Abstract:
Disclosed is a method and apparatus for automatically adjusting the amount of ice that may be delivered from an ice storage reservoir to a point of use, such as from an ice reservoir of a combination beverage dispenser and ice reservoir to a container, with a high degree of accuracy, consistency and repeatability. The method and apparatus may be controlled by means of a program and/or logic sequence stored in a memory to allow a wide range of ice volumes to be measured, metered and dispensed. The apparatus may include an ice reservoir, a mechanism for dispensing ice to a point of use disposed in communication with the ice reservoir, and an ice metering device disposed in communication with both the ice reservoir and the mechanism for dispensing ice.

Description:
CROSS-REFERENCED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Application No. 61/694,726 filed on Aug. 29, 2012, which is incorporated herein in its entirety by reference thereto. 
     
    
     BACKGROUND 
       [0002]    1. Field of the Disclosure 
         [0003]    The present disclosure relates to a method and apparatus for adjusting an amount of ice that may be delivered from an ice storage reservoir to a point of use. More specifically, the present disclosure relates to dispensing apparatus and method to deliver ice from an ice reservoir of, e.g., a combination beverage dispenser and ice reservoir, to a cup, container, package, etc. with a high degree of accuracy, consistency and repeatability. The method and apparatus of the present disclosure may be controlled by a program and/or logic sequence to allow a wide range of ice volumes to be metered and dispensed, thereby enabling a variety of different equipment to provide accurate and repeatable ice metering and delivery functions. 
         [0004]    2. Background of the Disclosure 
         [0005]    Current ice metering and delivery systems use either a predetermined weight of ice (which is difficult to change) or are regulated by human interaction to determine the amount of ice being delivered to the point of use. Such systems make it difficult to control the amount of ice that is delivered to a point of use, such as a cup container or package, accurately and repeatably to serve the desires and needs of the increasingly demanding beverage dispensing industry, such as that found, e.g., in fast food establishments (e.g., McDonald&#39;s®, Wendy&#39;s®, and similar establishments). 
         [0006]    Also, current ice metering and delivery systems can only provide for repeatability of, e.g., no less than about 20% from delivery of one ice portion to the next. This renders such ice metering and delivery systems further unsuitable for the demands of today&#39;s beverage delivery system environment that seeks to provide greater repeatability and lower variability between dispensed ice amounts. The desired greater repeatability and lower variability both serve to satisfy customer and industry demands. 
         [0007]    Accordingly, a need exists for ice metering and delivery systems that provide greater repeatability and lower variability between dispensed ice amounts. Also, a need exists for such ice metering and delivery systems that can be automatically adjusted with little difficulty to change and control the amount of ice delivered to a point of use depending upon the container selected (i.e., different sized cups). 
       SUMMARY 
       [0008]    The foregoing needs are met according to the present disclosure by an ice metering apparatus and method that can provide metering and delivery of ice that meets the demands of both greater repeatability and automatic adjustment. 
         [0009]    According to the present disclosure, there is provided an apparatus for metering the amount of ice delivered to a point of use, the apparatus comprising an ice reservoir, a mechanism for dispensing ice to a point of use disposed in communication with the ice reservoir, and an ice metering device disposed in communication with both the ice reservoir and the mechanism for dispensing ice. The ice metering device allows an adjustable and consistent amount of ice to be delivered from the ice reservoir to the mechanism for dispensing ice. The ice metering device may be located either in the ice reservoir, or may be disposed between the ice reservoir and the mechanism for dispensing ice but, in any event, ice to be dispensed passes from the ice reservoir to the mechanism for dispensing ice via the ice metering device. 
         [0010]    The volume of ice provided to be dispensed from the ice metering device to the mechanism for dispensing ice may be of any desired volume but is preferably between from about 0 cubic inches to about 40 cubic inches. In other embodiments, the volume of ice available to be provided from the ice metering device to the mechanism for dispensing ice may be automatically adjusted by the ice metering device, and the control logic therefor, depending upon the size of the container or cup that is to be used at the point of use (e.g., a child&#39;s cup, a 16 ounce cup, a 20 ounce cup and/or a 32 ounce cup). Also according to the present disclosure, the variability between the volume of ice dispensed from the ice metering device will be in the range of from about 2% to about 20%, preferably from about 5% to about 15% or less, more preferably from about 5% to about 10% or less and most preferably between from about 5% to about 7% or less. 
