Grinding device with self-cleaning and fermentation assist and methods of using the same

Automated grinder systems include several different automatic functions including liquid and substrate soaking, mixing, grinding, fermenting, and cleaning. Example grinders include storages for soaking and draining a substrate for grinding, a water or other fluid reservoir connected to provide soaking material, and a grinder connected to the storage to receive and grind the substrate. A resting unit may receive the ground batter and potentially ferment the same by controlling its temperature, humidity, pH, etc. Jets may be connected to a water reservoir and direct liquid water into the grinder, potentially with soap, to cleanse the same.

BACKGROUND

Preparing batter-based food conventionally includes soaking ingredients, like rice, lentils, etc., grinding them to a desired consistency to produce a batter, and optionally fermenting the batter. In some methods of making batter, an estimated or a measured quantity of dry ingredients are soaked in water, and then the soaked ingredients are ground for producing batter. The quality of the batter produced is typically measured by its consistency and its final physical appearance. Several variables affect the quality of the batter including the ratios of the ingredients used, time used for soaking the ingredients, quantity of water used, and how much water is added at intervals while preparing the batter.

Grinding stones and rollers have been used for creating batter through a laborious and skill intensive process. It takes years of practice for a person to achieve required proficiency of a batter using such wet grinding machines. Now, household appliances are being widely adapted for automated food preparation, including grinding and batter production. For example, electrically-operated mixers and grinders may perform a standardized function of grinding and mixing, with the remainder of the batter-production executed manually, including deciding the ratio and combination of the ingredients such as lentils, rice etc., pre-soaking, loading the ingredients in the grinder drum, removing and cleaning the grinder, resting the batter for fermentation, if required, and cleaning the grinder.

Conventional automatic grinding devices might include a grinder drum with a set of grinding rollers powered by an electric motor inside the grinding drum, which rotates along a fixed horizontal axis for grinding the ingredients. The grinder drum itself is provided with an electric motor to rotate on an axis perpendicular to the rotating axis of grinding rollers. Once ground into a batter, even fermentation may be ensured by a controlled environment and constant monitoring of the batter.

SUMMARY

Example embodiments and methods include automated grinder systems with several different automatic functions including liquid and substrate soaking, mixing, grinding, fermenting, and cleaning. Example grinders include storages for soaking and draining a substrate for grinding, a water or other fluid reservoir connected to provide soaking material, and a grinder connected to the storage to receive and grind the substrate. A resting unit may receive the ground batter and potentially ferment the same by controlling its temperature, humidity, pH, etc. Jets may be connected to a water reservoir and direct liquid water into the grinder, potentially with soap, to cleanse the same.

DETAILED DESCRIPTION

Because this is a patent document, general broad rules of construction should be applied when reading it. Everything described and shown in this document is an example of subject matter falling within the scope of the claims, appended below. Any specific structural and functional details disclosed herein are merely for purposes of describing how to make and use examples. Several different embodiments and methods not specifically disclosed herein may fall within the claim scope; as such, the claims may be embodied in many alternate forms and should not be construed as limited to only examples set forth herein.

It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited to any order by these terms. These terms are used only to distinguish one element from another; where there are “second” or higher ordinals, there merely must be that many number of elements, without necessarily any difference or other relationship. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of example embodiments or methods. As used herein, the term “and/or” includes all combinations of one or more of the associated listed items. The use of “etc.” is defined as “et cetera” and indicates the inclusion of all other elements belonging to the same group of the preceding items, in any “and/or” combinations.

It will be understood that when an element is referred to as being “connected,” “coupled,” “mated,” “attached,” “fixed,” etc. to another element, it can be directly connected to the other element, or intervening elements may be present. In contrast, when an element is referred to as being “directly connected,” “directly coupled,” etc. to another element, there are no intervening elements present. Other words used to describe the relationship between elements should be interpreted in a like fashion e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc. Similarly, a term such as “communicatively connected” includes all variations of information exchange and routing between two electronic devices, including intermediary devices, networks, etc., connected wirelessly or not.

