards the at least one conveyor, at least one temperature sensor arranged at the food product inlet relative to the at least one conveyor, and a controller. A current temperature is monitored at the at least one temperature sensor. A mode of operation is determined between an idle mode and a cooking mode with the controller based upon the current temperature. At least one of the heat sources is operated between a high fire condition and a low fire condition based upon the current temperature from the at least one temperature sensor and the mode of operation. The controller determines a cooking mode operation if the current temperature falls below a cooking temperature setpoint and a lower temperature setpoint, and otherwise determines an idle mode of operation.

In further examples, the cooking mode of operation includes operating at least one heat source of the plurality of heat sources in a high fire condition and starting a timer when the current temperature exceeds the lower temperature setpoint. When the timer exceeds a predetermined time, the at least one heat source of the plurality of heat sources is operated in the low fire condition and determining an idle mode of operation. The idle mode of operation includes operating the plurality of heat sources in the low fire condition and comparing the current temperature to a cooking temperature setpoint. If the current temperature falls below the cooking temperature setpoint, operating at least one heat source of the plurality of heat sources in the high fire condition and comparing the current temperature to an upper temperature setpoint. If the current temperature exceeds the upper temperature setpoint, the at least one heat source of the plurality of heat sources is operated in the low fire condition. The conveyor defines a plurality of food product lanes across the conveyor and comprising a plurality of temperature sensors which comprises the at least one temperature sensor, with a temperature sensor of the plurality of temperature sensors positioned at the food product inlet relative to each lane of the plurality of lanes across the conveyor.

DETAILED DISCLOSURE

FIG. 1depicts an example of a broiler100. It will be recognized that the broiler100ofFIG. 1is merely exemplary and other examples will fall within the scope of the present disclosure that includes more or fewer components than depicted inFIG. 1. That is, a person of ordinary skill in the art will recognize from the present disclosure that the example shown and described with respect toFIG. 1may be modified or rearranged or implemented with more or fewer systems or components and arrive at embodiments within the scope of the present disclosure.

Broiler100is shown to include multiple heat transfer elements or heat sources2surrounded by an enclosure1. Each heat source2as exemplarily described herein may be a gas burner. In other examples, the heat sources2may be electric heating elements, infrared heating elements, or any other suitable form of heating element as would be recognized by one of ordinary skill in the art. AlthoughFIG. 1depicts the broiler100as including three heat sources2, other embodiments may include one, two, four, or any other desired number of heat sources2, in any arrangement or configuration, as will be recognized by a person having ordinary skill in the art in view of the present disclosure.

The enclosure1is formed by a plurality of walls. The walls of the enclosure1may be constructed of sheet metal. The enclosure1includes a food product inlet12that permits the ingress of a food product9to the cooking area exposed to heat sources2and encapsulated by the enclosure1. The enclosure1further includes a food product outlet11that permits the egress of the food product9from the cooking area encapsulated by the enclosure1. The types of food product9cooked by a cooking appliance as described herein may include raw, uncooked, par-baked, or frozen versions of food products. The food products may have a variety of sizes or weights, and may include, but are not limited to, hamburger patties, chicken breasts, bread, and pizza. A cooking conveyor3moves the food product through the enclosure. The cooking conveyor3includes a wire, metal plate, or silicone belt that is driven between two gears. The cooking conveyor3receives the food product9at the food product inlet12and moves the food product through the enclosure past the heat sources2. In an example, the cooking conveyor may be configured with a plurality of lanes, each lane suitable to cook food product. In an example, the cooking conveyor3may include one, two, three, four, or more lanes, and be configured to simultaneously receive a food product in each lane across the width of the cooking conveyor3and advance such food product through the enclosure1. The lanes of the cooking conveyor3may be all defined upon a single cooking conveyor or may be spread across two or more cooking conveyors3.

In the present disclosure, the exemplary embodiment of a chain-driven charbroiler cooking a hamburger patty will be used, although it will be recognized that other forms of broilers, ovens, or toasters may be similarly configured and other foods, including, but not limited to pizza, pizza crusts, bread, buns, toasted sandwiches, chicken cuts or patties, fish cuts or patties, beef cuts, plant or other protein patties, or the aforementioned hamburger patties may be heat treated in the manners as described herein.

