Basket replenishment system

Abstract

Exemplary methods and systems relate to the transfer of a fixed amount of bulk food within an automated cooking system. A fixed amount of bulk food may be dispensed from a bulk food dispenser. The fixed amount of bulk food may be received from the bulk food dispenser by a lower transfer component. The fixed amount of bulk food may be transferred from the lower transfer component to an input bin at a first position. The input bin may move vertically from the first position to a second position above the first position. While the input bin is positioned at the second position, the fixed amount of bulk food may be supplied to or distributed to the automated cooking system.

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims the benefit of U.S. Provisional Patent Application No. 63 / 459,299, filed on April 14, 2023, and U.S. Provisional Patent Application No. 63 / 531,779, filed on August 9, 2023, and the disclosure of each is hereby incorporated by reference in its entirety for all purposes.

[0002] Preface The present disclosure is directed to an apparatus, system, and method for dispensing consumable items, and more particularly, to an apparatus, system, and method for moving stored consumable items from a storage area to a dispensing area.

Background Art

[0003] To automate various cooking operations in a restaurant, robotic automatic food cooking systems have been developed. For example, each of U.S. Patent Application No. 17 / 494,664 (filed on October 5, 2021) and U.S. Provisional Patent Application No. 63 / 088,162 (filed on October 6, 2020) discloses an embodiment of a robotic automatic food cooking system. This system can be used to fry consumable items such as French fries, onion rings, chicken, and other related consumable items.

[0004] In some robotic fryer systems, a robotic arm can be used to move consumables from storage containers or cabinets to, for example, the cooking medium of the fryer. Consumables may be pre-stored in cabinets, freezers, or other storage devices and portioned or weighed for cooking. Storage containers can distribute consumables at a relatively low position relative to cooking appliances such as fryers, especially when gravity-based dispensing mechanisms are used. The relative difference in vertical position increases the number and / or degree of robotic movements required to move the distributed consumables from the storage containers to the cooking appliances, increasing the time required to remove consumables from the storage containers and the overall cooking time associated with the consumables. [Overview of the project] [Means for solving the problem]

[0005] In at least some exemplary methods, a method for moving a certain amount of bulk food within an automated cooking system includes providing a certain amount of bulk food from a bulk food dispenser. The method further includes receiving a certain amount of bulk food from a lower transfer component and from a bulk food dispenser, and transferring the certain amount of bulk food from the transfer component to an input bin at a first position. The method further includes moving the input bin vertically from the first position to a second position above the first position, and providing a certain amount of bulk food to the automated cooking system while the input bin is at the second position.

[0006] In at least some illustrative diagrams, a bulk food dispensing system includes a bulk food dispenser configured to store bulk food and a dispenser configured to dispense a fixed amount of bulk food from the bulk food dispenser. The system also includes a lower transfer component configured to receive a fixed amount of bulk food from the dispenser and transfer the fixed amount of bulk food laterally away from the dispenser. Furthermore, the system includes an input bin configured to receive a fixed amount of bulk food from the lower transfer component at a first position. The input bin may be configured to move vertically from the first position to a second position above the first position. The input bin may also be configured to provide a fixed amount of bulk food to an automated cooking system while the input bin is positioned at the second location.

[0007] The aforementioned and other features and advantages of this disclosure may become apparent upon consideration of the following detailed description in conjunction with the accompanying drawings. [Brief explanation of the drawing]

[0008] [Figure 1] Perspective views of bulk food distribution systems according to several embodiments of the present disclosure are shown.

[0009] [Figure 2A] Figure 1 shows a perspective view of a bulk food dispenser with a loading bin in a first position, according to some embodiments of the present disclosure.

[0010] [Figure 2B] Figure 2A shows a perspective view of a bulk food dispenser according to some embodiments of the present disclosure, with the input bin raised to a second position relative to a first position.

[0011] [Figure 3A] Figures 1, 2A, and 2B show the input bins separated from the bulk food distribution system, with the upper deflectors attached to the input bins.

[0012] [Figure 3B] Figure 3A shows the feed bin with the upper deflector separated from the feed bin.

[0013] [Figure 4A] Figure 1 shows a perspective view of a bulk food dispenser with a plurality of baskets located in each basket holder and a feed bin in a first position, according to some embodiments of the present disclosure.

[0014] [Figure 4B] Figure 4A shows an enlarged perspective view of a basket and its respective basket holder, according to some embodiments of the present disclosure.

[0015] [Figure 5] Figure 1 shows a front view of another bulk food dispensing system with a lower transfer component including a pusher, according to some embodiments of the present disclosure.

