Patent Publication Number: US-2006011417-A1

Title: Food transport system

Description:
FIELD OF THE INVENTION  
      The present invention is directed to food transport systems, and more particularly food transport systems including automated food heating and food cooling.  
      Background Of The Invention Conveyor-based food movement systems are known in the art. Typically, food is placed onto the conveyor in a food preparation area and moved to a pick-up or dining room area. For example, such conveyor-based food movement systems have been used to transport food in sushi restaurants.  
      Turning our attention to U.S. Pat. No. 6,554,106, the patent discloses a food transport system for use with sushi and the like. This invention includes the ability to identify the particular type of food product passing by on the conveyor and, if that product is old, redirect the food product to be disposed of. The reference however, does not include the concept of heating or cooling the food product as it comes by.  
      U.S. Pat. No. 6,431,318 also discloses a sushi conveying system. This system includes a reader which is able to interpret the type of sushi passing by on the conveyor and then uses that information to instruct the kitchen to prepare types of food which are not currently on the conveyor system in the desired quantity. However, the system does not include the ability to heat or cool the food products on the conveyor.  
      U.S. Pat. No. 5,419,410 also includes a food conveying system. This system monitors the type of food, although for purposes of directing it to the right location. In this patent, the customer orders the product and the product which is then delivered directly to them by means of a smart conveyor system. It does not include heating or cooling of the food once it is placed on the conveyor system.  
      One disadvantage of these types of food conveyor systems is that they do not include automated heating of hot-served foods once they are placed onto the conveyor. Another disadvantage is that these types of food conveyor systems do not include automated cooling of cold-served foods once they are placed onto the conveyor  
      In view of the above, there exists a need for a food conveyor systems that permits automated heating of hot-served foods and automated cooling of cold-served foods once they are placed onto the conveyor.  
     SUMMARY OF THE INVENTION  
      The present invention provides a conveyor-based food transport system, wherein food is placed onto the conveyor in a food preparation area or kitchen and moved to a pick-up or dining room area. Advantageously, the system includes a food heater for heating food and drinks that require re-heating during circulation. The system further comprises a food cooler for cooling food and drinks that require re-cooling during circulation. According to one embodiment, the food heater is a steamer and the food cooler is a freezer.  
      The conveyor-based food transport system further comprises a system for identifying the individual food and drinks being moved by the conveyor. The conveyor includes a plurality of mounting stations adapted to receive plates and disposed at predetermined intervals along the conveyor. Each mounting station includes a unique machine-readable identifier (e.g., a barcode or similar) specifying the type of food or drink to be mounted thereon. Additionally, each plate includes a unique machine-readable identifier specifying the type of food or drink to be served thereon. In some embodiments, mounting stations are not provided.  
      One or more scanners preferably are disposed at predetermined locations along the conveyor. Scanner obtains information from the machine-readable identifiers concerning the type of food or drink disposed on each mounting station and plate. One or more temperature sensors (e.g., infrared sensors) are also disposed at predetermined locations along the conveyor. Temperature sensor determines the current temperature of each plate. Food or drinks that require heating are automatically directed toward food heater and food or drinks that require cooling are automatically directed toward food cooler. In some embodiments, a controller is provided for determining the circulation time of each plate of food and diverting foods to the food heater, food cooler or trash area based upon predetermined circulation time limits.  
      One aspect of the present invention involves a food transport system comprising a conveyor including a controller that controls the movement of plates of food around the conveyor and determines the circulation time of each plate of food, a food heater and food cooler. The controller automatically diverts individual plates of food to the food heater if they require reheating and automatically diverts individual plates of food to the food cooler if they require cooling.  
      A further aspect of the present invention involves a food transport system comprising a conveyor including a plurality of mounting stations for mounting individual plates of food. The conveyor comprises a controller that controls the movement of food around the conveyor, a food heater and a temperature sensor that senses the temperature of the individual plates of food. The controller includes a temperature monitor that checks whether individual plate of food fall within a predetermined temperature range and diverts individual plates of food to the food heater if they have a temperature that is below the predetermined temperature range.  