As used herein, the singular forms “a,” “an,” and “the” are intended to include both the singular and plural forms, unless the language explicitly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes,” and/or “including,” when used herein, specify the presence of stated features, characteristics, steps, operations, elements, and/or components, but do not themselves preclude the presence or addition of one or more other features, characteristics, steps, operations, elements, components, and/or groups thereof.

The structures and operations discussed below may occur out of the order described and/or noted in the figures. For example, two operations and/or figures shown in succession may in fact be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved. Similarly, individual operations within example methods described below may be executed repetitively, individually or sequentially, so as to provide looping or other series of operations aside from single operations described below. It should be presumed that any embodiment or method having features and functionality described below, in any workable combination, falls within the scope of example embodiments.

The inventors have recognized that existing wet grinders make it very difficult to get a good quality batter with proper consistency for a user, typically requiring years of experience to so. There are few clear guidelines, including quantity of ingredients that should be added, the grinding time, or amount of water to be added. Due to this a grinder often halts or slows down during the grinding process as overloaded. This mid-process shutdown is very inconvenient, and it is often unpleasant and interrupting to partially remove contents from the grinding drum to avoid it. This may lead to a longer grinding process and additional labor. Even fully-automatic wet grinders may suffer from this lack of clarity and requirement for load readjustment, which may require continuous human intervention and time.

Based on the foregoing, the Inventors have newly recognized a need for a fully automatic grinding device that does not require intervention or constant monitoring. There needs to be automation in selection and grinding of ingredients, water control, temperature control during grinding and resting of batter, and automatic cleaning at the end of the process. Remote monitoring, such as through Wi-Fi or Bluetooth, is also needed. The inventors have developed example embodiments and methods described below to address these and other problems recognized by the Inventors with unique solutions enabled by example embodiments.

The present invention is automatic grinder systems having several distinct automated functions and methods of using the same. In contrast to the present invention, the few example embodiments and example methods discussed below illustrate just a subset of the variety of different configurations that can be used as and/or in connection with the present invention.

Example embodiments provide automatic grinding and self-cleaning devices, potentially with fermentation assist, including a housing, storage for ingredients, grinder, grinding roller, resting unit, fixed ladle for mixing batter during grinding, drain, display, controller, thermostat, control buttons, soap dispenser, interconnected pipe lines, and/or power source. Ingredients may be added in the storage unit and dispensed into the grinder through user input. The time required for grinding may also be controlled by the user. Upon completion of the grinding process, the resultant batter may be emptied into a resting unit. This is followed by cleaning of the grinder and the grinding roller.

The resting unit may be associated with a thermostat and/or heater to maintain temperature and with a humidity sensor and/or humidifier to maintain humidity for assisting fermentation process inside the resting unit. Batter produced may be kept in the resting unit under controlled temperature monitored by the thermostat for aiding fermentation over a desired time. When the temperature is controlled during fermentation, the time required to obtain a good quality batter with appropriate consistency is reduced with precision. Fast fermentation, such as within 4-7 hours may be achieved through such control, opposed to the conventional 3-13 hours at uncontrolled room temperature, or even 16-20 hours when the room temperature is less than 27 degrees Celsius, such as during winter.

FIG. 1is a perspective view of example embodiment grinder system10. As shown inFIG. 1, grinder system10may include a housing12, storages26a,26b,26c(FIG. 2), grinder14, a grinding roller, display16, micro-controller or processor, thermostat, control buttons20, soap dispenser26d, interconnected pipe lines, and/or a control module. Ingredients may be stored in storage26and dispensed therefrom by a user's input. If storage26is empty, such as if the ingredients are not added, for the appropriate selection, an error message may appear on display16. The user may input a selection of a type of batter and the amount of batter to make through inputs such as control buttons or display16that is touch-enabled.

