Fryer Oil Level Control Using Dual Temperature Sensing
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Solution Overview
Problem
Existing fryers face challenges in maintaining a consistent cooking medium level, leading to uneven cooking results due to manual operator reliance and inadequate level sensing methods, which are prone to contamination and false readings.
Innovation Solution
An automatic cooking medium control system using multiple temperature sensors and a supply mechanism that preheats the cooking medium, allowing for automated level maintenance and energy-efficient operation, preventing overcycling and ensuring consistent cooking performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual monitoring and addition of cooking medium is used, then operator control flexibility is maintained, but cooking consistency deteriorates due to operator attentiveness and skill variations
Solution Approach 1:
The system enables self-service operation where the fryer automatically monitors its own cooking medium level and adds cooking medium as needed without operator intervention. The level sensing mechanism detects when cooking medium is low and triggers the supply mechanism to replenish it, making the system self-regulating and eliminating dependence on operator attentiveness.
Solution Approach 2:
The system implements continuous feedback through level sensing mechanisms that monitor cooking medium levels and provide information to the control system. This feedback loop enables automatic adjustment of cooking medium supply to maintain optimal levels, ensuring consistent cooking performance regardless of operator presence or skill level.
2Device complexity
If float switches are used for level sensing, then simple mechanism is achieved, but reliability deteriorates due to contamination and fragility
Solution Approach 1:
The patent replaces mechanical float switches with non-contact level sensing methods such as optical sensors or capacitive sensors. These electronic sensing mechanisms are not subject to mechanical wear, contamination of moving parts, or fragility issues associated with float switches, thereby significantly improving reliability while maintaining adequate system complexity.
3Ease of operation
If optical sensors are used for level sensing, then non-contact measurement is achieved, but measurement precision deteriorates due to reflections and contamination
Solution Approach 1:
The system applies local quality by positioning level sensors at specific locations where reflections from product holders and cooking screens are minimized. The patent carefully selects sensor placement zones within the cooking vessel where line-of-sight to reflective surfaces is blocked or where the sensing beam path is optimized to avoid contamination and reflection interference, thereby maintaining measurement precision.
4Ease of operation
If ultrasonic sensors are used for level sensing, then non-contact measurement is achieved, but cost deteriorates due to expense at required resolution
Solution Approach 1:
The patent employs cost-effective level sensing solutions such as capacitive sensors or simplified optical sensors that are inexpensive to manufacture and replace. These sensors provide adequate resolution for cooking medium level detection without the high cost of ultrasonic sensors, making the system more economically viable while maintaining ease of operation and replacement.
5Device complexity
If cooking medium level is not maintained, then equipment simplicity is preserved, but manufacturing precision deteriorates due to uneven cooking
Solution Approach 1:
The fryer system performs self-service by automatically monitoring its own cooking medium level and replenishing it when low. This self-regulating capability ensures consistent cooking quality without requiring complex external control systems or operator intervention, maintaining an balance between system simplicity and cooking precision.
Solution Approach 2:
The system implements feedback control where level sensors continuously monitor cooking medium levels and trigger automatic replenishment when thresholds are reached. This feedback mechanism ensures consistent cooking quality by maintaining proper cooking medium levels throughout operation, preventing the uneven cooking that would result from insufficient medium.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system maintains a consistent cooking medium level without operator intervention, reducing the risk of undercooking and temperature variations, while being energy-efficient and less expensive to maintain, thereby improving cooking quality and reducing operator workload.
Implementation Method 1
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
Implementation Method 2
a heating element that preheats a viscuous cooking medium to make it less viscous, which enables the use of a less expensive supply mechanism
Implementation Method 3
a supply mechanism disposed on a fluid communication path between the reservoir and at an inlet to the cooking vessel
Data Source
AI summary
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.