Note: Descriptions are shown in the official language in which they were submitted.
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Multi-Function Convevorized Food Broiling and Toastine Apparatus
The present invention relates generally to conveyorized apparatus and
methods for cooking foods anl, in particular, to such apparatus and methods
adapted
for use in a commercial restaurant setting for broiling meats (e.g.,
hamburgers, beef
S steaks, chicken fillets, etc.) and for toasting of bread products (e.g.,
sandwich bun
halves).
Commercial restaurants, particularly those restaurants commonly referred to
as "fast food" restaurants such as typically specialize in serving hamburgers
and like
sandwiches, are continually striving to reduce operating costs while at the
same time
increasing food cooking production and efficiency. Toward this end, many such
restaurants have begun in recent years to utilize conveyorized cooking
apparatus by
which cooking times and temperatures can be better regulated than by more
traditional manual cooking while at the same time eliminating or at least
reducing the
need for skilled labor.
Generally, such apparatus have been designed for a single dedicated function
which promotes reliable cooking consistency. For example, typical conventional
conveyorized hamburger broiling apparatus are equipped with a single conveyor
operating in a dedicated cooking chamber. Such apparatus may provide the
capability
for adjusting the temperature in the chamber and the traveling speed of the
conveyor,
whereby adjustments can be made for different food products {hamburgers of
varying
thicknesses or chicken fillets), but it is extremely impractical to make
regular
adjustments so as to switch back and forth between the cooking of small
quantities of
differing food items. Likewise, it is commonplace for an entirely separate
apparatus
to be used for the toasting of sandwich buns.
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The present apparatus and the methodology of its operation are therefore
intended and designed to provide within a single apparatus the capability of
cooking
multiple food products simultaneously and/or switching quickly and efficiently
between the cooking of differing food products, without compromising or
affecting
S efficiency or product quality and consistency. The present apparatus and its
method
of operation may be understood with reference to the accompanying drawings:
Figure 1 is an overall front perspective view of a mufti-function cooking
apparatus in accordance with vthe present invention;
Figure 2 is a front elevational view of the cooking apparatus of Figure 1;
Figure 3 is a right side elevational view of the cooking apparatus of Figures
1
and 2;
Figure 4 is a vertical cross-sectional view of the cooking apparatus of Figure
1-3, taken along the line 4-4 in Figure 2;
Figure 5 is another cross-sectional view of the cooking apparatus of Figures 1-
3 taken along the line 5-5 of Figure 2; and
Figure 6 is an elevational view of the keypad for actuating and controlling
operation of the microprocessor-based controller for the cooking apparatus of
Figures
1-5.
Referring now to the accompanying drawings and initially to Figures 1-3, a
conveyorized cooking apparatus according to the present invention is shown
generally
at 10 in an embodiment thereof particularly designed and intended for use in a
"fast-
food" style restaurant serving a variety of differing broiled meat sandwiches,
e.g.,
hamburger sandwiches (possibly of two different sizes of hamburger patties),
chicken
fillet sandwiches, steak sandwiches, etc. However, those persons skilled in
the art
will readily recognize and understand that the present cooking apparatus and
the novel
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features utilized therein are susceptible of various other specific
embodiments, all of
which are intended to be within the scope and substance of the present
invention.
As depicted in Figure:> 1-3, the cooking apparatus 10 includes a housing 12
subdivided by an interior vertical wall 14 to define two separate interior
meat broiling
chambers 16, 18 each general (y in the form of a tunnel extending horizontally
the
predominate lengthwise extent of the housing 12 from respective entry openings
16',
18' at the forward end of the housing 12 to respective discharging openings
16", 18"
at the rearward end of the housing 12 (see also Figures 4 and 5). The meat-
broiling
chamber 16 occupies the predominant portion of the width of the housing 12 and
accordingly forms the main cooking chamber for the apparatus 10.
Two endless wire mesh conveyors 20, 22 extend side-by-side though the entire
length of the meat broiling chamber I 6 and a third endless wire mesh conveyor
24
similarly extends through the length of the secondary meat broiling chamber 18
laterally adjacent the conveyors 20, 22. The three conveyors 20, 22, 24 are
supported
by common axle shafts 28, 30. The axle shaft 28 is rotatably supported
horizontally
at the forward side of housing 12 outwardly adjacent the respective chamber
entrance
openings 16', 18' by forwardly extending housing flanges 32. The axle shaft 30
similarly is rotatably supported horizontally within the housing 12 by the
outermost
housing sidewalls 12' and the interior vertical wall 14 to extend laterally
through the
chambers 16, 18 immediately adjacent the discharge openings of 16", 18"
thereof
and in essentially the same hori;aontal plane and in axially parallel relation
to the axle
shaft 28.
In this manner, the conveyors 20, 22, 24 are arranged such that their
respective
upper conveyor runs may travel along respective horizontal food transport
paths
laterally adjacent one another in a common horizontal plane lengthwise through
the
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respective chambers 16, 18 within the housing 12, but in accordance with the
present
invention, the conveyors 20, 22, 24 are adapted to be independently driven for
separate control of their respective traveling speeds and, in turn, cooking
times.
