Method and apparatus for the distribution of ice

An ice delivery system includes an ice bin with an ice maker thereon. An auger dispenses ice from the bin and agitators within the bin prevent blockage. The agitation may follow a pattern depending on the location of the agitators with some about the periphery less employed than those adjacent the auger. An ice gate receives ice and flowing air to direct the ice pneumatically to a multistation diverter. The flow through the diverter is vertically downwardly. Tubes from the diverter convey ice to remote dispensing stations. The dispensing stations have prechambers with drains and lockable gates to advantageously receive ice for delivery into the remote station bins or block the ice storage area to allow cleaning. Conduit couplings are configured to connect tubing without creating an area of ice blockage or allowing the buildup of contamination. Germicidal lights or ozone may be used in the ice bin to avoid contamination. Further, active agents for cleaning, de-scaling or sanitizing may be introduced through the ice gate on an automatic cycled basis.

BACKGROUND OF THE INVENTION

The field of the present invention is pneumatic ice distribution to dispensing stations.

Apparatus and methods for distributing ice to remote stations have been developed, particularly for use in the food service industry. Such systems incorporate a central ice bin, transport conduits, remote dispensing stations and a source of pneumatic energy to move the ice from the central bin to the dispensing stations. One such system is illustrated in U.S. Pat. No. 5,549,421, the disclosure of which is incorporated herein by reference.

In designing such systems, important considerations include enhancing ice flow, maintaining the integrity of the ice in a frozen state and avoiding contamination. In operating such systems, ice has been found to have a tendency to stick together and form blockages in the handling system. Avoidance of such blockages and the proper handling of a blockage when it does occur are of critical importance to the reliability to such systems. Maintaining the ice in an appropriate frozen state is also important. Localized thawing followed by re-freezing encourages the agglomeration of pieces of ice, resulting in blockage and inappropriate dispensing. The quality of the ice dispensed also is dependent upon the appropriate maintenance of uniform temperatures. Contamination has been a problem in such systems. Ice bins form a convenient source for manually taking scoops of ice. Further, placing foreign objects, such as glasses and bowls, in the ice for chilling has also been found to be a common, if inappropriate, use of ice bins. Resolutions of these issues is necessary for public safety and commercial acceptance of such systems.

SUMMARY OF THE INVENTION

The present invention is directed to an ice delivery system including various mechanical components therefor and modes of operation.

In a first separate aspect of the present invention, the ice delivery system includes a source of ice, an ice bin and two sets of at least one agitator each. Each set of at least one agitator includes a periodic cycle. The frequency of the periodic cycle of the set closest to the bin outlet is substantially greater than the frequency of the periodic cycle of the other set. Ice is thus able to move through the bin without bridging or blockage and, at the same time, without being excessively stirred.

In a second separate aspect of the present invention, the ice delivery system of the first aspect may have a ratio of frequencies between sets of 10:1. Additionally, the agitators may move less than one full revolution for each periodic cycle. The bin may have a V-bottom with an augur located at the convergence of the V-bottom. Various agitator configurations are contemplated. Agitators adjacent to the augur may include augur elements oriented to move ice away from the outlet. The augur may be of increasing pitch toward the bin outlet. Each contributes to consistent flow through the bin and discharge.

In a third separate aspect of the present invention, an ice delivery system includes an ice bin with a channel in the bottom thereof leading to an outlet. The outlet has a larger horizontal major cross-sectional dimension than the channel. An augur is rotatably mounted in the channel. The augur may extend outwardly of the ice outlet. Reduced blockage is contemplated. A breaker element may be arranged adjacent the augur outwardly of the ice outlet to avoid further any ice buildup.

In a fourth separate aspect of the present invention, an ice delivery system includes a multi-station diverter. The diverter is associated with an ice transport conduit and with distribution conduits which extend to a plurality of receiving stations. The ice transport conduit extends downwardly to the diverter while the distribution conduits extend downwardly from the diverter at the portions of those conduits adjacent the diverter. This orientation of the conduits avoids ice blockage in the diverter. The downward orientation of the conduits may additionally be vertical to further inhibit ice blockage.

In a fifth separate aspect of the present invention, the ice delivery system includes a multi-station diverter including a rotatably mounted diverter tube which has an inlet end concentric with the axis of rotation and an outlet end displaced from the axis by a fixed distance. A transport conduit is associated with the inlet end while distribution conduits are placed about the axis of rotation at the same distance as the outlet end of the diverter tube. A conduit is thus presented through the diverter matching up with the incoming transport conduit and the outgoing distribution conduits.

In a sixth separate aspect of the present invention, the multi-station diverter of the fifth separate aspect is contemplated to include further a support for the diverter tube which has sockets cooperating with an actuated pin to properly align the diverter tube with the distribution conduit inlets. Station markers may be associated with the support to provide input to a controller for properly locating the diverter tube.

In a seventh separate aspect of the present invention, the ice delivery system includes an air directional valve and a source of constant transporting air. The valve includes valve elements which selectively open to alternatively supply air to an ice transport conduit and to exhaust. In this way, the source of constant transporting air may be rapidly applied and rapidly diverted from the pneumatic conveyor.

In an eighth separate aspect of the present invention, the ice delivery system includes an ice transport conduit, a controlled source of transporting air and an ice gate which includes a substantially vertically extending passage, an ice inlet open laterally into the passage, an air inlet open into the passage below the ice inlet and an ice and air outlet below the air inlet. A gate in the passage has two extreme positions. One of the positions closes off the ice inlet to avoid air flow toward the ice inlet while the other provides for charging of ice into the transport conduit from the ice inlet.

