Patent Description:
This application relates generally to food product cooking systems. More specifically, this application describes mechanism for adding labor and time efficiencies in food production environments such as restaurants.

Cooking apparatuses, such as fryers, are used to cook various food products, e.g., poultry, fish, potato products, and the like. Such cooking apparatuses may include one or more cooking chambers, e.g., fryer pots or vats, which may be filled with a cooking medium, e.g., an oil, a liquid shortening, or a meltable-solid shortening. Such cooking apparatuses 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 preset cooking temperature, 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 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. Conventional fryers typically require basket movement and workflow to be handled manually by an operator. In such fryers, the maximum production of the fryer is often limited by the responsiveness of the operator and their ability to manage multiple baskets and cooking tasks at the same time.

However, restaurants continue to strive to increase production in order to satisfy customer demand. One way to increase production is to utilize a high-volume fryer, such as by replacing a restaurant's pre-existing traditional open fryer with a high-volume fryer. However, high-volume fryers are typically relatively large, and restaurants must operate within the space constraints imposed by the buildings which they occupy. As a result, restaurant equipment, including fryers, must be sized to fit within certain parameters. For example, kitchen layouts may allow a particular amount of space for a fryer and may be unable to accommodate fryers having footprints greater than that space. Some restaurants may allow a footprint of about <NUM>-<NUM> meters by about <NUM> meters (<NUM>-<NUM> inches by about <NUM> inches) for a fryer, as well as an associated preparation or holding area. A high-volume fryer of a conventional design may require significantly more space than this. Many restaurants would be required to undergo substantial building renovations, replace previously installed hoods, or sacrifice space intended for other uses in order to reap the benefits of high-volume fryers. Those reconfigu-rations are expensive, highly disfavored, and sometimes impossible.

Thus, it would be desirable to provide systems to cook food product in a more efficient manner, specifically with regard to time and labor considerations within a restaurant, while also achieving higher maximum production levels than traditional fryer systems relying on manual manipulation and handling of baskets.

In accordance with embodiments of the invention, an automated cooking system is described according to claim <NUM>. The automated cooking system avoid the problems associated with basket movement and workflow, traditionally handled manually by a human operator. Specifically, the automated cooking system described herein provides for systems to cook food product in a more efficient manner with regard to both time and labor considerations within the constraints of a restaurant.

The steps and elements described herein as part of various embodiments and implementations can be reconfigured and combined in different combinations to achieve the desired technical effects as may be desired. To this end, the embodiments and implementations can be combined in any combination or sub-combination.

Various additional features and advantages of the invention will become more apparent to those of ordinary skill in the art upon review of the following detailed description of one or more illustrative embodiments taken in conjunction with the accompanying drawings. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more embodiments of the invention and, together with the general description given above and the detailed description given below, serve to explain the one or more embodiments of the invention.

With reference to <FIG> and <FIG>, an automated cooking system <NUM> including a fryer <NUM> is shown in accordance with one exemplary embodiment. As set forth in further detail below, the system <NUM> and fryer <NUM> provide improved efficiency in cooking operations. The cooking system <NUM> achieves the increased production by efficiently managing the workflow of baskets <NUM> moving between a dispensing freezer <NUM>, the fryer <NUM>, and a hot holding station <NUM>. More specifically, the workflow of baskets <NUM> is primarily achieved using a gantry system <NUM>. The gantry system <NUM> includes a gantry <NUM> and a gantry control <NUM>, which may be a part of or separate from a system controller <NUM> for the automated cooking system <NUM>. The system described herein provides for cooking food product <NUM> in a more efficient manner with regard to both time and labor considerations within the constraints of a restaurant. The features of the automated cooking system <NUM> and the fryer <NUM> are set forth in further detail below to clarify each of these functional advantages and other benefits provided in this disclosure. Other advantages and technical effects of the embodiments of this invention will become evident to one skilled in the art from the following description.

A brief description of the environmental context (including the equipment surrounding the fryer <NUM>) is now provided before turning attention to a more detailed explanation of the gantry system <NUM> and how it manages the workflow of baskets <NUM> around the fryer <NUM> to achieve the technical advantages noted above.

Continuing with reference to <FIG>, an exemplary automated cooking system <NUM> is shown. The automated cooking system <NUM> includes the fryer <NUM>, a plurality of baskets <NUM>, a dispensing freezer <NUM>, a hot holding station <NUM>, and a gantry system <NUM>. The dispensing freezer <NUM> is of a mostly conventional design, and thus, is not shown in significant detail in the Figures. However, the dispensing freezer <NUM> shown in this embodiment includes a dispenser (not shown) for dispensing food product <NUM>. Food product <NUM>, for example, waffle fries, are dispensed into a basket <NUM> from the dispenser of the dispensing freezer <NUM>, cooked in the fryer <NUM>, and then transferred from the fryer <NUM> to the hot holding station <NUM> via the baskets <NUM>, as discussed in greater detail below. While a basket <NUM> is shown and described, it is appreciated that other moveable food product receptacles are also envisioned.

The hot holding station <NUM> of the embodiment shown in <FIG> receives cooked food product <NUM> from the basket <NUM> of the fryer <NUM>, to thereby enable operator manipulation and packaging to finalize preparation of the food products for delivery to fulfill customer demands, as well understood in the restaurant field. The hot holding station <NUM> is of conventional design and is briefly described as follows: it includes a hot holding cabinet <NUM> and a hot holding receiving area <NUM>. As shown, the hot holding cabinet <NUM> may include a plurality of vertical slots <NUM> or angled corrugated slots <NUM> to hold the now cooked food product <NUM>. For example, the hot holding receiving area <NUM> may include an angled front portion <NUM>, and a plurality of apertures <NUM> to enable circulating air flow to help the cooked food product <NUM> remain in a desirable state. Receptacles <NUM> for holding packaging to load food products into may be located in the front of the hot holding receiving area <NUM>. Since the throughput of this automated cooking system <NUM> exceeds current systems, the hot holding receiving area <NUM> is generally larger to enable one or more workers to package the cooked food product <NUM> and keep up with the throughput of the automated cooking system <NUM>. It will be understood that other types of hot holding <NUM> and preparation stations may be used with the fryer <NUM> in other embodiments. For example, an automated holding and packaging station may be later developed and combined with the features of the automated cooking system <NUM> described in detail below, without departing from the scope of this disclosure, which does not fall within the scope of the claims, but is given for illustrative purposes only.

Interfacing with a touch-screen control (not shown) or the like according to an embodiment, the operator selects the quantity of food product <NUM> and the repeating rate upon which they wish to cook, and the automated cooking system <NUM> automatically optimizes the dispensing schedule from the freezer <NUM> and where to perform the cooking within the fryer <NUM>. It will be understood that the food products to be cooked and the production rate may also be communicated to the cooking system <NUM> by other methods, including wireless communication from order management computer(s) that receive customer demands for food product and facilitate restaurant employees with fulfilling customer demands and orders accordingly. Regardless of how the control parameters are set, the automated cooking system <NUM> generally operates as follows: it automatically raises the predetermined basket <NUM>, moves the basket <NUM> to the position to accept the uncooked food product <NUM>, moves the basket <NUM> to the proper cooking chamber, e.g., fryer vat <NUM>, location, lowers the basket <NUM> into the cooking medium <NUM>, raises the basket <NUM> once cooked and moves the basket <NUM> to be dispensed into the hot holding receiving area <NUM>, and then moves the basket <NUM> back to a predetermined location at the fryer <NUM> or back to the freezer <NUM> to accept more uncooked food product <NUM>.

