fig1 depicts a generalized configuration for one type of flyer which may be used according to a preferred embodiment of the present invention . it will be understood by one of ordinary skill in the art that the present invention , which will be described below , may be readily implemented with various other fryer types and configurations and that the specific flyers in these figures are shown merely as a preferred embodiment and for illustration purposes . reference numeral 101 of fig1 depicts a front view of a fryer 104 according to a preferred embodiment of the present invention . fryer 104 is designed such that a cooking substance ( e . g ., shortening , oil , fat , etc .) may be inserted into the vessel , and after the substance is heated , food products may be inserted into the cooking substance and deep fried . fryer 104 may comprise a plurality of heating elements 106 for heating the cooking substance . heating elements 106 may comprise gas fired heat exchanger tubes , for example . such a flyer is commonly known by those of ordinary skill in the art . heating elements 106 may be controlled by operation of a computer control device connected to the heating elements and temperature sensors ( not specifically shown ) according to known methods in the art . due to the placement of the heating devices in such fryers , three zones develop : a heating zone 108 around the heating elements , a cold zone 110 , and a transition zone 112 . as described above , a problem arises if the transition zone is not at a specified temperature before the initial cooking cycle after each powering of the fryer or after a delay in use of the fryer . at about 12 p . s . i ., water boils at about 248 ° f . therefore , if the temperature of the transition zone 112 is not at least 250 ° f . prior to the cooking cycle , then moisture from the cooking product may settle into the transition zone during the cooking cycle . upon completion of the cooking cycle , when pressure is released , the moisture may boil off causing eruption of boiling in the vessel . this boiling action stirs up cracklings or other food residue from the cooking cycle , causing those particles to settle in the transition zone and cooking zone . when the next food product is placed in the vessel , that food product may then be intermixed with the cracklings which is an undesirable result . according to the present invention , the temperature in the fryer transition zone is raised to above 250 ° f . prior to the initial cooking cycle . additionally , a control system monitors the temperature of the heating zone and the duration since the last cooking cycle . a control circuit such as that shown in fig3 of u . s . pat . no . 5 , 232 , 151 may be used , for example . it will be appreciated by one of ordinary skill in the art that any control system capable of regulating a heating device based upon a detected temperature may be used without departing from the scope of the present invention . a temperature probe / sensor 105 may be provided for monitoring the temperature in the heating zone . temperature probe / sensor 105 may be connected to a control system for monitoring the temperature and effecting activation of heating and mixing mechanisms as described in detail below . according to one embodiment of the present invention , a fryer may be provided with auxiliary heating elements located proximate to the transition zone . fig2 depicts one embodiment of a fryer having auxiliary heating elements according to the present invention . common element numbers represent like elements with other figures . according to this embodiment , fryer 104 comprises a plurality of heating elements 114 and 116 . such heating elements may comprise 120 volt , 500 w electric heaters , for example . other types of heaters may also be used as would be recognized by one of ordinary skill in the art . to condition the oil in the transition zone prior to the initial cooking cycle , when the fryer 104 is initially turned on , both the heating elements 106 and auxiliary heating elements 114 and 116 may be powered so that both the heating zone and the transition zone may be heated simultaneously . therefore , when the heating zone reaches the desired cooking temperature , the transition zone will also be at the desired cooking temperature . heating using auxiliary heaters may take time and may require monitoring during use to ensure that the temperature within the transition zone is maintained at the required level . as such , the heating elements may be required to be on for lengthy periods of time which may cause burning of crumbs which may fall onto the slopes of the transition zone . according to another embodiment of the present invention , fryer 104 may comprise a mixing mechanism for mixing the cooking substance in the heating zone with the cooking substance in the transition zone . mixing mechanism 120 preferably comprises a device for mixing the transition zone substance and the heating zone substance without substantially disturbing the cooking substance in the cold zone . fig3 depicts one embodiment of a mixing mechanism 120 according to the present invention . mixing mechanism 120 comprises a pump 122 , a filter tank 124 , a filter 126 , and a return line 128 . pump 122 operates to draw air from filter tank 124 through return line 128 into transition zone 112 of fryer 104 . the introduction of air into the transition zone creates a mixing action which causes the cooking substances in the transition zone and the heating zone to internix . thereby , the temperature of the cooking substance in the transition zone rises to nearly