As shown inFIG. 2, multiple storages26a,26b,26cmay be aligned on a single top surface. Storages26may be gravity-fed and used to store a substrate, such as a grain, for batter preparation and water for soaking the same before it is ground. For example, first storage26amay contain grain that feeds by rationing, according to desired proportions by weight, and after the grain has been adequately soaked for the purposes of grinding. Second storage26bmay include water or another liquid and may be communicably coupled to first storage26afor soaking the grain in26a. Soaked grain may be releasably dispensed with a motor-driven flap at a bottom of the first storage26a. The flap may default to a closed position so that water is retained in storage26aand soaks the grain. After soaking, the water may be discharged, and the motor may then actuate the flap from the closed position to an open position to dispense the soaked grain.

Several storages26may be provided to add a combination of grains or other substrates to create the batter. Storages26may be communicably coupled. Each storage26may have a similar selective discharge flap as described above. Grinder14is configured to receive matter from any of the storages in any combination.

To adequately soak the ingredients from first storage26aand additional storage26b, each storage26may include valves to allow entry and exit of water. These valves may open and/or close in a time-controlled fashion, based on an amount of soaking required per ingredient. Further, water from storage26may be used for cleaning, soaking, and/or grinding.

Several valves62(FIG. 9) may reliably control fluid movement and release. Valves62may be controlled by a timer to effect their opening and closing. Pipes64(FIG. 9) may connect water storage26cto first storage26a, for example, or water storage26cto second storage26bto facilitate soaking. Pipes64may also connect first storage26ato drain35to drain out waste water after a soaking/rinsing cycle; such drain connection may be used for each storage26.

For example, first valve62may be located toward an exit of water from storages26aand26bto allow water to exit storages26aand26bafter soaking time is over. Or, for example, second valve62may be located toward an extreme bottom portion of storage26aor26bto remove soaked and drained ingredients from storage26aand26binto grinder14below it. For example, a sieve valve and/or seal valve may be used. These valves may be closed by default.

Once the ingredients are added, a water line may open, through pipes64to rinse the ingredients and clean. A seal valve may remain open while a sieve valve is closed to release the dirty water to be drained through the second set of pipes to drain35. Then, the seal valve may close. This valve and seal opening and closing may be achieved by a computer-based controller with preset soaking times for various types of batter and mixtures. After the soaking process, a water sprayer may cleanse the grinder. Finally, the seal and sieve valves may open and the soaked ingredients may drop in grinder14. Water storage26cmay include a single valve to dispense water from it into other storages26aor26bor grinder14.

A sieve (not shown) may be positioned at a bottom of each of first storage26aand second storage26bto allow water to enter the grinding drum after it has been soaked. This water is waste water and may be disposed before the ingredients are introduced into the grinder14for grinding into batter. The drum of grinder14may be tilted toward drain35in this instance, as discussed below.

Storages26aand26bmay include an agitator (not shown) to agitate the storages to properly rinse and/or soak the ingredients once filled with water. The agitator may be timed with the closure of valve62and thus holding of water in storages26aand/or26b. The agitator may be a simple flow agitator, for example. Alternatively, pressurized water may be used without an agitator.

Example embodiment grinder system10may include a frame50or housing, with grinder14placed below storages26in the same. Grinder14is configured angularly displace, or rotate, about a first axis or in a first degree of freedom while grinding. For example, this movement may be clockwise or anticlockwise, as shown by reference numeral A inFIG. 3, and grinder14may be limited to this motion only while grinding. Motor23may drive this rotation of grinder14, under the control of a processor or control module.

Grinder14may also be tilted about a different axis of rotation, potentially one orthogonal to the grinding axis, shown by reference letter C. Grinder14may also be attached to stepper motor25attached on the side of frame50. Stepper motor25may grinder14about this different axis C.

Storage26amay include a weight load sensor to measure the quantity of contents added to storage26a. The load sensor allows measurement of quantities of ingredients, ensuring correct amounts are used. This may eliminate motor overloading. For example, first storage26amay include a disposal portion extending toward grinder14, and a load sensor may be located toward a bottom of storage26aat this portion. Similarly, water storage26cmay include a water level sensor to allow a user or controller to know water level available or if a refill is needed. The controller may be programmed or otherwise configured with settings of quantity of ingredients and water from the storages. Additional items in other storages may be programmed to earmark ratios for customized grinding.