In an embodiment, the system controller <NUM> of the automated cooking system <NUM> may be configured to implement different modes of the system <NUM> or fryer <NUM>. In any event, the system controller <NUM> may be operatively coupled to a dispensing mechanism of the dispensing freezer <NUM> to enable coordination between the dispensing of uncooked food product <NUM> from the dispensing freezer <NUM> into the basket <NUM>, such that a predetermined amount of food product <NUM> is dispensed into the basket <NUM>. The system controller <NUM> may also interface with other equipment in a fully automated fashion, to cause cooking of food product <NUM> in response to customer orders or demand. To this end, while the system controller <NUM> is referred to separately from the gantry control <NUM> previously described and shown in <FIG>, it will be appreciated that the gantry control <NUM> may be an integral part of a single system controller <NUM> operating all elements of the cooking system <NUM> without departing from the scope of this invention.

Also initially shown in <FIG>, the fryer <NUM> also includes a gantry system <NUM> that is configured to move a basket <NUM> between a plurality of positions at the fryer <NUM>. The gantry system <NUM> includes a gantry <NUM>. The gantry <NUM> is moved by the gantry system <NUM> using a motor (not shown) which is controlled using a gantry control <NUM> enabling the gantry <NUM> to move to a desired position. The gantry control <NUM> interfaces with or is part of a system controller <NUM> (schematically shown in <FIG>), which is described in greater detail below. The gantry system <NUM> is configured to service each platform <NUM> associated with each fryer vat <NUM> with a basket <NUM>. The operation of the gantry system <NUM> and how it helps the cooking system <NUM> achieve higher food product throughput is described in further detail below.

<FIG> shows an exemplary embodiment of the fryer <NUM> used in the automatic cooking system <NUM>. The system <NUM> includes a frame <NUM> mounted on a plurality of casters or wheels <NUM>, so that the fryer <NUM> may be easily moveable on a surface, such as a floor. In one embodiment, one or more of the wheels <NUM> are lockable to prevent unwanted movement of the fryer <NUM> during operation. In a further embodiment, the frame <NUM> includes feet <NUM> so that the frame <NUM> of the system <NUM> is not placed directly onto a surface, such as a floor. In one embodiment, the feet <NUM> are adjustable such that the system <NUM> can be raised or lowered to a desired height above a surface, such as a floor. Alternatively, the wheels <NUM> or feet <NUM> may be eliminated if desired. A plurality of wall panels <NUM> are provided on the frame <NUM> to strengthen the frame <NUM>. Various fryer <NUM> components such as, for example, oil filtration and recirculation components, may be supported by or housed by the frame <NUM> within the wall panels <NUM>. These components are of a conventional design, and thus, are not shown in detail in the figures. Cabinets <NUM> may be located near the bottom of the fryer <NUM> and may be used to remove already-used cooking medium <NUM>. According to another embodiment, cabinets <NUM> may be used as storage for unused cooking medium <NUM> or other products.

With continued reference to <FIG>, in an embodiment, the fryer <NUM> includes five fryer vats <NUM>, each configured to hold a cooking medium <NUM>. As shown, each fryer vat <NUM> is configured to hold at least one basket <NUM>. However, more or fewer fryer vats <NUM> are also envisioned, with each fryer vat <NUM> being configured to hold one or more baskets <NUM>. For example, the fryer <NUM> may feature three fryer vats <NUM> wherein each fryer vat <NUM> is configured to accommodate two platforms <NUM> (and thus two cooking baskets <NUM>) each, for a total of six platforms <NUM> and six baskets <NUM>. At least one heating element <NUM> is disposed within each fryer vat <NUM>. However, it is envisioned that each fryer vat <NUM> may include any suitable number of heating elements <NUM> in any arrangement, as may be desired. The heating element <NUM> is configured to heat the cooking medium <NUM> to a predetermined temperature so as to cook the food products <NUM> therein. Further, in an embodiment the fryer <NUM> includes vertical transport assemblies <NUM>, which are configured to raise and lower the baskets <NUM> into and out of the fryer vats <NUM> on platforms <NUM> attached to the vertical transport assemblies <NUM>. It is envisioned that each fryer vat <NUM> may contain a single basket <NUM>, which is movable on a platform <NUM> of one of the vertical transport assemblies <NUM>. Alternatively, a fryer vat <NUM> may accommodate two or more baskets <NUM>, each moveable on a separate platform <NUM> on a separate vertical transport assembly <NUM>. It is also envisioned that a basket <NUM> may be used with different fryer vats <NUM> or different platforms <NUM> of the vertical transport assemblies <NUM>. Mounted in the rear of the frame <NUM> are the motors and other corresponding components (not shown) for each of the vertical transport assemblies <NUM>.

With reference to <FIG>, these Figures show elements of the cooking system <NUM> and operational steps taken at the adjacent stations to the fryer <NUM>, as initially introduced above. Referring first to <FIG>, the Figure shows a portion of the fryer <NUM> adjacent the dispensing freezer <NUM>. At the dispensing freezer <NUM>, a staging shelf <NUM> is shown in a deployed position and supporting an empty basket <NUM>. In the deployed position, the staging shelf <NUM> is in a generally horizontal orientation such that a basket <NUM> can be placed on the staging shelf <NUM> by the gantry <NUM>. When not supporting a basket <NUM>, the staging shelf <NUM> can alternatively be in a stowed position. In the stowed position, the staging shelf <NUM> is generally vertical such that the staging shelf <NUM> cannot support a basket <NUM>. In an embodiment, the state of the staging shelf <NUM> (e.g., in the deployed or stowed position) is determined by the system controller <NUM> in communication with the gantry control <NUM>. <FIG> also shows a basket <NUM> filled with uncooked food product <NUM> located in a basket movement receptacle <NUM>. The basket movement receptacle <NUM> of this embodiment defines a generally U-shaped support surrounding an open slot facing generally towards the staging shelf <NUM>. In <FIG>, the basket movement receptacle <NUM> is located in a pickup position and is waiting for the gantry control <NUM> to direct the gantry system <NUM> to move the gantry <NUM> to the location of the basket movement receptacle <NUM>, in the pickup position, to pick up a basket <NUM>. The gantry <NUM> will move the basket <NUM> filled with uncooked food product <NUM> from the basket movement receptacle <NUM>, in the pickup position, to one of the empty platforms <NUM> at the fryer <NUM> in preparation for the food product <NUM> to be cooked by the cooking medium <NUM> in the corresponding fryer vat <NUM>.