that of the substance in the heating zone . because most fryers 104 have a pump , filter and filter tank available for filtering oil in the fryer , the structural design of a fryer 104 requires little modification and thereby , re - engineering of the outer structure of the fryer is minimized . fig4 depicts another embodiment of a mixing mechanism 120 according to the present invention . mixing mechanism 120 &# 39 ; comprises a pump 122 , a filter tank 124 , a filter 126 , a return line 128 , a withdraw line 130 , and a valve 132 . pump 122 operates to withdraw oil from the fryer and return the oil into the vessel via return line 128 . valve 132 may comprise a three way directional flow valve to regulate flow of oil into and out of filter 126 . by withdrawing oil from one side of the vessel and retuning that oil to the other side of the vessel , a mixing action is generated in the vessel which causes the heating zone and transition zone cooking substances to mix . in both embodiment of fig3 and 4 , strategic placement of the return line and the withdraw line of fig4 ensures that the cooking substance in the cold zone is relatively undisturbed . due to the sloping walls of the vessel around the transition zone , placement of the return line at the top or slightly above the sloped walls may ensure that the movement of oil within the vessel is relatively limited to the heating zone and the transition zone . other placements of the return and withdrawal lines may also be used which avoid significant movement of oil from the cold zone . under certain conditions the cooking substance in the pump inlet may solidify . in addition , the filter tank may contain excess amounts of cooking substance . in either situation , the pump is unable to force air into the cooking vessel . this problem may be eliminated by providing an air inlet valve on the pump inlet pipe . the valve may be in the open position when power is supplied to the pump , and closed when power is shut off . this prevents unintentional draining of cooking substance in the event of a power loss . the outlet of the air inlet valve is positioned , so that any cooking substance that may enter the air inlet valve may be drained into the filter tank . further , the operation of the air inlet valve is coordinated with the draining and filtering processes to permit the heat regulation device of the fryer to function properly . thus , the air inlet valve is opened to allow air into the cooking vessel during air mixing and after the cooking substance is filtered , to allow liquid cooking substance to drain back into the filter tank . fig5 depicts still another embodiment of a mixing mechanism 120 &# 34 ; according to the present invention . mixing mechanism 120 &# 34 ; comprises a pump 122 , a filter tank 124 , a filter 126 , and a return line 128 . further , mixing mechanism 120 &# 34 ; includes an air inlet valve 150 positioned on the inlet side of pump 122 . air inlet valve 150 may be a solenoid operated , gate valve . suitable valves include the asco ® red - hat ® valve ( catalog no . 8262g36 ), which is commercially available from american switch company ( asco ) of florham park , n . j ., u . s . a . the cooking substance in fryer 104 may be drained through a drain valve 107 into filter tank 124 . when air inlet valve 150 is closed , the cooking substance may be returned to fryer 104 by using pump 122 to draw the cooking substance through a filter 126 . in addition , air inlet valve 150 includes a valve drain 152 , whereby any cooking substance that may enter air inlet valve 150 may be drained into filter tank 124 . thus , for example , after the cooking substance is filtered , any cooking substance remaining in return line 128 may be drained to filter tank 124 . this would prevent cooking substance from solidifying in return line 128 . according to an embodiment of the present invention , mixing mechanism 120 may be operated according to the following method through the operation of a suitable control system as described above -- for example , such as one described in fig3 of u . s . pat . no . 5 , 232 , 151 . the control system may include a series of operating instructions to direct the cooking process and , in particular , the heat regulation device of the present invention . for example , there may be at least about six modes of operation in the cooking process . a first mode is the cold start mode . the cold start mode is entered when the fryer heat source has been turned off for an extended period of time , such that the cooking substance temperature has dropped below a predetermined minimum temperature , e . g ., about 100 ° f . a second mode is the cooking mode . in the cooking mode , the fryer is operated to cook food product . a third mode is the cook idle mode . the cook idle mode is entered when the cooking substance is maintained at its cooking temperature , but the fryer is not being used to cook food product . a fourth mode is the cool mode . in the cool mode , the cooking substance is maintained at a temperature well below cooking temperatures . the cool mode may be entered when the fryer is not immediately needed for cooking , but may be used for cooking in the near future . a fifth mode is the forced filter mode . the forced filter mode causes the cooking substance in the fryer to be periodically filtered . as noted above , periodic filtering of the cooking substance lengthens the useful life of the cooking substance and improves its quality . for example , the forced filter mode may determine the filtering period based on the type of food product cooked and the number of cooking