System and method for piston detection in a metering mechanism for use with beverage dispensing system

A dispensing and pour control system for a regulated beverage having a metering system that provides a discharge in a controlled and metered manner. A sensor system uses a Line Control Board (LCB) that detects a piston location inside a metering conduit. A plurality of magnetic sensors is positioned at equal intervals and in the same plane collinear with the movement of a magnetic piston within the metering mechanism conduit. The piston position is detected by obtaining a set of momentary readings of the magnetic sensors and estimating a location of the piston by interpolation of the piston position as an anticipate location between sensors that are adjacent and showing readings of opposing signs.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to a system and method for the automated metering, dispensing, reporting and tracking of dispensing beverages and, more particularly, to an improved metering mechanism including anticipatory control adapted for use therewith.

2. Description of the Related Art

In the automated beverage dispensing systems of the Related Art, bulk alcoholic beverages such as beer, wine or cocktails have been successfully dispensed in a manner that meters, tracks, controls and continuous dispenses in a faster and more accurate manner. Such systems prevent oxidation of the beverage contents while allowing for necessary and routine delivery line cleaning through several mechanism.

A need exists for improvements in the operation, repeatability and accuracy in the metering mechanism for use with such beverage dispensing systems.

SUMMARY OF THE INVENTION

It is thus an object of the present invention to provide for more efficient, optimized fluid flow path metering mechanism for use with beverage dispensing systems.

It is a feature of the present invention to provide such a metering mechanism formed in a manifold style assembly.

The present application provides a dispensing and pour control system for a regulated beverage having a metering system that provides a discharge in a controlled and metered manner. A sensor system uses a Line Control Board (LCB) that detects a piston location inside a metering conduit. A plurality of magnetic sensors are positioned at equal intervals and in the same plane collinear with the movement of a magnetic piston within the metering mechanism conduit. The piston position is detected by obtaining a set of momentary readings of the magnetic sensors and estimating the exact location of the piston by interpolating the distance between the sensors that are adjacent and showing readings of opposing signs.

The anticipated piston location is estimated by processing the set of all sensor readings reported at a given moment in time. The exact piston location algorithm consists of two steps:a. determining the two sensors that show the maximum and minimum readings over the entire set; andb. performing a linear interpolation based on two readings of opposite sign to find the point when the curve crosses 0 between two points.
If the “0-point” is close to one of the two sensors a smoothing function is applied that is constructed based on actual data observed for a given hardware setup

An advantage of the present invention to provide a beverage dispensing system metering mechanism improves accuracy and repeatability of the metering function by anticipating the movement of the metering piston using a hardware setup that places multiple identical magnetic (Hall Effects) sensors at equal intervals and same plane, alongside the cylinder with a moving piston containing a magnet. In such a configuration, at equal time intervals readings on all sensors are fed into a function that estimates the magnet's (and therefore piston's) location, relatively to the center of the cylinder.

Further objects, features and advantages of the invention will become apparent in the course of the following description.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

1. Detailed Description of the Figures

Before explaining the present invention in detail, it is important to understand that the invention is not limited in its application to the details of the construction illustrated and the steps described herein. The invention is capable of other embodiments and of being practiced or carried out in a variety of ways. It is to be understood that the phraseology and terminology employed herein is for the purpose of description and not of limitation. It should be further apparent to a person having ordinary skill in the relevant art, in light of the present teachings, that the discussed enablement being described for use with bulk wine should be considered equivalent for use with any other beverages.

For purposes of the present disclosure the terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one (1) of the referenced items. Further for purposes of the present disclosure the terms “in”, “out”, “left” “right”, “up” or “down” are all spatial and functionally relative directions used to aid in the description to best explain the principles of the invention and its practical application, and to aid others skilled in the art to best utilize the invention and are not meant to be limiting to any particular orientation.

Referring now in conjunction withFIG. 1-6, a metering mechanism, generally noted as10, is shown according to an exemplary preferred embodiment of the present invention for use with a carbonated beverage dispensing system. The metering mechanism10includes a first manifold block12and a second manifold block14. Each manifold block12,14is formed as a generally rectangular cuboid element that each matingly interface with each other at an inner mating surface12a,14a, respectively. Each rectangular cuboid element12,14is affixed collinearly along a lateral centerline “c/L” such as to form the metering mechanism10as a minimized volume manifold block. The manifold metering mechanism thereby further forms essentially: a fluid conduit system; a sensor control system50; and a valve and actuator system.