In a ninth separate aspect of the present invention, the ice delivery system includes an ice bin and receiving stations with a pneumatic system for selectively distributing ice from the ice bin to the receiving stations. Ice level sensors are located in the bin and the receiving stations. A visual ice level monitor is coupled with the bin for maintaining the integrity of ice within the bin. A locking element may further restrict entry.

In a tenth separate aspect of the present invention, an ice delivery system conduit coupling has two end pieces, each with a tubular clamp section and a tubular extension section. The tubular extension sections have inner shoulders facing the tubular clamp sections and have attachments with sealing surfaces. The sealing surfaces are engaged facing one another with a sealing element therebetween. The tubular extension sections each have an inner shoulder facing the tubular clamp sections and inner truncated conical surfaces. One of the inner truncated conical surfaces tapers inwardly from the associated shoulder while the other tapers outwardly from the associated shoulder. The arrangement provides a coupling which is to avoid ice blockage. The tubular clamp sections may optionally be partially split longitudinally and include circumferential channels to receive clamp bands.

In an eleventh separate aspect of the present invention, an ice delivery system conduit coupling includes a coupling tube with a clamp sleeve extending thereover. The clamp sleeve includes longitudinally split ends and circumferential channels about the split ends which may receive clamp bands. The coupling tube fits within the clamp sleeve between annular sealing flanges located on the inner surface of the clamp sleeve. Conduit ends extend between the coupling tube and the clamp sleeve at either end thereof. Sealing and resistance to ice blockage are to be achieved by the annular sealing flanges capable of constricting the conduit to form sealed smooth transitions with the coupling tube.

In a twelfth separate aspect of the present invention, an ice delivery system conduit coupling includes a tubular insert having a flared end on an internal tubular surface and an external surface to receive the end of a conduit. A second portion of the tubular insert may also include a flared end and an external surface to receive another end of a conduit. A passage through the tubular insert may be larger toward the upstream end than toward the downstream end. In appropriate circumstances, a split sleeve may be wrapped about the tubular insert to extend beyond the insert for constricting the tubing for sealing and avoiding ice blockage.

In a thirteenth separate aspect of the present invention, the ice delivery system includes an ice bin with a germicidal aspect. This could be a germicidal light in the ice bin or a source of ozone. The presence of the germicidal light or the ozone is to reduce organic growth within the ice bin which might otherwise contaminate the ice.

In a fourteenth separate aspect of the present invention, the ice delivery system includes a remote dispensing station, a chamber between the distribution conduit and the remote dispensing station with a passageway from the chamber to the station. A gate selectively closes the passage as controlled by a system controller. Closure of the gate can prove advantageous to avoid blowing air, cleaning fluid or a sanitizing device into the remote station.

In a fifteenth separate aspect of the present invention, the ice delivery system of the fourteenth separate aspect might further include a liquid drain at the end of the gate to divert liquid from the receiving station. The gate may be both lockable by the controller in the closed position and independently biased toward the closed position.

In a sixteenth separate aspect of the present invention, the ice delivery system includes a drain at the end of a gate in a passage to a remote dispensing station. The drain exits from the end of the gate with the gate closing the passage. The drain may include a collector extending across the distal end of the gate with an outlet at one edge of the gate. The collector may be a trough in one surface of the gate or the collector may extend through the wall of the passage at the distal end of the gate with the gate in the closed position.

In a seventeenth separate aspect of the present invention, the ice delivery system includes auguring ice from a bin, dropping the ice away from the augur, timing a delay after auguring the ice before closing a gate and blowing transporting air to convey the ice. Where appropriate, the augur may be reversed before closing the gate. This allows ice to properly pass into the transporting area from the ice bin.

In an eighteenth separate aspect of the present invention, the ice delivery system includes auguring ice from an ice bin, dropping the ice away from the augur outside of the bin, closing a gate between the bin and a source of transporting air and sensing the state of closure of that gate. Cycling the action to close the gate until the gate is fully closed helps to clear away any ice blocking complete closure of the gate which might otherwise result in insufficient conveying pressure to convey the ice.

In a nineteenth separate aspect of the present invention, the ice delivery system includes auguring ice from a bin, dropping the ice away from the augur, stopping the augur, closing a gate to the ice bin, storing pressure in a source of transporting air and rapidly releasing that air to blow transporting air and provide an initial boost to provide momentum to the ice being transported.

In a twentieth separate aspect of the present invention, the ice delivery system includes auguring ice from an ice bin and transporting that ice through distribution conduits. The auguring of ice is disabled upon the opening of an access door into the ice bin. Once disabled, upon closure of the ice bin door, a test puff of air may be employed for determining the presence of ice in the distribution system. Maintaining ice bin integrity and reinitializing the distribution system inhibits contamination and avoids system blockage.

In a twenty-first separate aspect of the present invention, the ice delivery system initializes the system upon powering up, either initially or upon restart after system shutdown. The blowing of transporting air is cycled upon the sensing of a predetermined minimum pressure in the ice transport conduit.

In a twenty-second separate aspect of the present invention, the ice delivery system includes testing the system for blockage before auguring ice from the bin and blowing a burst of transporting air through the system before auguring ice upon sensing a pressure above a preset value within the distribution conduit.

In a twenty-third separate aspect of the present invention, the ice delivery system provides for the blowing of transporting air without release of the gate at the remote dispensing station. The blowing of transporting air with the gate closed at the remote station accommodates a drying cycle as well as a cleaning cycle without affecting the ice within the remote station.