         [0011]    Also according to the present disclosure, there is provided a method for metering the amount of ice dispensed to a point of use, the method comprising setting an amount of ice to be accepted by a mechanism for metering ice, delivering the set amount of ice from an ice reservoir to the mechanism for metering ice, stopping delivery of the set amount of ice from the ice reservoir to the mechanism for metering ice to obtain a metered amount of ice, and delivering the metered amount of ice to a mechanism for dispensing ice to a point of use. Delivering an amount of ice from the ice reservoir to the mechanism for metering ice may comprise transporting ice using an auger, a paddlewheel or other similar mechanism. Also, the method for delivering an amount of ice from the ice reservoir to the mechanism for metering ice may further comprise preventing additional ice from entering the mechanism for metering ice once the metered amount of ice has been placed into the mechanism for metering ice from the ice reservoir. 
       BRIEF DESCRIPTION OF THE DISCLOSURE 
       [0012]    The present disclosure will be further and more clearly understood in conjunction with the following drawings, in which: 
         [0013]      FIG. 1  is a schematic view of a combination ice reservoir and beverage dispenser including an ice metering apparatus according to an embodiment of the present disclosure; 
         [0014]      FIG. 2  shows a detailed view of an embodiment of an ice metering apparatus according to the present disclosure; 
         [0015]      FIG. 3  shows a schematic view of another embodiment of an ice metering apparatus according to the present disclosure; 
         [0016]      FIG. 4  shows an exploded view of the ice metering apparatus shown in  FIG. 3  according to the present disclosure; 
         [0017]      FIG. 5  shows a perspective view of an ice metering apparatus according to the present disclosure; 
         [0018]      FIG. 6  shows a perspective view of the ice metering apparatus of  FIG. 5  disposed between an ice reservoir and a mechanism for dispensing ice; 
         [0019]      FIG. 7  shows a close-up perspective view of the ice metering apparatus of  FIG. 5 ; 
         [0020]      FIG. 8  shows a view from inside an ice reservoir and an opening from the reservoir to an ice metering device (not shown) according to the present disclosure. 
         [0021]      FIG. 9  shows a flow and logic diagram for steps controlled by a controller for the ice metering device of the present disclosure. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0022]    In the description of the  FIGS. 1-9  that follows, like numerals will be used to designate like elements. 
         [0023]      FIG. 1  shows an ice reservoir  10  containing a quantity of ice  11 . Ice reservoir  10  has walls  12  and a bottom  13 . Walls  12  are disposed at an obtuse angle relative to axis “A” perpendicular to bottom  13 . Walls  12  have an inside surface  14  and an outside surface  15 . Disposed between inside surface  14  and outside surface  15  is an amount of insulation  16  that can be of various components and/or thickness. Disposed adjacent to an inside surface  14  of ice reservoir  10  is, e.g., a mechanism  17  for transporting ice  11  from ice reservoir  10  to the outside of ice reservoir  10 . Mechanism  17  may be any suitable mechanism for transporting ice from ice reservoir  10  to the outside of ice reservoir  10  and, in the schematic shown in  FIG. 1 , mechanism  17  is a paddlewheel. Mechanism  17  transports ice  11  to a chute  18  that is disposed in communication between ice reservoir  10  and a metering mechanism  20 . Chute  18 , as shown in  FIG. 1 , is exaggerated in length and size for ease of depiction. Metering mechanism  20  is adjustable, preferably via a controller (not shown), to adjust the amount of ice transported from ice reservoir  10  to a container  21  shown as a cup. Of course, container  21  receiving ice  11  from metering mechanism  20  can be any suitable container. Also shown in  FIG. 1  is ice chute  22  disposed between metering mechanism  20  and container  21 . In the embodiment shown in  FIG. 1 , ice reservoir  10 , mechanism  17 , metering mechanism  20  and chutes  18  and  22  form a portion of a beverage dispenser. In the embodiment shown in  FIG. 1 , beverage dispensing head  23  dispenses beverage to container  21  through delivery nozzle  24 . As mentioned above, chute  18  is exaggerated for ease of viewing in  FIG. 1 ; however, in practice and design, metering mechanism  20  is preferably adjacent to outside surface  15  of ice reservoir  10 , whereby chute  18  of limited length, i.e., the distance between inside surface  14  and outside surface  15  of ice reservoir  10  depicted as dashed lines at “B” in  FIG. 1 . 