The fluid conduit system is formed within each manifold block12,14as series of linear, interacting fluid channels including an upper fluid conduit16opposite a lower fluid conduit18and a left fluid conduit20opposite a right fluid conduit22. The upper and lower fluid conduits16,18are formed as through drilled conduit spanning through each manifold block12,14. While ‘drilling’ in the conventional sense may be used as the method of machining, such a term should be used without limitation to any machining operation and should broadly include any other milling, machining or other process capable of obtaining a functionally broadly equivalent result. The left and right fluid conduits20,22may thereby be formed, one within each manifold block12,14respectively so as to form a continuous hydraulic circuit within the metering mechanism. Each left or right conduit20,22merely needs to connect the upper and lower fluid channels16,18and may be similarly formed by drilling or the equivalent from one side of the respective manifold block12,14with the access orifice closed via a work port plug26.

A central linear conduit30may be formed in a similar manner spanning through each manifold block12,14to hydraulically connect the left and right fluid conduits20,22and forming a third channel parallel to and between the upper charnel16and lower channel18. A stainless-steel cylinder32may be formed and positioned as a continuous sleeve liner within the central linear conduit30. The cylindrical sleeve32may be sealed about each open end with an “O”-ring seal34to form a hydraulically sealed system when assembled. Similar resilient seals may further be sealed between aligning and connecting fluid channels throughout the system10.

An inlet port42and an outlet port44are oppositely formed to provide access to or egress within the fluid channels within the manifold10. The inlet42and outlet44are operatively coupled to communicate with a beverage supply (not shown) in further operative connection with the bulk storage and distribution system for carbonated beverages such as, preferably, beer (also not shown). The magnetic piston40within the cylinder32forms one operative portion of a metering mechanism for providing a metered discharge of beer or beverage between the bulk storage and a tap or spigot in a manner that provides for a beverage specific controlled metered pour into a beverage container. Such a beverage metering, pouring, controlling, and monitoring/reporting system may be of the type described by, anticipated within or equivalent to those described in the above referenced Related Art, all of which are incorporated by reference as if fully rewritten herein. In a preferred embodiment the cylinder of the present invention is shown in greater detail. The metering cylinder32and piston40combination function as a line pressure powered bi-directional dispenser by redirecting the pressure from one end of the chamber to the other end. Such a chamber32allows for accurate, repeatable metering, utilizing, and preserving line pressure without the inclusion of an additional pumping device.

The sensor control system50is in operative interaction with the piston40for providing piston location sensor data input to an electronic control system in connection with the bulk storage and distribution system. The metering mechanism10provides for a metered discharge in fluid communication with the tap or spigot in a manner that provides for a beverage specific controlled metered pour into a beverage container, as best described in the Related Art. Measurement of a location of the piston40within the cylinder allows for accurate, repeatable metering, utilizing and preserving line pressure without the inclusion of an additional pumping device. The sensor system50may be provided as (describe solid state board)

The sensor system50may provide one or more location sensors for providing electronic control signal that corresponds to piston location to a microprocessor controller. A plurality of hall effect sensors may be provided on a Line Control Board (LCB) that detect the piston location inside the cylinder. The control signal may further be provided as to include wireless communication capability, further integrated with or on the LCB, to communicate between a remotely positioned metering system10and a centrally located control system. Further communication may be provided with a standard PC or smartphone using the wireless protocol (such as Bluetooth, Wi-Fi, Internet, etc.). Bulk beverages from a number of sources may be metered upon demand as urged through the metering chamber32of an identified volume by a single system pressure generated from fluid communication with the bulk beverage container. In addition to eliminating the need to provide an accurate (rather than estimated) dispensed volume of various beverages, the present invention may also provide for the discharge to be dispensed at a temperature correlated as appropriate for the differing dispensed beverages (as described in greater detail below). With such operational characteristics, the present system10may provide a unique quality and quantity control can be easily accomplished, tracked, and reported.

As described in greater detail below, an anticipator piston detection method may be implemented on the Line Controller Board50based on a hardware setup that places multiple identical magnetic (Hall Effects) sensors at equal intervals and same plane, alongside the cylinder32with a moving piston containing a magnet40. In such a configuration, at equal time intervals readings on all sensors are fed into a function that estimates the magnet's (and therefore piston's) location, relatively to the center of the cylinder.

Referring now further in greater detail in conjunction withFIG. 4-5, the chamber40is provided in the form of a container having a selected, defined internal volume42. The chamber40is shown embodied as a cylindrical container; however, it should be noted that such a shape and configuration is not intended to be limiting to the present invention. As will be described in greater detail below, according to an aspect of the present invention the defined volume42may be equal to the volume of a desired beverage pour. Further, according to another aspect of the present invention the defined volume42may be equal to a fractional component of the volume of a desired beverage pour, thereby facilitating its use with mixed or blended drinks. Further still, according to yet another aspect of the present invention the defined volume42may be equal to a multiple of the volume of a desired beverage pour, thereby allowing for multiple dispenses from each reciprocating cycle.