Specifically, the first conveyor 20 within the main chamber 16 and the third
conveyor
S 24 within the secondary chamber 18 are each mounted in an idling manner
about the
respective axle shafts 28, 30 by means of respective sprockets 26 fixed to
idler tubes
34 supported by annular bearings coaxially on the shafts 28, 30 to rotate
independently thereof. The second conveyor 22 is similarly supported by
sprockets
26 on an idler tube 34 about the axle shaft 28, but in contrast is trained
about
sprockets 26 fixed directly to the axle shaft 30 to rotate integrally
therewith.
The outermost end of the axle shaft 30 at the right side of the housing 12
also
carries a sprocket 26 fixed directly to the shaft 30 by which the shaft 30 is
driven by a
motor 36 via an endless chain 38, whereby the second conveyor 22 is positively
driven at a speed determined by the drive speed of the motor 36 , but without
I S transmitting any drive motion vto or otherwise affecting the conveyors 20,
24 due to
their idling relationship with the axle shafts 28, 30. The first conveyor 20
is
independently driven by a separate drive motor 40 via a drive chain 42 trained
about
one of the sprockets 26 on the respectable idler tube 34 for the conveyor 20
on the
axle shaft 30, which as will be 'understood imparts drive motion only to the
conveyor
20 without affecting the drive motion of the axle shaft 30. Similarly, the
conveyor 24
is independently driven by its own respective drive motor 44 via a drive chain
46
trained about one of the sprockcas 26 on the respective idler tube 34 for
conveyor 24
on the axle shaft 30.
Each of the meat broiling chambers 16,18 is equipped with its own
independent cooking arrangement for applying cooking energy therewithin to
food
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articles being transported on the respective conveyors 20, 22, 24 from each
opposite
upper and lower side of the conveyors. Within the main chamber 16, the cooking
arrangement comprises a first plurality of gas-fueled burner assemblies 48
supported
by the housing 12 in generally side-by-side horizontal alignment with one
another at a
spacing above the food transport paths of the conveyors 20, 22 and a second
like
plurality of gas-fueled burner assemblies SO similarly arranged generally in
side-by-
side horizontal alignment at a spacing beneath the food transport paths of the
conveyors 20, 22. Within the secondary meat broiling chamber 18, a single gas-
fueled burner assembly 52 is mounted to the housing 12 to extend lengthwise
thereof
at a spacing above the food transport path of the conveyor 24 and a second
burner
assembly 54 is similarly mounted lengthwise of the housing 12 at a spacing
beneath
the food transport path of the conveyor 24.
The basic construction of each of the burner assemblies 48, 50, 52, 54 may be
of a generally conventional type having an elongate rectangular housing 56
with a
tubular venturi-type gas inlet fitting 58 affixed exteriorly to the housing 56
and
opening interiorly to a conventional form of burner unit (not shown) to
effectively
mix an incoming gaseous fuel, e.g., natural gas or propane, with air to
produce a
continuously burning flame across an outward screen face 60 covering
substantially
the entirety of one side of the housing 56. Each of the burner assemblies 48,
50, 52,
54 is equipped with an arcuate rectangular shield 62 generally conforming in
shape
and dimension to the rectanguhcr screen face 60, to protect the burners from
food
drippings and renderings.
In addition, the main chamber 16, may also be equipped with a plurality of
flame attenuators 64 disposed between the lower group of burners 50 and the
conveyors 20, 22 to arrest or deflect any flames which may be produced by the
lower
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burners 50, e.g. by the flashing, vaporization or other combustion of food
drippings
and renderings, to prevent such flames from reaching the food items on the
conveyors
20, 22 and potentially deleteriously affecting the cooking thereof. Such flame
attentuators 64 may be of various constructions which do not comprise any part
of the
present invention and, hence, are not believed to require further detailed
description
herein.
A driven automated food loading subassembly, generally indicated at 66, is
mounted to the housing 12 by a forwardly projecting bracket 68 immediately
adjacent
the entrance end 18' to the secondary chamber 18 and directly above the
respective
I 0 entrance end of the third conveyor 24 for automated dispensing of food
items onto the
conveyor 24. The food loading subassembly 66 comprises a frame 70 mounted at
an
upwardly inclined angle to the bracket 68, and a motorized drive roller 71 and
an idler
roller 72 mounted at opposite ends of the frame 70. An endless belt 74
equipped with
outwardly projecting cleats 76 at regular spacings along the belt 74 is
trained about
the rollers 71, 72 of the food lc>ading subassembly 66.
