Abstract:
A process for dispensing a beverage into a cup comprising the steps of : providing a dispensing structure; providing a transportation mechanism linked with the dispensing structure; providing a staging structure linked with the transportation structure; providing a control system linked with the dispensing structure, staging structure and the transportation mechanism; providing a sensor mechanism linked with the control system, the sensor mechanism providing signals indicating the position of a cup; providing a cup identification system having an interactive display connected to the control system; picking a cup from a storage device and positioning it within a dispensing structure; dispensing ice and a beverage at separate locations within the dispensing structure; transporting the filled beverage to a staging structure; positioning the filled cup in the staging structure; removing the filled cup from the staging structure for sale to a customer wherein the cup identification system and the display outputs visual characteristics indicating the position and characteristics of a cup at every stage of the process.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority of U.S. Provisional Application No. 61/537,709 filed Sep. 22, 2011, which is incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The invention relates to beverage dispensing apparatus including dispensing and staging of drinks. 
       BACKGROUND OF THE INVENTION 
       [0003]    Beverages may be dispensed through various valves such that fountain drinks may be prepared by restaurant employees. Commonly, restaurant employees may take an order and then manually pull cups and fill the beverages according to the order. There is therefore a need in the art for an improved beverage dispensing apparatus that is automated and allows a person filling an order to identify drinks grouped by order or type. There is also a need in the art for an improved beverage dispensing system that automates the drink dispensing procedure and transports beverages to a desired area where they may be identified and utilized by restaurant personnel. 
       SUMMARY OF THE INVENTION 
       [0004]    In one aspect there is disclosed, a process for dispensing a beverage into a cup comprising the steps of: providing a dispensing structure; providing a transportation mechanism linked with the dispensing structure; providing a staging structure linked with the transportation structure; providing a control system linked with the dispensing structure, staging structure and the transportation mechanism; providing a sensor mechanism linked with the control system, the sensor mechanism providing signals indicating the position of a cup; providing a cup identification system having an interactive display connected to the control system; picking a cup from a storage device and positioning it within a dispensing structure; dispensing ice and a beverage at separate locations within the dispensing structure; transporting the filled beverage to a staging structure; positioning the filled cup in the staging structure; removing the filled cup from the staging structure for sale to a customer wherein the cup identification system and the display outputs visual characteristics indicating the position and characteristics of a cup at every stage of the process. 
         [0005]    In another aspect there is disclosed, a process for dispensing a beverage into a cup comprising the steps of: picking a cup from a storage device and positioning it within a dispensing structure; dispensing ice and a beverage at separate locations within the dispensing structure; transporting the filled beverage to a staging structure; positioning the filled cup in the staging structure; removing the filled cup from the staging structure for sale to a customer wherein a cup identification system and display outputs visual characteristics indicating the position and characteristics of a cup at every stage of the process. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  is a perspective view of one embodiment of a beverage dispensing apparatus; 
           [0007]      FIG. 2  is a partial perspective view of the dispensing structure, transportation mechanism and staging structure; 
           [0008]      FIG. 3  is a partial sectional view of the sink structure including the housing and wipers and the lift platform; 
           [0009]      FIG. 4  is a perspective view of the actuators and bracket of the lift platform; 
           [0010]      FIG. 5  is a sectional view of the actuators and lift platform of the staging structure with the platform raised; 
           [0011]      FIG. 6  is a partial perspective view of the actuators and lift platform of the staging structure with the lift platform lowered; 
           [0012]      FIG. 7  is a partial perspective view of the dispensing structure, transportation mechanism and staging structure with the sensor; 
           [0013]      FIG. 8  is a top view showing the positions of the dispensing and staging lanes; 
           [0014]      FIG. 9  is view of the cup identification system and display; 
           [0015]      FIG. 10  is a partial perspective view of a cup placement device. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0016]    It should be realized that the descriptions provided herein and made with reference to an X, Y and Z axis of the apparatus as shown in the drawings. The X axis may refer to a lateral axis or lateral movement. The Y axis may refer to a forward and backward axis and corresponding movement forward and backwards. The Z axis may refer to an up and down axis and corresponding movement up and down. These terms may be used interchangeably in the specification and claims. 
