Steam generator with external probe housing unit

Abstract

A steam generator for use with a steam cooker includes a heating chamber defining a volume for holding water. A heating system is associated with the heating chamber that is configured to heat water in the heating chamber so as to generate steam. An external probe housing unit is in communication with the heating chamber. The external probe housing unit includes a housing part defining a cavity therein. The housing part includes a first end through which water passes to and from the heating chamber, a second end opposite the first end, a top, a bottom and sides extending between the ends. A first probe support surface is located at a first probe receiving portion at the top of the housing part and a second probe support surface located at a second probe receiving portion at the top of the housing part. The first probe support surface is offset vertically from the second probe support surface

1 . A steam generator for use with a steam cooker, the steam generator comprising:
 a heating chamber defining a volume for holding water;   a heating system associated with the heating chamber, the heating system configured to heat water in the heating chamber so as to generate steam; and   an external probe housing unit in communication with the heating chamber, the external probe housing unit comprising
 a housing part defining a cavity therein, the housing part including a first end through which water passes to and from the heating chamber, a second end opposite the first end, a top, a bottom and sides extending between the ends; 
 a first probe support surface located at a first probe receiving portion at the top of the housing part; and 
 a second probe support surface located at a second probe receiving portion at the top of the housing part; 
 wherein the first probe support surface is offset vertically from the second probe support surface. 
   
   
   
       2 . The steam generator of  claim 1 , wherein the first probe support surface and the second probe support surface are offset by a step defined by the top of the housing part. 
   
   
       3 . The steam generator of  claim 1 , wherein the external probe housing unit further comprises a first probe coupling member that includes the first probe support surface and a second probe coupling member that includes the second probe support surface, the first probe coupling member extending outwardly a greater distance from the top of the housing part than the second probe coupling member. 
   
   
       4 . The steam generator of  claim 1 , wherein the first probe receiving portion is nearer the first end than the second probe receiving portion. 
   
   
       5 . The steam generator of  claim 1  further comprising
 a first water level probe extending into the cavity of the external probe housing unit at the first probe receiving portion at the top of the housing part; and   a second water level probe extending into the cavity of the external probe housing unit at the second probe receiving portion at the top of the housing part.   
   
   
       6 . The steam generator of  claim 5 , wherein a tip of the first water level probe is a greater distance from the bottom of the housing part than a tip of the second water level probe, the first water level probe capable of providing a high water level indication and the second water level probe capable of providing a low water level indication. 
   
   
       7 . The steam generator of  claim 6 , wherein the first water level probe has a first probe length and the second water level probe has a second probe length, the first and second probe lengths being substantially the same. 
   
   
       8 . The steam generator of  claim 6  wherein the external probe housing unit is secured to a side portion of a heating chamber housing, the heating chamber housing includes an opening for delivering water into the cavity via the first end of the housing part, the opening of the heating chamber housing sized and located such during typical steam generator operation the heating chamber housing acts as a baffle against turbulent surface level water flow into the cavity of external probe housing unit. 
   
   
       9 . The steam generator of  claim 5 , wherein the external probe housing unit further comprises
 a pressure sensor coupling configured to operatively connect a pressure sensor to the housing part for detecting pressure within the cavity; and   a pressure sensor connected to the pressure sensor coupling that provides a signal indicative of a pressure within the cavity;   wherein the pressure sensor is located above the tip of the first water level probe.   
   
   
       10 . The steam generator of  claim 9 , wherein the external probe housing unit further comprises
 a temperature sensor coupling configured to operatively connect a temperature sensor to the housing part for detecting temperature within the cavity; and   a temperature sensor connected to the temperature sensor coupling that provides a signal indicative of a temperature within the cavity;   wherein the temperature sensor is located below the tip of the second water level probe.   
   
   
       11 . The steam generator of  claim 5  further comprising
 a third probe support surface located at a third probe receiving portion at the top of the housing part, wherein the third probe support surface is offset vertically from the second probe support surface and the first probe support surface; and   a third water level probe extending into the cavity of the external probe housing unit at the third probe receiving portion at the top of the housing part.   
   
   
       12 . The steam generator of  claim 1 , wherein at least a portion of the bottom of the housing part has a downward slant toward the first end. 
   