In a twenty-fourth separate aspect of the present invention, the gate associated with a remote dispensing station may be employed to sense the state of the remote dispensing station and disable the distribution of ice thereto when appropriate.

In a twenty-fifth separate aspect of the present invention, the ice delivery system includes the mode of blowing drying air through the system to inhibit the growth of contaminating agents.

In a twenty-sixth separate aspect of the present invention, the ice delivery system includes the cycle of transporting ice pneumatically through tubing from an ice bin to a remote dispensing station with a gate to the remote dispensing station closed, adding an active agent to the ice to be transported and blowing air through the tubing and over the transported ice. The active agent may be drained from the ice before entering the remote dispensing station.

In a twenty-seventh separate aspect of the present invention, any of the foregoing aspects are contemplated to be employed in combination.

Accordingly, it is a principal object of the present invention to provide an improved process and the apparatus therefor for distributing ice from a central station. Other and further objects and advantages will appear hereinafter.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Turning in detail to the drawings,FIG. 1illustrates an ice delivery system. The delivery system includes a source of ice10above an ice bin12. The source of ice10and the ice bin12are further illustrated in FIG.2. The source of ice10is an ice maker mounted to the top of the ice bin12with the ice bin12forming a mounting platform. An evaporator18and the condenser22along with the remaining components of the refrigeration system are shown in the ice maker10which can deliver ice into the ice bin12.

The ice bin12includes a hinged door24providing access to within the ice storage area16. The hinged door24is preferably hinged from above so as to naturally assume a closed position when released. Although the door24may be used for service, it is preferably to remain closed during all operation of the ice delivery system. A locking element26, retaining the door in the closed position, is preferably employed to prevent access to the ice storage area16to restrict entry as a mechanism for inhibiting contamination of the ice. Two different doors24are illustrated inFIGS. 1 and 2. As shown inFIG. 2, the location of the door may be such that when opened ice will pour out the door. This is accomplished by having the bottom of the door below the normal level for ice storage. With the device having this configuration, opening the door becomes very problematic and discouraged.

As can be seen fromFIGS. 2 through 5, the ice storage area16of the ice bin12is defined with a V-bottom28. This bottom28further includes a radiused apex to define a channel30. The channel30runs to an ice outlet32at the convergence of the V-bottom28. The ice outlet32extending through the wall of the ice bin12is preferably the only normally open port in the ice storage area16and it only leads into the transport system. The ice outlet32is configured to avoid any shoulders or other surfaces intruding into the ice storage area16which would prevent movement of the ice. Also contemplated is the radius of the ice outlet32being at least as large or larger than the radius defining the interior of the channel30to this end. A germicidal light34is included within the ice storage area16. With the ice bin being sealed except through the discharge port32into the transport system and with the inclusion of the germicidal light34, a clean environment is contemplated. Element34may also represent an ozone manifold34for dispensing germicidal ozone to the same end.

Positioned substantially concentrically within the channel30of the ice storage area16, an auger36is located at the convergence of the V-bottom. The auger36includes a flight38of increasing pitch to accelerate the ice pieces as they move toward the ice outlet32. InFIG. 4, the auger36is shown to extend only into the ice outlet32. InFIG. 8, the auger36is shown to extend through the ice outlet32to insure complete passage from the ice bin. This auger36is displaced from the opposed wall of a discharge passage by a dimension greater than the anticipated maximum major dimension of the pieces of ice to be handled. This displacement is intended to avoid ice buildup. A breaker element40further insures complete discharge of the ice including its disengagement from the auger36. The auger36is driven from the back of the unit as can be seen inFIG. 4by a drive wheel42which is coupled with a drive motor44shown in the layout of FIG.3.

A set of bin agitators is positioned about the top and sides of the ice storage area16. This set of agitators includes two upper agitators46and two side agitators48on each side of the ice storage area16. This first set of agitators including the two agitators46and four agitators48are coupled together by an endless elongate flexible element such as a chain or belt50. Pulleys52are engaged by the elongate drive element50. As can be seen inFIG. 3, the upper agitators46are driven more rapidly than the side agitators48. The drive element50also includes a first drive54which is a motor with a reduction gear. One of the agitators46and48is illustrated clearly inFIG. 4as having a main agitator shaft56with bars58extending outwardly from the shaft56. The bars58may include cross pieces60fixed at the distal end thereof. Such cross pieces are illustrated as being adjacent to the walls of the ice bin12in the representative agitator element of FIG.4.

A set of discharge agitators are arranged more proximate to the auger36. This second set of agitators includes two agitators62which are symmetrically placed in the ice storage area16and are equidistant from the V-bottom laterally of the auger36. The second set further includes two agitators64, the first of which is placed immediately above the auger36while the second is immediately above the first. The agitators62and64also include elements to agitate the ice contained within the ice bin12. The lowermost of the agitators64, directly above the auger36, includes a helical flight66acting as an auger. This flight66and the associated shaft is connected with the drive so as to move ice away from the ice outlet32. A second auger flight67of lesser diameter, as seen inFIG. 4, further displaced from the ice outlet32moves ice toward the outlet. The uppermost agitator64includes bars68extending from the shaft with transverse elements70arranged at the distal ends thereof. An auger flight72also moves ice away from the ice outlet32. The agitators62include bars68with transverse elements70without an auger flight. Naturally, various combinations of these elements can be employed with each of the agitators62and64. Further, other placement of these agitators might prove equally effective. This second set is, however, positioned about the auger36associated with the ice outlet32while the agitators46and48are located about the main cavity of the ice storage area16. While the second set of agitators62and64are more involved with the direct feeding of the auger36with a conditioning of the ice thereabout, the agitators46and48operate principally to insure that ice does not bridge across the bin or otherwise fail to appropriately flow toward the V-bottom of the bin.