      Another aspect of the present invention involves a food transport system comprising a conveyor including a plurality of mounting stations for mounting individual plates of food. The conveyor comprises a controller that controls the movement of food around the conveyor, a food cooler and a temperature sensor that senses the temperature of the individual plates of food. The controller includes a temperature monitor that checks whether individual plates of food are below a predetermined temperature. Individual plates of food having a temperature that is above the predetermined temperature are diverted to the food cooler.  
      to the food cooler if they These and other features and advantages of the present invention will be appreciated from review of the following detailed description of the invention, along with the accompanying figures in which like reference numerals refer to like parts throughout. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  is a top view of a food transport system in accordance with the principles of the present invention;  
       FIG. 2  is a block diagram of the food transport system of  FIG. 1 ;  
       FIG. 3  is a cross-sectional view of the food transport system of  FIG. 1  taken along line  3 - 3 ;  
       FIGS. 4A and 4B  are front and rear views, respectively, of a food heater suitable for use with the food transport system of the present invention; and  
       FIGS. 5A  and SB are front and rear views, respectively, of a food cooler suitable for use with the food transport system of the present invention. 
    
    
     DETAILED DESCRIPTION  
      In the following paragraphs, the present invention will be described in detail by way of example with reference to the attached drawings. Throughout this description, the preferred embodiment and examples shown should be considered as exemplars, rather than as limitations on the present invention. As used herein, the “present invention” refers to any one of the embodiments of the invention described herein, and any equivalents. Furthermore, reference to various feature(s) of the “present invention” throughout this document does not mean that all claimed embodiments or methods must include the referenced feature(s).  
      Referring to  FIG. 1 , a food transport system  10  in accordance with the principles of the present invention will now be described. Food transport system  10  comprises a conveyor  20  including a plurality of mounting stations  25  for mounting individual plates  30  of food and drinks, a food heater  40 , individual machine-readable identifiers  50  disposed on each plate  30 , individual machine-readable identifiers  55  disposed on each mounting station  25 , a scanner  60  for reading the machine-readable identifiers  50 ,  55 , and a temperature sensor  70  for determining the temperature of each plate. One suitable type of temperature sensor is an infrared sensor. Scanner  60  preferably obtains information from machine-readable identifiers  50 , 55  concerning the type of food or drink disposed on each mounting station  25 .  
      According to some embodiments of the present invention, mounting stations  25  are not employed, and the individual plates are positioned directly on top of conveyor  20 . In these embodiments, a plurality of scanners  60  are disposed at predetermined intervals around the conveyor. Scanners  60  obtain information from individual machine-readable identifiers  50  concerning the type of food disposed on each plate  30 , as well as the present location of the each plate  30  on the conveyor  20 .  
      In a preferred embodiment, the food heater comprises a steam heater. However, as would be understood by those of ordinary skill in the art, the heater may comprise any other type of food heater, including, but not limited to, a microwave oven, one or more heat lamps, a roaster without departing from the scope of the present invention. According to some embodiments, the food transport system further comprising a food cooler  100 , wherein individual plates  30  of food are diverted to the food cooler for cooling.  
      With further reference to  FIG. 1 , food transport system  10  is disposed within the interior of a restaurant, which includes a dining area  110  and kitchen  120 . A plurality of dining tables  130  are arranged within the dining area to accommodate the patrons of the restaurant. The dining area and kitchen may be separated by a partition  140 , for example a glass wall. According to a some embodiments, the conveyor  20  transports plates  30  of food directly to where patrons are seated. For example, the seating may be implemented in a typical bar style set-up, wherein the conveyor runs adjacent to the bar. Alternatively, the conveyor may be adapted to transport food in a zig-zag pattern through the tables in the dining area.  
