WO2000038527A1

WO2000038527A1 - Multi-function conveyorized food broiling and toasting apparatus

Info

Publication number: WO2000038527A1
Application number: PCT/US1999/031223
Authority: WO
Inventors: Robert M. Stuck
Original assignee: Stuck Robert M
Priority date: 1998-12-31
Filing date: 1999-12-29
Publication date: 2000-07-06
Also published as: CA2356996A1; AU2220900A; EP1139765A1; EP1139765A4

Abstract

A multi-function apparatus for broiling and toasting food items, particularly in a fast food restaurant, is equipped with multiple cooking chambers (16, 18), individual food transport conveyors (20, 22) in each thereof, and individually controllable food heating/cooking elements or units (48, 50, 52) in each such chamber, all selectively controllable via a central microprocessor based programmable controller (106), whereby the apparatus has 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 efficiency or product quality and consistency.

Description

Multi-Function Conveyorized Food Broiling and Toasting Apparatus

The present invention relates generally to conveyorized apparatus and methods for cooking foods and, in particular, to such apparatus and methods adapted for use in a commercial restaurant setting for broiling meats (e.g., hamburgers, beef 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. 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 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 multi-function cooking apparatus in accordance with the 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 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 Figures 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 generally 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 16 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 horizontal 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 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 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 transmitting any drive motion to 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 sprockets 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 there within to food 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 50 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 rectangular 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 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 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 loading 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 with 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 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 20. 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 separated 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 TEFLON^® 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. 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, are 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 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 apparatus 10 with separate meat broiling chambers 16, 18 and independently driven conveyors 20, 22, 24 travelling therethrough is the ability of 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. 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 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 1-8 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 as '"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. The second series of keys 112 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 116, e.g., "lo-l" or "lo-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 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 10, 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 22 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, 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 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 5-8 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 5-8 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 1 12.

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 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 106, 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 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 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, 18 (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 106. 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 116 as a prompt for the operator to enter the security code, typically a multi-digit number, through use of the first key series 110 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 time for hamburger patties to be broiled on the conveyor 20 within the main chamber 16, the operator would press key 1 of the key series 110, whereupon the controller 106 generates a display such as "SP" (conveyor speed) to appear on the alphanumeric 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 1 12 labeled "CLEAR" is pressed, causing the alpha-numeric display 1 16 to shift to a minutes/seconds display of 0, after which the operator uses the 0 through 9 alphanumeric 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" 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 1 10 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 1 12 has been pressed to store a desired cooking time for any one of the keys 110, the controller 106 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 1 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 time for any one of the keys 5 through 8 of key series 1 10, 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 "CLEAR" 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 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 be 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 must be cooked at least to a minimum internal temperature to be safe for human 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 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, 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 10. 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 112 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 the alpha-numeric display 116 to produce an appropriate display message, e.g. "CLEAN." Thereupon, the controller 106 causes the temperatures within the chambers 16, 18 to increase to the maximum possible temperature(s) by opening a regulator valve in the gas supply line to a fully open position to supply gas to the burners 48, 50, 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 16, 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, 50, 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 motors 36, 40, 44 to maintain traveling operation of the conveyors 20, 22, 24 within the chambers 16, 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 message such as "hot" to signify the status of the apparatus, and the controller 106 maintains this cooling sequence until the chambers 16, 18 have 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 36, 40, 44, and produces a display message such as "off on the alpha-numeric display 116. Electrical power to the apparatus 10 is maintained 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 1 16 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 10 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 of 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 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 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. 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 invention. 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.

Claims

WHAT IS CLAIMED IS:

1. A conveyorized food cooking apparatus essentially as illustrated and described.

2. A conveyorized food cooking method essentially as illustrated and described.

3. Means for controlling a food cooking apparatus essentially as illustrated and described.

4. A method for controlling a food cooking apparatus essentially as illustrated and described.

5. An apparatus or method according to one or more of the preceding claims, particularly designed for use in a fast food restaurant.

6. An apparatus or method according to one or more of the preceding claims, further comprising multiple independently-controllable meat broiling systems.

7. An apparatus or method according to one or more of the preceding claims, further comprising an automated food dispensing unit.

8. An apparatus or method according to one or more of the preceding claims, further comprising a microprocessor-based controller.

9. An apparatus or method according to one or more of the preceding claims, wherein the microprocessor-based controller is selectively programmable, e.g., for adjusting cooking times and temperatures and for performing diagnostic functions.

10. An apparatus or method according to one or more of the preceding claims, wherein the independent meat broiling systems comprise two or more separate meat broiling chambers, each with separate gas-fueled burners and separate meat- transporting conveyors.

11. An apparatus or method according to one or more of the preceding claims, further comprising an independent bread toasting system.

12. An apparatus or method according to one or more of the preceding claims, wherein the bread toasting system comprises an electrically heated platen and an independent conveyor for transporting bread items in contact with the platen.