         [0017]    Referring to  FIGS. 1-10 , there is shown one embodiment of a beverage dispensing apparatus  20 . In one aspect, the beverage dispensing apparatus  20  includes a dispensing structure  22 , a transportation mechanism  24 , and a staging structure  26 . In one aspect, the dispensing structure  22  may be decoupled from the transportation mechanism  24  and staging structure  26 . The beverage dispensing apparatus may include a housing  28  that contains the various structures of the beverage dispensing apparatus. 
         [0018]    Referring to  FIGS. 1 and 10 , there is shown one embodiment of a dispensing structure  22  of the beverage dispensing apparatus  20 . The beverage dispensing structure  22  may include a cup placement device  30 . Various cup placement devices  30  may be utilized. For example, various gripping type mechanisms may remove a cup  32  from a storage bin  34  and position it for dispensing of ice and beverage. In the depicted embodiment, the cup placement device  30  includes actuators  36  having suction cup gripping mechanisms  38  that may be actuated using a pneumatic air control system  40  linked with the suction cups  38 . Additionally, various actuators such as a Z and Y actuator  40 ,  42  as shown in the depicted embodiment may move the cup placement device  30  from one location to another such that cups  32  may be provided in a desired location. 
         [0019]    The dispensing structure  22  also includes a dispensing lane structure  44 . In the depicted embodiment, the dispensing lane structure  44  is positioned on a common X axis with the cup placement device  30 . The dispensing lane structure  44  includes a rail grid  46  having spaces  48  between a plurality of rails  50  such that water or a beverage may pass through the grid  46 . Additionally, the rail grid  46  includes an angled front edge  52  such that ice and foreign objects on the rail grid  46  may be moved from the rail by a lift platform  54 , as will be described in more detail below. Additionally, the dispensing lane structure  44  includes a lift platform  54  having a raised front edge  56  and a plurality of rails  58  that are positioned to move within the spaces  48  defined in the rail grid  46  of the dispensing lane. The lift platform  54  is coupled with Y and Z actuators  60 ,  62  such that the platform may be moved along a Y direction of the rail grid  46  as well as in a Z direction or up and down relative to the rail grid  46 . In this manner, the lift platform  54  may be moved below the rail grid  46  in the Y direction and then raised and lowered under a cup  32  that is positioned on the rail grid  46  such that the cup  32  may be moved from one location to another along the Y axis of the rail grid  46 . 
         [0020]    In one aspect, the lifting mechanism or Z actuator  62  is capable of at least supporting and lifting a minimum weight determined by the largest cup filled with beverage. Additionally, the Z actuator  62  may lift the lift platform  54  straight up and slow enough so that a cup  32  does not fall over or cause liquid to be sloshed over an edge of the side wall of the cup  32 . Further, the stopping and starting for the Y actuator  60  which may be a linear type mechanism maybe chosen such that the acceleration and deceleration coupled with the velocity of the motor move the cup  32  in a stable manner. 
         [0021]    The dispensing structure  22  additionally includes an ice dispenser  64  and a beverage dispensing valve  66  positioned above the rail grid  46  of the dispensing lane  44 . In one aspect, the ice dispenser  64  and beverage dispensing valve  66  are positioned along the Y axis of the dispensing lane structure  44  and are spaced from each other along the Y axis. The dispensing lane structure  44  includes a position (D 1 ) along the Y axis of the dispensing lane  44  that corresponds to an ice filling position below the ice dispenser  64 . Additionally, the dispensing lane structure  44  includes a position (D 2 ) along the Y axis of the dispensing lane  44  below the beverage dispensing valve  66  corresponding to a beverage filling position. 