cycles completed for the food product . a sixth mode is the non - forced filter mode . the non - forced mode also causes the cooking substance in the fryer to be filtered . however , this mode may be initiated at the discretion of the system operator . according to the present invention , the mixing mechanism may be activated for a predetermined period or until prescribed temperature set points are reached when certain operational conditions are realized . for example , the mixing mechanism may be activated following a transition from a cold start mode to a cool mode or a cook idle mode or a transition from a cool mode to a cook idle mode , when the cool mode has lasted for a predetermined period , e . g ., for more than about 30 minutes . in addition , the mixing mechanism may be activated when the control system has operated in a cook idle mode , without interruption , for a predetermined period , e . g ., for more than about 30 minutes . further , the mixing mechanism may be activated following operation in a forced or non - forced filter mode . at the first powering up of fryer 104 , fryer 104 may be programmed to heat to a &# 34 ; cool &# 34 ; mode which may be about 250 ° f ., for example . fryer 104 may maintain this temperature until the computer control circuitry indicates that a cooking cycle is to be entered . computer control circuitry may indicate this upon manual entry by a user of the fryer , for example . upon instruction by a user to enter a cooking cycle , computer control turns on heating elements 106 to instruct them to rise to the desired cooking temperature . at the same time , mixing mechanism 120 may be activated . according to a preferred embodiment of the present invention , when the temperature is about equal to 250 ° f . in the heating zone , mixing mechanism 120 may operate for less than about 3 minutes to raise the temperature in the transition zone to about 250 ° f . this time is less than required for the fryer to raise the temperature of the heating zone from 250 ° f . to the cooking temperature . according to another preferred embodiment of the present invention , mixing mechanism 120 may be activated for a shorter duration by allowing the temperature in the heating zone to rise before activation . according to this embodiment , mixing mechanism 120 may be activated when the temperature in the heating zone reaches the desired cooking temperature minus a predetermined differential , such as 5 ° f ., for example . in one embodiment , the cooking temperature may be about 345 ° f . and the predetermined differential may be about 5 ° f . in this embodiment , mixing mechanism 120 may be activated by the computer control circuitry when the temperature in the heating zone reaches 340 ° f . and may be active for a predetermined time such as about 35 seconds , for example . operation of computer control circuitry based on temperature and duration is well known in the fryer art , for example , as described in u . s . pat . nos . 5 , 232 , 141 and 4 , 913 , 038 . after the initial cooking cycle , fryer 104 may be idled for various periods of time . during these idle periods , the temperature in transition zone 112 may recede to a temperature less than the specified temperature ( e . g ., less than 250 ° f .). consequently , according to the present invention , mixing mechanism 120 may be activated during idle times to ensure that the temperature in transition zone 112 is maintained above the specified temperature . alternatively , mixing mechanism 120 may be reactivated before cooking cycles are entered . when fryer 104 has been in an idle cycle ( i . e ., when the oil temperature in the heating zone is considerably lower than the cooking temperature ) and then a command is received to proceed to a cooking temperature by a user , mixing mechanism 120 may be engaged when the temperature in the heating zone reaches the desired cooking temperature minus a predetermined differential . the length of time mixing mechanism 120 may be operated may be varied depending on the length of time fryer 104 has been in an idle cycle so as to minimize the use of mixing mechanism 120 while still raising the temperature in the transition zone above the specified temperature . essentially , operation times for mixing mechanism 120 may be determined such that the specified temperature is reached before the cooking operation proceeds . the flow charts fig6 - 9 depict various routines which may comprise the mixing mechanism control process . these routines include fig6 which is a flow chart depicting a pump control initialization routine 60 ; fig7 which is a flow chart depicting a pump request confirmation routine 70 ; fig8 which is a flow chart depicting a pump run time selection routine 80 ; and fig9 which is a flow chart depicting a pump control routine 90 . referring to fig6 the control process may begin by initializing the pump control . in an initial step , step 62 , a pump output switch is placed in the off position and the system confirms that pump operation has not been requested . the control system may include a plurality of internal clocks , timers , or timing devices for measuring and monitoring the duration of selected control system events . for example , the control system may include clocks for measuring the duration of the cook idle and cool modes and for measuring the duration of pump operation periods and total pump operations . in the following step , step 64 , the cook idle , cool , and pump clocks are stopped , i . e ., timed out , and are zeroed , the time value is reset to zero . finally , in step 66 , the control system confirms