Food product9may be supplied to the food product inlet12using a loading conveyor8and a loading assembly42. Operation of the loading conveyor8moves food product9toward the food product inlet12of the enclosure1. The loading assembly42may be any suitable device configured to store multiple food products9and to automatically deposit food product9onto the loading conveyor8, which may for example be a hopper or magazine. In this way, a cooking cycle can be completed for a desired amount of food product9even when the desired amount of food product9exceeds a capacity of the enclosure1. In an example, a loading assembly42and a loading conveyor8may sequentially introduce hamburger patties into an enclosure1having a maximum capacity of five patties to complete a cooking cycle of more than five patties without the need for manual intervention. However, in other examples, both the loading conveyor8and any associated loading assembly42may be omitted from the broiler100, and food product9may be manually inserted into the enclosure1by a user.

Food product9is moved through broiler100on a cooking conveyor3. In an example, heat sources2are situated both above and below the cooking conveyor3in order to complete a cooking process of the food product9. In the example ofFIG. 1, two heat sources2are arranged above the cooking conveyor3, while one heat source2is located below the cooking conveyor3. AlthoughFIG. 1depicts the cooking conveyor3as fully contained within the enclosure1, in other examples, the cooking conveyor3can extend to or beyond the food product inlet12. For example, the cooking conveyor3may extend beyond the inlet12and to the exterior of the enclosure1in cases where the loading conveyor8is omitted from the broiler100.

As will be explained in further detail herein, the broiler100may further include an inlet sensor44. It will be recognized that more or fewer sensors may be used in association with other embodiments while remaining within the scope of the present disclosure. In an example detailed further herein, at least one inlet sensor is associated with each lane of the plurality of lanes of the cooking conveyor3. Inlet sensor44may be any type of sensing device configured to collect data indicating the presence of a food product9in the vicinity of the food product inlet12. In examples provided with more detail herein, the inlet sensor44is a temperature sensor, for example a thermocouple. The inlet sensor44is exemplarily located on the interior of the enclosure1at a position above the loading conveyor8, so as to sense temperature fluctuations associated with the introduction of food products into the inlet12. The position of the inlet sensor44may be dependent on the field of view or the observable space the inlet sensor44is able to detect. In examples of broilers with more than one cooking conveyor3or more than one lane of product on one cooking conveyor, the broiler100may further include multiple inlet sensors44positioned relative to each lane to detect the introduction of food products to each lane.

Inlet sensor44transmits collected data as data signal Tnto a controller46. The controller46may be internal to the broiler100or it may be external to the broiler100. In an example, the controller46is a computer processor that is located within the broiler100, in a location shielded from the heat, humidity, and food particles of the broiler100. In another example, the controller46is a computer that is located remotely from the broiler100and for example, receives the sensor data either through wired or wireless communication and returns control signals as described in further detail herein through a similar communicative connection.

The computer processor of controller46may be integral with or communicatively connected to a computer-readable medium upon which computer-readable code is stored. Upon execution of the computer-readable code by the processor, the processor performs functions and calculations as described herein and subsequently transmits control signals to the heat sources2, the loading conveyor8, and the cooking conveyor3. The same or another computer-readable medium may be communicatively connected to the processor of the controller46and cooking models may be stored thereon for access and use by the processor. These cooking models, as described in further detail herein, may determine control signals B1-B3provided to the heat sources2. In still further examples, the controller46may further produce control signals C1and C2to control the speeds of the loading conveyor8and the cooking conveyor3.

The controller46, executing the computer-readable code and informed by the cooking models operates the various components of the broiler100at different conditions, for example, to provide more or less heat at the top or bottom of the food product9, or to control the speed of the cooking conveyor3to control the overall cooking time. Control of the cooking conveyor3can determine the cooking time or time that the food product9is exposed to particular conditions created by one or more heat sources2adjacent to the cooking conveyor3. Control of the heat sources2includes adjustment of the heat input into particular locations within the enclosure1.

As will be described in further detail herein, the heat sources2can be controlled to ensure that each food product receives the required thermal treatment to cook the food product, while further recognizing when the broiler100is not currently in use and operate with an efficient use of energy when not cooking a food product.

FIG. 2is a flowchart that depicts an example of a method200of control of the heating elements in a broiler. The method starts at202by monitoring the temperature at one or more temperature sensors, which may be thermocouples, arranged as inlet sensors44at the inlet to a broiler. In an example, a temperature sensor of the one or more temperature sensors is arranged relative to a lane of the cooking conveyor configured to receive food product. A non-limiting example of a broiler may include one cooking conveyor with four lanes of food product defined thereon. The heat sources are operated in a low fire condition at204. The low fire condition is understood to be a relative condition, and which may be based upon the operational specifications of the broiler, the food product to be cooked, and/or the environmental conditions to be achieved within the enclosure. For example, the low fire condition may be 50,000 BTU. In a further example, the low fire condition may be 50% of a maximum system BTU or may be between 60-80% of a high fire condition, as will be explained herein. The low fire condition is exemplarily an energy output that is less than the energy output needed to maintain a cooking temperature setpoint at the input sensors when the cooking conveyor3is free of food product.