   
       13 . The steam generator of  claim 1 , wherein the housing part is cast of metal. 
   
   
       14 . The steam generator of  claim 13 , wherein the external probe housing unit further comprises a flange extending outwardly from a periphery of the first end, the flange providing structure connecting the housing part to the heating chamber. 
   
   
       15 . The steam generator of  claim 1 , wherein the housing part is formed of a metal sheet. 
   
   
       16 . A steam oven comprising a steam cooking chamber with an access door, the steam generator of  claim 1 , a steam path from the heating chamber of the steam generator to the steam cooking chamber, and pan support structure within the steam cooking chamber for receiving food product pans. 
   
   
       17 . A method of monitoring operating conditions within a steam generator, the method comprising:
 connecting an external probe housing unit to an outer surface of a steam generator to provide communication between a heating chamber of the steam generator and a cavity of the external probe housing unit, the external probe housing unit including a housing part defining the cavity therein, the housing part including a first end through which water passes to and from the heating chamber, a second end opposite the first end, a top, a bottom and sides extending between the ends, a first probe support surface located at a first probe receiving portion at the top of the housing part and a second probe support surface located at a second probe receiving portion at the top of the housing part, wherein the first probe support surface is offset vertically from the second probe support surface; and   detecting a first water level within the cavity using a first water level probe supported by the first probe support surface and extending downward into the cavity;   detecting a second water level within the cavity using a second water level probe supported by the second probe support surface and extending downward into the cavity.   
   
   
       18 . The method of  claim 17 , wherein the step of connecting the external probe housing unit to the outer surface of the steam generator comprises welding. 
   
   
       19 . The method of  claim 17 , wherein the step of connecting the external probe housing unit to the outer surface of the steam generator comprises fastening using mechanical fasteners. 
   
   
       20 . The method of  claim 17  further comprising forming the housing part of a metal sheet or casting the housing part of metal. 
   
   
       21 . The method of  claim 17  further comprising controlling inflow of water to the heating chamber based on the water level detected within the cavity of the external probe housing unit. 
   
   
       22 . The method of  claim 17 , wherein the first water level probe and second water level probe have the same length, the first probe support surface locating a lower tip of the first water level probe at a first elevation within the cavity and the second support surface locating a lower tip of the second water level probe at a second elevation within the cavity, wherein the tip of the first water level probe is at a higher elevation than the tip of the second water level probe. 
   
   
       23 . The method of  claim 17  further comprising
 detecting water temperature of water located in the cavity using a temperature sensor connected to the housing part; and   detecting pressure in the cavity using a pressure sensor connected to the housing part.   
   
   
       24 . The method of  claim 17  further comprising forming the bottom of the housing part with a downward slant toward the first end. 
   
   
       25 . A steam generator for use with a steam cooker, the steam generator comprising:
 a heating chamber defining a volume for holding water, the heating chamber having a sidewall portion including an opening;   a heating system associated with the heating chamber, the heating system configured to heat water in the heating chamber so as to generate steam;   an external probe housing unit connected to the sidewall portion of the heating chamber at the opening, the external probe housing unit comprising
 a housing part defining a cavity therein, the housing part including a first end through which water passes to and from the heating chamber through the opening of the sidewall portion, a second end opposite the first end, a top, a bottom and sides extending between the ends; 
 a first water level probe extending through the housing part at the top of the housing part; and 
 a second water level probe extending through the housing part at the top of the housing part; 
 wherein a lower tip of the first water level probe is located at a higher elevation than a lower tip of the second water level probe; and 
   a baffle structure sized and located to limit migration of surface level turbulence from the heating chamber into the cavity of the external probe housing unit.   
   
   
       26 . The steam generator of  claim 25 , wherein the first water level probe has a first probe length and the second water level probe has a second probe length, the first and second probe lengths being substantially the same. 
   
   
       27 . The steam generator of  claim 25 , wherein at least a portion of the bottom of the housing part has a downward slant toward the opening of the chamber housing. 
   
   
       28 . The steam generator of  claim 25 , wherein the opening of the sidewall portion of the heating chamber is sized and located such that the sidewall portion of the heating chamber forms the baffle structure.