Abstract:
The present invention presents a kneading mechanism for a food preparation appliance. The kneading mechanism has a kneading container, a blade assembly and a kneading base. The kneading container has an open bottom face and the kneading base has a textured surface. An adaptive kneading technology which resides in a processor is used to form an optimal viscoelastic dough ball. Since there is variation in the gluten content and the amount of water used makes the dough ball have a viscoelastic nature this technology due to its self-learning mechanism optimizes the kneading of single dough balls using adaptive kneading technology.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims priority to and is continuation in part for a now pending U.S. Utility application Ser. No. 14/445,122 filed on 29 Jul. 2014 and a continuation of pending PCT application PCT/US 14/72403 filed on 24 Dec. 2014 which claims priority to Provisional Application 2013096110 filed on Dec. 26, 2013 in Singapore and are hereby incorporated by reference in its entireties for all of its teachings. 
    
    
     FIELD OF THE INVENTION 
     This disclosure relates generally to an apparatus, system and method for an adaptive kneading technology for a food preparation appliance. More specifically it relates to the apparatus that is controlled by the software to optimize the consistency of the dough while kneading to make a dough ball. 
     BACKGROUND 
     Dough kneading mechanisms are found in food preparation appliances as well as industrial processes for making various dough products. Most of these mixers are top loaded and the final product as a dough is removed from the top when done. However, it is difficult to automate the removal of dough from the mixer in such a setup. These apparatus are good for disparate function where separate equipment is required for each step of cooking or baking goods. Due to this disadvantage that the kneading process is not fully optimized. There are varies types of flour that require different types of water and flour proportions to make a dough but it is human judgment that determines the quantity of both at present. There is a need to automate this process. There is a need for optimized dough making apparatus for an automated use. 
     SUMMARY OF INVENTION 
     The present invention describes an apparatus, system and a method of kneading and optimizing the kneading using adaptive kneading technology is disclosed. The kneading apparatus is a part of the bigger apparatus for making edible flat bread using a compact apparatus. In one embodiment, the kneading apparatus, system and method may be a standalone product that may be used for kneading dough. In one embodiment, the kneading mechanism has a kneading container, a blade assembly and a kneading base. In another embodiment, the kneading container has an open bottom face and the kneading base has a textured surface. 
     In another embodiment, the kneading base has a textured surface that may have a grove, protrusion surface, ridge, projection or combination thereof. In one embodiment, the kneading container has a handle and the bottom is open. 
     In one embodiment, the blade assembly has a shaft that is spring loaded and is attached to a spring load cell. In another embodiment, the kneading container is detachable and can be washed clean after every use. In another embodiment, the blade is a part of the blade assembly. In another embodiment, the blade has several planar surfaces to mimic the hand motion kneading of the dough to form an optimal dough ball for flattening and cooking. 
     In one embodiment the blade assembly is supported by a kneading subsystem. The kneading subsystem comprises of a strain gauge, load cell, engaging gear, motor, spring, and a processor to control the movements. In another embodiment, a processor has a software system that does detection of the hardness of the dough ball, correction if necessary of the hardness using either adding flour or water and recording the ratio for historical values and self-learning management system is done. 
     In one embodiment, a method of kneading a dough ball is described. Several steps are used to obtain an optimal viscoelastic consistency dough ball. In one embodiment as a method, receiving a quantity of flour to make a single dough ball from a dough dispenser is performed. In another embodiment, mixing a selected amount of oil and a suitable amount of water to mix with the flour to make one dough ball at a time and optimizing a consistency of the dough ball by using an adaptive kneading process residing in a processor to have an optimal viscoelastic consistency for the single dough ball to be flattened into a flattened dough. In one embodiment, the kneading base is raised upwards to close the kneading container and hold a unmixed flour, oil and water till it forms a dough ball; and a blade assembly is rotated to mix the flour, water and oil is received in a kneading container. 
     In one embodiment, as a novel system and method, an upwards pressure is exerted through the blade assembly to determining a strain value to measure the hardness of the dough ball and a correction the consistency of the dough ball is done by adding at least one of a flour and water. In another embodiment, the strain value is recorded three times to determine the consistency of the dough ball as the optimal viscoelastic consistency for a given flour for future use as part of the self-learning process by the processor for a given flour type. Each flour type has its own gluten content and this is important to understand the optimal process steps and the amount for calculation. In one embodiment, the dispensing the dough ball to a transfer base for using it to flatten is done by moving the kneading base and allowing the dough ball to fall into the transfer base. 