The monitored temperatures are compared at206to the cooking temperature setpoint, which in a non-limiting example is 830° F. but may be controlled to any of a variety of temperatures. The cooking temperature setpoint may be based upon the type of food product to be cooked and/or the environmental conditions sought to be maintained within the enclosure. If any of the monitored temperatures from the inlet sensors44falls below the cooking temperature setpoint at206, the controller operates at least one heat source2to the high fire condition at208. In an example, the high fire condition may be 80,000 BTU. In further examples the high fire condition may be 80% of a maximum system BTU output or may be at least 50% greater than the low fire condition. The high fire condition is exemplarily an energy output that is greater than the energy output needed to maintain a cooking temperature setpoint at the input sensors, including when food product is on cooking conveyor3within the enclosure1.

In examples, the broiler includes a plurality of heat sources. In the example as currently detailed herein, the broiler includes three heat sources, two heat sources located above the cooking conveyor and one heat source located below the cooking conveyor. In examples, all of the heat sources are operable to at least one or both of the high fire condition and the low fire condition. In an example, all of the heat sources are operable to the low fire condition, while some (e.g. one or two) or all (e.g. three) of these heat sources may be operated to the high fire condition. In a specific example, heat source Heat 1 positioned above the cooking conveyor3and closest to the inlet12and the heat source Heat 3 positioned below the cooking conveyor3are operated between the high fire condition and the low fire condition as described herein while the heat source Heat 2 positioned above the cooking conveyor3and furthest from the inlet12is maintained in the low fire condition.

The inlet sensor44, of the plurality of inlet sensors44respectively positioned relative to lanes of food product on the cooking conveyor3, that produced the measured temperature below the cooking temperature setpoint is monitored by comparing a current temperature from that temperature sensor to an upper temperature setpoint at210. The upper temperature setpoint may exemplarily be 3° F. above the cooking temperature setpoint. In other examples, the upper temperature set point may be between 1° F. and 10° F. above the cooking temperature setpoint, other upper temperature setpoint values may also be used. So long as at least one of the input sensor(s) that measured a temperature below the cooking temperature setpoint continues to measure a temperature below the upper temperature setpoint, the at least one heat source is operated in the high fire condition at208. Once all of the current measured temperatures are at or above the upper temperature setpoint, the method returns to the monitoring at202and the at least one heat source is operated in the low fire condition at204. In an example, all of heat sources Heat 1, Heat 2, and Heat 3 are operated in the low fire condition.

The process described above may be considered to be an idle mode operation of the broiler. Idle mode operation is exemplarily depicted by reference220inFIG. 3.FIG. 3presents example coordinated graphs of temperature measurements of two different inlet sensors44as graph A and graph B. Graph A and graph B are exemplify the temperature outputs of input sensors respectively associated with different lanes of the cooking conveyor3.FIG. 3further presents a coordinated graph of the high fire/low fire operational condition of the at least one heat source as graph C. As in the example above, the Heat 2 may be maintained in the low fire condition, while the operation shown in graph C ofFIG. 3is representative of the operation of Heat 1 and Heat 3. The feedback of this idle mode operation will generally maintain the temperature at the inlet sensors44between the cooking temperature setpoint and the upper temperature setpoint.

At212, the measured temperatures from the temperature sensors are evaluated to detect if the broiler should enter a cooking mode operation, which is exemplarily depicted by reference222inFIG. 3. At206, if a determination is made that at least one monitored temperature has fallen below the cooking temperature setpoint, while the at least one heat source is operated into the high fire condition at208, the measured temperatures are further evaluated at212. The measured temperatures are further compared to a lower temperature setpoint (X0-X2). In a non-limiting example X2is 15° F., therefore in an example (X0-X2)=815° F. However, it will be recognized that X2may be any of a variety of temperatures which may be set by the manufacturer or by the user. X2may exemplarily be a value between 1-50° F. as suitable for the specific use of the broiler. In an example, X2is selected as a temperature indicative of a detected temperature drop temperature measurement from one or more of the input sensors when uncooked (or frozen) food product is introduced to the inlet of the broiler. Thus, a drop in the measured temperature to a temperature below the lower temperature setpoint is indicative of a new food product entering the broiler in the lane of the cooking conveyor associated with the monitored temperature sensor. This detection of the temperature below the lower temperature setpoint at212causes the broiler to be controlled to operate in the cooking mode operation as described herein.