         [0022]    The dispensing structure  22  additionally includes an X transport structure  68  positioned along a back of the beverage dispensing apparatus  20 . The X transport structure  68  includes a rail structure  70  having a rail grid  72  corresponding to the same spaced rail grid structure of the dispensing lane structure previously described above. However, the rail grid  72  is positioned above the dispensing lane structure  44  in the Z axis. Additionally, the X transport structure  68  includes a bracket  74  coupled with the rail grid  72  and attached to an actuator  76  that moves the rail grid structure  72  along an X axis as shown in the figures. Additionally, lateral support structures or members  78  may be attached to the bracket  74  of the X transport structure  68  for supporting a cup  32  as it travels along the X direction. Various actuators may be utilized to move the rail grid  72  about the X axis. For example, linear actuators may be utilized and may be calibrated such that movement does not spill a beverage after it has been filled underneath the beverage dispensing valve  66 . 
         [0023]    In one aspect, the dispensing structure  22  is a decoupled zone that allows ice to be dispensed into one cup  32  while the desired beverage is being poured simultaneously into a second cup  32 , and also while the cup placement device is positioning a cup on the dispensing lane  44 . This decoupled zone separates the dispense structure  22  from the cup placement device  30  and a staging structure  26 , as will be discussed in more detail below. 
         [0024]    Referring to  FIGS. 1 ,  2  and  7 , there is shown a staging structure  26  of the beverage dispensing apparatus  20 . The staging structure  26  includes a plurality of rail grids  80  that are laterally spaced from each other along the X axis. The rail grids  80  again are the same as that described above with respect to the dispensing lane structure  44 . The rail grid  80  includes a plurality of rails  50  having spaces  48  there between and an angled front edge  52  as previously described. Additionally, a lift platform  54  is positioned under each of the plurality of rail grids  80  and includes Y and Z actuators  60 ,  62  as described above. Again, the lift platform  54  may include a raised front edge  56  for defining a plowing structure such that ice or foreign objects that may be positioned on the rail grid  80  may be swept towards a front along the Y axis to the angled front edge  52  of the rail grid  80  such that foreign objects may be removed that can cause a cup  32  or drink to be spilled. Each of the plurality of rail grids  80  includes a plurality of positions along the Y axis of the rail grids  80  for locating filled beverage cups, as will be discussed in more detail below. 
         [0025]    The beverage dispensing apparatus  20  includes a housing  28  that surrounds the staging structure  26  as well as the dispensing structure  22 and defines a sink area  82 . In one aspect, the sink area  82  includes a trough  84  positioned at a front of the apparatus relative to the angled portion  52  of the rail grids  50  such that ice or foreign objects may be caught within the trough  84 . Additionally, the trough  84  may include drains  86  as seen in  FIG. 3 . In one aspect, a drain  86  may be positioned at all three of the staging lanes  80  and the dispensing lane  44 . The drains  86  may be linked with a drain tube to allow liquid to flow to a desired area. 
         [0026]    In one aspect, the Y and Z actuators  60 ,  62  associated with the lift platform  54  are protected from contact with a liquid or other object such as ice. In one aspect, the Y and Z actuators  60 ,  62  are located within the sink area  82 . To prevent the direct contact of liquid, housings  86  including wipers  88  are positioned above the moving parts protecting them. As best shown in  FIGS. 3-6 , the lift platform  54  attaches to a bracket  90  that slides in between the wipers  88 . In this manner, the bracket  90  makes it difficult for any liquid to penetrate to the Y and Z actuators  60 ,  62  positioned below. 
         [0027]    In one aspect, the dispense and staging structures  22 ,  26  as described above include a plurality of defined positions to identify where a specific beverage is located. In one aspect, the staging structure  26  may include four defined positions  92  for each of the rail grids  80  that progress together. Additionally, the dispensing structure  22  may include two dispensing positions  94  located between the ice dispense  64  and beverage valve  66  as well as an X translation position  96  that moves the filled beverage along an X axis into one of three X positions  98  on the rail grids as best seen in  FIG. 8 . It should be realized that various numbers of staging locations  92  and dispensing locations may be utilized. For example, the staging structure may include nine staging locations  92  rather than twelve staging locations  92 . In one aspect, the twelve cup locations  92  within the staging area are independent of one another allowing for control of any location on the staging grid  80 . A control system  100  can dispense the drink orders in a first-in, first-out method or an intelligent sorting type method. The control system  100  may make decisions on which order to process first based on food preparation times as well as other requirements that may be utilized such as the amount of drinks with an order as well as various other parameters from the point of sale orders. 