As is known and will be understood, the meat products typically cooked and
served by "fast food" restaurants, whether in the form of hamburger patties,
chicken
fillets, steaks, etc. are initially processed to be of a generally uniform
thickness to best
promote cooking consistency and uniformity and are then frozen for storage
until
ready for cooking. The dimensions of the belt 74 and the dimensions and
spacings of
its cleats 76 are accordingly selected to be particularly adapted to hold a
single frozen
meat item of this described type between adjacent cleats along the upper run
of the
belt 74 and, in conjunction witl~~ the upwardly inclined orientation of the
belt 74, are
adapted to deposit each such food item in sequence horizontally onto the
entrance end
of the conveyor 24 as the cleats 76 move in sequence from the upper run to the
lower
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WO 00/38527 PCT/US99/31223
run of the belt 74 about the idler roller 72. As more fully described
hereinafter, the
drive roller 71 of the food loading subassembly 66 is controlled to move in
discrete
indexing steps to control the placement of the food items onto the conveyor 24
at
desired time intervals and spacings between one another.
The apparatus 10 also includes a bread toasting arrangement, generally
indicated at 78 disposed directly beneath the main meat broiling chamber 16,
to
provide for the conveyorized toasting of sandwich bun halves at a rate of
production
compatible with that of the meat broiling conveyors 20, 22, 24 and without
requiring a
separate bread toasting apparatus. The bread toasting arrangement 78 basically
comprises an endless imperforate conveyor belt 80 trained about an idler
roller 82
supported by outwardly-extended brackets 84 at the forward end of the housing
12
and a drive roller 86 supported within the housing 12 at the rearward side
thereof,
which drive roller 86 carries a sprocket 88 driven via the chain 42 by the
same motor
40 as the first meat conveyor 2 0. Electric toasting platens 90 are mounted
from the
housing 12 directly above the upper run of the toaster belt 80 via pivoting
support
arms 92 and, if desired, it is contemplated that additional toasting platens
may be
situated beneath the upper run of the belt 80.
Sandwich buns are sep~~rated into their constituent crown and heel halves and
placed onto the exposed portion of the upper run of the belt 80 at the forward
side of
the housing 12, with the sliced surface of the bun halves facing upwardly
(i.e., the
crown and heel crust surfaces facing downwardly), to be transported by the
belt 80
through the toasting chamber 94 defined between the belt 80 and the platens
90. The
platens 90 are preferably provided with a TEFI,ON~ type or other stick-
resistant
surface to allow the upwardly facing sliced surfaces of the bun halves to
slide in direct
surface contact with the toaster platens 90.
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The bread toasting arrangement 78 is preferably separated from the main meat
broiling chamber 16 by one or more trays 100 oriented widthwise across
substantially
the entire extent of the main chamber 16 beneath the lower group of burners 50
at
both a lengthwise and widthwise inclination to collect and drain drippings and
other
renderings from meat broiled on the conveyors 20, 22 to a trough or funnel
102, and
therefrom through a tube or the like (not shown) into a collection pan 103,
thereby to
protect the bread toasting arrangement 78 from becoming soiled, contaminated,
and
possibly damaged or degraded. by such drippings and the like. The trays 100
also
serve secondarily to maintain heat within the main chamber 16 and to prevent
such
heat from affecting the operation of the toasting arrangement 78.
At the rearward discharge side of the housing 12, appropriate brackets,
collectively indicated at 96, arc: preferably mounted to the housing 12 to
support pans
or other containers, collectively indicated at 98, respectively beneath the
discharge
ends of the meat conveyors 20, 22, 24 and the bread conveyor 80 so that the
food
items exiting the housing 12 along the respective conveyors are
gravitationally
deposited into the collection containers.
As will be understood, the normal operation of the apparatus 10 will tend to
generate smoke as well as airborne particulate renderings from the meat items
being
broiled within the chambers 16" 18, especially in the case of broiling
hamburgers or
like food items with any significant degree of fat content. Thus, the
apparatus 10 will
normally be required to be operated in a commercial restaurant setting beneath
a fan-
powered exhaust hood (not shown) to withdraw such smoke and particulate matter
out
of the ambient restaurant environment. To significantly minimize the quantum
of
such effluent, the apparatus 10 is preferably equipped with a catalytic
combustion
system, indicated as a whole by 104, spanning the entire upper side of the
housing 12
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above the two meat broiling chambers 16, 18, such that substantially all
effluent from
the apparatus 10 must pass through the unit 104. The catalytic combustion
system
104 comprises one or more catalytic combustion units, e.g. one unit spanning
both
chambers 16, 18, or separate units for the respective chambers 16, 18, each of
an
essentially conventional construction adapted to substantially fully
incinerate the
uncombusted effluent so as to substantially eliminate or at least minimize
smoke and
other effluent exhausted through the hood.
A significant feature of the present apparatus 10 is the provision of a
microprocessor based controller unit 106 which provides for selective
programmable
variation and control of substantially all of the significant functions of the
apparatus
10, including the respective broiling and toasting temperatures within the
chambers
16; 18, 94, the respective traveling speeds of the individual food conveyors
20, 22, 24,
80, the actuation and the operational parameters of the automated food loading
subassembly 66, and controlled system shut-down of the apparatus 10, all as
more
fully described hereinafter. The controller unit 106 may comprise various
conventional electronic microprocessor and memory components and associated
programmable input means so long as capable of performing the control
functions and
logic of the present invention as described below. In the preferred
embodiment, the
various control functions and logic of the apparatus are input, actuated and
controlled
via a touch-type keypad which may preferably be in a form and layout depicted
in
Figure 6.