         [0024]      FIG. 2  shows one embodiment of the metering mechanism  20  according to the present disclosure. In  FIG. 2 , metering mechanism  20  is in communication with chute  18  from a position immediately adjacent to outer surface  15  of ice reservoir  10 . In the embodiment shown in  FIG. 2 , metering mechanism  20  is disposed adjacent to the outside surface  15  of ice reservoir  10  at the point where metering mechanism  20  and ice reservoir outer surface  15  meet, i.e., surface  25 . At surface  25  is a wall opening  26  of ice metering mechanism  20  that is in cooperative relation with an ice portal (see,  FIG. 8 ) located in the wall between surfaces  14  and  15  of ice reservoir  10 . In  FIG. 2 , mechanism  17  is inside ice reservoir  10 , and disposed at a position adjacent ice portal (see,  FIG. 8 ) in ice reservoir  10  at the location of the junction of surface  25  and outside surface wall  15  of ice reservoir  10 . In the embodiment shown in  FIG. 2 , ice  11  is transported via mechanism  17  through wall opening  26  to metering mechanism  20 . In  FIG. 2 , metering mechanism  20  comprises a moveable wall  27  that is capable of variable adjustment and can be releasably fixed in different positions, e.g.,  20   a,    20   b  and  20   c,  inside metering mechanism  20  as is shown in  FIG. 2 . Depending upon the position of moveable wall  27  (e.g., at position  20   a,    20   b  or  20   c ) inside metering mechanism  20 , varying amounts of ice  11  from ice reservoir  10  will provided to metering mechanism  20  through chute  18  and be available to be dispensed from metering mechanism  20  when moveable wall  27  is released, as will be explained below. Once the space between wall opening  26  and the side of moveable wall  27  disposed proximal wall opening  26  is filled with ice  11 , movable wall  27 , that is in releasably fixed position, e.g.,  20   a,    20   b  or  20   c,  is released by an actuator  28  (e.g. a solenoid, stepper motor and lead screw, rack and pinion or similar device known to those of skill in the art). When moveable wall  27  reaches outer opening  29  of metering mechanism  20 , the quantity of ice contained in space between wall opening  26  and the side of moveable wall  27  disposed proximal wall opening  26  will exit metering mechanism  20  and enter ice chute  22  for delivery to container  21 . 
         [0025]      FIGS. 3 and 4  show an alternative embodiment of metering mechanism  20  according to the present disclosure. Metering mechanism  20  of  FIG. 3  is shown in exploded view in  FIG. 4 . In the embodiment shown in  FIGS. 3 and 4 , metering mechanism  20  comprises a meter chamber housing  31 , a movable plunger  32  and trap floor/wall  33 . Moveable plunger  32  is disposed in meter chamber housing  31  and placed in proper alignment therein by the relationship between a movable plunger guide  42  and a movable plunger guide opening  43 , best seen in  FIG. 4 . In the embodiment shown in  FIG. 4 , moveable plunger guide  42  is comprised of a guide extension  44 , retaining plate  45  and retaining screw(s)  46 . The interactive relationship between movable plunger  32 , trap floor/wall  33 , movable plunger guide  42  and movable plunger guide opening  43  will be more fully described in relation with  FIG. 5 . In the embodiment shown in  FIGS. 4-7 , movable plunger  32  is moved in relation to meter chamber housing  31  using a stepper motor  54  and lead screw  47  (see,  FIG. 5 ). The interaction between stepper motor  54  and lead screw  47  will be more fully explained in relation to  FIGS. 5 ,  6  and  7 . In the embodiment shown in  FIGS. 3-7 , metering chamber housing  31  and movable plunger  32  have a cooperative trapezoidal-like shape. The angle “B” (see,  FIG. 3 ) between opposing nonparallel sides of the trapezoidal-like shape of meter chamber housing  31  is of no critical import. The opposing sides of meter chamber housing  31  forming angle “B” may in fact be parallel in which case meter chamber housing  31  will take the form of a square or rectangle. However, for purposes of ensuring improved and better release of ice  11  from adhering to inner surfaces of meter chamber housing  31  and to further ensure as complete and accurate dispensing of ice  11  as possible, meter chamber housing  31  is preferably designed with the above-described trapezoidal-like shape. The trapezoidal-like shape with respect to the non-parallel sides of meter chamber housing  31  may have an angle “B” of between about 5° to about 60°, preferably of from about 10° to about 30° and more preferably from about 10° to about 20°. 