The second set of agitators62and64is driven by a second elongate drive element74such as a chain or belt. Pulleys76couple the shafts of the agitators62and64to the drive element74. It may be noted that the pulley76around the lowermost of the agitators64is smaller, thus driving this agitator at a faster speed. This drive element74is coupled with a motor and drive reduction gear78to define a second drive for the second set of agitators.

FIGS. 6 and 7illustrate safety mechanisms associated with the agitators46,48,62and64and/or the auger36. InFIG. 6, a rotation sensor is illustrated which includes permanent magnets80located in a coupler82fixed to the shaft of one of the agitators or auger. A reed switch84is located on the bearing housing86to be attracted, and/or repulsed from the permanent magnets80. When the switch84is not actuated by rotation of the permanent magnets80, a fault can be detected. InFIG. 7, a motor mount operates as a torque sensor. Brackets88are fixed to the frame of the ice bin12. Sliding collars90are positioned about mounting shafts92between springs94and locked nuts96. A motor mount98is coupled with the sliding collars90through mounts100. A microswitch102is mounted to the motor mount98while an adjustable pin104is mounted to one of the brackets88. Excessive torque compresses the springs94sufficiently to actuate the microswitch102. The signal from the microswitch102may be employed to shut down the equipment as the system responds to excessive torque.

Returning toFIG. 1, a source of constant transporting air in the form of a blower106is conveniently mounted to the side of the ice bin12. The blower preferably includes a filter to minimize air contamination. The discharge108of the blower is directed to an air directional valve110. This valve is illustrated in subassembly with the source of constant transporting air such as a blower106in FIG.14and is further, illustrated in greater detail inFIGS. 10 through 13.

The air directional valve110includes a valve inlet112coupled with the blower106. The valve110includes a transition section114which acts as a manifold to direct air to two outlets116and118. The outlets116and118are controlled by a valve element assembly120which includes a first valve element122associated with the outlet116and a second valve element124associated with the outlet118. The first and second valve elements122and124are arranged substantially in perpendicular planes about a common axis. A crank126fixed to the composite bearing shaft of these valve elements122and124is coupled with a link128controlled by a solenoid130and a return spring132.

When the solenoid130is actuated in the air directional valve110, the first outlet116is closed by the first valve element122. When the solenoid is deactivated, the return spring132causes the valve element assembly120to rotate so that the second valve element124closes the outlet118. When one of the first and second elements122and124is closed, the other is fully open. The first outlet116exhausts from the system through an outlet134. The outlet118is ultimately coupled to an ice transport conduit through an air supply passage136. A high pressure switch138is located near the inlet112while a low pressure switch140is located at the outlet118to monitor the state of the system. With the blower106acting as a constant supply of pressurized air, the system may have the blower continuously operating or bring the blower up to speed before pneumatic transporting is undertaken. In either case, when the blower106is fully operating, the valve element assembly120may be actuated by the solenoid130to redirect air from exhaust thought the outlet134to the system through the air supply passage136.

To further insure an immediate burst of air into the system, a second valve138may be interposed within the air supply passage136. This valve may also employ a butterfly valve plate which can be rapidly opened to release the air pressurized by the blower106and directed by the air directional valve110into the air supply passage136.

FIG. 9illustrates an ice gate140which is arranged downstream of the ice outlet132from the ice bin12and the air supply passage136from the blower106. The ice gate140has a passage142extending substantially vertically. The passage142is coupled at its upper end to the ice outlet132defining an ice inlet144to the gate140. An air inlet146is open to the passage142and is coupled with the air supply passage136. This inlet146is located below the ice inlet144. An ice and air outlet148is then located below the air inlet.

A gate150is located in the passage142. The gate150is a flipper valve depending from the body of the ice gate to extend across and close off the air inlet146when not forced open by pressurized air, the closure of the air inlet146providing one extreme position for the gate150. When the air is fully pressurized and flowing through the air inlet146, the gate150is blown over to close the passage142. As the gate150is longer than the width of the passage142, the gate150will extend across the passage142without binding or blowing open in the opposite direction. This forms another extreme position for the gate. With this operation, when the air is off, ice can be dropped down into the ice and air outlet148. When the pressurized air is on, that pressurized air communicates with the ice and air outlet148and is prevented from blowing back and into the ice inlet144which is the ice outlet132of the ice bin12.

Returning toFIG. 1, below the ice gate140, the ice and air outlet148of the ice gate140is coupled with an ice transport conduit152which forms a plurality of coils154below the ice gate140. The ice transport conduit152then may extend upwardly to an appropriate level for distribution to individual ice stations. Naturally, the direction of the ice transport conduit152is determined by the relative location of the ice bin112relative to the stations.

The ice transport conduit152extend to a multi-station diverter156. The multi-station diverter156is best illustrated inFIGS. 15,16and17. The ice transport conduit152is arranged to terminate at the multi-station diverter156with a diverter approach portion158which extends vertically downwardly to the multi-station diverter156.

The multi-station diverter156includes a diverter tube160. The diverter tube160is rotatably mounted about a vertical axis. An inlet end162of the diverter tube160is concentric with that rotational mounting axis. An outlet end164is displaced from the axis by a first distance. The diverter tube160is driven by a V-belt166cooperating with a pulley168fixed to the tube160. A motor170drives the rotation.