that an exit cool key has not been depressed . as noted above , in the cool mode , the cooking substance is maintained at a temperature well below cooking temperatures . the cool mode may be entered when the fryer is not immediately needed for cooking , but may be used for cooking in the near future . when the exit cool key is depressed , the control system begins readying the fryer for cooking . the mixing mechanism may be activated following a transition from a cool mode to a cook idle mode , when the cool mode has lasted for a predetermined period , e . g ., for more than about 30 minutes . initialization is then complete , and , as indicated by step 68 , the control system exits routine 60 . referring to fig7 the control process may continue by confirming a pump operation request . with respect to step 71 , routine 70 is run when pump operation has not yet been requested , e . g ., initialization routine 60 including step 62 has been successfully run . in step 72 , the control system determines whether the pump clock is running . if the pump clock is running , pump operation has already been requested . consequently , as indicated by step 73 , the control system exits routine 70 . however , if the pump clock is not running , routine 70 proceeds to step 74 , in which the control system determines whether the cook idle mode has been selected and whether the exit cool key has been depressed . if both these conditions are met , an exit cool key flag or stop condition is cleared in step 75 , and the system proceeds to step 76 , in which the system determines whether the cool clock has been running for a period of time greater than or equal to a defined limit , e . g ., for more than about 30 minutes . if the cool clock has not been running for a period of time greater than or equal to the defined limit , the control system next considers in step 77 , whether a pump on clock has measured a period of time greater than or equal to a defined limit . the pump on clock measures and monitors the total time that the pump has been operating , for example , since cold start mode was initiated . if the pump on clock also has not been running for a period of time greater than or equal to the defined limit , pump operation has not been requested , and as indicated by step 73 , the control system exits routine 70 . however , if the answer to either of the questions asked in steps 76 and 77 is yes , a pump request is confirmed in step 79 . s confirmed in step 79 . alternatively , if the cook idle clock equals a defined limit , the pump request is confirmed in step 79 , and the control system exits routine 70 . referring to fig8 the control process may continue by selecting a pump run time . pump run times may be included in an array or set of time values , such as those set forth hereinafter in table 1 . an array index is a counter or marker for identifying the position or location of the control process in the array . for example , when pump operation is initiated according to an array including n pump controlling time values , the array index equals zero . the array index equals n when pump operation according to the array is complete . in step 81 , the array index is initially assigned a value of zero . in step 82 , the control system determines whether the pump on clock has measured a total time that is greater than or equal to a defined limit or whether a cold start is being initiated . if the answer to either question asked in step 82 is yes , the pump on clock is cleared and the display indicates that the clock is timed out . further , as indicated in step 83 , the pump clock is set to operate according to the cold start pump time instructions and the cold start flag is cleared . as indicated by step 84 , the control system exits routine 80 . however , if the answer to either of the questions posed in step 82 is no , the control system determines in step 85 whether the time measured by the cook idle clock equals a defined cook idle time . if so , the cook idle clock is cleared in step 86 , and the pump clock is set to the cook idle pump time . as indicated by step 84 , the control system again exits routine 80 . finally , if neither the questions asked in step 82 or 85 are answered yes , a cool time for step 87 is selected from a table of time values , such as are described in table 1 herein . the time measured on the cool clock is zeroed and the clock is timed out , as indicated in step 88 . once the pump run time has been selected , the control system exits routine 80 . referring to fig9 the control process may continue by controlling the operation of the pump . in step 91 , the system initially inquires whether the fryer is functioning in a service mode . the service mode permits operation of fryer elements , including the pump , manually . in this manner , these elements may be tested and maintenance may be performed on the fryer . if the service mode is selected , automatic or computer controlled pump operation is not desired , and the control system exits routine 90 . however , if the fryer is not in the service mode , the control system determines the position of a three position control switch ( not shown ) in step 93 . when the control switch is in a first position , a power - on position , the pump may operate automatically or under computer control . when the control switch is in a second position , a manual pump operation position , the pump may be activated at an operator &# 39 ; s discretion to override programmed operation . finally , when the control switch is in a third position , a power - off position , no power is supplied to the pump and the