      In operation, plates of food and drinks are prepared in kitchen  120  and manually placed on the conveyor. Alternatively, the plates may be automatically loaded onto the conveyor, for example using one or more robotic arms. Conveyor  20  transports the food and drinks to the dining area in a direction indicated by arrows  150 . Patrons of the restaurant may select individual plates of food and drinks passing through the dining area. Food and drinks that are not selected are transported along the conveyor back into kitchen  120 . Such food and drinks may require heating or cooling to maintain a desired temperature range. More particularly, food and drinks that require heating are directed into food heater  40  using diverter  170  and food and drinks that requires cooling are directed into food cooler  100  using diverter  180 . Additionally, food and drinks that have been in circulation on the conveyor for greater than a predetermined amount of time or revolutions are directed towards trash area  190  using diverter  200 .  
      In the illustrated embodiment, mounting stations  25  are formed to have a circular shape such that the similarly-shaped plates  30  may be mounted thereon. As would be understood to those of skill in the art, mounting stations  25  and plates  30  may comprise many other shapes without departing from the scope of the present invention. Each plate  30  preferably includes a unique machine-readable identifier  50  such that scanner  60  may determine the type of food disposed thereon. With this information, the system may determine the appropriate price to charge a customer for the plate of food. Also, the system preferably monitors the number and type of foods and drinks that are directed toward trash area  190  such that the kitchen workers know to reduce the preparation of unpopular foods and drinks. According to some embodiments, each mounting station  25  comprises a mounting display for advertising food and drink products. The mounting display may feature a graphical display and sound system that is preprogrammed to promote that type of food or drink disposed on the mounting station.  
      Referring to  FIG. 2 , food transport system  10  preferably includes a controller  300  for controlling movement of food. Information may be entered into controller  300  from one or more input devices  310  such as keyboards connected to an input side of controller  300 . Controller  300  includes a setting device  320 , a detector  330  and a temperature monitor  340 . Information obtained by controller  300  may be displayed by one or more monitors  370  disposed in the kitchen area to assist the cooks in determining which food and drinks to prepare.  
      Setting device  320  is used to set the type of food or drink that is to be served on a respective mounting station  25 . In addition, setting device  320  is also used to set the type of food or drink that is to be served on a respective plate  30 . Detecting means  330  is used to calculate the circulation time of each plate  30  circulating around conveyor  20  and locate plates  30  whose circulation time exceeds various predetermined time limits for the particular type of food or drink disposed on the plate. For example, when detecting means  330  detects a plate  30  whose circulation time exceeds a predetermined overall time limit, the controller automatically diverts the plate toward trash area  190 . More particularly, controller  300  shifts the plate onto trash conveyor  345  using diverter  200 .  
      Temperature monitor  340  is used to check whether the current temperature of each plate falls within a predetermined temperature range for that particular type of food. Certain foods such as dry foods do not require heating or cooling at any time. However, other foods such as hot-served foods and cold-served foods may require heating or cooling, respectively. If the hot food is determined to be too cold, the plate is diverted onto food heating conveyor  350 , which passes through food heater  40 . Contrariwise, if the cold food is determined to be too warm, the plate is diverted onto food cooling conveyor  360 , which passes through food cooler  100 . Advantageously, the heating and cooling aspects of the food transport system of the present invention may be used to meet various health code requirements of different countries.  
      According to some embodiments, some plates  30  include a predetermined heating circulation time or a predetermined cooling circulation time. If one of these circulation times are exceeded, the plate is automatically diverted to be heated or cooled. When detecting means  330  detects a plate  30  whose circulation time exceeds the predetermined heating time limit, the controller automatically diverts the plate onto food heating conveyor  350 . Likewise, when detecting means  330  detects a plate  30  whose circulation time exceeds the predetermined cooling time limit, the controller automatically diverts the plate onto food cooling conveyor  360 . According to other embodiments, the food transport system comprises more than one full-length conveyor line, for example including a hot line and a cold line, wherein one of the lines is disposed substantially concentrically inside of the other line. In these embodiments, the hot line passes through a food heater that may be used to heat hot-served foods and the cold line passes through a food cooler that may be used to cool cold-served foods.  