[0016] [Figure 6] Figure 1 shows a front view of another bulk food dispensing system with a lower transfer component including a paddle conveyor, according to some embodiments of the present disclosure. <​​​​​​​​​​​​​​​​​​​​

[0020] Exemplary illustrations in this specification generally target systems and methods that provide for automated food preparation (e.g., executed by at least one robotic device) including the handling of a fryer basket using a robotic arm. The exemplary automated systems described herein utilize robotic equipment and other automated functions to perform cooking operations on bulk or specialty foods, thereby making it easier to perform operations that, without robotic equipment and other automated functions, could pose significant problems with operator safety, ergonomics, and hygiene, in a safe, clean, cost-effective, and timely manner. This disclosure is described in the context of an automated fry system facilitated by one or more robotic arms, but the complementary systems described in this disclosure can be utilized with other automated components for other food preparation tasks.

[0021] A bulk dispenser can have a standard dispensing position or a designed dispensing position. For example, a bulk food dispenser can include one or more hoppers stored within an area having specific operating conditions such as a refrigerated, frozen, or otherwise controlled temperature and humidity environment. Bulk food can be supplied using gravity-assisted dispensing, e.g., by components such as a plunger or an auger. In order to store large quantities of food to be dispensed while utilizing gravity supply in a typically crowded space such as a restaurant's back-of-house food preparation area, the bulk dispenser can dispense food relatively close to the floor, when a user places an appropriate container (e.g., a basket or other container) under the dispenser (as sensed by, e.g., one or more sensors), or when the user manually requests the dispensing of an item. In the context of a manual system, repeated access to relatively heavy items at a position close to the floor can be ergonomically undesirable and can cause injury.

[0022] Furthermore, prolonged transfer times from such locations, or excessive waiting times in the background environment between distribution and processing, can result in unfavorable conditions for food cooking and processing. For example, foods stored frozen, refrigerated, heated, or in other controlled states may begin to approach room temperature, potentially reducing the effectiveness of controlled cooking operations intended to be performed in a particular manner (e.g., frozen foods in a frying system). In embodiments of the present disclosure, the food to be cooked may be distributed and set to a state where it is kept at a desired temperature for subsequent automated operations.

[0023] In some exemplary automated cooking systems, a robotic frying system may receive large quantities of bulk food from a dispensing system. For example, a robotic arm may be positioned near a bulk dispenser, a fryer, and a staged placement location for cooked food. Embodiments of such systems are described in U.S. Patent Applications 17 / 494,664 (filed October 5, 2021), 18 / 096,388 (filed January 12, 2023), and 18 / 098,437 (filed January 18, 2023), which are incorporated herein by reference. The frying and staged placement areas are located at similar heights relative to the floor, but substantial horizontal and vertical movement is required to access the dispensing locations.

[0024] Some embodiments of this disclosure use an automated basket replenishment system to avoid automated components such as robotic arms that would have to make repeated large vertical movements to access the food to be distributed. The dispenser is automated to precisely distribute a desired amount of frying food into a distribution and transfer area that automatically and reliably provides the distributed food into the input bin, for example, by utilizing gravity, a plunger, a conveyor, etc., to distribute the distributed food horizontally into the input bin. The input bin is fixed to the side of the dispenser and, once loaded with food, can move vertically at a relatively high speed. The input bin moves vertically to a position for distribution to the automated cooking equipment, which is a position identified as the location where the fry basket is located, for example, based on whether the fry basket is held in a position by a robotic arm or positioned there by a robotic arm to receive food. Distribution is performed by acting the input bin into its input configuration, for example, by a mechanical function that opens a portion of the input bin and properly orients the input bin itself.

[0025] Referring here to Figures 1, 2A, and 2B, an exemplary bulk food distribution system 100 for distributing large quantities of bulk food to an automated cooking system is illustrated and described in more detail. Generally, the distribution system 100 provides a certain amount of consumable bulk food at an elevated position relative to the gravity-based dispenser 102 of the system 100. Thereafter, the system 100 can increase the throughput of the associated automated cooking system by, for example, reducing the time required for the system's robotic arm to collect the distributed amount of bulk food.

[0026] Although this disclosure is described in the context of a fryer basket and distributing bulk food therein, it will be understood that it may be similarly applicable to bulk distribution into other containers or vessels. In the embodiments illustrated in Figures 1, 2A and 2B, the dispenser 102 includes a plurality of hoppers 108a, 108b (collectively 108), each hopper 108 configured to hold its respective bulk food (e.g., for frozen goods). However, different embodiments may utilize different numbers of hoppers. In some embodiments, the plurality of hoppers 108 may contain the same food to facilitate rapid distribution by preparing one hopper for distribution while another hopper is actively distributing. In some embodiments, different foods may be placed in different hoppers 108, and the distribution and selection of food may be selectively controlled on the basis of customer instructions, as described, for example, in U.S. Patent Application No. 16 / 780,797, which is invoked by reference in whole. While this disclosure may describe embodiments for dispensing a single type of food, it will be understood that modifications may be made to allow the selective dispensing of multiple types of food from a single bulk dispenser 102 hopper 108. For example, modifications may be made based on the availability of a fryer (e.g., to allow similar foods to be fried in the same frying oil) or customer orders.