It will be recognized that in certain instances, for example, if only one food item enters the inlet of the broiler, and the broiler currently has sufficient heat capacity, that none of the temperatures measured by the temperature sensors may fall below the lower temperature setpoint. In such a situation, the broiler may continue to operate in the idle mode, using the controls of the idle mode method to complete the cooking cycle of the food item without entering the cooking mode operation. However, particularly if multiple food products enter the inlet of the broiler simultaneously or in succession, such as by operation of the loading conveyor8and the loading assembly42, then the temperatures measured at the input sensors will fall below the lower temperature setpoint and the controller46will operate the broiler in the cooking mode operation.

If, at212, at least one of the monitored temperatures falls below the lower temperature setpoint, then at214, the at least one heat source is operated in a high fire condition. However, it is likely that the at least one heat source is already in operation in the high fire condition since, as described above in the idle mode operation, operation at the high fire condition is initiated upon the measured temperature at or below the cooking temperature setpoint, and the lower temperature setpoint is necessarily below the cooking temperature setpoint. In the cooking mode operation, initiated when the at least one measured temperature falls below the lower temperature setpoint, the control of the at least one heat source differs from that of the operation of the at least one heat source in the idle mode operation.

At216, the current temperature(s) of the input sensor(s) that fell below the lower temperature setpoint are compared to the lower temperature set point. If at least one of the temperature sensors produces a temperature measurement that is below the lower temperature set point, then the at least one heat source is maintained in the high fire condition. It is recognized that during use of the broiler in the cooking mode operation, that while the operation of the at least one heat source in the high fire condition increases the temperature inside the enclosure of the broiler, in use, new food product, either fresh or frozen may be sequentially introduced through the inlet into the broiler. The introduction of new food product has the effect of lowering the temperature, therefore, when new food product is continuously being introduced through the inlet to the broiler, the measured temperatures at the input sensors may remain below the lower temperature set point for an extended duration of time. Eventually, as the at least one heat source operates in the high fire condition the temperatures measured by the input sensors will increase. At216, once all of the temperature sensors produce temperature measurements above the lower temperature setpoint, then at218a timer is started to measure a predetermined length of time T1. In an example, the predetermined length of time is 45 seconds. In other examples the predetermined length of time may be between 15 seconds and 90 seconds. In still further examples, the predetermined length of time may be greater than 90 seconds. In another example, the predetermined length of time is ½ the length of time that it takes the cooking conveyor to make one complete revolution. This predetermined length of time thus may be determined from/calculated based upon a cooking conveyor speed, which itself may be fixed or dynamic.

During the time that the timer operates to count down the predetermined length of time, the at least one heat source is also operated at the high fire condition at214and the temperatures measured by the temperature sensors are monitored to remain above the lower temperature set point at216. If the measured temperature at any of the input sensors falls below the lower temperature setpoint, then the timer is reset and not started again until all of the temperature sensors measure a temperature above the lower temperature setpoint. If the timer at218counts down the entirety of the predetermined time and expires, then the method returns to the monitoring at202and the at least one heat source is operated according to the idle mode operation. In operation, maintaining the broiler in the high fire condition for the duration of time T1may result in a measured temperature above the upper temperature setpoint as shown inFIG. 3, thus when switching to idle mode operation, the controller46operates the heat sources in the low fire condition at204.

Referring back toFIG. 1, in some embodiments, the controller46is communicatively connected to a kitchen management system (KMS)48and receives cooking models or other control signals therefrom. In various embodiments, the KMS48may be directly communicatively connected to the broiler100or may be communicatively connected to the broiler100through an Internet-of-things (IoT) communications system which provides distributed communication to communication-enabled devices in the kitchen, including the broiler100. The warming assembly110may further include an indicator light14positioned on the exterior of the enclosure1. While a single indicator light14is depicted, in other examples, the warming assembly110may include two or more indicator lights14. Each indicator light14may be electrically controlled and may respond to sensors or timers that determine when food product has been deposited in the pan6.