         [0026]      FIG. 5  shows trap floor/wall hinge  51  and trap floor/wall linkage  52  that together serve to move trap floor/wall  33  between an open and closed positions(s).  FIGS. 5 ,  6  and  7  show a perspective end view, a perspective view and a perspective overhead view, respectively, of the embodiment of the metering mechanism  20  shown in a schematic view in  FIG. 3  and exploded view in  FIG. 4 . In  FIGS. 5 ,  6  and  7 , movable plunger  32  is shown in position disposed inside meter chamber housing  31 , with movable plunger  32  and meter chamber housing  31  having the preferred trapezoidal-like design. Lead screw  47  is disposed within stepper motor  54 . Movable plunger guide opening  43  is disposed at and through an upper surface of meter chamber housing  31  and, in conjunction with movable plunger guide  42 , serves to align and guide movable plunger  32  and maintain spatial relationship thereof in meter chamber housing  31 . In the embodiment shown in  FIG. 5 , trap floor/wall  33  is shown as an “L”—shaped sheet metal mechanism, with one side  33   a  forming a “wall” portion of meter chamber housing  31  and one side  33   b  forming a “floor” of meter chamber housing  31 . Trap floor/wall  33  is held in movable engagement/relation with meter chamber housing  31  via trap floor/wall hinge  51  that, in turn, is in cooperative relation with trap floor/wall linkage  52 , wherein trap floor/wall linkage  52  is in operable connection with solenoid  55 . In operation, when meter chamber housing  31  has received the appropriately measured amount of ice  11  from ice reservoir  10 , solenoid  55  is activated and controls trap floor/wall linkage  52  to thereby rotatably disengage trap floor/wall  33  from its position as “wall”  33   a  and “floor”  33   b  of meter chamber housing  31  via rotation about trap floor/wall hinge  51 . As shown in  FIG. 5 , trap floor/wall  33  is open position. Trap floor/wall  33  automatically returns to closed position in relation to meter chamber housing  31  via, e.g., a return spring mechanism (not shown), or it can be returned via solenoid. Trap floor/wall  33  may be of any convenient design or material. For example, trap floor/wall  33  may be made of sheet metal or plastic. Also by way of example, trap floor/wall  33  may be in the design of a sliding mechanism that slides across a lower opening on the bottom or side of meter chamber housing  31  or, alternatively, may be a flap mechanism that opens and closes over a lower opening or side of meter chamber housing  31 . In both of the latter instances, trap floor/wall  33  may be again returned to closed position via a return spring mechanism, or solenoid. 