Referring now more specifically to Figure 6, one embodiment of a suitable
keypad for the controller 106 is depicted. As will be understood, a
significant
advantage of providing the app~~ratus 10 with separate meat broiling chambers
16, 18
and independently driven conveyors 20, 22, 24 travelling therethrough is the
ability of
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the chambers to operate at different temperatures and the conveyors to be
driven at
differing traveling speeds which may be differentially selected to facilitate
automated
conveyorized broiling of differing food products (e.g., hamburgers, chicken
fillets,
sandwich steaks, etc.) on an automated high-production basis as necessary or
desirable in a restaurant setting.
By way of example, the greatest production requirements of a typical "fast
food" restaurant will be the broiling of hamburger patties for which there
will
typically be a predictable demand over the course of each business day and
predictable peak periods of demand at particular times such as lunch and
dinner times.
Accordingly, it is contemplated that the apparatus 10 when used in a typical
"fast
food" hamburger restaurant would dedicate the first conveyor 20 to the
broiling of
hamburger patties and, accordingly, as will be seen, the first conveyor 20 is
of a width
approximately twice that of the second conveyor 22 and the third conveyor 24.
Most
such restaurants also feature other specialty sandwiches, such as chicken
fillet
sandwiches, steak sandwiches, etc., which would typically require either a
differing
cooking temperature and/or differing cooking times from that of hamburger
patties.
Such specialty sandwiches will have a lesser but generally predictable level
of
demand over the course of a normal business day, whereby one or both of the
conveyors 22,24 may be designated and differentially set up for broiling such
meat
items. However, since the second conveyor 22 travels in the same cooking
chamber
16 as the first conveyor 20, the second conveyor 22 can be selectively
switched to
operate at the identical travelling speed as the conveyor 20 during periods of
peak
demand for hamburger patties, e.g., at lunch and dinner times, so as to
temporarily
increase the production capacity of the apparatus 10 for such items.
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Since this basic manner of multi-function operation of the apparatus 10 will
generally be applicable to many if not most "fast-food" restaurants, the
microprocessor-based controller 106 and the associated keypad 108 are
programmed
to facilitate this basic mode of operation and to permit selective variation
in the mode
S of operation within a predetermined range of parameters. Thus, as will be
seen in
Figure 6, the keypad 108 is equipped with two series of keys 110, 112, which
facilitate actuation of certain pre-programmed routine functions of the
apparatus 10
according to the aforedescribed normal mode of operation and also facilitate
some
reprogramming of such functions.
The upper series of keys 110 are prelabelled with both descriptive word
legends and symbolic icons designating and representing the programmed
functions
of such keys. In the illustrated embodiment, eight such keys are provided,
with the
keys additionally carrying numeric labels I-8 respectively. As will be seen,
key 1 is
dedicated to the operation of the first conveyor 20 (labelled as "belt 1 ")
for dedicated
broiling of hamburgers (as represented by the legend "burger" and a schematic
icon
depicting a hamburger). Keys :2-4 are designated for the selective operation
of the
second conveyor 22 (labelled a;s ''belt 2"), with key 2 carrying a "burger"
legend and
icon, key 3 carrying a "steak" legend and icon, and key 4 carrying a "chicken"
legend
and icon. Similarly, keys 5-8 are designated for the selective operation of
the third
conveyor 24 (labelled as "belt 3"). with each such key similarly carrying
legends and
icons representing differing operational modes for the conveyor 24. Also, a
single
LED 114 is provided directly above each of the keys 110 and, as more fully
described
below, are illuminated or not illuminated during normal operation of the
apparatus 10
to designate the selected active mode of operation of the three conveyors 20,
22, 24.
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The second series of keys I 12 disposed immediately below the first series of
keys 110 are functional for actuating the powering on or off of the apparatus,
and
certain diagnostic and reprogramming functions of the apparatus, as more fully
described hereinafter, with each key accordingly carrying appropriate alpha-
numeric
legends to designate the function or functions which can be initiated by each
key. In
addition, the two keys at the righthand end of the key series 112 carry
numeric
legends "9" and "0," respectively, whereby in one mode of operation
hereinafter
described these two keys in conjunction with the eight keys of series 110
serve
collectively as a full set of numeric keys 0 through 9. An alpha-numeric
display 116
is also provided and functions in conjunction with the keys 110, 112 to
provide
supplementary information in executing certain functions of the controller
106.
The various operational functions of the controller 106 and the keypad 108
may thus be described and understood. Once the apparatus 10 has been properly
set
up and installed, with correct electrical and gas supply connections made
according to
prevailing codes and regulations, the apparatus 10 is powered up by pressing
the
"on/off ' key of series 112, which initially actuates ignition of pilots to
the gas burners
followed by gas supply to and ignition of each of the burners 48, 50, 52, 54.