In other examples, as provided herein, the indicator devices14may include any device that alerts the user to the completion of a cook cycle, that is, a need to remove a pan6from the warming assembly110after such pan6has been filled with cooked food product9. For example, the indicator device14may be a light that illuminates to provide a visual alert or a speaker that emits a sound to provide an audible alert. In some cases, the indicator device14may include a user interface display or a component of a user interface display that displays a message to a user upon completion of a cook cycle. The indicator device14may be communicatively connected to the controller46and may provide a cook cycle alert responsive to a control signal Si. The controller46may for example determine the length of a cook cycle as described herein based at least in part upon the measurements from the temperature sensors and/or the operational mode of the broiler as described above.

One or more indicator devices14may be used in examples of the broiler100for example to accommodate multiple cooking conveyors of a boiler. Each cooking conveyor may be configured to deposit finished food product9into a different pan6. An indicator device14located proximate to the respective pan6and illuminate corresponding to the status of the cook cycle of that associated conveyor3/pan6. For example, if some cooked food product9has been deposited into a pan6but the cook cycle is still ongoing, the indicator light14may be illuminated red to indicate to a user that additional cooked food product9will be deposited into the pan6before the end of the cook cycle, and thus the user should not yet remove the pan6from the warming assembly110. Once the cook cycle has expired and the full batch of cooked food product9has been deposited into the pan6, the indicator light14may be illuminated green to indicate to a user that the pan6is ready to be removed from the warming assembly110. If the cook cycle has been completed for a set amount of time without the full pan6being removed, the indicator light14may illuminate yellow to indicate that the food product9has been held for a long time.

In various other examples come up the indicator device14may instead be an LED display or an LCD that includes a message component that is configured to display a status of the broiler or the pan (e.g., “Ready,” “Cycle in Progress”). In some implementations, the indicator device14may be common to all of the pans6within the warming assembly110, and the message component may be configured to indicate the status of each pan six. For example, the messages displayed by the message component may include “Pan 1 Ready,’ “Pan 3 Cycle in Progress” or the like. Such a message component may be presented in conjunction with an indicator light as described above.

A food product discharge ramp4is shown to be situated within the enclosure1at the end of the cooking conveyor3, opposite the food product inlet12. The food product discharge ramp4may be any device or assembly that deposits finished food product9in a desired location for further preparation, service, or storage. As will be described in further detail herein, in examples the discharge ramp4further redirects the finished food product9in a direction generally opposite the direction in which the food product9is moved by the conveyor3. That is, in examples, if the conveyor3moves the food product9from the inlet12at the front of the broiler toward a rear of the broiler, the discharge ramp4redirects the food product9towards the front of the broiler100.

The food product discharge ramp4may deposit finished food product9into a warming assembly110. In an example, the warming assembly110is disposed within the enclosure1and beneath the cooking conveyor3. In the example ofFIG. 1, the warming assembly110is shown to include an upper heating element5, a lower heating element7, and a blocking element10. In other examples as described herein, one or both of the upper heating element5and the lower heating element7may be replaced instead with heat redirected from at least one of the heat sources2. Variations of the warming assembly110are disclosed herein and all are considered to be within the scope of the disclosed warming assembly110as well as other combinations of these disclosed variations although not explicitly shown.

FIG. 4is a sectional view of an example of a broiler100. The broiler100ofFIG. 4may include many or all of the components as shown and described above with respect toFIG. 1.FIG. 4further depicts that the heat sources2are exemplarily different types of heat sources within the broiler100. In the example depicted inFIG. 4, the heat sources2located above the cooking conveyor3are exemplarily gas-fired infrared (IR) burners, while the heat source2located below the cooking conveyor3is a pipe or tube burner. The gas-fired IR burners may include a metal foam or a metal mesh that is heated by gas combustion to a temperature that emits IR energy in the direction of the cooking conveyor3. The broiler100further exemplarily includes at least one drip tray13positioned below the cooking conveyor3and above the pan6. In a further example, the broiler100includes a drip tray13associated with each lane for food product within the broiler. As described above, each lane for food product across the cooking conveyor(s)3may further have a pan6respectively located within the warming assembly110to receive the cooked food product9off of the ramp4from a respective lane of the cooking conveyor. The drip tray13is positioned below the cooking conveyor3to collect any liquid, fat, grease, and food particles from the cooking food product that falls through the cooking conveyor3. Additionally, the drip tray13is angled in a direction towards the ramp4, whereby liquid, fat, grease, and food particles are directed onto the ramp4and thereby into the pan6with the cooked food product.