<FIG> shows the basket <NUM> of <FIG>, still filled with uncooked food product <NUM>, moved from the basket movement receptacle <NUM> (in the pickup position) to the available platform <NUM> above the fryer vat <NUM> via the gantry <NUM>. Specifically, a clamping gripper <NUM> of the gantry <NUM> engages with a single pickup point <NUM> on the basket <NUM> to permit the gantry <NUM> to move the basket <NUM> from location to location. The engagement of the gantry <NUM> with a basket <NUM> is described in further detail below with reference to <FIG>.

<FIG> shows the basket <NUM> of <FIG>, previously located on the platform <NUM> above the fryer vat <NUM> and filled with uncooked food product <NUM>, being submerged into the cooking medium <NUM> of the fryer vat <NUM> by the vertical transport assembly <NUM>. In this regard, each platform <NUM> above a fryer vat <NUM> is attached to a vertical transport assembly <NUM> such that the vertical transport assembly <NUM>, upon receiving a signal from the system controller <NUM>, can lower the basket <NUM> with uncooked food product <NUM> into the fryer vat <NUM>. After a predetermined or specified amount of cooking time, the vertical transport assembly <NUM>, upon receiving a signal from the system controller <NUM>, lifts the platform <NUM> and the basket <NUM> sitting thereon from the fryer vat <NUM>. Through this process, the uncooked food product <NUM> in the basket <NUM> becomes cooked food product <NUM>.

Also shown in <FIG> is the empty basket movement receptacle <NUM>, following removal of the basket <NUM> by the gantry <NUM>. The U-shaped support configuration is clearly visible in this Figure. The front and rear sides of the basket movement receptacle <NUM> in this embodiment include ledges that engage with the front and back ends of a basket <NUM> during support of the basket <NUM> in the basket movement receptacle <NUM>. The gap between these ledges defines the open slot that is large enough to pass by the staging shelf <NUM> during movement of the basket movement receptacle <NUM>. The basket movement receptacle <NUM> can thus freely translate upwardly and downwardly past the staging shelf <NUM> regardless of the position the staging shelf <NUM> is in, which also allows for pickup of a basket <NUM> from the staging shelf <NUM> to then support that same basket on the basket movement receptacle <NUM>. Alternative constructions of the basket movement receptacle <NUM> are possible in other embodiments, so long as a transfer between the staging shelf <NUM> and the basket movement receptacle <NUM> continues to be enabled for the basket workflow process steps described herein.

After the gantry <NUM> transports a filled basket <NUM> from the basket movement receptacle <NUM> to a platform <NUM>, the basket movement receptacle <NUM>, upon receiving a signal from the system controller <NUM>, then receives a basket <NUM> from the staging shelf <NUM>. As described above, the basket movement receptacle <NUM> is shaped such that the staging shelf <NUM> can fit within the open slot of the generally U-shaped basket movement receptacle <NUM>. In order to transfer a basket <NUM> from the staging shelf <NUM> to the basket movement receptacle <NUM>, the basket movement receptacle <NUM> moves up to the position of the staging shelf <NUM>. In an embodiment, the basket <NUM> is transferred from the staging shelf <NUM> to the basket movement receptacle <NUM> by the basket movement receptacle <NUM> being positioned against the basket <NUM> and then, the staging shelf <NUM> pivoting from a deployed position to a stowed position. In this embodiment, the basket <NUM> is securely positioned in the basket movement receptacle <NUM> before the staging shelf <NUM> changes positions. In an alternative embodiment, the basket <NUM> is transferred from the staging shelf <NUM> to the basket movement receptacle <NUM> by the basket movement receptacle <NUM> being positioned slightly below the location of the basket <NUM> and then, the staging shelf <NUM> pivoting from a deployed position to a stowed position. In this embodiment, the basket <NUM> drops with movement of the staging shelf <NUM> a short distance from the staging shelf <NUM> and into the basket movement receptacle <NUM>. The basket movement receptacle <NUM> is generally adjacent to the staging shelf <NUM> whenever a transfer of the basket <NUM> occurs in accordance with these embodiments.

The basket movement receptacle <NUM> then moves the unfilled basket <NUM> to a filling position (not shown in detail in <FIG> as this position may vary depending on where the outlet(s) of the freezer <NUM> are located relative to the fryer <NUM>) where the dispensing freezer <NUM> dispenses uncooked food product <NUM> into the basket <NUM>. In an embodiment, the filling position may vary depending upon the type of food product <NUM> being dispensed by the dispensing freezer <NUM>. For example, the dispensing freezer <NUM> may dispense one uncooked food product <NUM> at one position and a different uncooked food product <NUM> at a second position. After the basket <NUM> is filled at the filling location, the basket movement receptacle <NUM> then moves the basket <NUM> to a pickup position as previously shown in <FIG>, where the basket <NUM> will wait to be picked up by the gantry <NUM> and moved to a platform <NUM> in preparation for a cooking cycle. In some embodiments, the filling location and pickup position may be different positions. For example, the basket <NUM> may be filled at one location and picked up in different location. In other embodiments, the filling location and the pickup position may be the same physical location. For example, the dispensing freezer <NUM> may fill a basket <NUM> at a filling location and then the basket <NUM> may remain in that position until the basket <NUM> is picked up by the gantry <NUM> and taken to a platform <NUM>.

Accordingly, the portions of the cooking system <NUM> on this end of the fryer <NUM> enable coordinated movement and actions to be performed with baskets <NUM> at/adjacent the dispensing freezer <NUM> while the gantry <NUM> works at other portions of the cooking system <NUM>. To this end, the gantry <NUM> does not need to manage movement of a basket <NUM> between filling and holding positions during a filling step, and this simplifies the operation and movement needed by the gantry <NUM> along this end of the fryer <NUM>. For example, the gantry <NUM> only needs to be able to move to the designated drop off point at the staging shelf <NUM> and to the pickup point at the lowered position of the basket movement receptacle <NUM> shown in <FIG>. Moreover, the gantry <NUM> can drop off an empty basket <NUM> at the staging shelf <NUM> and then immediately go pick up a filled basket <NUM> at the basket movement receptacle <NUM> without delay such that the gantry <NUM> can more rapidly move to the next basket <NUM> that needs workflow movements at the cooking system <NUM>. Put another way, the staging shelf <NUM> and the basket movement receptacle <NUM> automatically handle movement and filling of a basket <NUM> while the gantry <NUM> moves to the fryer <NUM> and to the hot holding station <NUM>, thereby avoiding the need for the gantry <NUM> to manage these steps. These concurrent actions improve the workflow control of baskets <NUM> at the cooking system <NUM> and thereby help enable the higher food product cooking throughput achieved by this invention.