At the
same time, electrical power is supplied to the toaster platens 90. Temperature
sensors
within the chambers 16, 18 and 94 monitor the progressing temperature
increases in
the respective chambers and transmits appropriate representative signals to
the
controller. The controller is programmed with minimum set point temperatures
for
each chamber. During the powering up cycle, the controller displays an
appropriate
statement on the alpha-numeric display I 16, e.g., "l0-1" or "l0-2",
signifying that the
temperature within one or more of the chambers is below the designated minimum
temperature for normal operation. As soon as the temperature sensors in the
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chambers transmit signals to 'the controller 106 indicating that each
programmed
minimum set point temperature has been reached or exceeded, the controller 106
produces a "ready" display to appear in the display window 116.
Upon powering up of the apparatus I 0, the main chamber 16 is within the
preprogrammed temperature range and the conveyor 20 is driven by its
respective
motor at the appropriate speed for the cooking time required for hamburgers at
such
temperature. The conveyor 2:? is driven by its respective motor at the
designated
speed for the last active setting of keys 2, 3 or 4. Similarly, the
temperature within the
secondary chamber 18 is within the designated temperature range and the
conveyor 24
is driven at the appropriate speed for the food item represented by the last
active
setting of keys 5, 6, 7 or 8. The LED above key 1 will be illuminated to
provide a
supplementary indication that the main conveyor 20 is ready for operation for
broiling
hamburgers. The LED above the last active key 2-4 and above the last active
key 5-8
will also be illuminated to signify the active mode of operation of the
conveyors 22,
1 S 24 respectively. For example, illumination of the LED above key 2
signifies that the
conveyor 22 is operating at the identical speed as the conveyor 20, to
facilitate the use
of both conveyors for the broiling of hamburgers.
If a different mode of operation of the conveyor 22 is desired, the operator
would press key 3 ("steak") or key 4 ("chicken"), whereupon the controller
actuates
an adjustment of the drive speed of the motor 36 to alter the travelling speed
of the
conveyor 22 as necessary to correspondingly adjust the cooking time within the
chamber 16 for the respective food item just selected. To signify the change
in the
operational mode of the conveyor 22, the controller 106 causes the LED 114
above
the previously designated key 2-4 to begin to flash while the conveyor speed
remains
unchanged for a sufficient period of time to discharge any food items already
being
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cooked on the conveyor 22 within the chamber 16, after which the conveyor
speed is
changed and the LED 114 above the newly-designated active key 2-4 is
illuminated.
The same procedure of pressing one of the keys S-8 is followed to change the
active mode of operation of the conveyor 24 and its respective cooking chamber
18,
and specifically to adjust the drive speed of the conveyor 24. Actuation of
any of the
keys 5-8 also serves to initiate a sequence of steps necessary to actuate the
automated
food loading subassembly 66. Specifically, according to the control program
stored in
the controller 106, a designated period of time, e.g., five seconds, is
allotted following
each actuation of any one of the keys 5-8 for the operator to then input a
quantity of
the selected food items to be fed by means of the food loading subassembly 66,
the
desired quantity being input to the controller 106 by means of the numeric
keys of the
key series 112. Thus, the sequence of steps to be carried out by the operator
during
each use of the conveyor 24 is to first press the appropriate key S-8 for the
type of
food product to be cooked within the chamber 18, and then within the ensuing
five
second period (or such other designated time interval) to load the desired
quantity of
the food items onto the belt 74 and to input such quantity into the controller
106 by
means of the numeric keys of the key series 112.
As previously mentioned, the controller 106 is programmed to operate the
automated food loading subassembly 66 in an indexing incremental manner
whenever
programming of the food loading subassembly 66 is carried out in the manner
just
described above. Thus, following the selection of one of the keys 5-8 and the
subsequent loading of a quantity of the food items and input thereof into the
keypad
108, the controller 106 after properly adjusting the speed of the conveyor 24
and the
temperature of the chamber 18 actuates the motorized drive roller 71 to index
the belt
74 by a distance equivalent to the spacing between the cleats 76 thereby to
deposit
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onto the conveyor 24 the first loaded food item. The belt 74 is then stopped
by the
controller 106. If a quantity of two or more food items has been input to the
controller 106 for dispensing by the food loading subassembly 66, the
controller 106
remains inactive for a predetermined period of time, e.g., thirty seconds,
before re-
actuating the drive roller 71 to again index the belt 74 forwardly by the
spacing
between the cleats 76 to deposit the next loaded food item. This incremental
indexing
operation of the food loading subassembly 66 continues until the belt 74 has
been
advanced by a number of indexing movements equivalent to the quantity of food
items input to the controller 1 l76, after which the food loading subassembly
66 is
deactuated until a subsequent :food loading operation is initiated by the same
above-
described sequence of steps.
