Patent Description:
This application relates generally to food product cooking systems and methods. More specifically, this application describes mechanisms and methods for adding time and labor 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. To this end, it can be quite labor-intensive for an operator to manage basket movements across multiple fryer vats or fryers, as these movements can include each of lifting and lowering the basket relative to the cooking medium, shaking the baskets and the food products container therein, and moving baskets for loading or unloading of food products.

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>-<NUM> (<NUM>-<NUM> inches) by about <NUM>,<NUM> (<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 reconfigurations are expensive, highly disfavored, and sometimes impossible.

Thus, it would be desirable to provide systems and methods 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 and methods relying on manual manipulation and handling of baskets.

<CIT> relates to an automated fryer with an overhead gantry and a method for cooking food products, wherein the movement of baskets carrying the food products is automated. The fryer includes a cooking chamber with a heating element adapted for heating a cooking medium in the cooking chamber.

<CIT> relates to an automatic fryer. The fryer comprises an oil tank and a heating element located in the oil tank. The fryer further comprises a basket, which carries the food product and a lifting structure, which is adapted to move the basket into and out of the oil tank. The lifting structure comprises a basket support onto which the basket is placed.

In accordance with embodiments of the invention, aspects of an automated cooking system with lift platforms for managing basket workflow during food preparation are described. Aspects of the automated cooking system help to avoid the problems associated with manually operating a cooking system. Specifically, the aspects of the automated cooking system described herein provides for systems and methods to prepare food product in a more efficient manner with regard to time and labor considerations within the constraints of a restaurant.

In one implementation of the invention, a fryer for use with an automated cooking system according to claim <NUM> is provided.

In one embodiment, the platform portion of the basket support platform is defined by a wire rack construction including a peripheral wire, which defines an outer periphery of the platform portion and an open top for the basket support platform. The platform portion of the basket support platform is further defined by a plurality of lateral cross wires and longitudinal cross wires that extend across a width and length surrounded by the peripheral wire, thereby collectively defining a support surface for receiving the basket.

In another embodiment, each of the lateral cross wires and longitudinal cross wires extend generally horizontally along a length thereof except adjacent connection points to the peripheral wire. Angled or bent portions are located adjacent the connection points such that the platform portion collectively defines an angled entry taper that narrows from the open top to the support surface. The angled entry taper guides the basket during insertion into the open top to correct any misalignments between the basket support platform and the basket as a bottom wall of the basket is moving into engagement with the support surface.

In yet another embodiment, the peripheral wire is located directly adjacent side walls of the basket when the bottom wall of the basket is engaged with the support surface. Additionally, each of the lateral cross wires extends above at least one of the longitudinal cross wires and extends below at least one of the longitudinal cross wires such that the lateral cross wires and longitudinal cross wires collectively define an interwoven construction at the support surface.

In a further embodiment, the platform portion of the basket support platform includes a top peripheral edge and a support surface located in elevation below the top peripheral edge. The top peripheral edge defines an open top for the basket support platform that is larger in size than the support surface such that the basket support platform includes an angled entry taper that narrows from the open top to the support surface. The angled entry taper guides the basket during insertion into the open top to correct any misalignments between the basket support platform and the basket as a bottom wall of the basket is moving into engagement with the support surface.

In one embodiment, the platform support hanger includes a hook receptacle and the support arm of the basket support platform includes a lateral rod sized to be inserted within the hook receptacle to releasably couple the support arm to the platform support hanger. Further, the platform support hanger includes a plurality of hook receptacles located at different elevations along a height of the platform support hanger. The support arm of the basket support platform includes a plurality of lateral rods sized and positioned to be inserted within the plurality of hook receptacles to releasably couple the support arm to the platform support hanger.

In another embodiment, the lift base includes a housing and a front panel that is moveably connected to the housing and driven to move upwardly and downwardly by the motor contained within the housing. The front panel includes connection elements configured to removably engage with connection elements on the platform support hanger such that the platform support hanger extends downwardly below a bottom end of the front panel. Additionally, at least one of the connections between the platform support hanger and the lift base or the basket support platform is configured to allow pivotal relative movement such that the basket support platform and/or the platform support hanger can be pivoted upwardly away from the fryer vat to allow the fryer vat to be accessed for cleaning or maintenance.

In yet another embodiment, the lift base for each vertical transport assembly is mounted on the frame behind and above a top opening of a respective fryer vat, thereby keeping a front end of baskets supported on the vertical transport assembly fully accessible for manipulation and movement by a gantry that may be included in the automated cooking system for moving baskets around to cooking stations. Further, when a basket is loaded onto the basket support platform, the motor of the vertical transport assembly is controlled to move the basket and the basket support platform between an upper position, in which the basket is located above the cooking medium, and a lower position, in which the basket is substantially submerged in the cooking medium.

In a further embodiment, the motor of the vertical transport assembly is further controlled to rapidly move the basket and the basket support platform in a reciprocating manner to selectively shake the basket while at or near the lower position to break up product marriages of food product that may develop during a cooking cycle at the fryer. Additionally, the movements of the basket and the basket support platform between the upper position and the lower position and the shaking movements of the basket and the basket support platform generated by the motor are both defined by generally vertical up-and-down movements. An amplitude and a frequency of shaking movements generated by the motor at the basket are adjustable.

In another implementation of the invention, a method of cooking food products with an automated cooking system according to claim <NUM> is provided.

In one embodiment, the platform portion of the basket support platform is defined by a wire rack construction including a peripheral wire. The peripheral wire defines an outer periphery of the platform portion and an open top for the basket support platform. The platform portion is further defined by a plurality of lateral cross wires and longitudinal cross wires that extend across a width and length surrounded by the peripheral wire, thereby collectively defining a support surface for receiving the basket. Further, and the method step of setting the basket of food product onto the platform portion further includes engaging a bottom wall of the basket with the support surface.

In another embodiment, the platform portion of the basket support platform includes a top peripheral edge and a support surface located in elevation below the top peripheral edge. The top peripheral edge defines an open top for the basket support platform that is larger in size than the support surface such that the basket support platform includes an angled entry taper that narrows from the open top to the support surface. Further, the method step of setting the basket of food product onto the platform portion further includes inserting the basket into the open top of the basket support platform and guiding the basket to the basket support platform by the angled entry taper. Additionally, the method step of setting the basket of food product onto the platform portion includes correcting misalignments between the basket support platform and the basket by laterally moving the basket with the angled entry taper as a bottom wall of the basket is moving towards and into engagement with the support surface.

In yet another embodiment, the method further includes rapidly moving the basket and the basket support platform in a reciprocating manner to selectively shake the basket while at or near the lower position to break up product marriages of food product that may develop during a cooking cycle at the fryer. Movements of the basket are defined by generally vertical up-and-down movements of the basket and the basket support platform, which are generated by the motor.

In a further embodiment, the method of cooking food products further includes adjusting an amplitude and a frequency of the generally vertically up-and-down movements of the basket generated by the motor, to thereby vary the shaking of the basket.

The steps and elements described herein as part of various embodiments and aspects can be reconfigured and combined in different combinations to achieve the desired technical effects as may be desired. To this end, the embodiments and aspects 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>, 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>. The workflow of baskets <NUM> is achieved, at least in part, by using a gantry system <NUM> as well as vertical transport assemblies <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>. Vertical transport assemblies <NUM> of this system <NUM> lift and lower baskets <NUM> into and out of the cooking medium <NUM> of the fryer vats <NUM> using innovative combinations of elements as described below to cook food product <NUM> in a more efficient manner, and thereby achieve higher maximum production levels with less labor cost than traditional fryer systems and methods relying on manual manipulation and handling of baskets. 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.

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>. 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>, without departing from the scope of this disclosure.

Still referring to <FIG>, 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 <NUM> 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>). The gantry system <NUM> is configured to service each platform <NUM> associated with each fryer vat <NUM> with a basket <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.

Referring now to <FIG>, an exemplary embodiment of the fryer <NUM> used in the automated cooking system <NUM> is shown. 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, the fryer <NUM> advantageously 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>. The vertical transport assemblies <NUM> are addressed in greater detail below. 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>.

Referring now 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>. Such cooking is effectuated by the vertical transport assemblies <NUM>.

Referring now to <FIG>, the Figure shows a series of vertical transport assemblies <NUM> with baskets <NUM> engaged with the platforms <NUM> of the assemblies <NUM>. Broadly, the vertical transport assemblies <NUM> are configured to support and transport baskets <NUM> of food product <NUM> upwardly and downwardly relative to the fryer vats <NUM>-thereby moving the baskets <NUM> of food product <NUM> into and out of the cooking medium <NUM> of the fryer vats <NUM>. As shown best in <FIG> and <FIG>, a portion of each vertical transport assembly <NUM> is mounted in a stationary manner on the frame <NUM> of the fryer <NUM>. Generally, the vertical transport assemblies <NUM> are located proximate to (e.g., on a rear end of the fryer <NUM>) and associated with each of the fryer vats <NUM> (e.g., located and above the fryer vats <NUM>). Specifically, a portion of each vertical transport assembly <NUM> is mounted on the frame <NUM> of the fryer <NUM> behind and above a top opening of a respective fryer vat <NUM>. This configuration allows for a front end of baskets <NUM> to be supported on the vertical transport assembly <NUM> while remaining fully accessible for manipulation and movement by the gantry <NUM>.

As shown in <FIG> and <FIG>, each vertical transport assembly <NUM> includes a lift base <NUM>, a platform support hanger <NUM>, and a basket support platform <NUM>. The lift base <NUM> is mounted on the frame <NUM> and contains a motor (not shown). The platform support hanger <NUM> extends from the lift base <NUM> and is operatively coupled to the motor. The lift base <NUM> of this embodiment more specifically includes a housing <NUM> and a front panel <NUM> that covers a portion of and is moveably connected to the housing <NUM>. The front panel <NUM> includes connection elements <NUM> configured to removably engage with connection elements <NUM> on the platform support hanger <NUM> such that when the platform support hanger <NUM> is attached to the front panel <NUM>, the platform support hanger <NUM> extends downwardly below a bottom end of the front panel <NUM>. The platform support hanger <NUM> includes a hook receptacle <NUM> for receiving a portion of the basket support platform <NUM>. In a further embodiment, the platform support hanger <NUM> includes a plurality of hook receptacles <NUM> located at different elevations along a height of the platform support hanger <NUM> for receiving a portion (or portions) of the basket support platform <NUM>.

The front panel <NUM> is driven to move upwardly and downwardly by the motor contained within the housing <NUM> of the lift base <NUM>. In turn the motor actuates to generate movement of the platform support hanger <NUM> (attached to the front panel <NUM>) relative to the fryer vat <NUM>. It will be understood that the operative connection between a motor and the front panel <NUM> may be made by a gear or by a number of gears (or similar). In an embodiment, a drive gear engages in a meshed engagement with a toothed rack in a rack- and-pinion arrangement, thereby causing up-and-down or generally vertical translation of the front panel <NUM> of the lift base <NUM> based on rotations of the drive gears. The motor is selected so that it can rotate drive gears in either direction as needed. It will further be understood that other embodiments of the vertical transport assembly <NUM> can include alternative drive mechanisms for achieving movements of the various components of the vertical transport assembly <NUM>. For example, a timing-belt based drive system could be used to link an input drive/motor with the front panel <NUM> of the lift base <NUM>. Other known drive mechanisms may also be substituted as the "motor" for generating the multiple types of generally vertical up-and-down movement according to further embodiments of this invention. Moreover, though one example of the interior drive structures that may be within the housing <NUM> is schematically shown in <FIG> described below, it will be understood that this interior drive structure may vary in the embodiments of the present invention.

Still referring to <FIG> and <FIG>, the basket support platform <NUM> is removably connected to the platform support hanger <NUM> and includes a support arm <NUM>. Particularly, the support arm <NUM> of the basket support platform <NUM> includes a lateral rod <NUM> sized and configured to be inserted within the hook receptacle <NUM> of the platform support hanger <NUM> to releasably couple the support arm <NUM> of the basket support platform <NUM> to the platform support hanger <NUM>. In a further embodiment, the support arm <NUM> of the basket support platform <NUM> includes a plurality of lateral rods <NUM> sized and positioned to be inserted within the plurality of hook receptacles <NUM> of the platform support hanger <NUM> to releasably couple the support arm <NUM> to the platform support hanger <NUM>. Further, at least one of the connections between the platform support hanger <NUM> and the lift base <NUM> or the basket support platform <NUM> is configured to allow pivotal movement such that the basket support platform <NUM> and/or the platform support hanger <NUM> can be pivoted upwardly away from the fryer vat <NUM> to allow the fryer vat <NUM> to be accessed for cleaning or maintenance. For example, at least one of the lateral rods <NUM> and the corresponding hook receptacle <NUM> are formed with a cylindrical or rounded shape that allows for relative rotation of the elements noted. The support arm <NUM> extends in a generally vertical direction (away from the rest of the basket support platform <NUM>) and connects the platform support hanger <NUM> with a tray-shaped platform portion <NUM>.

The tray-shaped platform portion <NUM> extends in a generally horizontal direction out from the support arm <NUM>. As will be discussed in greater detail below, the tray-shaped platform portion <NUM> is configured and shaped to circumferentially surround a bottom portion of a basket <NUM> when the basket <NUM> is set onto the basket support platform <NUM>. The configuration and shape of the tray-shaped platform portion <NUM> serves to reliably retain the basket <NUM> during movements of the vertical transport assembly <NUM> towards and away from the fryer vat <NUM> and cooking medium <NUM>. In this regard, the platform portion <NUM> prevents any lateral swinging movements of the basket <NUM> during a cooking cycle, which helps achieve less basket "touches" or undesirable contacts between baskets <NUM> in adjacent fryer vats <NUM>.

Referring now to <FIG> and <FIG>, the Figures show the various positions of the vertical transport assembly <NUM>-namely, an upper position (<FIG>) and a lower or cooking position (<FIG>). Generally, when a basket <NUM> is loaded onto the basket support platform <NUM>, the motor of the vertical transport assembly <NUM> is controlled to move the basket <NUM> and the basket support platform <NUM> between an upper position (<FIG>), in which the basket <NUM> is located above the cooking medium <NUM>, and a lower position or cooking position (<FIG>), in which the basket is substantially submerged in the cooking medium <NUM>.

<FIG> shows the vertical transport assembly <NUM> in a retracted state and at an upper position in which a basket <NUM> would be positioned above the fryer vat <NUM> and cooking medium <NUM>. In this upper position, food products <NUM> are not immersed in cooking medium and thus may be loaded or unloaded from the basket <NUM> as necessary, and the basket <NUM> may be temporarily removed from engagement from the vertical transport assembly <NUM> (e.g., by the gantry <NUM>) to perform these functions. To arrive at the upper position, the vertical transport assembly <NUM> (e.g., motor) is actuated to move the front panel <NUM> and thus the platform support hanger <NUM> and basket support platform <NUM> upwardly from the lower position. Further, as shown by arrow A1, the vertical transport assembly <NUM> is preparing (or ready) to move (via a motor or similar) the platform support hanger <NUM> and the basket support platform <NUM> downwardly to a lower position (or cooking position).

<FIG> shows the vertical transport assembly <NUM> in an extended state and at a lower position in which a basket <NUM> attached to the basket support platform <NUM> would be substantially submerged in the cooking medium <NUM> in a fryer vat <NUM>. This lower position may also be referred to as the cooking position. To arrive at the lower position, the vertical transport assembly <NUM> (e.g., motor) is actuated to move the front panel <NUM> and thus the platform support hanger <NUM> and basket support platform <NUM> downwardly from the upper position. Further, as shown by arrow A2, the vertical transport assembly <NUM> is preparing (or ready) to move (via a motor or similar) the platform support hanger <NUM> and the basket support platform <NUM> upwardly to an upper position.

Referring again to <FIG> and <FIG>, the motor of the vertical transport assembly <NUM> can be further controlled to rapidly move the basket <NUM> and the basket support platform <NUM> in an up-and-down reciprocating manner (e.g., shaking). As described in greater detail below with respect to <FIG>, selectively shaking the basket <NUM>, including while the basket <NUM> is at or near the lower position, serves to break up product marriages of food product <NUM> that may develop during a cooking cycle at the fryer <NUM>. The movements of the basket <NUM> and the basket support platform <NUM> between the upper position (<FIG>) and the lower position (<FIG>) and the shaking movements of the basket <NUM> and the basket support platform <NUM> generated by the motor are both defined by generally vertical up-and-down movements. The amplitude and frequency of the shaking movements can be adjusted using a controller connected to the motor (e.g., the system controller <NUM>), to thereby tailor the shaking force and movements applied to successfully break up any clumps of food product <NUM> that may be formed based on the type of food product <NUM> in the basket <NUM>. As described further below, the basket support platform <NUM> surrounds a bottom portion of the basket <NUM> in such a manner to reliably retain the basket <NUM> and prevent unwanted touches with other baskets regardless of the movement speed or amplitude and frequency applied by the motor.

Referring now to <FIG>, the Figure shows a tray-shaped platform portion <NUM> shaped and configured to receive a basket <NUM> thereupon. The platform portion <NUM> is defined by a wire rack construction including a peripheral wire <NUM> and a plurality of lateral cross wires <NUM> and longitudinal cross wires <NUM>. The peripheral wire <NUM> which defines an outer periphery of the platform portion <NUM> and an open top for the basket support platform <NUM>. The plurality of lateral cross wires <NUM> and longitudinal cross wires <NUM> extend across a width and length, respectively, of the platform portion <NUM> and are surrounded by the peripheral wire <NUM>.

Collectively, the peripheral wire <NUM> and plurality of lateral cross wires <NUM> and longitudinal cross wires <NUM> define a support surface <NUM> for receiving the basket <NUM>. The lateral cross wires <NUM> extend above at least one of the longitudinal cross wires <NUM> and extends below at least one of the longitudinal cross wires <NUM> such that the lateral cross wires <NUM> and longitudinal cross wires <NUM> collectively define an interwoven construction at the support surface <NUM>. It is to be understood that alternative weaving patterns could be employed without diverging from the scope of the disclosure. Further, the platform portion <NUM> of the basket support platform <NUM> includes a top peripheral edge <NUM>. The support surface <NUM> is located in (vertical) elevation below the top peripheral edge <NUM>. The top peripheral edges <NUM> define an open top for the basket support platform <NUM> that is larger in size than the support surface <NUM> such that the basket support platform <NUM> includes an angled entry taper <NUM>, described in greater detail below, that narrows from the open top to the support surface <NUM>. As shown in <FIG> and <FIG>, the peripheral wire <NUM> may connect to and/or be replaced by an L-shaped bracket <NUM> at a rear end of the platform portion <NUM>, the L-shaped bracket <NUM> defining the connection of the elements of the platform portion <NUM> to the support arm <NUM>. Likewise, the peripheral wire <NUM> at an opposite front end of the platform portion <NUM> may include a downwardly recessed portion <NUM> that is configured to provide clearance for basket-opening actuation or gripping point elements on the fryer basket <NUM>, such elements being shown best at <FIG>.

Referring now to <FIG>, <FIG>, and <FIG>, the Figures show further details of the tray-shaped platform portion <NUM>. As shown in <FIG>, the lateral cross wires <NUM> and longitudinal cross wires <NUM> extend in a generally horizontal direction along a length of the platform portion <NUM>. <FIG> shows angled or bent portions <NUM> located adjacent connection points of the lateral cross wires <NUM> and longitudinal cross wires <NUM> to the peripheral wire <NUM> (and/or to the L-shaped bracket <NUM>, when present). Some of the bent portions <NUM> extend upwardly form an elevation of the support surface <NUM> and some of the bent portions <NUM> extend downwardly from the elevation of the support surface <NUM>, depending on where the opposite end of the bent portions <NUM> must connect to the peripheral wire <NUM> (including its downwardly recessed portion <NUM>) and/or to the L-shaped bracket <NUM>. Collectively, the angled or bent portions <NUM> define an angled entry taper <NUM> that narrows from the open top to the support surface <NUM>. The angled entry taper <NUM> is shaped and configured to guide the basket <NUM> when the basket <NUM> is inserted into the open top of the platform portion <NUM> (arrow A3 in <FIG>) to correct any potential misalignments between the basket support platform <NUM> and the basket <NUM> as a bottom wall of the basket <NUM> moves into engagement with the support surface <NUM>. As <FIG> shows, when the bottom wall of the basket <NUM> is engaged with the support surface <NUM> the peripheral wire <NUM> is located directly adjacent to the side walls of the basket <NUM> to thereby circumferentially surround a bottom portion of the basket <NUM>.

Referring now to <FIG>, these Figures show a series of steps defining a portion of basket loading cycle and a portion of a basket discharge cycle according to embodiments of this invention, each of which may be repeatedly performed to manage basket workflow at the cooking system <NUM>. The movements of the baskets <NUM> with the vertical transport assemblies <NUM> are also shown as a part of this operation of the cooking system <NUM>.

Referring to <FIG>, the Figure shows a basket <NUM>, filled with uncooked food product <NUM>, to the left of the fryer <NUM> and located in a pickup position adjacent the dispensing freezer <NUM> (not shown). The basket <NUM> has previously been filled with uncooked food product <NUM> by the dispensing freezer <NUM> (not shown) at a filling location. If necessary, the basket movement receptacle <NUM> has moved the basket <NUM> from a filling location to the pickup location shown in the Figure such that the basket <NUM> is ready to be engaged by the gantry <NUM>. After receiving a signal from the gantry control <NUM>, the gantry <NUM> engages with the filled basket <NUM> and moves the basket <NUM> from the basket movement receptacle <NUM> to an open platform <NUM> above a fryer vat <NUM>, as shown by the rightward and downward movement arrows A4 in <FIG>. Which platform <NUM> the basket <NUM> is 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>. In this position, the bottom portion of the basket <NUM> is circumferentially surrounded by the tray-shaped platform portion <NUM> at the platform <NUM> of the vertical transport assembly <NUM> to reliably retain the basket <NUM> for future movement steps as set forth in the workflow below.

Further, the Figure shows a basket <NUM>, filled with partially cooked food product <NUM>, submerged in a cooking medium <NUM> in a fryer vat <NUM> near a right side of the fryer <NUM>. At a certain time within the cooking cycle, or alternatively at a series of set times within the cooking cycle, a basket shaking routine may be implemented (e.g., by the system controller <NUM> or the gantry control <NUM>). To this end, the motor within the lift base <NUM> actuates with rapid changes in direction repeatedly to quickly translate the basket support platform <NUM> and basket <NUM> through small upward and downward movements as indicated by shaking movement arrows A5. Such is similar to manual shaking of the basket <NUM> by an operator. The shaking or small upward and downward movements of the basket <NUM> jostles the food products <NUM> within the basket <NUM> to break up any product marriages that may occur during the cooking process in the cooking medium <NUM>. However, the food products <NUM> remain submerged within the cooking medium <NUM> during this shaking movement so that the cooking process continues.

Still referring to <FIG>, the frequency and the amplitude of the shaking movement can be adjusted based on the preferences of the end user (such as, for example, adjusted based on the type of food product <NUM> or the type of fryer vat <NUM>). In one example, the small upward and downward movements may extend through about <NUM>,<NUM> (<NUM> inches) of total movement and may cycle up-and-down once per second. The shaking movement may apply approximately <NUM>'s of force when accelerating the basket <NUM> in the upward and downward movements. It will be understood that the total length of shaking movement travel (e.g., the amplitude) and the frequency of the shaking movements can increase or decrease without departing from the scope of this disclosure. The amplitude and frequency of shaking movements simply needs to be set so that the movements are sufficient to reliably break up product marriages of food products <NUM> in the basket <NUM>, but without causing splashing of cooking medium <NUM> from the fryer <NUM> or the like. Moreover, the time periods between initial insertion of the basket <NUM> into the cooking medium <NUM> and the shaking movement, and/or the time period between shaking movements when multiple shaking movements are performed during a cooking cycle, can be adjusted at the electronic control of the motor (e.g., by the system controller <NUM>).

Although typically unnecessary because drip time for remaining cooking medium <NUM> on the food products <NUM> and the basket <NUM> is minimal, in some embodiments the shaking movement (or a smaller version thereof) can be performed by actuating the motor to quickly drive the basket <NUM> through small up-and-down movements while the vertical transport assembly <NUM> is located at an upper position. Such a shaking movement in the upper position (<FIG>) could help assure that all excess cooking medium <NUM> has dripped off before the basket <NUM> is moved to dump the cooked food products <NUM> to the next station or step.

Referring now to <FIG>, the Figure shows a basket <NUM> on the left side of the fryer <NUM> filled with uncooked food product <NUM> and located on a platform <NUM> above a fryer vat <NUM>. As indicated by arrow A6, the basket <NUM> will be lowered into a cooking medium <NUM> for a cooking cycle via the vertical transport assembly <NUM>. Further, <FIG> shows a basket <NUM> on the right side of the fryer <NUM> filled with cooking food product <NUM> that is preparing to emerge from the cooking medium <NUM> in a fryer vat <NUM>. As shown by the upward arrow A7, the vertical transport assembly <NUM> will lift the platform <NUM> on which the basket <NUM> sits, thus raising the basket <NUM> from the fryer vat <NUM> and out of the heated cooking medium <NUM> and ending a cooking cycle.

In general, 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 signals to initiate or end 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.

Referring now to <FIG>, the Figure shows a basket <NUM> on the right side of the fryer <NUM> filled with cooked food product <NUM> (after exiting a fryer vat <NUM>) preparing to be moved, as shown by arrow A8, from a platform <NUM> above the fryer vat <NUM> to a position above the hot holding station <NUM> via the gantry <NUM>. As a result, the basket <NUM>, filled with cooked food product <NUM>, will be suspended in a position at a height above the hot holding station <NUM> by the gantry <NUM>. Upon receiving a signal from the gantry control <NUM>, the gantry <NUM> will actuate the filled basket <NUM> to discharge the cooked food product <NUM> into the hot holding receiving area <NUM> of the hot holding station <NUM>. The cooked food is then held in the hot holding receiving area <NUM> for further preparation and packaging by an operator.

Nevertheless, the gantry <NUM> is configured to manage the workflow of <NUM> or more baskets <NUM> and cooking stations (platforms <NUM>) at the fryer <NUM> simultaneously to provide an increased maximum cooking volume throughput of the cooking system <NUM>. The automated cooking system <NUM> (specifically, the vertical transport assemblies <NUM> and the components thereof) therefore improves the field of cooking equipment and methodologies by limiting the need for operator intervention (and associated expense) while maximizing how much food product <NUM> can be cooked and prepared within the standard space used by fryers in commercial setting kitchens. As such, the reliability and throughput is significantly improved even over other automatic fryer designs.

Referring now to <FIG>, the Figures show an embodiment of a staging shelf <NUM>. As described above with respect to <FIG>, 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 with respect to <FIG>, 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 a 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 sat 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 from a deployed position to a stowed position.

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 <NUM> fits under the <NUM>,<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. Furthermore, although the operational improvements and efficiencies have been explained with reference to an automated cooking system <NUM> that uses both the gantry system <NUM> and the vertical transport assemblies <NUM>, it will be understood that many of the same technical improvements are achieved when using the vertical transport assemblies <NUM> with fryers that do not have a fully automated gantry system <NUM> as well. To this end, the present invention is not so limited to the specific examples and context shown in the drawings described above.

Claim 1:
A fryer (<NUM>) for use with an automated cooking system (<NUM>), the fryer comprising:
a plurality of fryer vats (<NUM>), each configured to hold a cooking medium (<NUM>), and each defining one or more cooking stations at the fryer;
at least one heating element (<NUM>) disposed within each of the fryer vats (<NUM>); and
a vertical transport assembly (<NUM>) located proximate to and associated with each of the fryer vats (<NUM>), the vertical transport assembly (<NUM>) configured to support and move a basket (<NUM>) of food product into and out of the cooking medium at the fryer vat (<NUM>), and each vertical transport assembly (<NUM>) including:
a lift base (<NUM>) mounted proximate to the associated fryer vat (<NUM>) and containing a motor;
a platform support hanger (<NUM>) extending from the lift base (<NUM>) and operatively coupled to the motor, such that the motor actuates to generate movement of the platform support hanger (<NUM>) relative to the fryer vat (<NUM>);
characterized by a basket support platform (<NUM>) removably connected to the platform support hanger (<NUM>), the basket support platform (<NUM>) including a support arm (<NUM>) extending generally vertically to connect with the platform support hanger (<NUM>) and a tray-shaped platform portion (<NUM>) extending generally horizontally from the support arm (<NUM>), the tray-shaped platform portion (<NUM>) being configured and shaped to circumferentially surround a bottom portion of a basket (<NUM>) set onto the basket support platform (<NUM>), to thereby retain the basket (<NUM>) during movements towards and away from the cooking medium.