         [0028]    In one aspect, the control system  100  may review outputs from a sensing system  102  such as an ultrasonic, infrared, or an optical and vision based system as shown in the figures. In this manner, the control system  100  identifies positions within the staging structure  26  as well as the dispensing structure  22 . As the point of sale orders are processed and a drink is completed, the drink will be positioned in various positions in the dispensing and staging structure  22 ,  26 . In one aspect, when the staging structure  26  is completely empty a completed drink will be positioned into lane  1 , position  1  or L 1 , P 1  as shown in  FIG. 8 . The control system  100  then looks to see if the next drink is within the same order and reviews the sensor feedback. If the next drink is for the same order and the first drink is still within the L 1 , P 1  position, then the control system  100  would actuate the lift platform  54  associated with the lane  1  and position the cup  32  into L 1 , P 2  position. If the previous drink has been removed, then the control system may move the new drink to the original position L 1 , P 1 . For example, if there are four drinks in an order and none are pulled, the fourth cup may be positioned in the L 1 , P 4  or in the L 2 , P 3  configuration. In this case, the first drink of the next order would then end in L 3 , P 1 . 
         [0029]    The control system  100  repositions open staging positions  92  by back filling. The control logic is programmed such that it allows the system to always have drinks located at the front of the unit so that they may be easily accessible by an operator of the beverage dispensing apparatus  20 . With each lane position being fully independent, cups  32  can be easily repositioned when the sensor provides feedback stating a cup in a specified position has been removed. For example, if P 1  is removed and P 2  and P 3  still exist within a lane, then the control mechanism  100  can perform an operation such that the lift platform  54  is raised below the cup  32  and can move these cups up one position at a time. If P 1  and P 2  are both removed, then a cup in P 3  can be moved to the front position P 1 . This movement opens up the back positions to be filled with new orders. 
         [0030]    Additionally, if the staging structure is partially filled the control mechanism  100  may move filled cups  32  to various positions. For example, if all lanes have P 1  filled with an order, the next order may fill in the next open positions. Orders may possibly be filled across multiple lanes. If only single positions are available and there are single and multiple drinks within a point of sale, then the control system  100  will populate the single orders filling in the open positions. Additionally, if there are twelve individual single orders the orders may start filling at L 1 , P 1 . As long as no cups are pulled, the next orders continue to fill up in the following progression: L 2 , P 1 ; L 3 , P 1 ; L 1 , P 2  all the way through until all twelve positions are occupied. 
         [0031]    As stated above, a sensor mechanism  102  is associated with the control system  100 . Various mechanisms may be utilized such as discrete sensors positioned at each location either in the sink area or positioned above a desired location along the Y axis of the rail grid. A further option is a vision or optical type system that utilizes one camera to view the entire area, as shown in  FIG. 7 . In one aspect, the vision system covers the staging structure  26  as well as the dispensing  22  and transport areas  24 . An optical type or vision system may utilize information provided by a camera to supplement error handling associated with the system. For example, should a cup  32  not be positioned correctly under the ice dispensing or beverage dispensing portion of the dispensing lane, the control system  100  may recognize that there is no cup  32  positioned in a desired location such that a beverage or ice is not dispensed into a cup  32  that is not present. 
         [0032]    In one aspect, as depicted in  FIG. 9  a cup identification system  106  is associated with the beverage dispensing apparatus  20 . The cup identification system  106  may include a touch screen or information unit  108  that identifies specific locations and orders associated with the beverage dispensing apparatus  20 . In one aspect, as the point of sale orders are received, the drink orders are populated on the screen  108 . Each order may be identified differently using a shape or color to make it easy to identify for an operator. In one aspect, each cup identifier  110  positioned on the screen  108  indicates the order number and a size or type of drink contents. As the desired drink progresses through the beverage dispensing apparatus  20 , the identifier  110  also moves on the screen  108  at the same locations corresponding to positions on the rail grids. In this manner, an operator may easily identify a desired drink associated with a specific order and know exactly where it is positioned within the beverage dispensing apparatus  20 . 