      Referring to  FIG. 3 , conveyor  20  preferably comprises a motor-driven endless chain  210  that is moved in circulation within a recess  220  between walls  230 , which are provided on either side of recess  220 . Such conveyors are per se known in the art. A plurality of mounting stations  25  are disposed at predetermined intervals along the endless chain. In operation, food and drinks (e.g., hamburger  250 ) are prepared in the kitchen and placed on appropriate plates  30 . The type of food or drink that is to be served on each plate  30  is associated with machine-readable identifier  50 . This information may be changed manually by a user using input device  310 . Plates  30  are then placed on appropriate mounting stations  25 . The type of food or drink that is to be served on each mounting station  25  is associated with machine-readable identifiers  55 . This information may also be changed manually by a user using input device  310 .  
      In some embodiments, each mounting station  25  is further provided with a visual marker  260  that indicates the type of food or drink that is to be served on that particular mounting station  25 . In the illustrated embodiment, the visual marker  260  comprises a drawing of the particular food or drink to be served on the mounting station. The visual marker alternatively may comprise one or more words, colors, objects or other visual signs that indicate the appropriate food or drink.  
      Plates  30  of food and drinks are then placed on the mounting stations based upon the types of food and drinks indicated by visual markers  260 . As the plates  30  are conveyed past scanner  60 , the machine-readable identifiers on the plate and mounting station are read and the data concerning the start of circulation is automatically entered into controller  300 . The information concerning the start of circulation is important for determining when the plate should be heated, cooled or sent to the trash area. Information concerning the start of circulation alternatively may be entered manually into controller  300  via input device  310 .  
      The plates are circulated along conveyor  20  through dining area  110  such that customers may select food and drinks of their choice to be eaten at dining tables  130 . Empty mounting bases  25  are conveyed back into the kitchen area where scanner  60  determines that the mounting base is vacant because it does not sense the presence of a machine-readable identifier  50 . The scanner then notifies the controller that the appropriate food or drink should be added to the empty mounting base. Controller  300  outputs this information to monitor  370  for display within the kitchen area, thereby notifying the cooks of the types of food and drinks that require replenishing.  
      Plates  30  that have not been selected are recirculated around the conveyor until they are selected or diverted to be heated, cooled or disposed of. More particularly, when scanner  60  identifies a plate  30  returning to kitchen  120 , detecting means  330  automatically calculates the total circulation time of the plate. Controller  300  automatically diverts plates  30  that exceed a predetermined circulation time onto trash conveyor  345 . The food and drinks on these plates are discarded in trash area  190  and the plates are removed for washing. In addition, the data concerning circulation time is cleared from controller  300 .  
      After being washed, the plates may be recirculated with fresh food and drinks. The empty mounting station  25  on conveyor  20  eventually reaches scanner  60 , which determines that the mounting base is vacant since it does not sense the presence of a machine-readable identifier  50 . The scanner then notifies the controller that the appropriate food or drink should be added to the empty mounting base. Controller  300  outputs this information to monitor  370  for display within the kitchen area, thereby notifying the cooks of the types of food and drinks that require replenishing.  
      Plates  30  returning to kitchen  120  also pass by temperature sensor  70 , which determines the current temperature of each plate  30 . This data is inputted into the controller such that temperature monitoring means can determine whether the plate requires heating or cooling. Controller  300  automatically diverts food and drinks that require heating into food heater  40  using diverter  170 . In addition, controller  300  automatically diverts food and drinks that requires cooling into food cooler  100  using diverter  180 .  
