The present invention relates to the field of professional kitchen. appliances and more particularly to an apparatus for the automated preparation of cooked food products which can be used in foodservice business such as for instance chain restaurants.
In the catering industry such as chain restaurants, the processes of food preparation are typically highly standardized and performance-optimized. However, food preparation requires at various steps manual interaction such as for loading a kitchen appliance with food products to be cooked, unloading the kitchen appliance when the cooking process is completed and for placing the cooked food products into a holding area. Moreover, the kitchen space in many restaurants is limited so that rational use of space as well as ergonomic arrangement and design of kitchen appliances is vital for smooth functioning of food preparation processes.
It is therefore an object of the present invention to provide an apparatus for the automated preparation of cooked food products which may improve efficiency both in terms of processes as well as use of kitchen space.
These and other objects that appear below are achieved by an apparatus for automated preparation of cooked food products having a food container for holding the food product during preparation, a dispensing station for controllably dispensing the food product to the food container, a cooking device designed for at least partially accommodating the food container and for heating the food product held by the container; a dumping station, to which the cooked food product is dropped from the food container and a conveyor mechanism for controllably conveying the food container between the dispensing station, the cooking device, and the dumping station.
In some embodiments, the dispensing station may be arranged above the dumping station, the cooking device may be arranged laterally to the dumping station, and the conveyor mechanism may be arranged to convey the food container along a predefined trajectory extending in vertical and lateral direction.
The arrangement of the dispensing station above the dumping station allows on the one hand a very compact design; on the other hand does it allow dispensing the food products by simply using gravity to fill these into the container placed by the conveyor mechanism below the dispensing station.
Particularly, the food products may be frozen food products and a freezer may be arranged in conjunction with the dispensing station for storing the frozen food products. The dispense station thus dispenses the frozen food products from the freezer into the food container, which is then automatically moved to the cooking device. It is particularly advantageous is the freezer together with the dispensing station is arranged above the dumping station.
The dispensing station may be adapted to portion the food products by weight or by a dispensing time so that the amount of food products prepared during one preparation cycle of the apparatus can be efficiently controlled and adjusted to the capability of the cooking device and to the current need in the restaurant.
In some embodiments, the food container has a drop bottom which is adapted to automatically open and close to dispense and load the food product based on the position of the food container at the conveying mechanism. A drop bottom mechanism allows an easy and safe unloading of the food container at the dumping station.
In one embodiment, the cooking device is a deep fryer. Deep fried food products such as fries, croquettes, or the like are constantly demanded in chain restaurants, taste best if prepared fresh on demand and are thus particularly suited for process automation. In other embodiments, the cooking device can be an oven, e.g., microwave or hot air oven, grill, salamander broiler, bain-marie, food steamer, cooker, frying pan, or other kind of cooking appliance.
According to another aspect of the invention, the apparatus is provided with a control system which controls the conveyor mechanism to convey the food container to several pre-programmed positions. The control system can be programmed to move the food container to the a dispensing station for loading the container with the food product to be cooked, to move the food container to the cooking device, where the food product is cooked, and to move the food container after a predetermined cooking time to the dumping station.
Preferably, the control system can be programmed to define any of basket positions, dwell times on each position, a conveyor speed, a conveyor direction, a basket shaking, a temperature of a freezer, a product dispensing time, and/or a product dispensing weight. In addition to this, the control system can also be programmed to monitor product availability, and/or alarms of the apparatus and display these to a user.
In another aspect, the control system can be programmed to execute a permanent loop of cooked food production while being in an active state, or a single loop upon receipt of a trigger signal. Thus, depending on the need of the restaurant, the control system controls the apparatus to periodically output freshly cooked food products or it can control the apparatus to prepare individual portions of food products on demand. In the latter case, a trigger signal can for instance be derived from an automatic ordering system of the restaurant.
Furthermore, in case of frozen food products, the control system can additionally be used to control the freezer arranged for storing the food products. In particular, the control system can be programmed to control a temperature, a product volume, and/or product availability within the freezer.