In addition to the concentric mounting172at the inlet end162of the diverter tube160, mounting is provided by a body174which is circular in plan with cylindrical sidewalls176and a circular plate178. The circular plate178concentrically receives a mounting pin180which forms a part of a support for the body174.

Indexing of the multi-station diverter156is provided by the mechanism best illustrated inFIG. 16. Asolenoid182retracts a spring biased actuated pin184from sockets186located in the upper rim of the cylindrical sidewall176. The spring187otherwise extends the actuated pin184to one of the sockets186to retain the multi-station diverter156in registry with one of the distribution conduits to remote dispensing stations.

The multi-station diverter156extends to diverter discharge portions188which transition to distribution conduits. The diverter discharge portions188are displaced from the axis of rotation of the diverter tube160of the multi-station diverter156by a distance equal to the displacement of the outlet end164. Thus, the outlet end164is able to align with the diverter discharge portions188. The circular plate178includes a port190therethrough aligned with the outlet end164of the diverter tube160. As there are multiple diverter discharge portions below the circular plate178, the remaining discharge portions are covered over when one is aligned with the port190.

Looking momentarily toFIG. 1, distribution conduits192extend from the diverter discharge portion through distribution conduit inlets194. These distribution conduits192then extend to remote dispensing stations. To cooperate with the diverter discharge portions188so as to appropriately feed the distribution conduits192, the sockets186are appropriately located about the rim of the cylindrical sidewall176so as to specifically align the outlet end164of the diverter tube160with each of the diverter discharge portions188, respectively. To do this, station markers are provided on the periphery of the body174. These station markers are in the form of cams196as illustrated in FIG.17. The cams uniquely identify each distribution conduit inlet by station sensors which are switches198extending into the path of travel of the cams196. As illustrated inFIG. 17, with three switches198, several stations can be recognized. Four are illustrated. However, a fifth could be added through cams196located in the middle and bottom positions. A sixth station can be recognized by a single cam located in the bottom position. Finally, a seventh station can be recognized with a single cam located in the middle position.

Remote ice receiving and dispensing stations200are located at the ends of the distribution conduits192. These stations are receiving stations for ice and provide conventional ice storage bins202with conventional dispensing equipment therefrom.FIGS. 18 through 22illustrate a prechamber and the mechanism thereof for an otherwise conventional remote dispensing station200. A chamber204receives ice and conveying air from a distribution conduit192. The chamber204is preferably an S-shape in cross section with a first end of the S extending to be coupled with the outlet end of the distribution conduit192and a second end extending down to be coupled to a passage206into the remote dispensing station200. The chamber204is open to the atmosphere through an air outlet208. The air outlet208may be a series of strips spaced from one another to allow air flow therethrough while capturing all pieces of ice. A first liquid drain210is shown to drain the upstream portion of the chamber. The drain entrance is arranged such that ice entering the chamber204will not be hung up by the edge of the drain.

A gate212extends across the passage206into the remote dispensing station200to selectively close the passage. The gate212is shown to be pivotally mounted with a counterweight214. Alternatively, a spring may be employed. The counterweight biases the gate212toward a position closing the passage. The gate212swings downwardly to open under the weight of delivered ice or may be opened by an electromagnetic or pneumatic mechanism. When advantageous, the gate may be locked by an electromagnet216attracting a ferromagnetic counterweight214. A position sensor determines the orientation of the gate212as to whether or not it is fully closed.

Inhibiting liquids from flowing into the remote dispensing station200is advantageous. Such liquids may simply be melted ice but can be cleaning fluid. Therefore, in addition to the liquid drain210, a further liquid drain is advantageously associated with the gate212.FIGS. 19 and 20illustrate a first embodiment for such a drain whileFIGS. 21 and 22illustrate a second. In the first embodiment, a liquid drain extends from the end of the gate through the wall of the passage206. This drain218includes bars220to prevent ice from flowing through the drain218. A channel222on the backside of the wall of the passage206is angled downwardly to communicate with a discharge tube224.

In the embodiment ofFIGS. 21 and 22, the drain from the end of the gate is through a passage in the gate212itself. In this embodiment, bars226extend from the upper surface of the gate212, overlaying a channel228offset to promote flow to one side of the gate212as can be seen inFIG. 21. Acup230receives the collected liquid and communicates with a discharge tube232to exhaust the liquid away from the ice storage bin202of the remote dispensing station200. For either drain of these two embodiments to work, the gate212is to be closed for optimum operation. The second embodiment is better able to capture liquid even if there is a slight opening of the gate212within the passage206.

The foregoing structure is preferably configured for operation with a controller. An electronic or microprocessor-based control system is preferred. The controller is contemplated to specifically control the mode of operation of each element and to provide responses to specific events. Several sensors are used with the controller to trigger control operation.

Looking first to the ice bin12, the controller is employed to operate both the drive54which actuates the agitators46and48and the drive78which actuates the agitators62and64. During normal operation, the drives54and78are actuated on a periodic basis to define a first periodic cycle for the drive54and a second periodic cycle for the drive78. The first drive54is cycled approximately once ever ten cycles of the second drive. Further, the first drive only moves a part of a revolution with each, cycle. This motion is sufficient to insure that the ice is able to move downwardly toward the outlet. The partial revolution is enough to break any bridges and columns which may form in the upper or lateral portions of the ice bin12. The drive78is actuated at a substantially greater frequency but is contemplated to have the same approximate duration of agitator rotation per cycle as the first drive54. The second drive also moves the agitators less than one full rotation per cycle. The controller also regulates operation of the auger36through the drive motor44. The signal from the reed switch84indicative of a failure of one or more of the agitators to rotate provides input to the controller as does the microswitch102of the motor torque sensor. The ice bin12may also include a sensor to determine the amount of ice in storage. The amount may be used to control the source of ice10, either through the controller or directly. Such a sensor could be electronic or mechanical.