[0027] As will be further described below, exemplary bulk foods may include any consumable items convenient for processing or cooking in an automated cooking system, and / or are usually provided in quantities containing multiple consumable items. For example, consumable items herein may be french fries, onion rings, mozzarella sticks, fried vegetables, fried chicken tenderloins, or chicken nuggets. Furthermore, as described above, in at least some embodiments, bulk foods may typically be suitable for frying by dipping in heated oil or another cooking medium. Generally, the bulk food dispenser 102 can store consumable items in a refrigerated or freezer environment, which may be convenient for maintaining such exemplary consumable items in a state such as frozen, thereby facilitating the storage of bulk foods within the dispenser 102 and allowing for the dispensing of a certain amount of bulk food on demand.

[0028] Furthermore, as will be further described below in some embodiments, multiple dispensers 102 may be used to facilitate the storage and distribution of additional bulk food. Thus, the automated cooking system may use the distribution system 100 to selectively provide different types or quantities of bulk food. For example, the system 100 may be instructed to distribute a desired amount of bulk food stored in one of the hoppers 108, e.g., a desired weight or volume of bulk food. Accordingly, the relevant dispenser 102 of the multiple dispensers 102 can distribute the instructed or desired amount of bulk food.

[0029] As described above, the dispenser 102 can generally store and dispense bulk food in a refrigerated or frozen environment suitable for storing bulk food. In the illustrated embodiment, the hopper 108 is located within a temperature-controlled environment in the dispenser 102. The temperature-controlled environment in the embodiments herein is relatively lower than the room temperature environment, for example, below or near the freezing point. Any suitable temperature-controlled environment may be provided by the dispenser 102 depending on the bulk food, and in some cases, the temperature-controlled environment may be heated or otherwise kept relatively warmer than room temperature.

[0030] Bulk food placed in hopper 108 may be distributed vertically downward in various ways, such as by augers, paddle wheels, or plungers, to assist and facilitate the gravity-fed distribution of the desired amount of food to be distributed. Distributing mechanisms such as augers or paddle wheels generally allow for the loosening and / or individualization of bulk food or frozen products in general, and can facilitate precise particle size control of the bulk food being distributed. Loosening or individualizing bulk food by exemplary distributing mechanisms can facilitate the weighing of bulk food by a desired weight. In the illustrated embodiment, hopper 108a has a screw-type dispenser or auger 110a inside hopper 108a. Similarly, hopper 108b has an auger 110b. The auger 110 is configured to rotate to loosen a desired amount of bulk food, facilitating distribution from each hopper 108, and allowing that amount of bulk food to be lowered down to the lower transfer component 104. Hopper 108 can allow bulk food to be brought onto and from auger 110 by gravity. To this end, gravity-based feeding is used in each of hoppers 108 to transport bulk food to auger 110. Rotation of auger 110 moves the bulk food vertically downward and horizontally to distribution positions within hopper 108, for example, pushing the bulk food to an opening in hopper 108 and dropping it onto lower transfer components 104. The movement of the auger can be controlled according to the appropriate amount of bulk food to be distributed. For example, commands from an automated cooking system can be translated into the amount of rotation or movement of auger 110. The auger 110 can then distribute the desired amount of bulk food by performing the rotation.

[0031] The lower transfer component 104 is configured to receive a fixed amount of bulk food from the hopper 108 and transport that amount of bulk food laterally to the input bin 106. In the embodiment illustrated in Figures 1 to 2A, the lower transfer component 104 includes a conveyor 112 that transports the bulk food laterally or horizontally from a position below the hopper 108 to the opening 105. The bulk food is distributed by the conveyor 112 through the opening 105 and then received into the input bin 106. The movement of the conveyor may be controlled on a variety of basis, for example, on a known or estimated amount of food being distributed from the hopper 108 (e.g., based on the movement of a feeding mechanism such as an auger, or the volume of the distributed volume), on the weight of the items on the conveyor, or on indirect sensing of a fixed amount of distributed items on the conveyor.

[0032] Figures 1, 2A, and 2B illustrate a single replenishment area, for example, an opening 105 on the left side of the dispenser 102. The replenishment area or opening may be located in multiple positions, such as on any side or as an attachment to the front door of the bulk dispenser. Multiple replenishment areas may be arranged on a single bulk dispenser 102, for example, with lower transfer components such as multiple actuators or conveyors that move in multiple directions. In this way, food dispensed from the bulk storage environment within the dispenser 102 can be quickly distributed into input bins 106 or other containers for immediate processing.

[0033] The input bin 106 is vertically movable between a first position (shown in Figures 1 and 2A) and a second position (shown in Figure 2B). In the first position, the input bin 106 is configured to receive a certain amount of bulk food from the lower transfer component 104 and is therefore in a replenishment position for the system 100 and the dispenser 102. For example, the conveyor 112 can move the bulk food to the input bin 106 through the opening 105. Next, the input bin 106 may move vertically upward to a second position above the first position, for example, as shown in Figure 2B. In the second position or the raised position, the input bin 106 is configured to distribute a certain amount of bulk food to, for example, an automated cooking system. The timing of the vertical movement may be based on whether a container, such as a frying basket, is available for distribution. For example, the vertical movement may stop at an intermediate position until a container is available to receive food at the second position. Therefore, the second position can be the distribution position of the system 100 and the dispenser 102.

