Automatic cooking medium level control systems and methods
An automatic cooking medium level control system for a cooking apparatus, e.g., a fryer, may include a cooking vessel having a first temperature sensor at a first level of the cooking vessel and a second temperature sensor at a second level of the cooking vessel. A reservoir holding a cooking medium, such as cooking oil, may be in fluid communication with the cooking vessel. A controller may monitor temperature data from the first and second temperature sensors to determine whether the level of cooking oil in the cooking vessel has lowered. Upon determining that the cooking oil level has lowered, the controller may actuate a supply mechanism, such as a pump, which may be disposed on a fluid communication path between the reservoir and cooking vessel, which may enable the introduction of cooking medium from the reservoir to the to the cooking vessel.
1. A method for automatically maintaining a level of cooking medium in a cooking vessel, the method comprising the steps of:
heating the cooking medium in the cooking vessel to a predetermined temperature for cooking a food product;
detecting temperature data within the cooking vessel when cooking the food product therein, comprising the substeps of:
detecting first temperature data at a first level within the cooking vessel by making a plurality of first temperature readings at the first level, and
detecting second temperature data at a second level within the cooking vessel, which is below the first level, by making a plurality of second temperature readings at the second level,
wherein each of the plurality of second temperature readings corresponds to one of the plurality of first temperature readings taken substantially contemporaneously therewith;
comparing the first temperature data and the second temperature data by comparing each of the first temperature readings with each of the corresponding second temperature readings;
determining a level of cooking medium in the cooking vessel based on the comparison of the first and second temperature data, the step of determining the level of cooking medium in the cooking vessel comprising the substeps of:
determining that a cooking medium level is at a start-fill value when the difference between a pair of substantially contemporaneous first and second temperature readings is greater than a predetermined start-fill value threshold, and
determining that the level of cooking medium in the cooking vessel is inadequate when a number of start-fill values equals or is greater than a majority of a number of the comparisons of the first and second temperature readings;
adding an amount of cooking medium in the cooking vessel through at least one inlet along a first communication path upon determining that the level of cooking medium in the cooking vessel is inadequate, the step of adding cooking medium comprising the substeps of:
adding the cooking medium at a third level within the cooking vessel that is below the second level within the cooking vessel, and
adding the amount of cooking medium to be less than an amount that would exceed the capacity of the cooking vessel;
determining a fill time, which corresponds to an amount of time elapsed while adding the amount of cooking medium in the cooking vessel;
notifying a status of a source of the cooking medium added to the cooking vessel when the fill time exceeds a predetermined value; and
filtering cooking medium, the step of filtering cooking medium comprising the substeps of:
causing cooking medium to exit the cooking vessel through at least one outlet along a second fluid communication path,
filtering the cooking medium exited from the cooking vessel through said at least one outlet, and
supplying filtered cooking medium to the cooking vessel through said at least one inlet along said second communication path.
2. The method of claim 1 , wherein the determining step further comprises:
determining that the cooking medium level is a stop-fill value when the difference between the substantially contemporaneous first and second temperature readings is less than a predetermined stop-fill level threshold;
determining that the cooking medium level is indeterminate when the difference between the substantially contemporaneous first and second temperature readings is less than or equal to a predetermined start-fill level threshold and greater than or equal to a predetermined stop-fill level threshold; and
determining that the level of cooking medium in the cooking vessel is inadequate when a number of start-fill values equals or is greater than a majority of the number of the comparisons of the first and second temperature readings less a number of determinations that the cooking medium level is indeterminate,
wherein the predetermined start-fill level threshold is less than or equal to the predetermined stop-fill level threshold.
3. The method of claim 2 , wherein the adding step is performed when the temperature of the cooking medium is greater than or equal to a predetermined cooking set point.
4. The method of claim 3 , wherein the predetermined cooking set point is at least about 120° C.
5. The method of claim 2 , further comprising heating the quantity cooking medium to be added to the cooking vessel.
6. The method of claim 5 , wherein the replenishing step comprises the substep of pumping the quantity of heated cooking medium to be added to the cooking vessel.
7. The method of claim 1 , wherein:
the detecting first temperature data step further comprises the substep of making a plurality of third temperature readings at the first level;
the comparing step further comprises comparing each of the third temperature readings with each of the corresponding second temperature readings, wherein each of the plurality of third temperature readings corresponds to one of the plurality of second temperature readings taken substantially contemporaneously therewith; and
the determining step further comprises:
determining that a cooking medium level is at a start-fill value when the difference between either a pair of substantially contemporaneous third and second temperature readings or the pair of substantially contemporaneous third and second temperature readings is greater than the predetermined start-fill value threshold, and
determining that the level of cooking medium in the cooking vessel is inadequate when a number of start-fill values equals or is greater than a majority of a number of the comparisons of the third and second temperature readings.
8. The method of claim 7 , wherein the determining step further comprises:
determining that the cooking medium level is a stop-fill value when the difference between the substantially contemporaneous first and second temperature readings and the difference between the substantially contemporaneous third and second temperature readings is less than a predetermined stop-fill level threshold; and
determining that the cooking medium level is indeterminate when the difference between the substantially contemporaneous first and second temperature readings and the difference between the substantially contemporaneous third and second temperature readings is less than or equal to a predetermined start-fill level threshold and greater than or equal to a predetermined stop-fill level threshold,
determining that the level of cooking medium in the cooking vessel is inadequate when a number of start-fill values equals or is greater than a majority of the number of the comparisons of the third and second temperature readings less a number of determinations that the cooking medium level is indeterminate
wherein the predetermined start-fill level threshold is less than or equal to the predetermined stop-fill level threshold.
9. The method of claim 1 , wherein the adding step comprises adding the amount of cooking medium for a predetermined supply time period.
10. The method of claim 9 , wherein the adding step comprises a predetermined rest time period, wherein the amount of cooking medium cannot be added to the cooking vessel during the predetermined rest time period.
11. The method of claim 10 , wherein the supply time period is about six (6) seconds.
12. The method of claim 11 , wherein the rest time period is about 54 seconds.