The controller energizes the solenoid130of the air directional valve110to direct air selectively through the outlets116and118. The controller might also turn the blower106on and off based on the time of day or responsive to volume of ice distribution. Input to the controller is received from the high pressure switch138and the low pressure switch140associated with the air directional valve110. The solenoid of the valve130is also to be actuated by the controller.

The positioning of the diverter tube160of the multi-station diverter156is also positioned through the motor170by the controller. As greater alignment accuracy is necessary for the diverter tube160than is conventionally provided by the motor170, the controller also lifts and releases the actuated pin184through control of the solenoid182. Positional information regarding the diverter tube160is supplied, as described above by the cams196and the switches198. The input from the switches198is directed to the controller for feedback on the accurate manipulation of the actuated pin184.

The controller is programmed to select a new distribution conduit192by drawing the actuated pin184from the associated socket186. The diverter drive is then sequentially powered in one direction for a short pulse and then powered in the other direction to a new position at which time the actuated pin184can be positioned within a new socket186. The controller routinely determines which direction of rotation will result in the least movement and, consequently, time. The initial short pulse would then be initiated in the reverse direction so that the main driving of the diverter tube160will be along the shortest path to the next position.

At the remote dispensing stations200, the ice storage bins202include ice level sensors234. These sensors provide signals to the controller indicative of the levels of ice in the bins202. When the ice level falls below a preset level in one of the bins202, the sensor associated with the low bin202sends a demand call to the controller for additional ice.

The overall condition of the system is tested through the positioning of doors and gates as well as by pressures. The door24on the ice bin12includes a sensor or switch236to indicate to the controller when the door24is open. The ice gate140includes a sensor238on the gate150to determine closure of the passage142. A like device240is found on the gate212of the remote dispensing stations200. The controller further energizes the electromagnet216when the gate212is to remain locked.

The remote dispensing stations200preferably include a visible ice level monitor242which can be seen from outside the ice bin. Such a monitor may be electronic and coupled with the ice level sensor. Alternatively, a less sophisticated means, such as a sight glass, may be employed. The value of such an ice level monitor is that the bin need not be opened to insure the existence of an adequate supply.

Turning to the operation of the ice delivery system, ice is supplied by the source of ice10to the ice bin12. As noted above, some means for controlling the generation of ice based on the quantity of ice in the ice bin12is preferred. This may occur through conventional means such as a mechanical arm or may rely on a sensor through the controller. Also as noted above, agitators within the ice bin12periodically move to insure that the body of ice within the bin12is able to flow toward the outlet. Only a relatively small amount of agitation is required. Greater amounts of agitation reduce the piece size of the ice and can operate to generate heat within the ice. Ultimately, the ice moves toward the ice outlet32at the bottom of the ice bin12. The auger36at the bottom of the ice bin12, activated by the controller, delivers ice from the ice bin12into the passage142of the ice gate140. The controller is programmed to run the auger36in a series of intermittent runs to accumulate a full load of ice to be distributed to a remote dispensing station200. With each run, ice is augered from the bin12through the ice outlet32and dropped away from the auger. The auger may then be reversed through a partial turn to insure that additional ice is not discharged until the auger resumes the discharging operation.

The ice released from the auger36falls through the ice gate140to the coils154. The ice from several periodic runs of the auger are retained in the coils154before being transported onto a selected remote station200. Puffs of air alternate with the auger operation to distribute the ice within the coils154. During the distribution operation, the blower106may be constantly running. Between puffs of air, the air directional valve110directs air to the outlet116. This air may be used to pass over other components which may become hot during operation for cooling purposes. The solenoid130is actuated following an auger run. Preferably, a short delay is programmed into the controller between the operation of the auger36and the actuation of the air directional valve110to blow air into the ice gate140. The delay may be no more than a second or two from the time the auger36ceases to rotate. When the auger reverses direction at the end of each run, the delay would begin from the termination of the reverse rotation of the auger. Following the delay, the solenoid130is pulsed to open the air directional valve110. Where employed, the valve138would also open.

The puff of air from the blower106directed by the air directional valve110to the ice gate140is directed through the air inlet146to close the gate150and flow through the ice and air outlet148. The closure of the gate is monitored by a sensor238. If, during the puff of air, the gate150does not close, there is an assumption that ice is blocking the gate150from closure. With an open gate signal, the auger36is not further enabled. Rather, the air directional valve110is cycled to provide repeated puffs of air to the ice gate140so as to enable and test for full closure of the gate150. Once closure is sensed, the system may again returns to a cycle of alternating augering and puffing. Alternatively, the need to induce full closure of the gate may suggest the possibility of other concerns with the condition of the flow paths. Consequently, before returning to normal operation, a long pulse of transporting air may be generated to send the batch currently being accumulated in the coil154to a remote station. The pulse may be controlled by the shorter of a timed amount sufficient for the batch or partial batch to reach the remote station or a pressure drop signaling arrival of the ice at a remote station. A pressure drop may not be sensed if the batch accumulated in the coil154was small when the open ice gate was sensed. A solenoid might also be employed to supplant the use of air to close the ice gate.