Thus, it will be understood that the secondary meat broiling chamber 18 and
the automated food loading subassembly 66 associated therewith will typically
be
utilized for the preparation of specialty sandwiches in relatively small
quantities and
may be utilized only intermittently. Since the discharge end of the belt 74
must
necessarily be situated in close adjacency to the entrance end of the cooking
chamber
18, it may be possible that this end of the belt 74 may become overheated and
discolor, warp or even potentially melt the polymeric material from which the
belt 74
and its cleats 76 are fabricated if the food loading subassembly 66 remains
idle for
extended periods of time. Therefore, as a safety feature, the controller 106
is
programmed to monitor the elapsed time after each actuation of the food
loading
subassembly 66 and, in the event the subassembly 66 remains inactive for
greater than
a predetermined period of time, e.g., ten minutes, the controller 106 will
actuate the
drive roller 71 to advance the belt 74 by a sufficient distance to move the
portion of
the belt previously facing the entrance end of the chamber 18 to the opposite
end of
CA 02356996 2001-06-27
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the food loading subassembly 66. Such periodic movements of the belt 74
prevent
overheating of any portion thereof and maintain the belt at a safe and
relatively
consistent overall temperature;.
Many of the operational parameters of the apparatus 10 may be selectively
S reprogrammed through use of the microprocessor-based controller 106 by means
of
the keypad 108. In particular, the elapsed times required for cooking meat
products in
the chambers 16, I 8 (determined by the drive speed of the conveyors 20, 22,
24) and
the cooking temperature within the respective chambers 16, 18 may be displayed
and,
if desired, changed through the: controller I 06. As a safety precaution, the
programming mode of the controller 106 may be actuated only by entry of a
security
code, to prevent tampering by unauthorized persons. Specifically, the
programming
mode of the controller 106 is initiated by first pressing the second key of
the key
series 112 labeled "PROGRAM" for a period of two seconds, whereupon the
controller 106 causes the word "code" to be displayed on the alpha-numeric
display
I 16 as a prompt for the operator to enter the security code, typically a
mufti-digit
number, through use of the first key series I 10 and the two rightmost keys of
the
second key series 112 as the 0 through 9 keys of a numeric keypad, as
aforementioned. After the code has been entered in this manner, the "ENTER"
key
112 is pressed, whereupon the controller 106 produces a display such as "PROG"
to
appear on the alpha-numeric display 116 to signify to the operator that the
programming mode has been successfully initiated.
Once the programming mode has been entered in this manner, the operator
may press any one of the eight product keys 110 to initiate programming of the
cooking time within the respective meat broiling chamber 16, 18 for the
particular
product represented by the selected key 110. For example, to program the
cooking
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CA 02356996 2001-06-27
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time for hamburger patties to be broiled on the conveyor 20 within the main
chamber
I 6, the operator would press k:ey I of the key series 1 I 0, whereupon the
controller
106 generates a display such as "SP" (conveyor speed) to appear on the alpha-
numeric display 116 to signify the programming function initiated, followed
shortly
thereafter by a numeric display of the last programmed cooking time (conveyor
speed) in minutes and seconds for hamburger patties on the first conveyor 20
travelling through the main chamber 16. If this cooking time/conveyor speed is
satisfactory to the operator, the' "ENTER" key 112 may be pressed to re-enter
the
displayed time as the programmed cooking time to be stored for the designated
product. If, however, the operator desires to change the cooking time, the
adjacent
key 112 labeled "CLEAR" is pressed, causing the alpha-numeric display I 16 to
shift
to a minutes/seconds display of 0, after which the operator uses the 0 through
9 alpha-
numeric keys (i.e., the first series of keys 110 and the two righthandmost
keys 112) to
enter the new desired cooking time. Thereafter, the operator presses the
"ENTER"
1 S key 112 to store the entered value as the new programmed cooking time for
hamburger patties to be cooked on the first conveyor 20.
Since as aforementioned the key 2 of the key series I I 0 is used for
selecting
the second conveyor 22 to operate at the identical speed as the first conveyor
20 so
that both conveyors 20, 22 may be utilized for cooking hamburger patties
within the
chamber 16 during periods of peak restaurant demand, this described sequence
of
steps for programming the cooking time for the conveyor 20 also automatically
re-
programs the cooking time associated with key 2 of the key series 110.
Otherwise,
the identical series of steps may be followed for programming the cooking time
for
any of the meat products represented by keys 1 through 8 of the key series
110. Thus,
after the ENTER key 112 has been pressed to store a desired cooking time for
any one
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WO 00/38527 PCT/US99/31223
of the keys 110, the controller I 06 remains in the programming mode to allow
the
operator to proceed to reprogram the cooking time for the meat products
represented
by any of the other keys one through eight of the key series I 10. Once of the
operator
has completed the re-programming of the controller 106, the "PROGRAM" key is
pressed to exit the programming mode of the controller and return to the
normal
operating mode.
Whenever the programming mode is utilized to reprogram the cooking time
for meat products on the conveyor 24 represented by the keys 5 through 8 of
the key
series 110, the programming mode of the controller 106 will also prompt the
operator
to confirm or reset the dwell time for the operation of the automated food
loading
subassembly 66, i.e., the time ;period which elapses between each stepwise
indexing
movement of the dispensing belt 74. Thus, when in the programming mode for
reprogramming the cooking tune for any one of the keys 5 through 8 of key
series
110, after a cooking time has been entered and then stored by pressing of the
"ENTER" key, the controller 106 next causes the alpha-numeric display 116 to
present a display such as "DT" to signify the stored dwell time for the
automated food
loading subassembly, followed immediately by the numeric value in minutes
and/or
seconds for the last programmed value for such dwell time. The operator may
verify
and maintain such stored dwell time by pressing the "ENTER" key 112 or
alternatively may press the "CL,EAR" key 112 to delete the previously stored
value,
whereupon the alpha-numeric display 116 shifts to a zero minutes/seconds
display
after which the operator may enter a new dwell time value utilizing the 0
through 9
numeric keys followed by pressing of the ENTER key to store the new dwell time
value for the respective one of the keys 5 through 8 originally selected for
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reprogramming. The operator may then press the PROGRAM key to exit the
programming mode or can progress to another programming sequence.