As shown inFIG. 7, grinder14may be configured to angularly displace or rotate in a second direction opposite to the first direction. This dual angular displacement motion, shown by reference Z inFIG. 7, such as agitation with rotation back and forth in opposite directions about a same axis, may aid cleaning grinder14.

As shown inFIG. 3, grinder14may angularly displace about a different axis, or in a second degree of freedom. This second degree of freedom may permit the batter to be poured into resting unit21below grinder14. Reference numeral C illustrates this direction. Resting unit21and drain35are both located below the grinder14such that when grinder14tilts or rolls in a first direction of the second degree of freedom, it pours its contents or portion thereof into drain35and when grinder14tilts or rolls the other direction in the second degree of freedom, it pours its contents or portion thereof into resting unit21. Still further, grinder14may move in any or all six degrees of freedom. Operative bottom side of grinder14is fitted with a pan cake motor which can sustain high loads and provide high torques.

Resting unit21may include a pH sensor to sense pH level of the batter, a viscosity sensor to sense viscosity of the batter, a humidity sensor to sense humidity of the batter, and/or a temperature sensor to sense temperature of the batter. All of these sensors may be used to adjust resting time and change temperature, humidity, etc. of resting unit21for desired fermentation and other batter characteristics, potentially automatically by a processor. For example, resting unit21may include a heating element, such as an IR light, to heat resting unit21to aid fermentation of batter therein. A humidifier and/or a dehumidifier may be provided in resting unit21. Or, for example, a cooling element may be located in resting unit21to cool the batter as desired. Thus, an optimum temperature and other fermentation characteristics can be achieved and the problems of over fermenting in warm climates and under fermenting in cold climates avoided. These systems may be monitored and controlled using a thermostat and other sensors connected to the controller, where all sequence and settings are computed, stored, and/or executed.

In example embodiment grinder system10, the grinding roller31may be located inside grinder14to enable grinding of the substrate. As shown inFIGS. 7 and 13, the grinding roller may be grinding stones at the end of shaft29. Shaft29, and hence the grinding stones, may be configured to be angularly displaced, or rotate, opposite to grinder14about a same axis. For example, if grinder14angularly displaces by a motor clockwise, the internal grinding roller may rotate counterclockwise. to provides the grinding action. Grinding roller shaft29and stones thereon may of course move in any other fashion, about any or all six degrees of freedom.

Grinder14may receive support from frame assembly50surrounding grinder14periphery. Frame assembly50derives support from the internal walls of housing22. Bearings51allow for tilting grinder14. Bearings51are laterally located with respect to grinder14and derive support from frame assembly50.

Grinding roller31are held by shaft29connected from the bottom with the motor21. Coupling mechanism70may couple motor21to grinder14. Motor21may also tilt along with grinder14. Coupler70may be supported by frame assembly50. First set of gears41drives the displacement of grinder14and second set of gears engaged with first set of gears41drives the displacement of grinding roller31. This may ensure synchronized grinding. First set of gears angularly displace in a direction which is opposite to the second set of gears. Ground batter may be transferred by a collector tube into a collector communicably coupled to grinder14. A vacuum or suction device, such as a pump or pneumatic pressure source may be coupled with resting unit21for sucking or otherwise driving the fermented batter out of resting unit21.

Example embodiment grinding device10may include a programmable control with a display interface which allows user to operate the device. The display interface may show the weight of the different ingredients, selection menu, temperature inside the device and timer. This data may be derived from a load sensor or a weighing balance which transfers data to the interface.