<FIG> shows a portion of the fryer <NUM> along an opposite end of that shown in <FIG> and the hot holding station <NUM> adjacent this opposite end of the fryer <NUM>. The gantry <NUM>, at the direction of the gantry control <NUM>, has engaged a basket <NUM> filled with cooked food product <NUM> (via the clamping gripper <NUM> of the gantry <NUM> and the single pickup point <NUM> of the basket <NUM>, as more fully explained below in reference to <FIG>) and brought the basket <NUM> to a position at a designated height above the hot holding station <NUM>. The gantry <NUM>, upon receiving a signal from the gantry control <NUM>, actuates the basket <NUM> so that the basket <NUM> opens along a bottom thereof to discharge the cooked food product <NUM> into the hot holding receiving area <NUM>. The particular height above the hot holding station <NUM> at which the gantry <NUM> discharges the cooked food product <NUM> from the basket <NUM> can vary depending upon the particular cooked food product <NUM>. For example, one cooked food product <NUM> may be discharged from one height above the hot holding station <NUM>, while a different cooked food product <NUM> may be discharged from a different height above the hot holding station <NUM> (e.g., more fragile cooked food product <NUM> may be dropped from a basket <NUM> at a lower height above the hot holding receiving area <NUM> than other cooked food products <NUM>, such differences being programmed into the gantry control <NUM> based on what types of food product are to be cooked and prepared at the cooking system <NUM>). It will be understood that the hot holding receiving area <NUM> may be subdivided in some embodiments and the gantry <NUM> is able to discharge cooked food product from baskets <NUM> into any of these subdivided areas.

Referring now to <FIG>, these Figures show a series of steps defining a basket loading cycle and a basket discharge cycle according to the invention, each of which may be repeatedly performed to manage basket workflow at the cooking system <NUM>. Referring to <FIG>, the Figure shows portions of a basket loading cycle in accordance with one embodiment. The basket loading cycle begins with an empty basket <NUM> sitting on one of the platforms <NUM> positioned over a center one of the fryer vats <NUM>. The empty basket <NUM> is waiting to be picked up by the gantry <NUM>, which is shown positioned over by the dispensing freezer <NUM> in this state of <FIG>. When the gantry <NUM> receives a signal from the gantry control <NUM>, the gantry <NUM> will move laterally to the platform <NUM> holding the empty basket <NUM> so as to engage the empty basket <NUM>. Further, <FIG> shows in a leftmost one of the fryer vats <NUM> two baskets <NUM> filled with recently cooked food product <NUM> emerging from the cooking medium <NUM> in a fryer vat <NUM>. The vertical transport assemblies <NUM> lift the platforms <NUM> on which the baskets <NUM> sit, thus raising the baskets <NUM> from the fryer vats <NUM> and out of the heated cooking medium <NUM> at the end of a cooking cycle, as shown by the upward arrow in <FIG>.

<FIG> shows the gantry <NUM>, after receiving a signal from the gantry control <NUM>, engaging the empty basket <NUM> on the platform <NUM> and moving that basket <NUM> as shown by the upward and leftward movement arrows in <FIG> from the platform <NUM> to the staging shelf <NUM> adjacent the dispensing freezer <NUM>. Sometime before the empty basket <NUM> arrives at the staging shelf <NUM>, the system controller <NUM> sends a signal to the staging shelf <NUM> so that the staging shelf <NUM> pivots into a (generally horizontal) deployed position if the staging shelf <NUM> was previously in a stowed position. With the staging shelf <NUM> in the deployed position, the gantry <NUM> places the empty basket <NUM> on the staging shelf <NUM> by lowering the basket <NUM> onto the staging shelf <NUM> and then disengaging from the basket <NUM>. The mechanics of engagement and disengagement between the gantry <NUM> and a basket <NUM> are further explained below with respect to <FIG>.

<FIG> shows a basket <NUM> filled with uncooked food product <NUM> in the basket movement receptacle <NUM>, located in a pickup position adjacent the dispensing freezer <NUM>, being engaged by the gantry <NUM>. To this end, after dropping off the empty basket <NUM> onto the staging shelf <NUM>, the gantry <NUM> moves downwardly to the basket movement receptacle <NUM>. After a basket <NUM> has been filled by the dispensing freezer <NUM> at a filling location, the basket movement receptacle <NUM> moves (if necessary) the basket <NUM> into a pickup position such that the basket <NUM> is ready to be engaged by the gantry <NUM> as shown in <FIG>. The gantry <NUM>, after receiving a signal from the gantry control <NUM>, engages with the filled basket <NUM> and moves the basket <NUM> to an open platform <NUM> above a fryer vat <NUM>, as shown by the rightward and downward movement arrows in <FIG>. Which platform <NUM> the basket <NUM> should be moved to is typically determined by the system controller <NUM>. Once the gantry <NUM> has placed a basket <NUM> on an open platform <NUM>, the gantry <NUM> disengages with the basket <NUM> and leaves the basket <NUM> on the platform <NUM> above the fryer vat <NUM>. Note that although a filled basket <NUM> was previously shown in <FIG> at this platform <NUM> where the gantry <NUM> drops off the new basket of food to be cooked in <FIG>, this prior basket is understood to have been separately moved and discharged at the hot holding station <NUM> before the step shown in <FIG> (as set forth in the description of basket discharge cycles below), or the filled basket <NUM> from the basket movement receptacle <NUM> is moved to a different, open/empty platform <NUM> during the basket loading cycle. The drop-off of the filled basket <NUM> onto the platform <NUM> completes the basket loading cycle of this embodiment.

<FIG> shows the basket movement receptacle <NUM> moving upwards as shown by the arrow towards the staging shelf <NUM> in order to transfer the empty basket <NUM> on the staging shelf <NUM> from the staging shelf <NUM> to the basket movement receptacle <NUM>. As described above, the staging shelf <NUM> can be pivoted to the generally vertical stowed position to complete the transfer of the basket <NUM> into the basket movement receptacle <NUM> as shown. Further, <FIG> shows baskets <NUM> filled with uncooked food product <NUM> on platforms <NUM> above a fryer vat <NUM> being lowered into a cooking medium <NUM> for a cooking cycle via the vertical transport assemblies <NUM>. The platforms <NUM>, on which the baskets <NUM> sit, are attached to the vertical transport assemblies <NUM> which move the baskets <NUM> into and out of the cooking medium <NUM> in the fryer vats <NUM> upon receiving a signal to initiate a cooking cycle from the system controller <NUM>. These actions can automatically occur at the cooking system <NUM> while the gantry <NUM> moves to perform actions on other baskets and platforms, such as in the exemplary basket discharge cycle to now be described.

<FIG> shows a basket <NUM> in the basket movement receptacle <NUM> being transported. The staging shelf <NUM> has been pivoted to the vertical, stowed position as shown. The basket movement receptacle <NUM> transports the basket <NUM> to a filling location. At the filling the location, the dispenser freezer <NUM> dispenses uncooked food product <NUM> into the basket <NUM>. The basket movement receptacle <NUM> then transports the basket <NUM> from the filling location to the pickup position, if these positions are different from one another. In an embodiment, the filling location and the pickup position may be distinct physical locations. In a further embodiment, the filling location and the pickup position may be the same physical location. Regardless of how the basket movement receptacle <NUM> may move to and from the filling location, the end result is filling of the basket <NUM> and movement from the initial drop-off position on the staging shelf <NUM> downwardly as shown by the arrow in <FIG> to the pickup position that is accessed by the gantry <NUM> in a future basket loading cycle. Once in the pickup position, the filled basket <NUM> waits in the basket movement receptacle <NUM> until the basket <NUM> is engaged by the gantry <NUM>. These movements can occur simultaneous to other actions being taken by the gantry <NUM> at the fryer <NUM>.