      Referring again to  FIG. 1 , diverter  170  includes a shaft  380  mounted at one end to a pivot  390 . Diverter  170  includes a first position wherein shaft  380  is disposed substantially parallel to conveyor walls  230  and a second position (shown in dotted lines) wherein shaft  380  is disposed at an oblique angle with respect to conveyor walls  230 . Similarly, diverter  180  includes a shaft  400  mounted at one end to a pivot  410 . Diverter  180  includes a first position wherein shaft  400  is disposed substantially parallel to conveyor walls  230  and a second position(shown in dotted lines) wherein shaft  180  is disposed at an oblique angle with respect to conveyor walls  230 . Preferably, diverters  170 ,  180  are disposed at substantially the same height as plates  30  on the conveyor, but slightly above mounting stations  25 . This configuration is preferred so that the diverters may be pivoted to their respective second positions without colliding with a mounting station  25 . Diverters  170 ,  180  include a motorized driving device connected to an output side of controller  300  such that shafts  380 ,  400  can be pivoted under the direction of controller  300 .  
      When diverters  170 ,  180  are in the first position, plates  30  that are moving along conveyor  20  are permitted to pass by without being redirected. To redirect a plate  30  onto food heating conveyor  350 , controller  300  causes diverter  170  to pivot into the second position. The plate is automatically transferred from mounting station  25  onto a food heating conveyor mounting station  205  under the direction of controller  300 . Likewise, to redirect a plate  30  onto food cooling conveyor  360 , controller  300  causes diverter  180  to pivot into the second position. The plate is automatically transferred from mounting station  25  onto a food cooling conveyor mounting station  215  under the direction of controller  300 . According to some embodiments, robotic arms are provided to permit the plates to be automatically transferred from one conveyor to another. According to other embodiments, the plates may be manually transferred from the one conveyor to another.  
      With further reference to  FIG. 1 , diverter  200  includes a shaft  420  mounted at one end to a pivot  430 . Diverter  200  includes a first position wherein shaft  420  is substantially parallel to conveyor walls  230  and a second position (shown in dotted lines) wherein shaft  420  is at an oblique angle with respect to conveyor walls  230 . To redirect a plate  30  onto trash conveyor  345 , controller  300  causes diverter  200  to pivot into the second position. The plate is automatically transferred from mounting station  25  onto a trash conveyor mounting station  225  under the direction of controller  300 . Alternatively, the plates may be manually transferred onto the trash conveyor. Diverter  200  also includes a motorized driving device connected to an output side of controller  300  such that shaft  420  can be pivoted under the control of controller  300 .  
      Referring to  FIGS. 4A and 4B , a preferred embodiment for food heater  40  will now be described. Food heater  40  comprises a steamer  440  adapted to heat hot-served foods (e.g., hamburger  250 ) that have been circulating on the conveyor for more than a predetermined amount of time. Steamer  440  is in fluid communication with a boiler  450 , which provides the requisite steam to heat the food. Steam enters the steamer by way of a steam inlet  460 . According to other embodiments of the present invention, food heater may comprise other types of heaters, including, but not limited to, microwave ovens, heat lamps and roasters without departing from the scope of the present invention. Of course, as would be understood to those of skill in the art, food heater  40  may be positioned at other positions around the conveyor  20  without departing from the scope of the present invention.  
      In the illustrated embodiment, steamer  440  includes a front sliding door  470  and a rear sliding door  480 , both of which are dimensioned for the passage of plates  30  moving on food heating conveyor  350 . Sliding doors  470 ,  480  are adapted to move up and down as indicated by arrows  490  between open and closed positions. Sliding doors  470 ,  480  also include a motorized driving device connected to an output side of controller  300  such that opening and closing of the doors is controlled by controller  300 . Plates  30  of food enter the steamer through an front opening  500  in the steamer, which is formed when front sliding door  470  is in the open position. Food heating conveyor  350  preferably is disposed beneath the steamer such that only the plates disposed on top of conveyor  20  enter the steamer through opening  500 .  