         [0027]    In  FIG. 6 , the interaction between ice reservoir  10  and meter chamber housing  31 , movable plunger  32  and ice chute  22  may be more clearly seen. Meter chamber housing  31  is disposed adjacent to ice reservoir  10  along an angled wall  12  thereof. This relationship between meter chamber housing  31  and angled wall  12  may be more clearly seen in  FIG. 7 . The placement of meter chamber housing  31  adjacent to angled wall  12  of ice reservoir  10  effects the transfer of ice  11  within ice reservoir  10  into meter chamber housing  31  by means of gravity. Ice  11  from ice reservoir  10  is transferred to meter chamber housing  31  to fill the space in the interior of meter chamber housing  31  defined by the walls of meter chamber housing  31 , outside surface  15  of ice reservoir  10 , trap floor/wall  33  and surface  49  of moveable plunger  32 . Also included in space filled with ice  11  from ice reservoir  10  is chute  18  disposed within wall  12  of ice reservoir  10  between inside surface  14  and outside surface  15 . When the space in the interior of meter chamber housing  31  is filled with ice  11 , trap floor/wall  33  is rotatably moved away meter chamber housing  31  via activation of solenoid  55  that, in turn, causes trap floor/wall linkage  52  to move in the direction of arrow “C”, and rotate meter chamber housing  31  about the axis defined by trap floor/wall hinge  51 . This movement allows ice  11  to pass through ice chute  22  and into receptacles/containers disposed at the distal end of ice chute  22 . 
         [0028]    Also shown in  FIGS. 6 and 7  are limit switch  61  and limit switch  62 . Limit switch  62  detects when surface  49  of movable plunger  32  is disposed to a position adjacent to and against outer surface  15  of ice reservoir  10 . This sets the “zero” position for the next amount of ice  11  to be transferred from ice reservoir  10  to ice metering mechanism  20 . Controller  91  (see,  FIG. 9 ) may then communicate with stepper motor  51  to count “steps” to retract moveable plunger  32  away from outside surface  15  of ice reservoir  10  to the desired position. Controller  91  is an electronic control system that exchanges control signals with stepper motor  54  and solenoid  55 . Controller  91  is comprised of a processor, a memory and a control program stored in the memory. Limit switches  61  and  62  are communicatively coupled to controller  91  to confirm the positions of the movable plunger  32  and trap floor/wall  33  respectively. Limit switch  61  recognizes when trap floor/wall  33  is in a closed position, thereby in a “ready” state for the next amount of ice  11  to be transferred from ice reservoir  10  to ice metering mechanism  20 . 
         [0029]      FIG. 8  shows one embodiment of mechanism  17  for transporting ice  11  to ice metering mechanism  20 , i.e., a paddlewheel  80 . Paddlewheel  80  is comprised of a plate  81 , a plurality of vanes  82 , ice blockers  83  having magnetic sensors (not shown) disposed therein and agitators  84 . In the embodiment shown in  FIG. 8 , there are two ice blockers disposed 180° apart around circumference of paddlewheel  80 . Also shown as part of paddlewheel  80  is a collar  85  connecting paddlewheel  80  to a shaft  86  via a pin  87 , with shaft  86  rotatably mounted to a drive stem of a drive motor (not shown in  FIG. 8 ). As also shown in  FIG. 8 , collar  85  is releasably connected to shaft  86  via pin  87  that interlocks collar  85  and shaft  86 . Also shown in  FIG. 8  is ice portal opening  87  that leads to chute  18 . In the embodiment shown in  FIG. 8 , paddlewheel  80  rotates in the direction of arrow “D”. The operation of paddlewheel  80  and interaction thereof with ice metering mechanism  20  will be explained in more detail below. 