     In one embodiment, an adaptive kneading technology residing in the processor is applied to create a dough ball and recording a hardness index for the forming the dough ball using a type of flour. In another embodiment, for a method, a strain value of the flour to create the hardness index by the upward force exerted by the blade assembly is measured. In another embodiment, the flour is either added or water is added to correct the hardness index of the flour to obtain an optimal viscoelasticity consistency. 
     Other features and advantages will be apparent from the detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the current apparatus and method. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Example embodiments are illustrated by way of example and not limitation in the figures of the accompanying drawings, in which like references indicate similar elements and in which: 
         FIG. 1  shows a perspective view of the blade assembly, in one embodiment 
         FIG. 2  shows an enclosure to house the blade assembly, in one embodiment. 
         FIG. 3  shows the kneading base for the kneading apparatus, in one embodiment. 
         FIG. 4  shows the whole assembly for the kneading apparatus, in one embodiment. 
         FIG. 5  shows the gears and wheels attached to the blade shaft, in one embodiment. 
         FIG. 6  shows a flow chart for a method of making the dough ball. 
     
    
    
     Other features of the present embodiments will be apparent from accompanying drawings and from the detailed description that follows. 
     DETAILED DESCRIPTION 
     Several components for an apparatus, system and method of making a dough ball for flattening it to make a flattened edible are disclosed. Although the present embodiments have been described with reference to specific example embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the various embodiments. 
     The adaptive kneading technology residing in the processor is a system for detection, correction and self-learning by the apparatus and all other parts associated with the kneading mechanism. Different flour types or brands have different water absorption capacity, the right proportion of flour and water is essential in achieving the right consistency of dough. Driven primarily by the inputs in the process, flour and water had to be pre-calibrated and is this was done by either human judgment or very expensive laboratory equipment. We have found a novel system to overcome this technological challenge. Innovative design for inducing stress on dough ball coupled with analysis of understanding of change in elasticity as a function of time and stress are inputs into the adaptive kneading technology system. The stress is measured in terms of force exerted on the blade by the developing dough. Constant recording and the adjustment to detect and correct is done till a threshold is reached that is between the golden band for viscoelastic consistency and then the dough ball is purged out to be flattened. 
       FIG. 1  shows a perspective view of a blade assembly  110 . The blade assembly is part of a kneading mechanism that will be discussed in the following paragraphs. The blade  110  comprises of a two dimensional and three planar face horizontal blade assembly that has a flat surface  112 , upwards facing angular plane  106  and downwards facing vertical plane  108 . This blade  110  is attached to a cylindrical shaft  102 . The cylindrical shaft has a groove for locking  114  the kneading container  204 . This locking mechanism  114  when unlocked also enables the kneading container to separate from the apparatus and be washed. The groves  102  at the end of the cylindrical shaft allow the whole blade mechanism to attach to an engaging gear and a spring gauge. The three dimensional structure of the blade with its angular planes imitates the hand kneading mechanism to create an optimal viscoelastic consistency dough ball for each flour type. The blade  110  while kneading feels the resistance from the dough ball and is forced upwards. The spring loaded blade shaft  104  which is also in contact with the spring gauge or a load cell registers the strain value in real time. The blade assembly  110  by engaging itself to a strain gauge provides the reading for strain value in real time. In real time a strain vs time graph is created and recorded for self-learning of the adaptive kneading technology that resides in a processor. Typical strain value is between 250-300 units which is the range of optimal viscoelastic consistency value for most flour. Since all flour have its own gluten content and other factors that influence the optimal viscoelastic consistency it is novel to record that in real time and keep that as an intelligent knowledge value to use for given flour when the resistance is encountered the very first time. No other dough kneading equipment has this automated feature for making single dough for any flour. 
       FIG. 2  shows the kneading container  204  enclosing the blade assembly  110 . The bottom opening  210  is not covered and the handle  206  enables the kneading container  208  to be dislodged from the machine and be washed properly. There is a lock mechanism  202  to secure the kneading container to the locking mechanism  114 . The extra space inside the container  208  allows the dough ball to rotate without hindrance. The whole kneading container may be made up of transparent material and may be coated with food grade coating so it is not easily contaminated. Preferably, kneading container  204  has a bore at its top surface and blade assembly  102  extends through the bore into kneading container  101 . 