FIG. 5is a flow chart that depicts an exemplary embodiment of a method300of detecting the length of a cooking cycle, for example, using the broiler100depicted inFIGS. 1, 4or any other broiler configuration as will be recognized in view of the present disclosure. It will be recognized that the controller46may execute computer-readable code as previously described to carry out the functions and perform the control operations as described in the performance of method300. The method300may be carried out in conjunction with the method200as described above.

At302, the controller46operates the loading assembly42to move the food product9to the loading conveyor8. Once deposited on the loading conveyor8, at304, the controller46operates the loading conveyor8to move the food product9to the food product inlet12. As noted above, in some embodiments, the broiler100does not include one or both of the loading conveyor and the loading assembly42. In these embodiments, a user may manually place food product9onto the cooking conveyor3.

Next, at306the controller46detects the presence of the food product9at the food product inlet12. The controller46detects the presence of the food product9based on data received from the inlet sensor44. In the examples provided above, the inlet sensor44is a temperature sensor of the temperature internal the broiler100at the food product inlet12. The temperature measured by the temperature sensor falling below the lower temperature setpoint is indicative a food product9entering the food product inlet12. The continued measurement of temperatures from by the temperature sensor that are below the lower temperature set point is indicative of additional food product9entering the food product inlet12.

At308, the controller46starts a timer. The timer is exemplarily the same timer operated at218in method200. At310, the controller46determines whether additional food product9has been detected by the inlet sensor44at the food product inlet12. This detection can for example be as previously described above with the measured temperature falling below the lower temperature set point. In response to a determination that additional food product has been detected, method300continues with312in which the controller resets the timer and does not begin the timer again until the monitored temperatures are above the lower temperature set point as described above.

However, if at310the controller46determines that additional food product9has not been detected at the inlet12(e.g. the monitored temperatures have remained above the lower temperature set point), method300proceeds to314as the controller46detects that the timer has expired. The expiration of the timer may be detected by the controller46once the timer reaches a target value. In some examples, the target value of the timer corresponds with an expected length of time for the food product9to travel the full length of the cooking conveyor3. It will be recognized that this may be determined for a conveyor speed and thus the expected time at314may be calculated or otherwise determined by the controller based upon a set or detected conveyor speed. In some examples, the target timer value includes the travel time of the cooking conveyor3plus a buffer time. For example, the buffer time may account for the time the finished food product9must travel along the discharge ramp4before being deposited in a food storage container.

Upon expiration of the timer, the controller46proceeds to signal the end of the cook cycle at316. In addition, as explained above, the controller may operate the at least one heat source to idle mode operation. In an exemplary embodiment, signaling the end of the cook cycle comprises transmitting a signal to operate the indicator device14. In various examples, the indicator device14may provide a visual or audible notification of the completion of the cook cycle. For example, an indicator light mounted on the broiler may illuminate, or an indicator speaker may emit a beeping noise. In still further examples, the controller46may transmit the signal indicating the end of the cook cycle to the KMS48. Upon receipt of the signal, the KMS48may operate additional kitchen equipment to store or serve the finished food product9.

Returning to the example from above, if the KMS48transmits a signal to the controller46to prepare 30 hamburger patties, the controller46operates the loading assembly42to deposit 30 patties in succession onto the loading conveyor8. The controller46operates the loading conveyor8to move each patty into the field of view of the inlet sensor44positioned above the food product inlet12. The presence of each new patty in the field of view of the inlet sensor44prompts the controller46to reset a cook cycle timer. The controller46operates the heat sources2and the cooking conveyor3to cook each patty. After the 30th patty has passed out of the field of view of the inlet sensor44, the cook cycle timer runs until the target value has expired and the 30th patty has been deposited into a storage area by the discharge ramp4. At this time, the controller46sends a signal to the indicator device14to alert a user that all 30 hamburger patties have been prepared. Advantageously, the systems and method described herein significantly reduce the need for a user to actively monitor the broiler100. Because the user is notified of the end of the cook cycle by the indicator device14, the user can promptly attend to the finished food product, and ensure it is stored or served in a manner that prevents degradation of the food product in temperature or quality.

In a further example, the broiler may operate in an initial or warm-up operation upon being turned on and/or initialized. Recognizing that the broiler may operate for example, with a cooking temperature set point of 830° F., the broiler may further operate in an initial or warm-up operation wherein all of the heat sources are operated in a high fire condition until the cooking temperature set point is reached. In a further example, at least one of the heat sources may operate at an output temperature greater than the high fire condition, for example, at a maximum rated operational output for the heat source. In one example, this may be an output of 120,000 BTUs.