A pressure sensor downstream of the ice gate140may also be employed to sense sufficient closure of the gate150to allow continued operation. The controller may accept one or the other of a gate closure signal or a minimum pressure signal to continue ice distribution from the auger36. The differential pressures may be enhanced through the storage of pressure in the source of transporting air through the valve138with rapid release of that pressure from the source of transporting air in the direction of the ice dropped from the auger by a rapid opening of the valve138. Once a preselected number of auger runs have been performed, the amount of ice within the coils154is ready to be discharged to a selected remote dispensing station200. The controller then activates the valve element assembly120through the solenoid130to send a long pulse of transporting air in the direction of the ice dropped from the auger36. The high pressure switch138on the air directional valve110measures the back pressure as the ice is transported to a remote distribution station. A pressure drop in the line signals that the ice has been appropriately distributed. The transporting air is supplied for a few seconds after the pressure drops to insure that all pieces of ice are appropriately distributed.

The ice level sensors234within the remote dispensing stations200signal the controller when the ice has lowered to a level requiring more to be supplied. The controller recognizes which remote dispensing station200is indicating a low level of ice and activates the multi-station diverter156. The controller is continuously supplied with the diverter position based on the status of the switches198. When a remote dispensing station200calls for ice, the multi-station diverter position to accomplish satisfying the need for ice is determined. The direction of rotation of the diverter tube160to move the shortest distance to the appropriate station is determined. A small reverse pulse is initiated in the opposite direction and the solenoid182withdraws the actuated pin184from the socket186. The diverter tube160is then rotated in the appropriate direction to reach the next station. The cams196and switches198indicate arrival at the appropriate station and the controller releases the actuated pin184to drop into the appropriate socket186. Once this occurs, ice distribution can begin.

The gate212of each of the remote dispensing stations200is biased to a closed position by the counterweight214. The sensor240indicates gate closure and the gate may be locked in this position by an electromagnet216. When the gate212does not fully close, there can be an indication of ice blocking the passage206. When ice is transported, the gate212opens under the weight of the ice. The air may continue for a time after the batch of ice has been delivered, signaled by a drop in pressure, to insure clearance of the passage and the chamber204. If the gate212does not close at this time, the system is disabled from providing additional ice to the remote station200until the gate212closes. Further delivery of air without ice may be provided if the station200continues to call for ice. The sensor240may also be employed to indicate the ability of the gate212to fully open. When the gate is unable to fully open, it is assumed that the ice storage bin202is full. In either case, the system is disabled from delivering ice to the remote dispensing station200where the gate212can either not fully close or not fully open.

A number of operating modes and conditions are also recognized by the controller. The controller continually senses the state of closure of all ice bin access doors. With the opening of any such access door associated with an ice bin, the system is disabled. Thus, augering of ice, blowing puffs of air and blowing transporting air are disabled with an open ice bin access door. When this occurs, the system preferably operates to reinitialize. This also occurs with power failure and with initial startup of the system.

Upon initializing, the system may be actuated to provide a test puff of air. The test puff would be used to determine the amount of back pressure in the system. Alternatively, a transporting cycle for a fixed period of time might be employed where transporting air is blown through the system to insure that no ice is present. The puff or transporting cycle might be employed with each remote station200when it initially requests ice. Such testing is considered unnecessary after the initial delivery of ice to a given remote station200during any series of deliveries to the same station. This is because each delivery is verified to be complete when the characteristic pressure drop is sensed with the ice leaving the transport conduit152. The auger36would be disabled until such time as pressure within the system drops below a preselected minimum. Repeated cycling may be employed in an effort to clear the system when pressure exceeds the minimum. During the test distribution of air, the gates212are preferably maintained in the closed position. This avoids the blowing of transporting air into the associated ice storage bins202.

The system contemplates cleaning and drying cycles which may be manually commanded or periodically initiated by the controller. The cleaning cycle is provided to allow the passage of a device through the pneumatic tubing which distributes cleaning fluid as it passes along. With such a cycle, the gates212would remain closed at all times. The cleaning device containing the cleaning fluid might be introduced at the ice gate140and driven by the blower106. The device would then end up in one of the chambers204of a remote dispensing station200. The process may be repeated with the diverter tube160of the multi-station diverter156repositioned to access additional distribution conduits192. The use of the blower106to propel the device through the pneumatic tubes would result in closure of the gate150of the ice gate140. As a result, the ice in the ice bin12would not be heated by the flow of air therethrough. The same is true for the ice storage bins202through locking of the gates212by the lock216. An identical configuration is used for drying the distribution system but for the passage of a cleaning device through the pneumatic tubes. A periodic drying of the system helps to reduce organic contamination.

Rather than a cleaning device, the vehicle used for conveying an active agent may be a batch of ice itself. Liquid or gas cleaning, de-scaling or sanitizing agents may be introduced at any location. Introduction into the ice gate140, either through the ice inlet144or the air inlet146or both, of such liquid or gas agents may be conveyed with a batch of ice through the system. Alternatively, small amounts of agent may be released during normal operation.

Where the agent is such that it would make the stored ice in the remote stations200less desirable if it was allowed to enter the ice storage, the gate212may be locked in the closed position, even with a batch of ice as the delivery vehicle. Continued air flow would melt the ice to some extent in the prechamber204and carry the agent with the water through the drain210or one of the drains associated with the gate212illustrated inFIGS. 19 through 22. Such a process may be scheduled for automatic actuation on a periodic basis, by number of batches, say once in every 2000 batches, or by lapse of time. The actuation may also be scheduled for times when ice is not being demanded from the remote stations200.