For example, <FIG> also shows a basket <NUM> with cooked food product <NUM> (after exiting a fryer vat <NUM>) being moved from a platform <NUM> above the fryer vat <NUM> to a position above the hot holding station <NUM> via the gantry <NUM>. This movement is shown by the rightward arrow in <FIG>, resulting in the positioning of the basket <NUM> and the gantry <NUM> shown in <FIG> and described below. This pickup and movement of the filled basket <NUM> is the beginning of an exemplary basket discharge cycle that is repeatedly performed by the gantry <NUM> in this embodiment.

<FIG> shows the basket <NUM> filled with cooked food product <NUM> suspended by the gantry <NUM> in a position at a height above the hot holding station <NUM>. Further, <FIG> shows the gantry <NUM>, upon receiving a signal from the gantry control <NUM>, actuating the filled basket <NUM> to open the bottom of same and thereby discharge the cooked food product <NUM> into the hot holding receiving area <NUM> of the hot holding station <NUM>. As set forth above, the gantry <NUM> can vary the height above the hot holding station <NUM> at which this discharge step occurs depending on the specific type of food product contained within the basket <NUM>. The cooked food is then held in the hot holding receiving area <NUM> for further preparation and packaging by an operator.

<FIG> shows, like in <FIG>, a basket <NUM> filled with cooked food product <NUM> suspended in a position at a height above the hot holding station <NUM> by the gantry <NUM>. However, the basket <NUM> from which the cooked food product <NUM> is being discharged in <FIG> is positioned at a different height than the basket <NUM> from which the cooked food product <NUM> is being discharged in <FIG>. Depending upon the particular food product <NUM> being discharged, the basket <NUM> from which the cooked food product <NUM> is discharged may be positioned above the hot holding station <NUM> at different heights. For example, one cooked food product <NUM> may be discharged at a first height while a different cooked food product <NUM> may be discharged at a different, second height either higher or lower than the first height.

<FIG> shows the gantry <NUM>, at the direction of the gantry control <NUM>, transporting the basket <NUM> from a position above the hot holding station <NUM> (after discharging cooked food product <NUM>) to an open platform <NUM> above one of the fryer vats <NUM>. The gantry <NUM> disengages with the basket <NUM> and leaves the basket <NUM> on a platform <NUM> above a fryer vat <NUM>, which completes the basket discharge cycle of this embodiment. The empty basket <NUM> is then ready to be engaged by the gantry <NUM> again when customer demand necessitates. It will be understood that the gantry <NUM> could omit this drop-off step in other embodiments and instead take the empty basket <NUM> directly to the staging shelf <NUM> to begin another basket loading cycle. Further, <FIG> shows the staging shelf <NUM> pivoting from a vertical, stowed position to a horizontal, deployed position in preparation for any empty basket <NUM> to be placed upon the staging shelf <NUM> by the gantry <NUM>. The gantry <NUM> can then move again to start a new basket loading cycle, a new basket discharge cycle, or to the basket movement receptacle <NUM> as specifically shown in <FIG>.

Generally, <FIG> show features of the system's <NUM> basket loading and discharge cycles for managing basket <NUM> workflow during food preparation at an automated cooking system <NUM>. The automated cooking system <NUM> prioritizes and orders the basket loading cycles and basket discharge cycles for the gantry system <NUM> to satisfy varying levels of demand for cooked food product <NUM> from the automated cooking system <NUM>. A basket loading cycle, as performed by the gantry system <NUM>, includes in one embodiment: the gantry <NUM> picking up an empty basket <NUM> from a platform <NUM>, transporting the empty basket <NUM> to the dispensing freezer <NUM> to be filled with uncooked food product <NUM>, picking up a basket <NUM> filled with uncooked food product <NUM> from the dispensing freezer <NUM>, and transporting the filled basket <NUM> from the dispensing freezer <NUM> to a selected platform <NUM> above a fryer vat <NUM> (as determined by the gantry control <NUM>) to be cooked in the fryer vat <NUM>. In such an embodiment, the basket loading cycle can be completed in a time period of less than <NUM> seconds. The exemplary embodiment shown performs a basket loading cycle as described here in about <NUM> seconds, for example. A basket discharge cycle, as performed by the gantry system <NUM>, includes in one embodiment: the gantry <NUM> picking up a filled basket <NUM> containing cooked food product <NUM> from a platform <NUM>, transporting the filled basket <NUM> to a position above the hot holding station <NUM>, the gantry <NUM> actuating the basket <NUM> to discharge the cooked food product <NUM> therein into the hot holding station <NUM> awaiting below, and transporting the emptied basket <NUM> to a selected platform <NUM> above a fryer vat <NUM> (as determined by the gantry control <NUM>). In such an embodiment, the basket discharge cycle can be completed in a time period of less than <NUM> seconds. The exemplary embodiment shown performs a basket discharge cycle as described here in about <NUM> seconds, for example. Furthermore, the gantry system <NUM> can complete both one of the basket loading cycles and one of the basket discharge cycles in a time period of less than <NUM> seconds (e.g., the exemplary embodiment performs one of each cycle in about <NUM> seconds total). This is an improvement in speed by over <NUM>% as compared to conventional automated fryer designs. This arrangement allows for successful management of up to <NUM> or more baskets cooking food product simultaneously at the fryer <NUM>, which can result, for example, in throughput levels of <NUM> (<NUM> pounds) of cooked French fries an hour in one operational example.

It is envisioned that the basket loading and basket discharge cycles could include additional or fewer steps in other embodiments. Nevertheless, the gantry <NUM> is configured to manage the workflow of <NUM> or more baskets and cooking stations (platforms <NUM>) at the fryer <NUM> simultaneously to provide an increased maximum cooking volume throughput of the cooking system <NUM>. The automatic cooking system <NUM> therefore improves the field of cooking equipment and methodologies by limiting the need for operator intervention (and associate expense) while maximizing how much food product can be cooked and prepared within the standard space used by fryers in commercial setting kitchens. Additionally, as described next, the design of the gantry <NUM> in this cooking system <NUM> advantageously controls the baskets <NUM> during the rapid movements of the basket loading and discharge cycles to avoid uncontrolled pivoting or rotations and/or undesired impacts with other baskets <NUM> held at the cooking system <NUM>. As such, the reliability and throughput is significantly improved even over other automatic fryer designs, one such version of which is described now for reference from previous developments of the original Applicant of the present application.

Referring now to <FIG>, these Figures show engagement between the clamping gripper <NUM> of the gantry <NUM> and the single pickup point <NUM> of a basket <NUM> in accordance with the embodiments of this invention. Referring to <FIG>, the Figure shows an embodiment of a single pickup point <NUM> of a basket <NUM> facing in the direction of the gantry system <NUM>. The single pickup point <NUM> is in the form of a spool that may be grasped by the clamping gripper <NUM> as shown and described here. The gantry system <NUM> includes a gantry <NUM> which, in turn, includes a clamping gripper66. In one embodiment, the clamping gripper <NUM> is a two-piece clamping mechanism which engages with the single pickup point <NUM> of a basket <NUM> from opposing sides. Upon receiving a signal from the gantry control <NUM>, the clamping gripper <NUM> engages and secures the single pickup point <NUM> of the basket <NUM> within the clamping gripper <NUM>.