[0034] In some embodiments, the dispenser 102 includes a vertical stage with a vertical track 116 fixed adjacent to a lower transfer component 104 (e.g., a conveyor, actuator, etc.). In embodiments illustrated in Figures 1, 2A, and 2B, the input bin 106 is mounted on the vertical track 116, and as a result, the input bin 106 may selectively rise to distribute food to other automated components (e.g., a basket held by a robotic arm) and lower to receive the next food for distribution. The input bin 106 may move vertically, for example, along the vertical track 116 perpendicular to the ground between positions on the vertical track 116. As shown in Figures 2A and 2B respectively, the input bin 106 may move between a first position where the height of the input bin 106 above the floor is H1 and a second position where the height of the input bin 106 above the floor is H2.

[0035] The interface between the input bins 106 may include one or more doors, hatches, etc., that selectively open to allow distribution from the bulk dispenser 102 to the input bins 106 based on criteria such as the availability of food to be distributed, the location of the input bins, the location of the containers, and the requested food (determined, for example, by sensors). Although a single input bin 106 is shown in the embodiments herein, multiple input bins can be utilized, for example, by “storing” the input bin above the distribution point to an automated food processing component (i.e., above the second position shown in Figure 2B), by rotating one or more input bins 106 around a vertical track 116, or by providing adjacent stepped arrangement areas. In this way, multiple input bins 106 can provide a short-term “stock” of items for direct distribution. In some embodiments, the stepped arrangement areas and / or specific input bins 106 may provide heating, cooling, or other desired controlled environmental characteristics for the food.

[0036] As shown in Figure 2B, the input bin 106 may include a lower support for bulk food having an automatically acting (e.g., spring-loaded) door 118 that operates to distribute the bulk food in the input bin 106. For example, the input bin 106 may move along a vertical track 116 to a position where a mechanical feature (e.g., an inclined actuation block 120 connected to a vertical stage 116) acts to the door 118 as the input bin 106 moves vertically upward. The vertical stage 116 may be configured or instructed not to move the input bin 106 to a position for distribution until the associated automated cooking system is ready to receive a certain amount of bulk food from the input bin 106. In an embodiment of a robotic frying system that uses a robotic arm to move bulk food from a distribution system 100 to a frying medium, the system 100 may prevent the input bin 106 from moving to a distribution position until the robotic arm positions a basket to receive a certain amount of bulk food. The spring-driven door 118 may be actuated by a plunger on the vertical track 116 that manually operates the door 118, or by other means such as a signal provided to an internal operating mechanism of the input bin 106. The input bin may include other components (e.g., augers, plungers, rakes, etc.) to facilitate distribution to the basket, which can be actuated by mechanically interfaced with the vertical track 116, or by receiving electrical signals to actuate such components inside the input bin 106. The controlled and rapid movement of the input bin 106 within the vertical track 116 and the bulk dispenser 102 ensures rapid and repeatable transfer from a controlled environment (e.g., within the temperature-controlled environment of the hopper 108) to an automated cooking area (e.g., a robotic frying unit).

[0037] The input bin 106 is illustrated and described in more detail here with reference to Figures 3A and 3B. The input bin 106 may include various modifications, such as those described herein, but the exemplary input bin 106 may be removablely mounted on the vertical track 116 to facilitate switching of the input bin 116, such as for washing or processing different types of food. The input bin deflector 124 guides food into the input bin 106 (e.g., from the lower transport component 104 and / or conveyor 112) and prevents people or other objects from being caught in its movement as the input bin 106 moves along the vertical track 116. The input bin 106 may have an opening 114 configured to interface with the lower transport component 104. For example, when the input bin 106 is positioned in a first position / lowered position (see, e.g., Figure 2A), a certain amount of bulk food may be moved horizontally relative to the opening 114 of the input bin 106 and aligned with the opening 105 of the dispenser 102. Additional sensors can also monitor the path of the input bins 106 on the vertical track 116 to prevent damage to the user and equipment. Some of the input bins 106 are perforated with small holes to facilitate the release of fine food particles or other small food particles before they are placed in the basket for frying. For example, bulk food may be contained in the input bins 106 and placed on top of the door 118 when the door 118 is closed (see Figure 2B), and the door 118 may have multiple openings 119 (see Figure 2B) that provide a perforated surface. The openings 119 of the door 118 may be sized to release fine food particles or parts of food smaller than a given size. In some embodiments, trays may be provided to catch fine food particles or small food particles falling through the openings 119, facilitating the collection of even smaller food particles, or to allow them to be distributed to a storage / trash area when the input bins 106 reach a specific position (e.g., the bottom of the vertical track 116).