In one embodiment, the food preparation apparatus can further be provided with an automatic salting mechanism arranged for salting the food products in accordance with at least one programmable parameter.
The conveyor mechanism in one embodiment can be implemented using a rotary column with a vertically movable lifting arm, which lifting arm is pivotably connected to the rotary column and holds the food container.
Preferably, the lifting arm is provided with a gear that when the lifting arm pivots around the rotary column simultaneously turns the food container to maintain an orientation thereof.
The conveyor mechanism in another embodiment can be implemented using a guideway with a gear rack curved along the guideway and a gear which engages with the gear rack and wherein the food container suspends from a gear link attached to the gear.
In yet another embodiment, the conveyor mechanism can be implemented with a curved rail, a belt tensioned in a loop along the curved rail, and a motion block slidably held between back and forth guided strands of the belt, wherein the food container suspends from the motion block.
In some embodiments, the apparatus can further be equipped with a debris catcher arranged to catch debris of frozen food products falling through perforations of the food container when the food product is dispensed by the dispensing station into the food container.
Preferred embodiments of the present invention will now be described with reference to the accompanying drawings in which
The invention described in this document is not limited to the particular systems and methodologies described, as these may vary. The terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present disclosure.
It should be understood that as used herein and in the appended claims, the singular form “a”, “an”, and “the” include plural reference unless the context clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one ordinary skill in the art. As used herein, the term “comprising” means “including, but not limited to”. The term “cooking” as used herein refers to any kind of food preparation using heat, including but not limited to frying, boiling, baking, roasting, broiling, stir-frying, or toasting.
The embodiments described below relate, to kitchen appliances for use in the foodservice business such as for instance chain restaurants. In the embodiment shown in
Beside the main rack 10 is the actual fryer 15 with a deep-frying basin 16, into which the food basket 13 can be (at least partly) immersed. The main rack 10 further has an upper cabinet portion 17, which accommodates a freezer 18 for storing refrigerated food products and a dispenser 19, which controllably dispenses refrigerated food products from the freezer 18 into the food basket 13 when the latter is arranged in a loading position below the dispenser 19. Freezer 18 and dispenser 19 can be seen in
A conveyor mechanism 20 serves as a transporter for the food basket 13 and controllably conveys the food basket 13 from below the dispenser 13 into the deep-frying basin 16 and from there to the dumping station 12. As will be explained in more detail below, the conveyor mechanism 20 in the first embodiment contains a rotary column 21 also referred to as a “spindle”. A vertically movable lifting arm 22 is pivotably connected to the rotary column 21 and holds the food basket 13.
Under the upper cabinet portion 17 is a debris catcher 23 and a salting system 24. The debris catcher can be moved in lateral direction by a corresponding drive (not shown).
In
In
The gear mechanism 26 in the embodiment contains a gear rack 26a, an corresponding gear wheel 26b engaged with the gear rack 26a and a linear motor 26, which moves the rear rack 26a to turn the gear wheel 26b and with it the basket 13 relative to the lifting arm 22 when the latter pivots. The gears 25, which effect turning of the lifting arm 22 around the axis of the spindle 21, contain a main gear wheel 25a and a drive pinion 25b, which is driven by an associated motor (not shown). The angle by which the food basket 13 is turned relative to the lifting arm 22 corresponds—at least substantially—to the angle by which the lifting arm 22 pivots around the spindle axis, but in opposite directions. The two rotary motions are controlled in synchronism in the embodiment by a common controller. As will be appreciated by those skilled in the art, a forced mechanical control and coupling would equally be possible through an appropriate coupler mechanism.