         [0033]    It is also disclosed herein a process for dispensing and locating a beverage. The process includes the step of an order being entered by an operator with a corresponding display on the cup identification system  106  displaying a drink to be dispensed. The cup  32  will then be picked by the cup placement device  30  using one of two methods. In one method, cups  32  may be stored in a linear storage system such that a linear actuator along the Y axis moves to a proper cup  32  within a plurality of tubes oriented in a single row. Alternatively, a rotary cup storage device as shown in  FIG. 1  may include a cup turret that rotates to a proper cup so it is aligned with the center of the dispense lane  44 . A Z actuator  40  then moves the cup  32  upward to align the suction cups  38  to the highest exposed part of the cup  32  just below the tube. Input air is then provided to the suction cup  38  such that vacuum generators  112  are actuated. Next an actuator in the Y direction  42  moves the suction cups  38  toward the cup  32  perpendicular to the center line of the cup  32  and engages with the cup  32 . If vacuum sensors are utilized, a control signal will notify that a cup  32  is ready to be pulled. Next the Z actuator  40  moves the cup  32  downward and the cup  32  is then removed from the storage device. The dispense lane actuator drives forward with the platform  54  raised such that the raised front edge  56  of the platform  54  clears any ice that might exist on the dispense lane  44 . Once the platform  54  has reached the front of the rail it then lowers all the way down. Next the Y actuator  42  of the cup placement device  30  moves the cup  32  towards the dispense lane  44  and pushes the cup  32  into a desired position. Input air is then closed causing the vacuum generators  112  to shut off. The Y and Z actuators  42 ,  40  move simultaneously down and away to place the cup  32  on the dispense lane grid underneath the ice dispenser  64 . The Y actuator  42  moves the suction cups  38  to a rest position away from the dispensing zone. A gate then opens and a portion amount of ice is dispensed into the cup  32 . The drink identifier  110  on the display  108  indicates that ice is dispensing into a desired cup  32 . The platform  54  is then actuated in the Z direction below the cup  32  such that the cup  32  is raised above the rails  50 . Following movement in the Z direction, the cup  32  is then moved along the Y axis to the position below the beverage dispensing nozzle  66 . Once the cup  32  has been positioned to the desired location, the platform  54  then lowers the cup  32  onto the rails  50  on the desired beverage dispensing position. Following movement of the cup  32 , a proper amount of beverage is dispensed by actuating multiple valves such that a syrup and water exit through a single dispense point nozzle. The drink identifier  110  on the display screen  108  indicates that a beverage is dispensing into a desired cup  32 . The platform  54  below the dispense lane  44  following dispensing of the beverage into the cup  32  again positions below the cup  32  and actuates in a Z direction such that the cup  32  is lifted above the rails  50 . Following movement in the Z direction, the platform is then moved in the Y direction such that it transports the cup  32  to the X transport structure. Once the cup is positioned on the rail grid of the X transport structure  68 , the platform  54  then lowers below the dispensing lane grid  44 . The X transport structure  68  moves the filled beverage along the X axis to a desired position on one of the staging lanes  80 . Once the X transport structure is positioned along a desired lane  80 , the lift platform  54  below that lane actuates in a Y direction directly underneath the X transport structure  68  and lifts the filled drink to a desired position along the Y axis of a desired staging lane  80 . The control mechanism  100  provides instructions for the X transport structure  68  as well as the various lift platforms  54  of the staging lanes  80  such that drinks may be stationed within one of the staging positions based on order sequence and location availability. The staging lanes  80  as indicated above may be equipped with a sensing system  102  that states whether a cup or object exists in a desired location. The drink identifier  110  associated with the display  108  moves to that location in the staging lane once the beverage has been positioned within a specific location. In one aspect, the identifier  110  includes the order number as well as a size and drink contents for an individual cup. Once a location has been vacated by an operator removing the cup, the staging Y and X actuators and lift platforms  54  move various other cups  32  to back fill empty spaces within the staging lanes  80 . 
         [0034]    The invention has been described in an illustrative manner. It is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than limitation. Many modifications and variations of the invention are possible in light of the above teachings. Therefore, within the scope of the appended claims, the invention may be practiced other than as specifically described.