       FIG. 3  shows the kneading base  306 . This kneading base has a unique feature because it has a specially designed surface. The base stand  304  enables the user to hold it and get it out so it can be washed. The square surface  304  gives the stability for the round surface to move inside the container without resistance. The square part  304  also enables the food making machine to raise the base up and down the kneading container. The distance between the blade and the kneading base is controlled by the software residing in the processor. The surface is specifically designed so that the dough ball while being formed does not slip and a cohesive dough ball can be made easily. The textured surface  302  is at least one of a protrusion surface, groove, ridge, projection and a combination thereof. The kneading base also provides coverage for the kneading container so that the kneading container can receive the flour, water and oil for mixing to make a dough ball. The kneading base has at least one of a textured surface, made of a material with different frictional properties and a combination thereof, than the blade to support slip free kneading for kneading the dough in to a dough ball. 
     This allows the invention for creating a Kneading mechanism  100  comprises kneading container  204 , blade assembly  102  and kneading base  306 . Kneading container  204  is hollow and has an open bottom face. Preferably, kneading container  204  has a bore at its top surface and blade assembly  102  extends through the bore into kneading container  204 . In the figures, textured surface  302  is shown to be protrusions extending radially from the center of kneading base  306 . Textured surface  302  can be any form of protrusion, groove, ridge, projection or the like. What is important is that textured surface  302  applies a counter force to the dough product when it is being kneaded by blade assembly  102 , thereby keeping the dough product in place and from slipping, so that mechanical forces can be effectively applied by blade assembly  102 . Furthermore, textured surface  302  helps prevent the dough product from sticking to kneading base  306 . Once kneading has been completed, kneading base  103  move downwards such that it no longer contacts kneading container  204 , exposing the dough product. The dough product can then be easily transported to the cooking station to be cooked. The advantages are apparent here as the kneading operation disclosed herein can be easily automated. 
       FIG. 4  shows the whole assembly of the kneading base  306  with the kneading container handles  206  locked in with a secure clasp  402  and dough ball  406  made and placed between the kneading base and the blade mechanism of the blade assembly  122 . The shaft of the blade assembly  104  is outside the kneading container to be connected with the gear box and motor. The speed of this motor is software controlled using feedback from an encoder. The top has an opening for the flour dispenser  408  and for the water dispenser  410 . 
       FIG. 5  shows the shaft  104  of the blade  110  engaging with the gear box  504  and being attached to the spring  502 . The gear box in turn is connected with the motor  504 . This whole assembly drives the blade assembly and is controlled by the processor. 
       FIG. 6  shows the method of making the dough ball. To initiate or start  602  the kneading operation, and before dispensing of water and flour, kneading base  306  moves up to contact  606  kneading container  204 , effectively sealing the open bottom face of kneading container  204 . Water, oil and flour is then dispensed  606  to be received into kneading container  204 . Blade assembly  110  than rotates and stirs and mixes the water and flour mixture to begin kneading  608 . During kneading, kneading base  306  (a kneading base having a textured surface to support slip free kneading for kneading the dough in to a dough ball) can move downwards such that it no longer contacts kneading container  204 . Wherein the textured surface is at least one of a protrusion surface, groove, ridge, projection and a combination thereof. Kneading may be done when adjusting the rotational speed of blade assembly  110  to properly form a dough ball. Kneading may also be done in the event when there is a large quantity of flour, so blade assembly  110  requires more displacement from kneading base  306  to apply sufficient mechanical force to form well kneaded dough. The detection of hardness is done to estimate and optimize the viscoelasticity property of the flour  610 . This is an important step because the dough ball once formed and dispensed cannot be used if it is not of proper consistency and will stick to the flattening surface and the cooking surface and the machine will be halted from further use. Once the hardness of the dough ball is detected the correction may be made in two ways. If the hardness is very less than some more flour may be added while making the dough by kneading and if the hardness is high then water may be added to reduce the hardness and make an optimal viscoelastic property having dough ball. The detection of hardness is done there times to not only average and correct but to record for historical purposes for that particular flour. 
     The repetition of the process for correction is shown in process  618 . Once an ingredient is added than the determination of hardness is performed again at step  620 . The formation of the dough ball then takes place  612 . The dough ball is than dispensed out of the kneading container to the transfer base  614 . The transfer base is not shown in this instance specifically as an apparatus but can be seen in the cited prior depended application. Once the machine runs out of flour the process is ended  616 . The novel adaptive kneading technology as described above also has a self-learning process by creating a golden band of strain value for the strain vs time graph for each flour type between 250-300 units. 
     Although the present embodiments have been described with reference to specific example embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader sprit and scope of the various embodiments. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense.