Patent Description:
This application relates generally to a food product cooking system. More specifically, this application describes mechanisms 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.

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 a fully automated robotized system and a method for cooking food products. The system uses a plurality of fry baskets to prepare food products like French fries. Each fry basket comprises a gripping handle, which is configured to be gripped by a gripping unit of the system.

<CIT> relates to an automatic fryer system, which includes a fry basket, a fryer unit, a horizontal and a vertical drive system and an actuator for grasping and holding the fry basket. The fry basket comprises a vertical member at which indentations are formed, which cooperate with first and second clamps of the grasping actuator.

In accordance with embodiments of the invention, aspects of an automated cooking system and a corresponding method for discharging cooked food product are described. Aspects of an automated cooking system and a corresponding method for discharging cooked food product help to avoid the problems associated with manually operating a cooking system. Specifically, the aspects of an automated cooking system described herein provide for systems and methods to cook and dispense food product in a more efficient manner with regard to both time and labor considerations within the constraints of a restaurant. The problem stated above is solved by an automated cooking system according to claim <NUM>.

In one implementation of the invention, an automated cooking system including a fryer basket and a gantry according to claim <NUM> is provided.

In one embodiment, the head portion is substantially coextensive in diameter with the main body. Further, the main body and the head portion are tapered inwards towards the neck portion to help correct potential misalignment of the jaws of the clamping gripper on the pickup point. Moreover, the neck portion is substantially coextensive in width to the jaws of clamping gripper.

In another embodiment, the pickup point includes a flat surface along a chord of a cross-section of the neck portion. The pickup point also includes a dowel located above the flat surface of the neck portion. The dowel spans a distance from the head portion to the main body. Additionally, at least the dowel is configured to engage with the jaws of the clamping gripper to prevent uncontrolled rotational movements of the basket when the basket is moved as to avoid impacts of the basket with any other basket of the automated cooking system.

Additionally, each of the jaws of the clamping gripper is C-shaped as to snugly fit the pickup point between the pair of jaws when engaging with the basket. Moreover, an edge of the jaw that contacts the pickup point of the basket is contoured to facilitate easier gripping of the pickup point.

In a further embodiment, the basket further includes a product discharge mechanism positioned adjacent the frame and operatively coupled to the angled panels. Additionally, the gantry further includes an actuator arm configured to interact with the basket, suspended in place by the clamping gripper, in such a way as to cause the basket to discharge its contents. Moreover, the actuator arm is pneumatically powered. Further, when not in active use the actuator arm is rotated away from the front of the gantry as to not cause inadvertent contact with the basket.

In one embodiment, the automated cooking system further includes a basket detection device. The basket detection device is configured to detect the presence of a basket in front of the clamping gripper. The basket detection device is used to line up the jaws of the clamping gripper with the pickup point of the basket. Further, the basket detection device can be selected from the group consisting of a proximity switch, a torque sensor, and a laser.

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> and <FIG>, an automated cooking system <NUM> including a fryer <NUM> is shown in accordance with an exemplary embodiment which is not within the scope of the claims. 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 gantry <NUM> of this system <NUM> engages with and actuates the baskets <NUM> using innovative interface elements described below that collectively improve both the movement precision and reliability for baskets <NUM> while also allowing for better system cycle efficiencies resulting at least in part from rapid basket opening and closing operations performed using such interface elements. The system <NUM> 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.

Continuing with reference to <FIG>, an exemplary automated cooking system, which is not within the scope of the claims, <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.

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 <NUM> 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 air flow 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 <NUM> 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.

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 <NUM> 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 which is not within the scope of the claims, 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>.

Referring now to <FIG>, an exemplary embodiment of the fryer <NUM> used in the automatic cooking system <NUM> is shown, which is not within the scope of the claims. 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 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 fryer 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 not within the scope of the claims, 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>.

Referring now to <FIG>, these Figures illustrate an embodiment of the basket <NUM>. As shown in <FIG>, the shape of the basket is defined by the basket frame <NUM>. The basket frame <NUM> is made up of a series of connected panels-the front panel <NUM>, the back panel <NUM>, and two side panels <NUM>. The panels <NUM>, <NUM>, <NUM> are connected to each other at or near their sides edges. Specifically, the front panel <NUM> is connected at one edge to a side panel <NUM> and at an opposing edge to a different side panel <NUM>. Similarly, the back panel <NUM> is connected at one edge to a side panel <NUM> and at an opposing edge to a different side panel <NUM>. Together, the panels <NUM>, <NUM>, <NUM> form a rectangular cuboid shape with two opposing open faces-the top and the bottom of the basket frame <NUM>. It is to be understood that other constructions and shapes of the basket <NUM> are possible. Further, it is to be understood that the front <NUM>, back <NUM>, and side panels <NUM> could be different sizes from one another depending on a user's needs or preferences. For example, <FIG> shows that the side panels <NUM> of the basket <NUM> are significantly shorter than the front and back panels <NUM>, <NUM>. In the pictured embodiment, the side panels <NUM> are shortened to allow for the addition of angled panels <NUM>, described in further detail below. Regardless of the shape or construction of the basket frame <NUM>, the interior of the connected panels <NUM>, <NUM>, <NUM> defines the bounds of a storage space <NUM> therein. The storage space <NUM> is used to, for example, hold food product <NUM>.

Completing the bounds of the storage space <NUM> of the basket <NUM> are the two angled panels <NUM>. Each angled panel <NUM> is roughly L-shaped. It is to be understood that the angled panels <NUM> could be differently shaped and still perform the function described herein. An angled panel <NUM> is coupled to and extends from each of the side panels <NUM>. Specifically, an angled panel <NUM> extends downwardly from a side panel <NUM> and then extends inwardly, towards a center of the basket <NUM> along a bottom face of the basket <NUM>. The angled panels <NUM> are coupled to the side panels <NUM> and are configured to pivot about their couplings <NUM>-between a closed position and an open position. In the closed position, the edges of the angled panels <NUM> are approximately coextensive with the edges of the front and back panels <NUM>, <NUM> such that they, collectively, define a closed bottom of the storage space <NUM>. Further, the edges of the angled panels <NUM> meet each other roughly in the middle of the bottom face of the basket <NUM>. Thus, in the closed position the angled panels <NUM> form the bounds for the bottom and part of the sides of the basket <NUM> to prevent food product <NUM> from falling out of the basket <NUM>. Transitioning from the closed position to the open position, the angled panels <NUM> pivot about their couplings <NUM> to extend outwardly from the side panels <NUM> to form an opening in at least the bottom of the basket <NUM>. The opening may also extend to the side of the basket <NUM> depending on where the angled panels <NUM> are coupled to the side panels <NUM>. Regardless, with the angled panels <NUM> in the open position food product <NUM> in the basket <NUM> will exit the basket <NUM> through an opening in at least the bottom of the basket <NUM> formed by the absence of the angled panels <NUM> (e.g., the angled panels <NUM> no longer form a bottom of the basket <NUM>). When the angled panels <NUM> are in the open position, the baskets <NUM> are configured such that food product <NUM> will exit the basket <NUM> in less than <NUM> seconds. Specifically, the baskets <NUM> are configured to be emptied of food product <NUM> in less than <NUM> seconds. Such rapid evacuation of the food product <NUM> from the basket <NUM> when the angled panels <NUM> transition from the closed position to the open position offers an advantage over some other baskets known in the art.

Still referring to <FIG>, a product discharge mechanism <NUM> is positioned on the front panel <NUM> of the basket <NUM>. The product discharge mechanism <NUM> functions to control the position of the angled panels <NUM>-which in turn determines if and when the basket <NUM> will discharge food product <NUM>. Specifically, the product discharge mechanism <NUM> is responsible for changing the position of the angled panels <NUM> from a closed position to an open position and vice versa. The product discharge mechanism <NUM> is coupled to both of the angled panels <NUM> such that actuating the product discharge mechanism <NUM>, in turn, causes the angled panels <NUM> to change position (e.g., from closed to open or vice versa). The product discharge mechanism <NUM> is biased to keep the angled panels <NUM> in the closed position until the product discharge mechanism <NUM> is actuated. Actuating the product discharge mechanism <NUM> generates pivotal movement of the angled panels <NUM> about their couplings <NUM> such that the angled panels <NUM> move away from each other into an open position. In the open position, the angled panels <NUM> no longer form the bottom face of the storage space <NUM> of the basket <NUM>. In other words, in the open position an opening or void is created in the bottom of the basket <NUM>. Thus, when the angled panels <NUM> are in the open position, the food product <NUM> can exit the basket <NUM>, for example into the hot holding receiving area <NUM>. Further, when the product discharge mechanism <NUM> is not actuated, the product discharge mechanism <NUM> returns the angled panels <NUM> to the closed position-thereby creating a bottom 'floor' for the basket <NUM>-so that more food product <NUM> can be deposited into the storage space <NUM> of the basket <NUM>.

Still referring to <FIG>, located near the top of the front panel <NUM> of the basket <NUM> and connected to the product discharge mechanism <NUM> is the pickup point <NUM>. The pickup point <NUM> is described in greater detail below with respect to <FIG>. Briefly, the pickup point <NUM> is configured to be gripped, for example, by the clamping gripper <NUM> so that the basket <NUM> can be moved from location to location within the automated cooking system <NUM>. Features of the pickup point <NUM> provide for greater ease of handling and enhanced stability when gripping and transporting the basket <NUM> by the pickup point <NUM>.

Turning to <FIG>, the Figure shows the product discharge mechanism <NUM> in greater detail. Generally, the product discharge mechanism <NUM> serves to maintain the angled panels <NUM> in a closed position until the product discharge mechanism <NUM> is actuated. When actuated, the product discharge mechanism <NUM> moves the angled panels <NUM> from the closed position to an open position. After actuation, the product discharge mechanism <NUM> moves the angled panels <NUM> back to the closed position from the open position.

<FIG> and <FIG> show the basket with the angled panels <NUM> in the closed position. Specifically, <FIG> more clearly shows some details of the product discharge mechanism <NUM> and interactions of the product discharge mechanism <NUM> with the angled panels <NUM>. Further, <FIG> shows the rear of the basket <NUM> when the angled panels <NUM> are in the closed position.

Referring now to <FIG>, the Figure shows the front of the basket <NUM>-and specifically the product discharge mechanism <NUM>-when the angled panels <NUM> are in an open position. Further, <FIG> shows the rear of the basket <NUM> when the angled panels <NUM> are in the open position.

Referring to <FIG>, the Figures show an embodiment of a pickup point <NUM> of a basket <NUM>. The pickup point <NUM> is in the form of a spool that may be grasped by the clamping gripper <NUM>, as shown and described in relation to <FIG>. The pickup point <NUM> includes a cylindrical main body <NUM>. The main body <NUM> connects the pickup point <NUM> to the front surface of the front panel <NUM> of the basket <NUM>. Extending outwardly from the main body <NUM> is the cylindrical neck portion <NUM> of the pickup point <NUM>. In an embodiment, the neck portion <NUM> is smaller is diameter than the main body <NUM>. The neck portion <NUM> is the part of the pickup point <NUM> intended to be gripped, by the clamping gripper <NUM>. Extending outwardly from the neck portion <NUM> is the cylindrical head portion <NUM>. In an embodiment, the head portion <NUM> is greater in diameter than the neck portion <NUM>. The neck portion <NUM> being smaller in diameter than the main body <NUM> and the head portion <NUM> is intended to make it easier to grip the neck portion <NUM>. Further, the main body <NUM> and the head portion <NUM> may be tapered inwards towards the neck portion <NUM> to further aid in gripping the neck portion <NUM>. Moreover, tapered portions <NUM> of the main body <NUM> and head portion <NUM> will help to correct potential misalignment of the clamping gripper <NUM> when the clamping gripper <NUM> initiates contact with the pickup point <NUM>.

Further, in an embodiment the pickup point <NUM> includes additional features to increase the stability of the basket <NUM> when picked up and transported via the pickup point <NUM>. To that end, in an embodiment the neck portion <NUM> of the pickup point <NUM> features a flat surface <NUM> located along a chord of a cross-section of the neck portion <NUM>. For example, the flat surfaces <NUM> may be located on the top and bottom of the neck portion <NUM>. The flat surfaces <NUM> help to prevent the pickup point <NUM> from rotating within the grip of the clamping gripper <NUM> when picked up to the transported by offering space for the jaws <NUM> of the clamping gripper <NUM> to rest. To further prevent the pickup point <NUM> from rotating within the grasp of the clamping gripper <NUM>, dowels <NUM> are added on the top and bottom of the pickup point <NUM>. For example, in an embodiment the dowels <NUM> may extend over the flat surfaces <NUM>. The dowels <NUM> extend from the head portion <NUM> to the main body <NUM> thereby spanning the neck portion <NUM>. Like the flat surfaces <NUM>, the dowels <NUM> provide a further feature for the clamping gripper <NUM> to rest against to prevent the pickup point <NUM> from rotating within the clamping gripper <NUM>.

Referring now to <FIG>, these Figures show engagement between the clamping gripper <NUM> of the gantry <NUM> and the pickup point <NUM> of a basket <NUM> in accordance with the embodiments of this invention. The gantry system <NUM> includes a gantry <NUM> which, in turn, includes a clamping gripper <NUM>. In one embodiment, the clamping gripper <NUM> is a two-piece clamping mechanism which engages with the pickup point <NUM> of a basket <NUM> from opposing sides.

As shown in <FIG>, the clamping gripper <NUM> includes a pair of jaws <NUM>. In an embodiment, the jaws <NUM> are C-shaped and spaced apart from each other a distance equal to or greater than the diameter of the head portion <NUM> of the pickup point <NUM>. Each jaw <NUM> of the pair of jaws <NUM> is arranged on a side of the pickup point <NUM>. Upon receiving a signal from the gantry control <NUM>, the clamping gripper <NUM> engages with and secures the pickup point <NUM> of the basket <NUM> within the clamping gripper <NUM>. When the clamping gripper <NUM> is activated (as indicated by arrows A2), each jaw <NUM> engages with a side of the pickup point <NUM> to snugly sandwich the pickup point <NUM> between the C-shaped jaws <NUM>-thereby securing the pickup point <NUM> in the clamping gripper <NUM>. Further, the interior edges of each of the jaws <NUM> can be contoured to facilitate easier gripping of the pickup point <NUM>. Like the tapered main body <NUM> and head portion <NUM> of the pickup point <NUM> (e.g., as shown in <FIG>), the jaws <NUM> may similarly be fashioned to allow for the clamping gripper <NUM> to correct for slight errors in alignment between the basket <NUM> and the clamping gripper <NUM>. Such tapering and contouring makes it easier for the jaws <NUM> of the clamping gripper <NUM> to engage with the pickup point <NUM>, even when the pickup point <NUM> and clamping gripper <NUM> are not perfectly aligned. The engagement of the clamping gripper <NUM> and the pickup point <NUM> defines a single-location engagement between the gantry <NUM> and the basket <NUM> in this embodiment.

As shown in <FIG>, the two-piece clamping gripper <NUM> is clamped into engagement with the pickup point <NUM>. To effectuate the engagement, the clamping gripper <NUM> may be pneumatically powered. However, it is to be understood that the clamping gripper <NUM> could be alternatively powered-hydraulically or electrically, for example. In an embodiment, the clamping gripper <NUM> clamps in engagement with the 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). This engagement of the clamping gripper <NUM> and the pickup point <NUM> improves the operation of the gantry <NUM> and the basket <NUM> as compared to prior known designs for these reasons, while also enabling just a single pickup point on the basket <NUM> to be used in this system <NUM>, thereby simplifying the structure needed.

Additional structure may be provided adjacent the pickup point <NUM> to help avoid any undesirable or uncontrolled pivoting of the basket <NUM> during engagement and movement with the gantry <NUM>. For example, as shown in <FIG> the pickup point <NUM> includes dowels <NUM> that span the distance from the head portion <NUM> to the main body <NUM> (above and below the neck portion <NUM>) as well as flat surfaces <NUM> on the neck portion <NUM> that provide for more secure engagement between the clamping gripper <NUM> and the pickup point <NUM>. To that end, the jaws <NUM> of the clamping gripper <NUM> engage with the dowels <NUM> and flat surfaces <NUM> 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> and <FIG>, the Figures show a portion of the gantry <NUM> in greater detail. Specifically, the Figures show the relationships between clamping gripper <NUM>, actuator arm <NUM>, and basket detection device <NUM>. The clamping gripper <NUM>, actuator arm <NUM>, and basket detection device <NUM> work in concert to allow for the gantry <NUM> to pick up and transport baskets <NUM> as well as to dispense food product <NUM>. In an embodiment, the actuator arm <NUM> is in the form of an elongated rod that is generally cylindrically shaped, attached to the gantry <NUM>, and located on a side of the clamping gripper <NUM> and the basket detection device <NUM> is located on an opposing side of the clamping gripper <NUM>. It is to be understood that alternative arrangements are envisioned. With respect to the actuator arm <NUM>, <FIG> shows the actuator arm <NUM> in a retracted position. In the retracted position, the actuator arm <NUM> is held away from the basket <NUM> (e.g., rotated <NUM>° out of the way) to prevent inadvertent contact with the basket <NUM> that could cause uncontrolled and/or unintended movement and/or openings of the basket <NUM>. Arrow A3 illustrates the transition of the actuator arm <NUM> from the retracted position to the extended position. In transitioning to the extended position, the actuator arm <NUM> rotates and moves upwardly with a force to engage with the product discharge mechanism <NUM>.

<FIG> shows the actuator arm <NUM> in the extended position. In the extended position, the actuator arm <NUM> is positioned to interact with the product discharge mechanism <NUM> to cause the basket <NUM> to dispense food product <NUM>. Such interaction is described in greater detail with respect to <FIG>. Arrow A4 illustrates the transition of the actuator arm <NUM> from the extended position to the retracted position. Pneumatic power is used to move the actuator arm <NUM> from the retracted position to the extended position and back, as demonstrated by arrows A3 (in <FIG>) and A4 (in <FIG>). It is to be understood that the actuator arm <NUM> could be alternatively powered-hydraulically or electrically, for example.

Referring now to both <FIG> and <FIG>, the Figures also show the basket detection device <NUM>. The basket detection device <NUM> is attached to the gantry <NUM> and is configured to detect the presence of a basket <NUM> when a basket <NUM> is located in front of the clamping gripper <NUM>. The basket detection device <NUM> is used to line up the jaws <NUM> of the clamping gripper <NUM> with the pickup point <NUM> of the basket <NUM>. The basket detection device <NUM> can take on many forms. For example, in <FIG> and <FIG> the basket detection device <NUM> is shown as a laser. However, the basket detection device <NUM> could also be a proximity switch or a torque sensor. Further, it is to be understood that the basket detection device <NUM> could take on other forms besides those explicitly described herein.

Referring now to <FIG>, the Figures show the interaction between the actuator arm <NUM> of the gantry <NUM> and the product discharge mechanism <NUM> of the basket <NUM>. In <FIG>, the actuator arm <NUM> is in the retracted position-held away from the basket <NUM> to prevent inadvertent contact with the basket <NUM>. Arrow A5 illustrates the path that the actuator arm <NUM> will take to interact with the product discharge mechanism <NUM>. Specifically, the actuator arm <NUM> will rotate <NUM>° towards the basket <NUM> and move upwards with a force to meet and lift the collar <NUM>, thereby overcoming the bias (e.g., spring bias) of the biasing element <NUM>. Such actions can happen concurrently or in individual stages.

<FIG> shows the actuator arm <NUM> in the extended position and interacting with the product discharge mechanism <NUM>.

Referring now to <FIG>, these Figures show a series of steps defining a basket loading cycle and a basket discharge cycle according to embodiments which are not within the scope of the claims, each of which may be repeatedly performed to manage basket workflow at the cooking system <NUM>. As evidenced in these workflow Figures, the newly-developed basket-gantry interface of the system <NUM> described herein helps achieve more reliable and precise movements of the baskets <NUM> and a quicker cycle time for automated cooking of various food products.

Referring to <FIG>, the Figure shows a basket <NUM> filled with cooked food product <NUM> sitting on a platform <NUM> after exiting a fryer vat <NUM>. At the end of the cooking cycle, the vertical transport assembly <NUM> lifts 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>, as shown, for example, by arrow A7. The basket <NUM> is waiting to be picked up by the gantry <NUM>, which is shown positioned by the dispensing freezer <NUM> in <FIG>. When the gantry <NUM> receives a signal from the gantry control <NUM> and/or system controller <NUM>, the gantry <NUM> will move to the platform <NUM> holding the filled basket <NUM> and engage the basket <NUM>, as described in greater detail below with reference to <FIG>. Further, the Figure shows a basket <NUM> in the basket movement receptacle <NUM> located at the filling location. At the filling location, the dispenser freezer <NUM> dispenses uncooked food product <NUM> into the basket <NUM> in preparation of transport by the gantry <NUM> to a fryer <NUM>.

Referring to <FIG>, the Figure shows the gantry <NUM>, after receiving a signal from the gantry control <NUM> and/or system controller <NUM>, engaging with the filled basket <NUM> on the platform <NUM>. To line up the clamping gripper <NUM> with the pickup point <NUM> of the basket <NUM>, the gantry <NUM> can employ a basket detection device <NUM> (e.g., proximity switch, torque sensor, laser, etc.) configured to detect the presence of a basket <NUM> in front of the clamping gripper <NUM>. The basket detection device <NUM> is addressed in greater detail above with respect to <FIG> and <FIG>. Once properly lined up, the gantry <NUM> activates the jaws <NUM> (e.g., pneumatically) of the clamping gripper <NUM> and secures the pickup point <NUM> of the basket <NUM> between the jaws <NUM>. The engagement of the jaws <NUM> with the pickup point <NUM> is described in greater detail with respect to <FIG>. In general, the clamping gripper <NUM> is configured to prevent uncontrolled rotational movements of the basket <NUM> when the basket <NUM> is transported. Such helps to avoid impacts of the basket <NUM> with other elements (e.g., other baskets <NUM>, parts of the fryer <NUM>, etc.) of the automated cooking system <NUM>.

Referring to <FIG>, the Figure 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> and/or system 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 shown by arrow A8. Actuation of the product discharge mechanism <NUM> is described in greater detail above with reference to <FIG>; however, in short the actuator arm <NUM> of the gantry <NUM> interacts with the product discharge mechanism <NUM> to cause the basket <NUM> to discharge the cooked food product <NUM> contained therein.

Further, as shown in the Figure in phantom, 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 <NUM> contained within the basket <NUM>. 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. Further, cooked food product <NUM> may be discharged while the basket <NUM> is moving from a first height to a second height, as shown by arrow A15. Such is helpful if the cooked food product <NUM> is long and fragile, for example, to prevent the cooked food product <NUM> from getting damaged by the basket <NUM> or by the drop impact into the hot holding station <NUM>. Regardless of the discharge height, after discharge from the basket <NUM> the cooked food product <NUM> is then held in the hot holding receiving area <NUM> for further preparation and packaging by an operator.

Furthermore, and still referring to <FIG>, the Figure shows the staging shelf <NUM> preparing for the arrival of an empty basket <NUM>. Sometime before an empty basket <NUM> arrives at the staging shelf <NUM>, the gantry control <NUM> and/or system controller <NUM> sends a signal to the staging shelf <NUM> so that the staging shelf <NUM> pivots into a (generally horizontal) deployed position from a stowed position (e.g., as shown in <FIG> and <FIG>), as illustrated by arrow A9. With the staging shelf <NUM> in the deployed position, the staging shelf <NUM> is ready to receive an empty basket <NUM> from the gantry <NUM>.

Referring to <FIG>, the Figure shows the gantry <NUM>, at the direction of the gantry control <NUM> and/or system controller <NUM>, transporting the basket <NUM> from a position above the hot holding station <NUM> (after discharging cooked food product <NUM>) to the staging shelf <NUM>. The gantry <NUM> disengages with the basket <NUM> and leaves the basket <NUM> on the staging shelf <NUM>. The empty basket <NUM> is then ready to be engaged by the gantry <NUM> again later when customer demand necessitates.

Further, <FIG> shows a basket <NUM> in the basket movement receptacle <NUM> being transported, as indicated by arrow A10. After a basket <NUM> has been filled by the dispensing freezer <NUM> at a filling location (as shown starting in <FIG>), 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>. It is to be understood that the filling location and the pickup location may be the same position and thus movement from the filling location to the pickup location may be unnecessary. 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>, as shown in <FIG>. These movements can occur simultaneous to other actions being taken by the gantry <NUM> at the fryer <NUM>.

Referring to <FIG>, the Figure 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>. After dropping off the empty basket <NUM> onto the staging shelf <NUM> (as shown in <FIG>), the gantry <NUM> moves downwardly to the basket movement receptacle <NUM> to engage the next basket <NUM>.

Referring to <FIG>, the gantry <NUM>, after receiving a signal from the gantry control <NUM>, moves the basket <NUM> from the basket movement receptacle <NUM> to an open platform <NUM> above a fryer vat <NUM>. Which platform <NUM> the basket <NUM> should be moved to is typically determined by the system controller <NUM>. Note that although a filled basket <NUM> was previously shown in <FIG> at the platform <NUM> where the gantry <NUM> places the new basket <NUM> in <FIG>, any available appropriate and available platform <NUM> could be utilized.

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>. The platforms <NUM>, on which the baskets <NUM> sit, are attached to the vertical transport assemblies <NUM>. Upon receiving a signal to initiate a cooking cycle from the system controller <NUM>, the vertical transport assembly <NUM> then lowers the basket <NUM>, filled with uncooked food product <NUM>, into a cooking medium <NUM> for a cooking cycle, as shown by arrow A11. These actions can automatically occur at the cooking system <NUM> while the gantry <NUM> moves to perform actions on other baskets <NUM> and platforms <NUM>.

Further, <FIG> shows the basket movement receptacle <NUM> moving upwards, as shown by arrow A12, 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>. 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>.

Referring to <FIG>, the Figure shows a completed transfer of the basket <NUM> from the staging shelf <NUM> to the basket movement receptacle <NUM>. After a successful transition, the basket movement receptacle <NUM> transports the basket <NUM> downwardly to the filling location, as indicated by arrow A13. The basket <NUM> is then filled with uncooked food product <NUM> and awaits later engagement by the gantry <NUM> to the bring the basket <NUM> to a platform <NUM> above a fryer vat <NUM>. Further, <FIG> shows, in the leftmost fryer vats <NUM>, a basket <NUM> emerging from the cooking medium <NUM> in a fryer vat <NUM> (with cooked food product <NUM>), as shown by arrow A14. Once emerged from the fryer vat <NUM>, the basket <NUM> is engaged by the gantry <NUM> to be brought to the hot holding station <NUM> to discharge the cooked food product <NUM>.

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>. This arrangement allows for successful management of up to <NUM> or more baskets <NUM> cooking food product <NUM> simultaneously at the fryer <NUM>, which can result, for example, in throughput levels of about <NUM>,<NUM> (<NUM> pounds) of cooked French fries an hour in one operational example. These operational throughput levels are enabled at least in part by the innovative basket-gantry interface described in this application.

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 <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 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 <NUM> 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>.

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.

Claim 1:
An automated cooking system (<NUM>) comprising:
a fryer basket (<NUM>), comprising:
a frame (<NUM>) defining a storage space (<NUM>) within the basket (<NUM>);
a pickup point (<NUM>) operatively connected to the frame (<NUM>), wherein the pickup point (<NUM>) comprises:
a main body (<NUM>), the main body (<NUM>) operatively connected to the frame (<NUM>) and extending outward therefrom; and
a gantry (<NUM>), comprising:
a clamping gripper (<NUM>) that clamps a pair of jaws (<NUM>) into engagement with the pickup point (<NUM>) of the basket (<NUM>), wherein the gantry (<NUM>) engages with the basket (<NUM>) at only the pickup point (<NUM>) and this single-location engagement between the pair of jaws (<NUM>) and the pickup point (<NUM>) is configured to prevent uncontrolled rotational movements of the basket (<NUM>) when the basket (<NUM>) is moved,
characterized in that the fryer basket (<NUM>) comprises further
a neck portion (<NUM>) attached to and extending outwardly from the main body (<NUM>), wherein the neck portion (<NUM>) is narrower in diameter than the main body (<NUM>) and wherein the neck portion (<NUM>) is the part of the pickup point (<NUM>) that is intended to be gripped; and
a head portion (<NUM>) attached to and extending outwardly from the neck portion (<NUM>), wherein the head portion (<NUM>) is greater in diameter than the neck portion (<NUM>).