In accordance with another programmable function of the controller 106, the
predetermined temperature settings in the two meat broiling chambers 16, 18
and in
the bread toasting chamber 94 may also be reprogrammed in the following
manner.
After entering the programming mode of the controller 106 in the
aforedescribed
manner, the "TEMP" (i.e. temperature) key 112 is pressed, causing the alpha-
numeric
display 116 to initially produce a display such as "TE1" signifying the
temperature for
chamber 1 (i.e., chamber 16) previously stored in memory within the controller
106,
followed immediately by a numeric display signifying the stored temperature
for such
chamber in degrees Fahrenheit. The operator can accept and maintain the
previously
programmed temperature by pressing the "ENTER" key 112 or may clear the
previously stored temperature setting by pressing the "CLEAR" key 112. A new
temperature setting may then b<: entered through use of the 0 through 9
numeric keys
for the new desired temperature in degrees Farenheit, followed by pressing of
the
"ENTER" key 112 to store the newly selected temperature. The controller 106
then
progresses through the same sequence of steps for the secondary chamber 18
(displayed as "TE2") followed by the bread toasting chamber 94 (displayed as
"BUN") to prompt the operator to confirm or reset the desired temperatures for
these
chambers. Upon completion of the temperature programming sequence, the
operator
can proceed to another programming cycle or press the "PROGRAM" key to exit
the
programming mode and return to normal operation of the apparatus 10.
Persons skilled in the relevant art will recognize that hamburger, chicken
fillet,
steak and like meat products which will typically be broiled utilizing the
apparatus 10
;~S must be cooked at least to a minimum internal temperature to be safe for
human
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WO 00/38527 PCTNS99/31223
consumption and, likewise, certain maximum temperature values must be observed
to
prevent burning or other overcooking so that the meat products will have an
acceptable taste. Hence, the main control program stored in memory within the
controller 106 includes preset non-changeable minimum and maximum temperature
S values for the meat broiling chambers 16, 18 and the toaster chamber 94
which may
not be exceeded and, thus, if an operator attempts to reprogram the
temperature
setting for either chamber outside of the range established between the
maximum and
minimum stored values, the controller 106 will refuse to accept the value
attempted to
be input and stored by the operator.
The controller 106 is also pre-programmed to execute a defined shutdown
sequence whenever the apparatus 10 is to be turned off, e.g., at the end of
each
business day. As will be understood, over the course of the operation of the
apparatus
10, some drippings and renderings from the meat products being cooked will
collect
on the conveyors 20, 22, 24 and on the surfaces of the respective burners 48,
50, 52,
1 S 54 and elsewhere within the cooking chambers 16, 18, which preferably
should be
removed to prevent contamination of the apparatus. Also, at the significantly
high
temperatures at which the chambers 16, 18 are typically operated (often in
excess of
800 degrees Fahrenheit), it is desirable to promote uniform cooling of the
operating
components of the apparatus 1 CI. The shutdown sequence executed by the
controller
106 is designed to achieve such objectives.
Specifically, the shutdown sequence of the controller 106 is initiated by
pressing the "ON/OFF" key 11:? for a sufficiently extended length of time,
e.g., three
seconds, to signify the affirmative intent to shut down the entire function of
the
apparatus 10, whereupon the controller 106 acknowledges the initiation of the
shutdown sequence by causing t:he alpha-numeric display 116 to produce an
CA 02356996 2001-06-27
WO 00/38527 PCT/US99/31223
appropriate display message, e.g. "CLEAN." Thereupon, the controller 106
causes
the temperatures within the chambers 16, 18 to increase to the maximum
possible
temperatures) by opening a regulator valve in the gas supply line to a fully
open
position to supply gas to the burners 48, S0, 52, 54 at the maximum available
gas
pressure. Simultaneously, the controller 106 actuates the respective drive
motors 36,
40, 44 to adjust the drive speeds of the respective conveyors 20, 22, 24 to an
appropriate traveling speed for cleaning, usually a higher speed than their
normal
operating speeds. These settings of the chamber temperatures and the conveyor
speeds are maintained by the controller 106 for a predetermined period of
time, e.g.,
ten minutes, sufficient to incinerate drippings, renderings and the like which
have
collected on the conveyors 20, 22, 24, the burners 48, 50, 52, 54, and other
interior
surfaces within the chambers I 6, 18. During this phase of operation, the belt
74 of the
automated food loading subassembly 66 may be driven either intermittently or
continuously to maintain a uniform temperature along the entire length of the
belt.