Referring to <FIG>, the Figure shows the clamping gripper <NUM> of the gantry <NUM> engaged with the single pickup point <NUM> of a basket <NUM>. As shown, the two-piece clamping gripper <NUM> is clamped into engagement with the single pickup point <NUM>. In an embodiment, the clamping gripper <NUM> clamps in engagement with the single pickup point <NUM> in such a way to prevent the basket <NUM> from uncontrollably rotating when the basket <NUM> is engaged with the gantry <NUM> (e.g., when the basket <NUM> is being moved from one position to another). For example, additional wires or structure may be provided adjacent the spool to help avoid any undesirable or uncontrolled pivoting of the basket <NUM> during engagement and movement with the gantry <NUM>. In this regard, preventing uncontrolled rotational movements of the basket <NUM> during engagement with the gantry <NUM> serves to prevent a basket <NUM> engaged with the gantry <NUM> from impacting other baskets <NUM> at the system <NUM> or fryer <NUM>, thereby preventing damage to baskets <NUM>, the gantry <NUM>, the fryer <NUM>, or the system <NUM>, as well as preventing food product spills and/or cycle delays associated with such spills and impacts. The improved speed and basket workflow management is therefore enabled in part by this engagement of baskets <NUM> with the gantry <NUM>.

Referring now to <FIG>, another exemplary fryer <NUM> is shown for automatic cooking of food product and basket workflow management. The fryer <NUM> includes a front wall panel 644a, a left side wall panel 644b, a right side wall panel 644c, and a rear wall panel 644d adjacent a rear side of the fryer <NUM> to cover various interior portions of a frame of the fryer <NUM> and/or various fryer components such as, for example, oil filtration and recirculation components. The illustrated fryer <NUM> includes three cooking chambers 648a-c, each configured to hold a cooking medium. As shown, each cooking chamber 648a-c is configured to hold a single basket 622a-b, for a total of three baskets 622a-b. However, more or fewer cooking chambers 648a-c are also envisioned, with each cooking chamber 648a-c being configured to hold one or more baskets 622a-b. At least one heating element <NUM> is disposed within each cooking chamber 648a-c. However, it is envisioned that each cooking chamber 648a-c may include any number of heating elements <NUM> in any arrangement, as may be desired. The heating element <NUM> is configured to heat the cooking medium to a predetermined temperature. An exhaust or vent hood <NUM> is positioned generally above the cooking chambers 648a-c. The illustrated fryer <NUM> includes touch screen controls 653a-c for each cooking chamber 648a-c. As shown, the fryer <NUM> includes a transport assembly <NUM> that is configured to raise and lower the baskets 622a-b out of and into the cooking chambers 648a-c and also to transfer the baskets 622a-b between a plurality of horizontal positions. By providing both vertical and horizontal movement to the baskets 622a-b with the transport assembly <NUM>, the aforementioned hand-off of baskets 622a-b between dedicated vertical and horizontal transport assemblies may be eliminated.

The transport assembly <NUM> includes an overhead gantry <NUM> which travels horizontally along a track <NUM> fixed relative to the frame of the fryer <NUM>. Horizontal movement of the gantry <NUM> along the track <NUM> may be enabled by an actuator (not shown). For example, the gantry <NUM> may be belt driven or gear driven in a manner similar to that described above with respect to the aforementioned horizontal transport assemblies. In one embodiment, the actuator of the gantry <NUM> and/or a motor thereof may be mounted behind the track <NUM>. In any event, the gantry <NUM> includes a hollow body <NUM> having a shoulder <NUM> for engaging the track <NUM> such that the weight of the gantry <NUM> may be supported by the track <NUM>. In this manner, the vertical position of the hollow body <NUM> of the gantry <NUM> may be fixed. As shown, the gantry <NUM> further includes a generally vertical telescoping arm <NUM> configured to be extendable, retractable, and/or rotatable relative to the hollow body <NUM>. More particularly, the arm <NUM> may be vertically extended from and retracted into the hollow body <NUM>, and may also be rotated about a vertical axis defined by the hollow body <NUM> and/or arm <NUM>. Vertical and rotational movement of the arm <NUM> may be enabled by one or more actuators (not shown). For example, the arm <NUM> may be belt driven or gear driven in a manner similar to that described above with respect to the aforementioned vertical transport assemblies. In one embodiment, the actuator of the arm <NUM> and/or a motor thereof may be mounted within the hollow body <NUM> so as to move horizontally along the track <NUM> therewith.

The gantry <NUM> also includes a multi-handed manipulator <NUM> pivotably coupled to a base <NUM> which is, in turn, fixedly coupled to the arm <NUM>. The illustrated base <NUM> includes a hollow sleeve <NUM> configured to rotatably receive a portion of the manipulator <NUM>, such as a rod <NUM> thereof (<FIG>). Other suitable configurations may be used. In any event, the manipulator <NUM> may be rotated about a horizontal axis defined by the rod <NUM>, for example. Rotational movement of the manipulator <NUM> may be enabled by one or more actuators (not shown). In one embodiment, the actuator of the manipulator <NUM> and/or a motor thereof may be mounted within one or more of the hollow body <NUM>, the telescoping arm <NUM>, and/or the base <NUM> so as to move horizontally along the track <NUM> therewith.

In the embodiment shown, the manipulator <NUM> includes two or more hands <NUM>, <NUM> fixedly coupled to each other. As shown, the hands <NUM>, <NUM> extend away from the rod <NUM> in generally opposite directions. In other embodiments, the hands <NUM>, <NUM> may not be coupled to each other. In addition, or alternatively, more than two hands <NUM>, <NUM> may be provided. For example, an alternative manipulator may include three hands offset from each other by approximately <NUM>°.

Each hand <NUM>, <NUM> includes a coupling <NUM> (<FIG>) for selectively attaching and releasing a basket 622a-b to and from the manipulator <NUM>. For example, each coupling <NUM> may include a generally cylindrical protrusion configured to be received by a corresponding recess <NUM> of a handle <NUM> of a basket 622a-b. In one embodiment, frictional engagement between the protrusion <NUM> and the recess <NUM> may attach the manipulator <NUM> to the basket 622a-b. In addition, or alternatively, an auxiliary lock may be selectively engaged to assist in attaching the manipulator <NUM> to the basket 622a-b. For example, the handle <NUM> may include a permanent magnet (not shown) and the manipulator <NUM> may include one or more electromagnets (not shown) which may be selectively activated to magnetically attach the manipulator <NUM> to the basket 622a-b. In one embodiment, each coupling <NUM> may be configured to allow the corresponding basket 622a-b to rotate relative to the manipulator <NUM> about the coupling <NUM>, such as under gravity, and/or may be configured to rotatably fix the corresponding basket 622a-b relative to the manipulator <NUM>. For example, each coupling <NUM> may be configured to selectively rotatably fix and selectively rotatably release the corresponding basket 622a-b.