pump may not operate . an exit fill key provides a direct override of pump operation . if the pump is running , it may be deactivated by depressing the exit fill key . therefore , if the control switch is in the third position or if the exit fill key has been depressed or if an error has been detected in the system ; then the pump has not been requested , and the pump clock is timed out and zeroed . further , as indicated in step 93 , a pump output switch is deactivated , and the cold start flag is cleared . if the answer to each of the inquiries posed in step 93 is no , the control system inquires whether a pump request has already been initiated in step 95 . if no request has been made , the control system confirms whether a new pump request is initiated in step 96 . if a pump request has already been initiated or if a new pump request is initiated , i . e ., if either of the inquiries posed in steps 95 or 96 is answered yes ; the system inquires in step 97 confirms that the pump has been requested , that the temperature of the cooking substance ( the &# 34 ; pot temp &# 34 ;) is greater than or equal to a defined lower limit , e . g ., a heating temperature minus a predetermined differential , and that the system is in the cook idle mode . if all of the conditions of step 97 are satisfied ; in step 98 , a pump time is selected , the pump clock is started , and the system indicated that no pump request was made . if not , the control process proceeds to step 99 . in step 99 , the control system confirms whether the pump clock is running . if so , the pump is turned on , as indicated in step 99a . if not , the pump is turned off , as indicated in step 99b . once a determination has been made to turn the pump on ( step 99a ) or to turn the pump off ( step 99b ), the control system exits routine 90 . the present invention may be further understood by considering the following example , which is intended to be purely exemplary of the invention . according to the invention , the control system may include computer controlled circuitry , and the controlling computer may be programmed with software , such as that included in the microfiche appendices . the following table illustrates an example of the duration of operation of the mixing mechanism based on different idle cycle times . table 1______________________________________length of time in idle cycle mixing mechanism operation duration______________________________________0 - 29 minutes 0 30 minutes 10 seconds 50 minutes 17 seconds 90 minutes 25 seconds 120 minutes and up 35 seconds______________________________________ during cook cycle , there may be idle times of non - use , i . e ., an idle time during the cook cycle . during idle times mixing mechanisms , e . g ., mixing mechanism 120 , may be activated to ensure that the transition zone temperature does not fall below the specified temperature . every predetermined amount of idle time , mixing mechanism 120 may be activated for second predetermined amount of time . for example , every 30 minutes , mixing mechanism 120 may be activated for 15 seconds . these times are designed to ensure that the temperature in the transition zone does not fall below 250 ° f . other times and durations may be used for other specified temperatures for the transition zone . all of the process parameters may be programmed and executed using the fryer process controller . other embodiments of the invention will be apparent to persons skilled in the relevant art from a consideration of this specification or practice of the invention disclosed herein . it is intended that the specification and examples be considered as exemplary only . although a detailed description of the present invention is provided above , it is to be understood that the scope of the invention is not limited thereby , but is determined by the claims which follow .
the invention relates to a cooking device including a vessel for heating a cooking substance . the cooking substance is divided between a heating zone , a transition zone , and a cold zone . a first heating element is used to heat the cooking substance in the heating zone , and a transition zone heating device is used to heat the cooking substance in the transition zone . the transition zone heating device may be a pump for introducing a mixing medium into the cooking substance in the transition zone whereby the cooking substance in the heating zone mixes with the cooking substance in the transition zone . the mixing medium may be air , whereby the cooking substance in the heating zone is turbulently mixed with the cooking substance in the transition zone . the mixing medium also may be a portion of the cooking substance withdrawn by the pump from the transition zone and then reintroduced to the transition zone , thereby creating turbulence in the transition zone . the transition zone heating device may also be a second heating element . a method for operating a cooking device includes a vessel for heating a cooking substance . the cooking substance is divided between a heating zone , a transition zone , and a cold zone . the method comprises the steps of heating the cooking substance in the heating zone to a predetermined temperature and mixing the cooking substance in the transition zone with the cooking substance in the heating zone , thereby creating turbulence within the cooking substance in the transition zone . the turbulence is created by introducing air into the cook substance in the transition zone or by withdrawing a portion of the cooking substance from the transition zone and reintroducing the portion to the transition zone .