[0038] Referring here to Figures 4A and 4B, the illustrative illustrations describe a case where one or more baskets may be positioned on the vertical track 116. More specifically, the distribution system 100 may include a plurality of baskets 128 or other storage containers which may be placed on each basket holder 130 of the vertical track 116. Furthermore, the input bin 106 is positioned below the baskets 128 in a first position.

[0039] The basket hanger 130 may be used in any convenient manner. For example, it may be desirable to create special orders that are not dispensed from the bulk dispenser 102. Such items are dispensed by a user entering the zone of the bulk dispenser 102 (e.g., identified by a beacon on the user or requested via an indicator on the system) or by a basket 128 previously stored in a certain location (e.g., a temperature-controlled storage bin for infrequently used items). A user and / or robotic arm may place the basket 128 in one of the basket hangers 130 on the vertical track 116, thereby temporarily halting the movement of the input bin 106 along the vertical track 116 and / or halting the distribution of bulk food until the basket 128 is removed, or moving via a second path (e.g., an adjacent path or a path on another side of the bulk dispenser). The basket 128 may include mechanical and / or electrical sensors to identify the basket 128, and / or other information such as the food in the basket and its quantity, and the association of the order.

[0040] As described above, the lower transfer component 104 may include a conveyor 112 for moving bulk food dispensed from the dispenser 102 to the input bin 106. In other embodiments, different mechanisms may be used to move the dispensed food horizontally from the dispenser 102 to the input bin 106, or to other replenishment areas adjacent to the dispenser 102. Figures 5 and 6 show additional embodiments of mechanisms for supplying bulk food to input bins and / or alternatives to input bins. For example, the input bin 106 may be supplied by a conveyor, actuator, track, refillable container, or other suitable mechanism. As described herein, food may be delivered from the lower distribution position of the bulk dispenser 102 to a position for distribution to, for example, a robot in an automated cooking system.

[0041] In one embodiment, as shown in Figure 5, the bulk food dispensing system 200 uses an actuator 132 to push bulk food laterally into the input bin 106. In this embodiment, the actuator 132 may include a solenoid or other mechanism to push or propel a certain amount of bulk food toward the input bin 106 after it has been distributed by the dispenser 102. The bulk food may be distributed onto a smooth surface beneath the dispenser 102 to facilitate the actuator 132 pushing the bulk food toward the input bin 106. In another embodiment, the surface beneath the dispenser 102 may be sloped.

[0042] Referring here to Figure 6, another exemplary bulk food distribution system 300 is illustrated comprising a lower transport component 104 including a continuous track 134. The ridged track 134 may include a base track 138 and a plurality of ridges or paddles 140 fixed to the base track 138 so that each of the paddles 140 moves with the base track 138. In other embodiments, the continuous track may include components of containers (not shown) or baskets (e.g., components that fit into handles provided by a robotic arm) or otherwise allow distribution into baskets (e.g., pausing to position baskets below the continuous conveyor and then resuming movement to distribute food). Generally, the paddles 140 or other containers may move with the base track 138 as the base track 138 moves, with each paddle 140 collecting and transporting the distributed bulk food as the paddle moves around the ridged track 134. In the illustrated embodiment, the ridged track extends horizontally below the dispenser 102 and vertically along the dispenser 102. In this embodiment, the ridged track 134 may replace the input bin 106, the vertical track 116, and the associated components within the lower transfer component 104, distributing large quantities of bulk food as the ridged track 134 moves counterclockwise. The ridged track 134 lifts large quantities of bulk food, and the paddles 140 distribute the amount as they move over the upper or top position of the ridged track 134 (for example, into baskets positioned by an automated cooking system), with each paddle then returning downward along the ridged track 134. Thus, in the approach of this embodiment, the input bin 106 is not necessary to such an extent that the ridged track 134 and paddles 140 can deliver large quantities of bulk food to a high position (for example, corresponding to a second position for distribution to an automated cooking system). Alternatively, the ridged track 134 can deliver bulk food to input bins 106 that move along the vertical track 116, as described in other exemplary approaches.

[0043] As described above, in some embodiments, a single dispenser 102 is illustrated as part of a distribution system for bulk food, but multiple dispensers 102 may be used as convenient. In general, any number of dispensers 102 can be connected together in a network to provide various types or quantities of bulk food. Each dispenser 102 may distribute bulk food to an adjacent dispenser 102, and the bulk food eventually reaches the input bin 106.