In
In
The gear 32 and hinged arm 33 is shown in more detail in
In
In
A third embodiment of the transport mechanism for the food basket 13 is shown in
A detail of the looped belt 41 and motion block 42 is shown in
The looped belt 41 with its back and forth guided strands is shown in
Various positions of the food basket 13 and transport mechanism of the third embodiment are shown in
The cooking apparatus and in particular the transport mechanism for the food basket is controlled by a control system, such as the one shown schematically in the block diagram of
The complete process cycle is: dispense food into the basket 13, transport the basket 13 into the cooking apparatus 15, wait for time or command, shake product, at the end of the cooking process move to the salting area 12, salt, dump product into the holding 14 and then move basket 13 to the dispense area for next batch; the process can be executed in full or partially according with the programmed parameters to achieve the best performance and product quality.
In the control system of
In addition CPU 50 can be connected with the ordering system 53 of the restaurant, which will send a signal to the controller 50 when fresh food products need to be prepared. Moreover, controller 50 can be connected to a safety system 54, which serves to protect of any injuries with humans through light barriers and contact switches. A buzzer 55 may also be connected to the controller 50 to output audible alarms to the service personnel.
The controller 50 controls the motor M1 of the transport system 51, for instance the motor of the spindle 21 in the first embodiment. The transport system 51 has switches 51a, 51b, which serve as position sensors and tell the controller the actual position of the food basket 13. Controller 50 controls the motor M1 of the transport system to transport food basket 13 from the dispense position to or into the cooking device and to the holding station 14. Motor M1 is shown by way of example, only, while as will be appreciated the transport system can include several motors instead of just one, all or some of which will be controlled by controller 50.
Based on its position, the drop bottom 13′ of the food basket 13 can be automatically opened, e.g. mechanically or electronically, and closed to load and dispense the food product.
The dispenser 19 has two motors M2, M3. A drum motor M2 rotates to move fries from the freezer compartment into a dispenser compartment of dispenser 19 and a motor M3 opens the flaps 19′ of the dispenser compartment, as can be seen for instance in
The automatic salting mechanism 24 is shown to have a motor M4 that when activated by controller 50 will salt the food product in the dumping station 12 according to pre-programmed parameters such as volume and timing.
The freezer 18 may send a status signal “Bin empty” 56 to the controller 50. The dumping station 12 may send status messages “Ready” 57a and “Tray Full” 57b to the controller 50. The dumping station 12 will dump the cooked and salted product into the holding area 14.
With the signal “cycle done” 58, controller 50 tells the fryer 15 that the cooking cycle is complete. The fryer 15 may use this signal for reheat purpose and fry cycle count.
The above description and drawings merely illustrate the principles of the invention. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described or shown herein, embody the principle of the invention and are included within its spirit and scope. Furthermore, all examples recited herein are principally intended expressly to be only for pedagogical purposes to aid the reader in understanding the principles of the invention and the concepts contributed by the inventors to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions. Moreover, all statements herein reciting principles, aspects, and embodiments of the invention, as well as specific examples thereof, are intended to encompass equivalence thereof.
The functions of the various elements shown in the figures, including any functional blocks labeled as “processors” or “CPUs”, may be provided through the use of dedicated hardware as well as hardware capable of executing software in association with appropriate software. When provided by a processor, the functions may be provided by a single dedicated processor, by a single shared processor, or by a plurality of individual processors, some of which may be shared. Moreover, explicit use of the term “processor” or “controller” should not be construed to refer exclusively to hardware capable of executing software, and may implicitly include, without limitation, digital signal processor (DSP) hardware, application specific integrated circuit (ASIC), field programmable gate array (FPGA), read only memory (ROM) for storing software, random access memory (RAM), and non-volatile storage. Other hardware, conventional and/or custom, may also be included. Any functional blocks of block diagrams shown in the figures are conceptual only. Their function may be carried out through the operation of program logic, through dedicated logic, or through the interaction of program control and dedicated logic, the particular technique being selectable by the implementer as more specifically understood from the context.
This Application is a nonprovisional of U.S. Provisional Application No. 62/236,256, dated Oct. 2, 2015, and is incorporated by reference as if fully set forth
Number | Date | Country | |
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62236256 | Oct 2015 | US |