A self-cleaning system may clean automatic grinding device10through pipes, nozzles, brushes, and/or soap dispenser26dwithin automatic grinding device10. The cleaning action may be based on pressure or steam-based cleaning, for example. Device10may be programmed for self-cleaning at least two times during one complete grinding process. A first cleaning process may be a pre-cleaning process before the ingredients are added to grinder14, and only water may be used for rinsing grinder14and roller31in this pre-cleaning. Used water may be drained out after rinsing into drain35. A second cleaning process, a post-grinding cleaning, may start after the ingredients are ground and the resultant batter is dispensed into resting unit21, wherein soap dispenser26dincorporated within device10dispenses soap into water. This wash cycle includes water and soap suspension directed into grinder14and roller31, with fixed retention time and further replenished with continuous spraying of water to rinse any residual batter or soap. Water from water storage26cmay supply water spray channels33with water to spray into grinder14. Soap from dispenser26dmay also be used. Grinder14may automatically rotate, agitate, and/or tilt while being cleaned. Optionally brushes may scrub grinder14from inside. Brushes may be provided in frame50for being lowered into grinder14while it is being cleaned. Soap from the soap dispenser26dis fed into the grinding drum through openings in the frame above grinder14.

The used water is drained into drain35. Drain35is located operatively below grinder14in a manner such that when grinder41tilts to a certain degree, dirty water drains into the drain35. Drain35may be located operatively below grinder41in a manner such that when grinder14tilts to a certain degree, the mixture to be drained can spill over into the drain35. Drain35may be offset, in its axis, with respect to grinder41. Drain35is connected to drain pipe37which drains out the water collected.

Wet grinding may require large amounts of water, and grinder14may receive correct amounts of water at correct intervals in example embodiment device10. This may reduce or prevent ingredient dry up, motor overload, and heatup of grinding stones. After a start of a grinding process, water, at regular intervals, may be fed through the water spray channels33to keep the grinder wet, potentially based on a desired wetness of output batter.

Example embodiment automatic grinding device10may be wirelessly connected over a network to a remote device for analysis and feedback. The remote device may include, but not limited to, a computer, or a tablet or a smart phone. The user may download an application also called program/software on the remote device. The network may be any suitable networks or links, including, but not limited to, a local area network LAN, wide area network WAN, Ethernet, an intranet or any wireless communication links. Similarly, device10may be controlled by a user by a user-interface. An example of operation may include adding ingredients into storage26, setting batter parameters using the user interface, a pre-cleaning process, automatic addition of the ingredients in designated amounts to grinder41based on user input, grinding of the ingredients, dispensing of the ground ingredients into resting unit21, a post-grinding cleaning process, and fermentation of the ground ingredients in resting unit21.

FIGS. 11-17illustrate an example embodiment grinder14awith inner drum102and external drum104along with grinding roller31. Typically, inner drum102angularly displaces or rotates while external drum104is fixed, similar to a washer mechanism. Motor106is fixed, on top, of the grinding system to angularly displace inner drum102. Inner drum102includes opening108at its operative base to dispense ground batter as well as to dispense rinsed water after cleansing of the inner drum. Inner drum102is angularly displaceable or rotatable about an axis.

FIG. 13is an alternative configuration with of grinding roller14aincluding grinding stones31, which may be freely angularly displaceable about their central axis. Grinding roller14amay be rotatable about an axis of shaft110. Shaft110may extend from the motor106holding grinding roller14aand driven by motor106. Scrapper109may scrape batter off the inner walls of inner drum102while shaft110is rotating. Scrapper109may be coupled to shaft110through another shaft in a manner such that it is offset and radially spaced apart from the central axis of inner drum102. In this way, a lateral edge of scrapper109scrapes the inner wall of inner drum102to scrape off any and all batter. Grinding roller14amay be rotated opposite of inner drum102on a same axis of rotation. Shaft110of roller14aends, at its operative bottom, in base plate114with female connectors so as to receive the clutch and lock ofFIG. 16.

Inner drum102may be driven by a top motor, which ensures that opening108aligns with the dispensing pump ofFIG. 14to dispense ground batter or to dispense rinsed water to cleanse the drum. An iris gate may be used for opening and closing opening108with respect to the dispensing pump ofFIG. 4. Additionally, a proximity sensor may be placed adjacent to opening108and dispensing pump inlet so that a proximity signal may be sent to the top motor driving the inner drum's angular displacement so as to ensure that the inner drum102stops exactly when its opening is aligned with the dispensing pump entry point. A stepper motor may disengage the male connector from the female connector, thereby separating corresponding shafts. This may achieve alignment of an iris gate in inner drum102with a dispensing pump. Once the openings are aligned, the top motor starts again and, at this time, only the grinding rollers rotate so that scrapper109scrapes out the batter toward opening108into the dispensing pump while the inner drum remains stationary. Motor106may be a pancake and a direct drive motor, for example.