         [0030]      FIG. 9  shows a block diagram of one form of controller  91  for the ice metering apparatus and method of the present disclosure. When controller  91  receives a signal  92  that a drink is desired (e.g., via a user interface in a point of sale (POS) device (not shown)), the first step  93  is to determine how much ice is required for the drink (e.g., based upon a stored value in memory for the drink/cup size combination). Controller  91  communicates with limit switch  61  and limit switch  62  to verify that they are in a closed (or “home”) position in steps  94  and  95 , respectively, before continuing with the ice metering. If limit switch  61  and/or limit switch  62  is not in a “home” position, error handling step(s)  96  are taken, as indicated. Error handling step(s)  96  may include actuating the trap/floor  33  and/or movable plunger  32  to reset limit switch  61  and/or limit switch  62 . If no error handling step  96  is indicated or if error handling step  96  is successfully performed, movable plunger  32  is directed to move out from “home” position a specific distance in step  97  by controller  91 . At the same time, paddlewheel  80  is also rotated in step  98  in the direction of arrow “D” to feed ice into ice metering mechanism  20 . Once the correct moveable plunger  32  position is reached and recognized in step  97 , controller  91  verifies that paddlewheel  80  is in a suitable position in step  100  to be stopped by sensing the location of ice blockers  83 . If ice blocker(s)  83  is in the correct position, controller  91  moves movable plunger  32  out an additional number of steps (e.g.,  500  steps) in step  99  and opens trap/floor  33 , step  101 , to release ice into ice chute  22 . Immediately after releasing the ice, controller  91  de-energizes actuator (e.g., disengages solenoid  55 ) for trap door, step  102 , and reverses the movement, step  103 , of movable plunger  32  until limit switch  62  closes indicating that moveable plunger  32  is at the “zero” position. When controller  91  de-energizes, e.g., solenoid  55 , and trap door  33  is closed which also engages and energizes limit switch  61 . The control program of controller  91  executes the method of  FIG. 9 . 
         [0031]    In operation, paddlewheel  80  is generally substantially and/or completely covered with ice  11  inside ice reservoir  10 . Paddlewheel  80 , in the embodiment shown in  FIG. 8 , rotates clockwise in direction of arrow “D” from the perspective shown in  FIG. 8 . The rotation of paddlewheel  80  serves several purposes. First, the rotation of paddlewheel  80  serves to rotate agitators  84  also, and the rotation of agitators  84  has the effect of breaking up and/or maintaining in loose configuration ice  11  that is stored in ice reservoir  10 . At the same time, vanes  82  have hollow surfaces opposite the surface of vanes seen in  FIG. 8 , i.e., the side disposed facing ice portal opening  88 . These hollow surfaces capture ice  11  disposed in ice reservoir  10  and transport ice  11  to ice portal opening  88  for disposal through chute  18  and into ice metering mechanism  20 . Likewise, ice  11  from ice reservoir  10  flows into spaces  89  between vanes  82  and ice  11  trapped in spaces  89  also becomes disposed through ice portal opening  88 , into chute  18  and, subsequently, into ice metering mechanism  20 . When the space in the interior of meter chamber housing  31  defined by the walls of meter chamber housing  31 , outside surface of ice reservoir  15 , trap floor/wall  33  and surface  49  of moveable plunger  32  is filled with ice  11 , controller  91  stops rotation of paddlewheel  80 . However, controller  91  continues rotation of paddlewheel  80  for a time sufficient to move the nearest counter-clockwise disposed ice blocker  83  into position in front of ice portal opening  88 . In practice, rotation of paddlewheel  80  may be effected in either a clockwise or counter-clockwise direction through the use of a universal motor, in which case rotation of paddlewheel  80  may either clockwise or counter-clockwise direction to place the nearest ice blocker  83  (whether disposed in a counter-clockwise of clockwise direction away from ice portal opening  88 ) in position to block ice portal opening  88 . Magnetic sensors (not shown) embedded into ice blockers  83  signal to controller  91  when ice blocker  83  is positioned in front of ice portal opening  88 . Covering ice portal opening  88  with ice blocker  83  prevents errant flow of ice  11  into metering mechanism  20  via ice portal opening  88  and chute  18  during dispensing of ice  11  from the metering mechanism  20  through ice chute  22  via opening of trap floor/wall  33 . 
         [0032]    In the above detailed description, this disclosure has been described in connection with its preferred embodiments. However, to the extent that the above description is specific to a particular embodiment of or a particular use in this disclosure, this is intended to be illustrative only and merely provides a concise description of exemplary embodiments of the disclosure. Accordingly, the disclosure is not limited to the specific embodiments described above, but rather the disclosure includes all alternatives, modifications, and equivalents falling within the scope of the appended claims. Various modifications and variations of this disclosure will be apparent to a worker skilled in the art and it is to be understood that such modifications and variations are to be included within the purview of this application and the spirit and scope of the claims. 
         [0033]    All of the patents referred to herein are incorporated herein as if set forth herein in their entirety.