The motion of the baskets 622a-b will now be described in connection with <FIG>. Initially, the gantry <NUM> is positioned proximate the right-side wall panel 644c with the first hand <NUM> of the manipulator <NUM> attached to the first basket 622a via the corresponding coupling <NUM>, while the second basket 622b is initially positioned in the second cooking chamber 648b with a rear downwardly facing hook <NUM> of the basket 622b engaging a support (not shown) for holding the basket 622b. The arm <NUM> may be initially oriented such that the first basket 622a extends laterally away from the fryer <NUM>, such as for receiving uncooked food product from a freezer (not shown). The second basket 622b may contain food product (not shown) whose cooking time is nearing completion.

<FIG> shows the transport assembly <NUM> moving the first basket 622a laterally from proximate the right-side wall panel 644c to above the second cooking chamber 648b, as indicated by the arrow A1. During this time of travel, the arm <NUM> rotates counterclockwise about the vertical axis to align the first basket 622a directly above the second basket 622b, as indicated by the arrow A2.

<FIG> shows that upon reaching the second cooking chamber 648b, the second hand <NUM> of the manipulator <NUM> attaches to the second basket 622b via the corresponding coupling <NUM> while the first hand <NUM> of the manipulator <NUM> remains attached to the first basket 622a.

<FIG> shows the transport assembly <NUM> raising the baskets 622a-b via retraction of the arm <NUM> into the hollow body <NUM> of the gantry <NUM>, as indicated by the arrow A3. In this manner, the transport assembly <NUM> raises the second basket 622b out of the second cooking chamber 648b.

<FIG> shows the manipulator <NUM> rotating clockwise about the horizontal axis, as indicated by the arrows A4, A5. During this rotation of the manipulator <NUM>, the couplings <NUM> are configured to allow the baskets 622a-b to rotate relative to the manipulator <NUM> about the respective coupling <NUM>, such that the weight of the food product contained in the baskets 622a-b may allow the baskets 622a-b to remain in a substantially level orientation while the manipulator rotates. In this manner, the baskets 622a-b may avoid spilling the food product during this rotation.

<FIG> shows that upon rotating the manipulator <NUM> about the horizontal axis such that the vertical positions of the first and second baskets 622a-b have switched, the transport assembly <NUM> lowers the baskets 622a-b via extension of the arm <NUM> from the hollow body <NUM> of the gantry <NUM>, as indicated by the arrow A6. In this manner, the transport assembly <NUM> lowers the first basket 622a into the second cooking chamber 648b for cooking the food product contained therein. When lowered into the second cooking chamber 648b, a rear downwardly facing hook <NUM> of the basket 622a may engage a support (not shown) for holding the basket 622a. While <FIG> shows that the vertical positions of the first and second baskets 622a-b have switched, alternative embodiments may simply change the heights of the first and second baskets 622a-b to position the first basket 622a relatively lower than the second basket 622b, such as in embodiments have more than two hands <NUM>, <NUM>.

<FIG> shows the transport assembly <NUM> moving the second basket 622b laterally from above the second cooking chamber 648b to a position proximate the left side wall panel 644b, as indicated by the arrow A7, with the first hand <NUM> of the manipulator <NUM> detached from the first basket 622a to leave the first basket 622a in the second cooking chamber 648b. During this time of travel, the arm <NUM> rotates counterclockwise about the vertical axis, such as to align the second basket 622b over a holding unit (not shown), as indicated by the arrow A8.

<FIG> shows that when proximate the left side wall panel 644b, the manipulator <NUM> rotates counterclockwise about the horizontal axis, as indicated by the arrow A9. During this rotation of the manipulator <NUM>, the coupling <NUM> of the second hand <NUM> of the manipulator <NUM> is configured to rotatably fix the second basket 622b relative to the manipulator <NUM>, such that this rotation of the manipulator causes the second basket 622b to tilt away from the substantially level orientation.

<FIG> shows the second basket 622b tilted as a result of the orientation of the manipulator <NUM> relative to the horizontal axis, such that the cooked food product carried by the second basket 622b may be dispensed therefrom into a holding unit.

After dispensing food product from the second basket 622b, the transport assembly <NUM> may return to a position proximate the right-side wall panel 644c and repeat the above process for subsequent batches of food product. While two baskets 622a-b are shown, it will be appreciated that additional baskets may be incorporated, such as for cooking food product in the first and third cooking chambers 648a, 648c.

The multi-handed manipulator <NUM> of the transport assembly <NUM> enables rapid placement of a basket 622a-b into a cooking chamber 648a-c immediately following removal of a basket 622a-b from that same cooking chamber 648a-c. In this regard, rather than being capable of only manipulating a single basket 622a-b at a time, which would require first moving the original basket 622a-b of cooked food product to a separate holding area before placing the next basket 622a-b into the cooking chamber 648a-c, the multi-handed manipulator <NUM> is able to place the next basket 622a-b into the cooking chamber 648a-c while continuing to hold the original basket 622a-b, prior to moving the original basket 622a-b to an unloading station, thereby maximizing the time that the cooking chamber 648a-c is used for cooking and minimizing down time to improve the throughput of the fryer <NUM>. In one embodiment, this may save between approximately <NUM> and <NUM> seconds per batch as compared to a single-handed manipulator.

The double arm gantry embodiment of the fryer <NUM> shown in <FIG> improves production and food product throughput as compared to conventional fryers and systems. To this end, the fryer <NUM> manages the workflow of baskets 622a-b to allow for up to <NUM> baskets of food product to be cooked at the same time. The food product is cooked reliably and quickly to provide high throughput of desirable quality cooked foods to meet the customer demands in the restaurant setting.

As compared to this "double arm gantry" embodiment shown in <FIG>, the automated cooking system <NUM> of the first embodiment described above with reference to <FIG> achieves several additional operational advantages. In the first embodiment (<FIG>), the gantry system <NUM> engages with the baskets <NUM> in such a manner as to eliminate any rotational basket <NUM> swinging that may lead to adjacent baskets <NUM> hitting one another, which may occur with the double arm gantry design. The gantry system <NUM> also simplifies the movements needed when engaging with and transferring baskets <NUM> to and from the platforms <NUM> in the fryer <NUM>. To this end, the gantry system <NUM> is not primarily responsible for vertical movements of baskets <NUM> into and out of the fryer <NUM>, and complicated rotation mechanisms for managing two baskets <NUM> at the same time can be omitted from this version of the gantry system <NUM>. Consequently, the cycle time needed for various basket <NUM> movement and drop-off and pickup actions is decreased even further by the automated cooking system <NUM> by an additional <NUM>%-<NUM>%. The cooking system <NUM> achieves the increased production by efficiently managing the workflow of baskets <NUM> moving between a freezer <NUM>, the fryer <NUM>, and a hot holding station <NUM>. The automated cooking system <NUM> and its methods of operation described herein therefore improve the fryer art in a significant manner to add the efficiencies with regard to both time and labor considerations and production levels required in modern restaurants without necessitating a significantly bigger fryer footprint.