FIG. 14illustrates dispensing pump120configured to selectively dispense ground batter or water from inner drum102into respective storages or resting unit21for ground batter though corresponding outlets of the dispensing pump. Dispensing pump108may be located at an operative bottom of inner drum102. During cleaning, draining, and dispensing, this pump may be switched on to allow contents of the drum to flow through.

Dispensing pump108may include an input108awhich receives ground batter or rinsed water from inner drum102. Depending upon content, batter release valve108bor water release valve108cmay be opened. Inlet108aextends to a common pipe which, then, splits into batter release pipe108dand water release opening108e. A batter storage mechanism or resting unit21receives ground batter from inner drum102through the dispensing pump108.

As shown inFIG. 16, clutch and locking system130is provided at the operative bottom of inner drum102. Clutch and locking system130includes a base motor stepper motor132with an engaging stub134protruding outside of base motor132. Engaging stub134is a threaded stub configured to move in and out of base stepper motor132enclosure so as to effect engaging and disengaging of inner drum102with motor132. Stepper motor132helps to align the male connectors with the female connectors. Bearing holder136may engage co-axially with the stepper motor132and the engaging stub134in order to hold a bearing138which enables angular displacement of the inner drum102. Inner drum102is co-axially and concentrically fitted with this inner ring of bearing138so that as the bearing linearly displaces due to the top motor action, the inner drum102simultaneously and concurrently linearly displaces. An operative top plate142with operatively upwardly male connectors144may be co-axial with the bearing138and engage with the bearing138through a shaft extending operatively downward from top plate142and fits within the inner diameter of the bearing138. As the inner ring angularly displaces, the inner drum angularly displaces.

During operation for making ground batter, the clutch and locking system130effects an engagement of the male connectors144, of the clutch and locking system130, with the female connectors114, of the shaft of grinding roller14a, by pushing the engagement stub134operatively upward. During operation before dispensing ground batter, to angularly displace the inner drum102, to a synchronized position, the engagement stub134retracts, thereby spacing apart, or disengaging, the male connectors144, of the clutch and locking system130, with the female connectors114, of the shaft of modified grinding roller14a. Thus, in the disengaged position, when grinding stops, modified roller14amay angularly displace freely, while the inner drum102is driven by the motor towards the position where it aligns with the dispensing pump120.

When the grinding process starts, the clutch and transmission engages with a bush of the inner drum and grinding roller. During this step, the inner drum will angularly displace itself. Once the batter formation is completed, the clutch mechanism disengages and only the grinding roller and a scrapper connected to the shaft will angularly displace. A door, is provided, in the inner rotating drum which opens and which connects to the dispensing pump. A valve opens automatically with the help of solenoid to allow batter to be dispensed on to the resting unit. During this operation, the modified grinding roller14awill be angularly displacing. With the help of the scrapper109that is attached to the grinding roller, all the batter is pushed out of the opening/door of the inner drum102which is placed at the operative bottom. Once all the batter is pushed out, the door closes, dispensing valve closes, and the pump shuts off. Then, pressurized water is sprayed on to the inner drum for cleaning. Motor stops for a moment with an integrated braking mechanism in the motor. The clutch engages to lock the bush male and female connectors with the inner grinding drum to angularly displace. Then, the door in the drum opens to let the dirty water to be drained. The pump opens and a drain is opened to let the dirty water drained through the drain pipe connected to the drain valve and to the draining of the device. Once this process is completed, the motor stops and the valves go back to the lock position.

It will be appreciated by one skilled in the art that example embodiments may be varied through routine experimentation and without further inventive activity. For example, although a wet grinder is described, it is understood that other fluids, or a relatively dry grind, are useable with the wet grinder. Variations are not to be regarded as departure from the spirit and scope of the exemplary embodiments, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.