The valve and actuator system provide a number of pneumatic actuators60that open and close the beer flow path. The actuators60urge the actuator piston62and opens the beer flow path. The actuator piston62threads or otherwise mates to a poppet spool70that forms a valve plug72, with the corresponding valve seat74formed at the end terminus of each upper and lower fluid conduits16,18.

As described above, the metering mechanism10of the described teachings provides for a fluid communication input from the beverage supply, and a fluid communication discharge to a spigot or tap. The provided manifold design is compact and efficient, eliminating various three-way switching valves and flow splitters.

2. Operation of the Preferred Embodiment

The actuators60, in de-energized state, keep the beer flow path closed. When the pour cycle is started, two diagonally opposite pneumatic valves are opened to let air into the actuators. The air retracts the actuator piston62and opens the beer flow path. The beer enters flows through the valve into the cylinder32and pushes the piston40. The beer on the other side of the piston40is then pushed out of the cylinder32through the valve that is diagonally opposite. Once the piston reaches the end of the stroke, the cycle is repeated with the flow reversed using the other two valves.

Using the sensor hardware configuration where multiple identical magnetic (Hall Effects) sensors are positioned at equal intervals and in the same plane collinear with the movement of the magnetic piston, for a given set of momentary readings the sensors to the left and right of the piston will show also show anticipatory readings that are higher in absolute values than those on sensors farther away from the piston. The two readings of the two opposing sensors will also be opposite in sign, relative to an appropriately chosen zero value. (Zero value represents reading on a sensor absent of a magnet). In this particular setup, depending on the exact location of the piston, these two sensors can be adjacent, or have another sensor in between. In the earlier case, the reading on the sensor in the middle will be lower in absolute value than either of the other two, and if the magnet is perfectly aligned with the middle sensor, its reading will be close to the zero value.

A typical distribution of signals on an array of sensors is shown in the graph ofFIG. 11. Here, X axis are the sensors numbered from 1 to 15, values on the Y axis are readings on corresponding sensors. The piston is located between sensors6(reading +1.5) and7(reading −2). Its exact location corresponds to a 0 “reading” between sensors6and7and can be estimated using any method of interpolation.

Referring in conjunction to the graph ofFIG. 12, a case is illustrated when the sensors with minimum/maximum readings are located 2 sensors apart. Here, even though the sensors with the maximum and minimum values are 5 and 7 respectively, the piston is located somewhere between sensors6and7, since they are adjacent and show readings of opposing signs. The interpolation in this case will use readings on sensors6and7as its starting points.

By calculating the location of the magnet based on the set of readings reported by the sensors at a given moment of the, the calculated location of the piston may be utilized in the control even when the actual sensor location is questionable. The logic of such a calculation function consists of 2 steps:a. Step 1 determines the two sensors that show the maximum and minimum readings over the entire set. The hardware setup, as stated earlier, guarantees that they will be 1 or 2 sensors apart.
If sensors with minimum/maximum readings are adjacent (as6and7onFIG. 1), their readings are used in Step 2.b. If sensors with minimum/maximum readings are two sensors apart, the function chooses the two sensors out of the three that show readings with opposite signs (as6and7onFIG. 12) and uses them as inputs to the Step 2.
Step 2 performs linear interpolation based on two readings of opposite sign to find the point when the curve crosses 0 between two points. If the “0-point” is close to one of the two sensors, it additionally applies a smoothing function which has been constructed based on actual data observed for the given hardware setup.

The result of the interpolation is reported as the estimated location of the middle of the piston.

The foregoing descriptions of specific embodiments of the present invention are presented for purposes of illustration and description. They are not intended to be exhaustive nor to limit the invention to precise forms disclosed and, obviously, many modifications and variations are possible in light of the above teaching. The embodiments are chosen and described in order to best explain principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and its various embodiments with various modifications as are suited to the particular use contemplated. It is intended that a scope of the invention be defined broadly by the Drawings and Specification appended hereto and to their equivalents. Therefore, the scope of the invention is in no way to be limited only by any adverse inference under the rulings of Warner-Jenkinson Company, v. Hilton Davis Chemical, 520 US 17 (1997) or Festo Corp. v. Shoketsu Kinzoku Kogyo Kabushiki Co., 535 U.S. 722 (2002), or other similar caselaw or subsequent precedent should not be made if any future claims are added or amended subsequent to this or any prior parent patent application.