After the completion of this predetermined period of time, the controller 106
then deactuates the burners 48, S0, 52, 54, e.g., by closing the regulator
valve and the
gas supply line or otherwise shutting off the gas fuel supply to the apparatus
10 to
initiate a cooling sequence. During this cooling period, the controller 106
continues
the operation of the drive motoxs 36, 40, 44 to maintain traveling operation
of the
conveyors 20, 22, 24 within the: chambers I 6, 18 to promote uniform cooling
of the
operating components of the conveyors and thereby to prevent or at least deter
warping of the components. The belt 74 may continue to travel during this
period.
During this cooling sequence, the controller 106 causes the alpha-numeric
display 116
to produce an appropriate mess<~ge such as "hot" to signify the status of the
apparatus,
and the controller 106 maintains this cooling sequence until the chambers 16,
18 have
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cooled to an acceptably low temperature, e.g., 400 degrees Fahrenheit, as
signaled by
the temperature sensors within the chambers 16, 18. Thereupon, the controller
106
deactuates the drive motors 3ti, 40, 44, and produces a display message such
as "off"
on the alpha-numeric display 116. Electrical power to the apparatus 10 is
maintained
S to keep the apparatus in a ready state to be powered up when needed, e.g.
the morning
of the next business day.
The controller 106 may also be programmed to perform certain diagnostic
functions which may be advantageous to monitor the performance of the
apparatus 10
over a course of operation. For example, according to one advantageous
feature, the
controller 106 is programmed such that whenever the "TEMP" key 112 is pressed
without first entering the programming mode, the alpha-numeric display 116
will
produce a sequence of display messages reflecting the actual prevailing
temperatures
within the meat broiling chambers 16, 18 and the bun toasting chamber 94 as
reflected
by respective temperature sensors within such chambers to enable the operator
to
assess the temperature performance of the apparatus I 0 and, more
particularly, to
determine whether reprogramming of the temperature settings may be desirable
or
necessary.
Likewise, the controller 106 is programmed such that, whenever the "ENTER"
key 112 is pressed without first entering the programming mode, the alpha-
numeric
display 116 produces a series o:f numeric display messages reflecting the
respective
elapsed times required during the immediately previous powering up of the
apparatus
10 for the chambers 16, 18 to reach a predetermined temperature setting. When
the
apparatus 10 is initially placed into service and powered up for the first
time, these
elapsed time values may be noted for use as benchmark values representative of
the
most efficient operating state of the apparatus (i.e., with the burners 48,
50, 52, 54
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WO 00/38527 PCTNS99/31223
new, clean and at the optimal operating settings determined by the factory).
By
periodic comparison of the actual elapsed time values experienced over the
ensuing
life of the apparatus 10, the operator is enabled to recognize problems with
the
apparatus 10 in advance of an actual breakdown, e.g., significantly greater
elapsed
S times than the benchmark settings required for either chamber 16, 18 to
reach the
predetermined temperature will be indicative of a lack of cleaning or other
deterioration of the respective burners. Those persons skilled in the art will
recognize
that many other various diagnostic functions may be programmed into the
controller
106, e.g., similar diagnostic evaluation of the performance of the drive
motors for the
apparatus 10.
The advantages of the present apparatus 10 will thus be readily recognized and
understood by persons skilled in the art. Fundamentally, in comparison to
prior art
commercial "fast-food" restaurant cooking equipment, the present apparatus
provides
in a single self contained unit the capability for preparing substantially
every
sandwich item which may be carried on the menu of a given fast food
restaurant,
including both broiling of the .meat items and toasting of the sandwich buns.
The
conventional need to utilize two or more differing apparatus for these
functions, the
attendant difficulties in operating and maintaining individual items of
equipment, and
the inefficiencies of the additional space required for multiple units, are
thereby
eliminated. At the same time, the microprocessor-based control,
programmability and
diagnostic functions provided by the controller 106 and the automated food
dispensing capabilities of the food loading subassembly 66 provide an even
higher
level of uniformity in the quality and consistency of the food products,
without
sacrificing (and indeed increasing) the flexibility of the restaurant to
produce differing
products and to make appropriate adjustments for such products.
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WO 00/38527 PCT/US99/31223
It will therefore be readily understood by those persons skilled in the art
that
the present invention is susceptible of broad utility and application. Many
embodiments and adaptations of the present invention other than those herein
described, as well as many variations, modifications and equivalent
arrangements,
will be apparent from or reasonably suggested by the present invention and the
foregoing description thereof, without departing from the substance or scope
of the
present invention. Accordingly, while the present invention has been described
herein
in detail in relation to its preferred embodiment, it is to be understood that
this
disclosure is only illustrative and exemplary of the present invention and is
made
merely for purposes of providing a full and enabling disclosure of the
inventian. The
foregoing disclosure is not intended or to be construed to limit the present
invention
or otherwise to exclude any such other embodiments, adaptations, variations,
modifications and equivalent arrangements, the present invention being limited
only
by the claims appended hereto .and the equivalents thereof.
24