[0044] Referring now to Figure 7, a bulk food distribution system 100' including a plurality of dispensers 102a and 102b is illustrated. As shown in Figure 7, the plurality of dispensers 102 can be located adjacent to each other, providing a transport path through which food from the rightmost dispenser 102b is transported to a vertical track 116 and input bins 106, for example, via a lower transport component 104 of the left-hand dispenser 102a located adjacent to the vertical track 116 and input bins 106. Various lower transport components 104 may be used in different embodiments, but in an exemplary embodiment, each of the transport components 104 of both dispensers 102 may be a conveyor 112 (e.g., a conveyor belt, a conveyor with partitioned compartments, etc.). Food from the right-hand dispenser 102b can be transferred from its conveyor 112b to the conveyor 112a of the left-hand dispenser 102a, and via that conveyor 112a, it can be transferred to the input bin 106 and vertical track 116. In some embodiments, the right-hand conveyor 112b may be higher (e.g., 1 to 4 inches higher) than the floor to facilitate transfer from conveyor 112b to conveyor 112a. Furthermore, an appropriate feeding speed of conveyor 112b can be provided to facilitate the food reaching the left-hand conveyor 112a without requiring additional components such as transfer sections between conveyors 112. In another embodiment, a cleated belt or ramp on conveyor 112b may advance or “feed out” the material onto another conveyor. In other embodiments, the transfer section may be located between the transfer components of each dispenser, such as a lateral movement or rotating shuttle attached to one of the dispensers 102. In another embodiment, an electromechanical or pneumatic pusher or a rotary sweep arm may be provided to facilitate the movement or transfer of objects from one conveyor to another.

[0045] As shown in Figure 7, dispensers 102a and 102b may each include multiple hoppers, such as the two hoppers 108a and 108b shown for dispenser 102a, and the three hoppers 108c, 108d, and 108e shown for dispenser 102b. The integrated transport components and high-speed vertical distribution via the input bin 106 allow a wide variety of items and combinations of items to be supplied to automated cooking systems such as frying systems. The timing of the distribution operation from each hopper to the integrated transport system is controlled in conjunction with the operation of the input bin and the available fryers, allowing for the supply of any one of up to five different food items in the embodiment of Figure 7. In some embodiments, multiple input bins may be used to accommodate additional throughput from multiple dispensers, for example, by providing a horizontal stepped placement area next to the vertical track, rotating the input bin at a position within the vertical track to create space within the vertical track for other input bins to pass through, or by loading into baskets placed in basket holders that do not interfere with the vertical track.

[0046] Referring here to Figure 8, the dispensing system 100 is illustrated to include an automated cooking system 800. The automated cooking system 800 includes a multi-axis robotic arm 802 configured to transfer large quantities of bulk food dispensed from the dispenser 102 of system 100 to a fryer 804. The automated cooking system 800 also includes a holding unit 806, for example, a "crispy hold" unit, configured to keep cooked bulk food such as french fries warm. The holding unit 806 may also facilitate the application of seasonings such as salt, pepper, or other specific seasonings as desired.

[0047] The input bin 106 may move between the first and second positions described above in Figures 2A and 2B. This facilitates dispensing a desired amount of bulk food for cooking in the automated cooking system 800. Furthermore, the robotic arm 802 may grasp the basket 128 via the handle 129 and position the basket 128 below the input bin 106 after the input bin 106 has moved to a second position or other higher position on the vertical track 116 to collect a desired amount of bulk food from the dispenser 102 and then distribute the bulk food from the input bin 106. In Figure 8, it is illustrated that the input bin 106 moves back to a first position adjacent to the lower transport component 104a of the dispenser 102a closest to the input bin 106, and the robotic arm 802 grasps the handle 128' of the basket 128 (for example, to transport the contents received from the input bin 106 after the input bin 106 has distributed a certain amount of bulk food into the basket 128). The vertical track 116 may be positioned between the distribution system 100 and the automated cooking system 800. The robotic arm 802 may receive bulk food contained in the input bin 106 by moving the basket 128 horizontally toward the input bin 106, for example by opening a spring-driven door 118 so that the contents of the input bin 106 can fall into the basket 128. In this way, the robotic arm 802 does not need to perform complex downward articulation movements for the elevated positioning of the input bin 106. Thus, the robot 802 can move almost entirely above and within the open space immediately adjacent to the fryer 804. In some configurations, such as those illustrated in Figure 8, the robotic arm 802 may be positioned on a track 808 and configured to move horizontally on the track 808. For example, the track 808 for the robotic arm 802 may be a low-friction rail that facilitates the movement of the robotic arm 802, for example to allow access to a cabinet 810 below the fryer 804, in order to move the robotic arm 802 when not in use. Therefore, track 808 can facilitate access to cabinet 810 when robot arm 802 is not moving or in use.In this way, there is no need to remove the robot arm 802 from the automated cooking system 800 during maintenance, cleaning, etc., to allow access to the cabinet 810 or other components of the automated cooking system 800. Thus, the robot arm 802 can be moved via the track 808, and the basket 128 held by the robot arm 802 can be positioned below the input bin 106, after which the robot arm 802 can be returned to the work area above the fryer 804, for example, the robot arm 802 can load the basket(s) 128 into one of the fryers 804.