Several additional drawings showing more detail of elements near the dispensing freezer <NUM> are now described in detail with reference to <FIG> (the reference numbers used below are shown applied in earlier views including <FIG>). Referring now to <FIG>, the Figures show an embodiment of a staging shelf <NUM>. As described above, the staging shelf <NUM> is generally located in the vicinity of the dispensing freezer <NUM>. As shown in <FIG>, in a deployed position the staging shelf <NUM> can support a basket <NUM>. When not supporting a basket <NUM>, the staging shelf <NUM> can, alternatively, be in a stowed position. Referring now to <FIG>, the Figures show an embodiment of a basket movement receptacle <NUM>. As described above, the basket movement receptacle <NUM> is a generally U-shaped support surrounding an open slot. The basket movement receptacle <NUM> engages with a basket <NUM> (<FIG>) and moves the basket <NUM> from a filling location, where the basket <NUM> receives uncooked food product <NUM> from the dispensing freezer <NUM>, to a pickup position, where the basket <NUM> can be engaged by the gantry <NUM> to be delivered to a platform <NUM> above a fryer vat <NUM>. Referring now to <FIG> and <FIG>, the Figures show a basket movement receptacle <NUM> and a staging shelf <NUM> arranged such that the open slot of the basket movement receptacle <NUM> faces generally towards the staging shelf <NUM>. In the depicted embodiment, the basket movement receptacle <NUM> and the staging shelf <NUM> are configured such that the staging shelf <NUM> fits within the open slot of the basket movement receptacle <NUM>. As <FIG> shows, the basket movement receptacle <NUM> and the staging shelf <NUM> work in tandem to engage a basket <NUM>. For example, a basket <NUM> located at a filling location and sitting atop a staging shelf <NUM> may be engaged from below by a basket movement receptacle <NUM>, such that the basket movement receptacle <NUM> can transport the basket <NUM> downward to a pickup position after the staging shelf <NUM> transitions/pivots from a deployed position to a stowed position. Further details of the elements shown in <FIG> are described in detail above in the overall context of the automated cooking system <NUM> and therefore are not repeated here for the sake of conciseness.

Generally, many benefits may arise through use of the automated cooking system <NUM>. The automated cooking system <NUM> allows the operator to perform other tasks while the automated cooking system <NUM> is working. Additionally, an automated cooking system <NUM> allows for improved quality control of the food product <NUM> (e.g., precise cooking time, more precise weight of product being cooked, optimized heat management by alternating product drops between the various cooking chambers, or synchronized mini-filtration during idle periods). Additionally, the automated cooking system <NUM> increases the hourly product throughput versus a manually-operated system. Further, the automated cooking system <NUM> provides superior up-time and predictive fault diagnostics due to continual baseline performance comparisons and configurable warning thresholds.

Additional benefits of the automated cooking system <NUM> include, for example, an improved operator experience, availability of manual override at any point of the process, easy cleaning (typical cooking chamber cleaning procedure where the actuator surfaces can be easily wiped down), the system <NUM> fits into customer's current fryer width footprint, the gantry fits under the <NUM> (<NUM> inch) minimum hood clearance, minimal interference with existing fire suppression systems due to the design of the system <NUM> and fryer <NUM>, making retrofit and site approvals easier, moving parts and controls being shielded from operator and extreme heat, optimized motions allowing for minimal speeds to reduce risk of operator contact, and being retrofittable to existing fryers.

In general overview, the routines executed by the system controller <NUM> (or a series of control elements as noted above in alternative embodiments) to implement the embodiments of the invention, whether implemented as part of an operating system or a specific application, component, program, object, module, or sequence of instructions, or a subset thereof, may be referred to herein as "computer program code," or simply "program code. " Program code typically comprises computer-readable instructions that are resident at various times in various memory and storage devices in a computer and that, when read and executed by one or more processors in a computer, cause that computer to perform the operations necessary to execute operations or elements embodying the various embodiments of the invention. Computer-readable program instructions for carrying out operations of the embodiments of the invention may be, for example, assembly language or either source code or object code written in any combination of one or more programming languages.

Various program code described herein may be identified based upon the application within which it is implemented in specific embodiments of the invention. However, it should be appreciated that any particular program nomenclature which follows is used merely for convenience, and thus the invention should not be limited to use solely in any specific application identified or implied by such nomenclature. Furthermore, given the generally endless number of manners in which computer programs may be organized into routines, procedures, methods, modules, objects, and the like, as well as the various manners in which program functionality may be allocated among various software layers that are resident within a typical computer (e.g., operating systems, libraries, API's, applications, applets, etc.), it should be appreciated that the embodiments of the invention are not limited to the specific organization and allocation of program functionality described herein.

With continued reference to <FIG>, the program code embodied in any of the applications or modules described herein is capable of being individually or collectively distributed as a 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 the embodiments of the invention.

Computer-readable storage media, which is inherently non-transitory, may include volatile, non-volatile, removable, and non-removable tangible media implemented in any method or technology for storage of information, 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 the desired information 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 flow-charts, 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 another 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 flow-charts, sequence diagrams, or block diagrams.

Claim 1:
An automated cooking system (<NUM>), comprising:
a fryer (<NUM>) including a plurality of fryer vats (<NUM>) each configured to hold a cooking medium (<NUM>);
a dispensing freezer (<NUM>) positioned adjacent to one lateral side of the fryer (<NUM>);
a hot holding station (<NUM>) positioned adjacent to an opposite lateral side of the fryer (<NUM>);
a plurality of baskets (<NUM>) configured to receive and hold food products during cooking cycles at the fryer; and
a gantry system (<NUM>) including a gantry control (<NUM>) operatively coupled to a gantry (<NUM>) configured to engage and move each of the baskets (<NUM>), wherein the gantry control (<NUM>) operates the gantry system (<NUM>) to:
perform a plurality of basket loading cycles, each basket loading cycle defined by at least the following: picking up a filled basket (<NUM>) from the dispensing freezer (<NUM>), moving the gantry (<NUM>) and the filled basket (<NUM>) to a selected one of the platforms (<NUM>) at the fryer (<NUM>), and dropping off the filled basket (<NUM>) onto the selected one of the platforms (<NUM>) to allow the fryer (<NUM>) to cook food product in the filled basket (<NUM>); and
perform a plurality of basket discharge cycles, each basket discharge cycle defined by at least the following: picking up a filled basket (<NUM>) containing food product that has been cooked by the fryer (<NUM>) from one of the platforms (<NUM>) at the fryer (<NUM>) with the gantry (<NUM>), moving the gantry (<NUM>) and the filled basket (<NUM>) to the hot holding station (<NUM>), and discharge the cooked food product into the hot holding station (<NUM>) to empty the basket (<NUM>),
wherein the gantry (<NUM>) control prioritizes and orders the basket loading cycles and the basket discharge cycles for the gantry system (<NUM>) to satisfy varying levels of demand for cooked food products from the fryer (<NUM>),
characterized in that each fryer vat (<NUM>) includes at least one platform (<NUM>) for receiving and moving a basket (<NUM>) into and out of the cooking medium, and
wherein each basket discharge cycle is further defined by: actuating the filled basket (<NUM>) with the gantry (<NUM>) to open the filled basket (<NUM>) and thereby discharge the cooked food product from the basket (<NUM>).