      After a plate  30  enters through opening  500 , front sliding door  470  is automatically closed and a blast of steam is delivered from boiler  450 . The plate continues to move through the steamer while it is being heated by the blast of steam. According to some embodiments, the plate of food remains in the steamer for approximately 5-15 seconds. Of course, as would be understood by those of skill in the art, plates may remain in the steamer for longer or shorter durations without departing from the scope of the present invention. According to other embodiments, plates that enter the steamer are removed from the conveyor one after another until a plurality of plates  30  are disposed within the steamer. At this point, the boiler provides a steam blast that heats all of the food and drinks disposed within steamer  440 .  
      With further reference to  FIGS. 4A and 4B , after the plate of food is heated within steamer  440 , the rear sliding door is automatically opened by the controller, thereby permitting the plate to exit the steamer through a rear opening  510  as the plate continues along food heating conveyor  350 . In a preferred embodiment, the controller controls the speed of the food heating conveyor such that the plate is automatically transferred from a food heating conveyor mounting station  205  to its original mounting station  25  on conveyor  20 . According to other embodiments, the transfer of the plate from the food heating conveyor onto conveyor  20  may be performed manually.  
      Referring to  FIGS. 5A and 5B , a preferred embodiment for food cooler  100  will now be described. Food cooler  100  comprises a freezer  540  adapted to cool cold-served foods (e.g., salad  545 ) that have been circulating on the conveyor for more than a predetermined amount of time. Freezer  540  is in fluid communication with a refrigerator  550 , which provides refrigerant or coolant to cool the food. Refrigerant enters the freezer by way of a refrigerant inlet  560 . As would be understood to those of skill in the art, food cooler  100  may be positioned at other positions around the conveyor  20  without departing from the scope of the present invention.  
      In the illustrated embodiment, freezer  540  includes a front sliding door  570  and a rear sliding door  580  dimensioned for the passage of plates  30  moving on food cooling conveyor  360 . Sliding doors  570 ,  580  are adapted to move up and down as indicated by arrows  590  between open and closed positions. Sliding doors  570 ,  580  also include a motorized driving device connected to an output side of controller  300  such that opening and closing of the doors is controlled by controller  300 . Plates  30  of food enter the freezer through an front opening  600  in the freezer, which is formed when front sliding door  570  is in the open position. Food cooling conveyor  360  preferably is disposed beneath the freezer such that only the plates disposed on top of conveyor  20  enter the steamer through opening  500 .  
      After a plate  30  enters through opening  600 , front sliding door  570  is automatically closed and a blast of refrigerant is delivered from refrigerator  550 . The plate continues to move through the freezer while it is being cooled by the blast of refrigerant. According to some embodiments, the plate of food remains in the freezer for approximately 5-15 seconds. Of course, as would be understood by those of skill in the art, plates may remain in the freezer for longer or shorter durations without departing from the scope of the present invention. According to other embodiments, plates that enter the freezer are removed from the conveyor one after another until a plurality of plates  30  are disposed within the freezer. At this point, the refrigerator provides a refrigerant blast that cools all of the food and drinks disposed within freezer  540 .  
      With further reference to  FIGS. 5A and 5B , after the plate of food is cooled within freezer  540 , the rear sliding door is automatically opened by the controller, thereby permitting the plate to exit the freezer through a rear opening  610  as the plate continues along food cooling conveyor  360 . In a preferred embodiment, the controller controls the speed of the food cooling conveyor such that the plate is automatically transferred from a food cooling conveyor mounting station  215  to its original mounting station  25  on conveyor  20 . According to other embodiments, the transfer of the plate from the food cooling conveyor onto conveyor  20  may be performed manually.  
      Thus, it is seen that a food heating and transport system is provided. One skilled in the art will appreciate that the present invention can be practiced by other than the various embodiments and preferred embodiments, which are presented in this description for purposes of illustration and not of limitation, and the present invention is limited only by the claims that follow. It is noted that equivalents for the particular embodiments discussed in this description may practice the invention as well.