[0048] The automated cooking system 800, in particular the robotic arm 802, can move in coordination with the input bin 106 to collect the distributed bulk food and cook them in the fryer 804. In just one embodiment, the input bin 106 may move to take a certain amount of bulk food from the dispenser 102 while the robotic arm 802 is performing other tasks in the automated cooking system 800, for example, while cooked bulk food is being moved from the fryer 804 to the holding unit 806. Thus, each of a certain amount of bulk food can be processed or cooked relatively quickly within the automated cooking system 800, in particular when the automated cooking system 800 is in batch mode, which is tasked with the production of a certain amount of processed or cooked bulk food. In other cases, for example, the input bin 106 may be in standby mode while the robotic arm 802 is accessing a manually placed basket 128, for example, located on a basket holder 130 on a vertical track 116.

[0049] Referring here to Figure 9, an exemplary process 1000 for distributing one or more bulk foods for, for example, an automated cooking system is illustrated. Process 1000 can begin in block 1002, where one or more bulk foods may be stored in one or more hoppers, e.g., hoppers 108. As described above, in some embodiments, the hoppers 108 may be provided in a single dispenser 102 or in a plurality of dispensers 102 arranged adjacent to one another. Furthermore, the exemplary distributing system 100 may be configured to include one or more baskets 128 for transferring bulk foods from the dispensers 102 to components of the automated cooking system 800. For example, a robotic arm of the automated cooking system 800 may grasp and manipulate a basket 128, position the basket 128 to receive a distributed amount of bulk food, place it in a fryer 804, and after frying, transfer that amount of bulk food to a holding unit 806. Process 1000 can then proceed to block 1004.

[0050] In block 1004, an order for a certain quantity of stored bulk food may be received. For example, an order for a certain quantity of bulk food, such as one or more orders of french fries, may cause the automated cooking system 800 to generate a command to retrieve that quantity of bulk food from the distribution system 100. In another embodiment, the automated cooking system 800 may be set to a "batch" mode in which bulk food is cooked as quickly as possible, for example, during peak order times or dinnertime. The process 1000 can then proceed to block 1006.

[0051] In block 1006, process 1000 can identify the location of bulk food to be processed by the automated cooking system 800. For example, the bulk food to be accessed may be in a specific hopper that has a known location relative to the distribution location to the input bin, and in embodiments with multiple distribution refrigerators, transfer between transfer units (e.g., conveyors) may be required. Proceeding to block 1008, the distribution system 100 can, in response to an instruction or command, determine a specific hopper 108 from among several hoppers 108 in the system 100 and distribute the ordered amount of bulk food. For example, during batch mode, the distribution system 100 may need to switch between different hoppers 108 and / or dispensers 102. In another embodiment, less frequently ordered items may be placed in a queue based on the availability of a specific fryer for those items. Process 1000 can then proceed to block 1010.

[0052] In block 1010, process 1000 may cause the bulk food dispenser 102 to dispense a desired amount of bulk food by causing the distribution components of the hopper 108, such as an auger 110. In block 1012, process 1000 may receive a certain amount of bulk food in the lower transfer component 104 of the bulk food dispenser 102. For example, as described above, a conveyor 112 may be provided to move the dispensed amount of bulk food laterally or horizontally away from the dispenser 102 toward the input bin, or, in a multi-dispenser embodiment, through the transfer components to the input bin. Moving on to block 1014, process 1000 may deliver a certain amount of bulk food to the input bin 106 at a first position or a relatively low position, for example, later using a vertical feed to enter through the opening of the input bin. Process 1000 can then proceed to block 1016.

[0053] In block 1016, once the input bin has received all the bulk food, process 1000 may move the input bin 106 vertically, for example, perpendicular to the floor supporting the distribution system 100, from a first position to a second position above the first position. In some embodiments, this movement is set for a set amount of time until the container is available to receive food. In additional embodiments, the input bin may be set temporarily, and the second input bin may be filled for distribution and moved vertically. A vertical track 116 may be provided, which facilitates moving the input bin 106 upward toward the second position or distribution position.

[0054] Moving on to block 1018, process 1000 may cause the input bin 106 to dispense or supply a certain amount of bulk food to the automated cooking system while the input bin 106 is positioned in a second location. For example, as described above, a spring-loaded lower support or door may be provided, which is actuated by the upward movement of the input bin 106 and its interaction with the mechanical features of the track, thereby allowing the contents of the input bin 106 to be placed into a basket 128 positioned by the robotic arm 802 and emptied.

[0055] In the exemplary systems and methods described above, the distribution system can generally reduce the number or degree of movements required for the robotic arm to retrieve bulk quantities of food. For example, providing or distributing bulk food at a relatively higher position compared to a typical gravity-based distribution system can increase overall throughput by reducing the time consumed by requiring the robotic arm to collect bulk food from a lower position. Thus, potential obstacles in automated cooking systems can be reduced. Furthermore, automated cooking systems increase the available space for baskets (or other containers) of food that is not immediately available.

[0056] The foregoing is merely illustrative of the principles of the Disclosure, and various modifications can be made by those skilled in the art without departing from the scope of the Disclosure. The embodiments described herein are provided for illustrative purposes only and are not limiting. Accordingly, the Disclosure is not limited to the expressly disclosed systems, devices, apparatus, components, and methods, but rather includes variations and modifications thereof within the spirit of the appended claims.