The distribution of ice through the pneumatic tubes from the ice bin12to the remote dispensing stations200has been found to be quite sensitive to any blockage within the system. Consequently, ice delivery system conduit couplings must be appropriately designed to avoid any disruption in the passage of the ice. Further, cleanliness at any break or crevice within the tube is of concern. A number of embodiments of ice delivery system conduit couplings are disclosed inFIGS. 23 through 29.

A first embodiment of an ice delivery system conduit coupling is illustrated inFIGS. 23 and 24. The coupling is preferably circular in cross section and is shown to be an integral tube, generally designated244. The tube244is integral in the embodiment ofFIG. 24but is defined in two sections for purposes here as having a first end portion246and a second end portion248. The first end portion246includes a tubular clamp section250while the second end portion248includes a tubular clamp section252. Between the two clamp sections, the end portions246and248define tubular extension sections254and256. These sections254and256include an inner truncated conical surface which is continuous in the embodiment of FIG.24. These tubular extension sections254and256include outwardly facing inner shoulders258and260. Between these shoulders, the inner surface of these sections defines a truncated conical surface with the diameter decreasing from the shoulder258toward the shoulder260. As illustrated inFIG. 23, the tubular clamp sections250and252are partially split longitudinally. The slits262are formed with a lateral dimension such that the tubular clamping sections250and252may be compressed diametrically. As can be seen inFIG. 23, band clamps264may be strategically positioned to compress the tube244. Channels may be provided to receive the band clamps and maintain them in position. InFIG. 24, conduits266and268are shown in place abutting into the outwardly facing shoulders258and260. FromFIG. 24, it can be seen that the conduit266has a smaller inner diameter than the adjacent inner shoulder258while the conduit268has a larger inner diameter than the adjacent shoulder260. As ice flows from the left toward the right inFIG. 24, it can be seen that no shoulder extends into the ice path using this configuration.

As noted, the embodiment ofFIG. 24shows a continuous inner surface between the shoulders258and260. In the embodiment ofFIG. 25, the first end portion246and the second end portion248are split. The first end portion246includes a first attachment270defined by an annular outwardly extending flange272with threads about the outer peripheral surface thereof. A second attachment274provides a second flange276of slightly smaller outer diameter. An engagement278is defined by a locking nut having an annular inner flange280to mate with an annular channel on the flange276. Inner threads then mate with the threads on the outer periphery of the flange272to tighten the two components together. A sealing element284is positioned between the two attachments270and274. Silicone sealant may be provided at appropriate part lines. In the embodiment ofFIG. 25, the inner surfaces of the tubular extension sections254and256are shown to be truncated conical surfaces which are, in this case, not continuous. Again, no inner shoulder extends into the path of ice flowing from left to right as seen in FIG.25.

The embodiment ofFIG. 26illustrates an ice delivery system conduit coupling which includes a coupling tube286which easily fits within two conduits266and268. The coupling tube286is of fairly thin wall to avoid disruption of ice flow. A coupling tube288as seen in another embodiment shown inFIG. 27is contemplated to be employed with the embodiment ofFIG. 26as well. The tube288has an inner surface290which is flared at the ends to further reduce any shoulder which may be found in the final assembly. In the embodiment ofFIG. 26, a clamp sleeve292circular in cross section extends around the coupling tube286. The clamp sleeve292has longitudinally split ends where the slits294have width to allow for compression of the ends of the clamp sleeve292. Circumferential channels296accommodate clamp bands as shown. At or near the ends, annular sealing flanges300extend radially inwardly. When the clamp bands298are tightened, the annular sealing flanges300both bite into the conduits266and268and compress the conduits inwardly. This compression forces the conduits266and268to cover over the shoulders at the ends of the coupling tube286. To insure that the coupling tube286fits within the clamp sleeve292and between the annular sealing flanges300, a pin302extends between the coupling tube286and the clamp sleeve292. The conduits266and268are introduced by sliding axially between these components.

In the embodiment ofFIG. 27, the clamp sleeve ofFIG. 26is abbreviated to include one or more strips304which extend from the pins302coupled with the coupling tube288outwardly to clamp band assemblies306. With the strips304, the clamp band assemblies306are properly spaced to be at the ends of the coupling tube288to properly seal the interior. In all cases, silicone may act as a sealant to insure complete closure and the avoidance of cracks and interstices which may harbor organic growth.

The ice delivery system conduit coupling ofFIGS. 28 and 29includes a tubular insert308which is shown to be unitary in construction. In this instance, the tubular insert308is shown to partially expand the conduits266and268when placed over the insert308. Alternatively, the conduits266and268may be preflared to allow a smooth sliding fit with the outside diameter of the insert308. The insert is circular in cross section. The insert308includes an internal surface310which is generally cylindrical but may include a slight flaring at the outer ends thereof. The external surface312is also substantially cylindrical but is tapered inwardly at the upstream and downstream ends. A longitudinally split sleeve314which may be formed as indicated inFIG. 28is wrapped about the section of the conduits containing the tubular insert308. Band clamps316tighten the longitudinally split sleeve314to draw the conduits266and268down to immediately overlay the tapered ends of the external surface312of the tubular insert308. In this way, a continuous inner surface across the coupling can be achieved. Again, silicon sealant may be employed where appropriate. While embodiments and applications of this invention have been shown and described, it would be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein. The invention, therefore is not to be restricted except in the spirit of the appended claims.