[0057] The systems, devices, apparatus, components, and methods described herein may be modified or changed to optimize them. Furthermore, it is understood that there may be many applications for the systems, devices, apparatus, components, and methods. The subject matter disclosed should not be limited to any single embodiment described herein, but rather should be interpreted in accordance with the claims.

Claims

1. A method for moving a certain amount of bulk food within an automated cooking system, To provide a certain amount of bulk food from a bulk food dispenser, The lower transfer component receives a certain amount of bulk food from the bulk food dispenser, Transferring a certain amount of bulk food from the transfer component to the input bin at the first position, Moving the input bin vertically from the first position to a second position above the first position, The method, comprising providing the automatic cooking system with a certain amount of bulk food while the input bin is positioned in the second location.

2. The method according to claim 1, wherein the bulk food dispenser includes a plurality of hoppers.

3. The method according to claim 2, wherein the plurality of hoppers are located in a temperature-controlled environment.

4. The method according to claim 2, wherein the auger of the first hopper among the plurality of hoppers provides the fixed amount of bulk food.

5. The bulk food is supplied from the first hopper. Receiving an instruction to switch from providing the first bulk food from the first hopper to providing the second bulk food from the second hopper among the plurality of hoppers, The method according to claim 4, further comprising providing the second bulk food from the second hopper in response to the aforementioned command.

6. The method according to claim 1, wherein the transfer component includes a conveyor, and the transfer includes moving the fixed amount of bulk food horizontally to the corresponding opening of the input bin.

7. The method according to claim 1, wherein the transfer component includes an actuator, and the transfer includes the actuator horizontally pushing the fixed amount of bulk food into the corresponding opening of the input bin.

8. The method according to claim 1, wherein the transfer component includes a ridged track, and the transfer includes the ridged track horizontally pushing the fixed amount of bulk food into the corresponding opening of the input bin.

9. The method according to claim 1, wherein moving the input bin vertically includes moving the input bin vertically along a vertical track perpendicular to the floor surface.

10. The method according to claim 9, wherein the input bin is removable from the vertical track.

11. The method according to claim 10, wherein the input bin includes a lower portion configured to support a certain amount of bulk food, the lower portion defines a plurality of openings of a size that allows a portion of the bulk food smaller than the opening to be released from the input bin.

12. The method according to claim 1, wherein the input bin is equipped with a spring-loaded door, the spring-loaded door is operated in the second position to dispense a fixed amount of bulk food.

13. The method according to claim 9, further comprising receiving a basket on the vertical track.

14. The method according to claim 13, further comprising accessing the basket by a robotic arm of the automated cooking system, wherein the input bin is temporarily suspended from moving vertically while the basket is positioned on the vertical track.

15. The method according to claim 1, wherein the automated cooking system includes a robotic arm, and the fixed amount of bulk food is provided to a basket held by the robotic arm.

16. The method according to claim 1, wherein the bulk food dispenser is a first bulk food dispenser, and the method further comprises arranging a second bulk food dispenser positioned on a first side of the first bulk food dispenser, the second bulk food dispenser being configured to transfer a large quantity of bulk food to the first bulk food dispenser on a first side of the first bulk food dispenser, and the first bulk food dispenser being configured to distribute the large quantity of bulk food into the input bins on a second side of the first bulk food dispenser opposite to the first side.

17. A bulk food distribution system, A bulk food dispenser configured to store bulk food in a hopper, wherein the hopper is configured to dispense a fixed amount of the bulk food, The lower transfer component is configured to receive a fixed amount of bulk food from the hopper and transfer the fixed amount of bulk food laterally away from the hopper, A bulk food distribution system comprising: an input bin configured to receive a fixed amount of bulk food from the lower transport component at a first position, the input bin configured to move vertically from the first position to a second position above the first position, and configured to provide the fixed amount of bulk food to an automated cooking system while the input bin is positioned at the second position.

18. The bulk food distribution system according to claim 17, further comprising a vertical track configured to move the input bin from the first position to the second position perpendicular to the floor.

19. The bulk food distribution system according to claim 17, wherein the bulk food dispenser is a first bulk food dispenser configured to store bulk food, and the bulk food distribution system includes a second bulk food dispenser configured to store a second bulk food, the second bulk food dispenser being located on a first side of the first bulk food dispenser, the second bulk food dispenser being configured to transfer a certain amount of the second bulk food to the first bulk food dispenser on a first side of the first bulk food dispenser, and the first bulk food dispenser being configured to distribute a certain amount of the second bulk food to an input bin from a second side opposite to the first side.

20. The bulk food dispensing system according to claim 17, wherein the bulk food dispenser defines an opening located on a first side of the bulk food dispenser and configured to receive a certain amount of a second bulk food, and the lower transfer component is configured to transfer a certain amount of the second bulk food located to the side of the input bin.

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