Abstract:
A system for an ice merchandiser having a compressor in a compressor enclosure to cool the ice merchandiser includes a proximity sensor positioned to detect an amount of ice within the ice merchandiser, and a communications component coupled to the proximity sensor to receive signals from the proximity sensor representative of the amount of ice in the ice merchandiser, wherein the communications component is configured to convert the received signals to a digital format and publish the signals via a network connection.

Description:
RELATED APPLICATION 
       [0001]    This application claims priority to U.S. Provisional Application Ser. No. 61/807,131 (entitled PROXIMITY DETECTION IN NETWORKED FREEZER STOCKING MANAGEMENT, filed Apr. 1, 2013) which is incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    Managing ice merchandisers to keep them stocked with bags of ice has been performed by drivers of ice trucks, who visit sites and check the ice merchandisers visually to determine whether more bags of ice should be added. This process leads to wasted effort when the ice merchandisers do not need more ice. It also may lead to delay in refilling ice merchandisers and result in lost sales if not refilled quickly enough. 
         [0003]    One proposal to begin to address such problems has been to add weight sensors under the ice merchandiser to weigh the entire ice merchandiser. This retrofit solution is not able to offer level information on more than one product inside the merchandiser. Additionally, the retrofit solution components are all located on the exterior of the ice merchandiser, and may be negatively affected by adverse weather conditions or subject to tampering or vandalism. 
       SUMMARY 
       [0004]    A system for an ice merchandiser compartment having a compressor in a compressor enclosure to cool the ice merchandiser compartment includes a proximity sensor positioned to detect an amount of ice within the ice merchandiser compartment, and a communications component coupled to the proximity sensor to receive signals from the proximity sensor representative of the amount of ice in the ice merchandiser compartment, wherein the communications component is configured to convert the received signals to a digital format and publish the signals via a network connection. The proximity sensor can include one or more of a capacitive sensor, Doppler sensor, inductive sensor, infrared sensor, laser rangefinder, magnetic sensor, optical sensor, reflective photocell sensor, radar, sonar, and combinations thereof. 
         [0005]    In one embodiment, the proximity sensor includes a heating element proximate the proximity sensor. The proximity sensor provides an output to a system outside a cooled volume of the ice merchandiser compartment. The system takes the output and provides a signal on a network representative of the level of ice inside the ice merchandiser compartment. 
         [0006]    In some embodiments, multiple proximity sensors may be used in the chest to measure the level of different sized bags of ice. 
         [0007]    In further embodiments, temperature sensors and contact switches may be coupled to the system to provide signals representative of temperature inside and outside of the chest, and to indicate whether a chest door is open. 
         [0008]    The system may provide signal processing to provide signals representative of the sensed parameters to the network. In one embodiment, the system includes a device having an IP address to facilitate exposing the sensed information via a website like interface. A wireless modem may be included. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIGS. 1A-1B  are block diagrams of systems to detect stocking of ice in an ice merchandiser, according to example embodiments. 
           [0010]      FIG. 2  is a top view block diagram of components in a compressor enclosure for the ice merchandiser of  FIGS. 1A-1B , according to an example embodiment. 
           [0011]      FIGS. 3A-3B  are side block diagrams illustrating further details of sensor enclosures within the ice merchandiser compartment of  FIGS. 1A-1B , according to example embodiments. 
           [0012]      FIG. 4  is a block schematic diagram of an example heater, according to an example embodiment. 
           [0013]      FIG. 5  is a block flow diagram illustrating sensed parameters and components involved in data flow, according to an example embodiment. 
           [0014]      FIG. 6  is an example interface to interact with the system of  FIGS. 1A-1B , according to an example embodiment. 
           [0015]      FIG. 7  is a block diagram a system for performing functions and communications, according to an example embodiment. 
       
    
    
     DETAILED DESCRIPTION 
       [0016]    In the following description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific embodiments that may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural, logical, and electrical changes may be made without departing from the scope of the present invention. The following description of example embodiments is, therefore, not to be taken in a limited sense, and the scope of the present invention is defined by the appended claims. 
         [0017]    The functions or algorithms described herein may be implemented in software or a combination of software and human implemented procedures in one embodiment. The software may consist of computer executable instructions stored on computer readable media such as memory or other type of storage devices. Further, such functions correspond to modules, which are software stored on a storage device, hardware, firmware, or any combination thereof. Multiple functions may be performed in one or more modules as desired, and the embodiments described are merely examples. The software may be executed on a digital signal processor, ASIC, microprocessor, or other type of processor operating on a computer system, such as a personal computer, server or other computer system. 
         [0018]      FIGS. 1A-1B  are block diagrams of systems  100 A and  100 B to detect stocking of ice in an ice merchandiser  110 , according to example embodiments. The ice merchandiser may include one or more ice merchandiser compartments  112 . One or more different types of sensor enclosures may be placed inside an ice merchandiser compartment  112  in various embodiments.  FIG. 1A  depicts a system  100 A that includes a single sensor enclosure  115 A.  FIG. 1B  depicts a system  100 B that includes two sensor enclosures  115 B. The ice merchandiser may include one or more sensor electronics modules  142 , which may control or provide power to the sensor enclosures  115 A or  115 B. In one embodiment, two proximity sensors may be housed in one or two sensor enclosures  115 A or  115 B. The proximity sensors may be arranged to obtain proximity measurements of items, such as bags of ice placed on the floor of the ice merchandiser. For example,  FIG. 1A  may include a single sensor enclosure  115 A that includes two proximity sensors, and  FIG. 1B  may include two sensor enclosures  115 B that each include a proximity sensor. In one embodiment, one side of the ice merchandiser compartment is used to hold bags  124  of one size or weight, and the other side is used to hold bags  126  of a different size or weight. While each proximity sensor is shown located within sensor enclosure  115 A or  115 B, each proximity sensor may be positioned within a wall of the compartment  112  or outside the compartment  112 , with a hole in the compartment permitting sensing of the amount of ice in the compartment  112  in further embodiments. 
         [0019]    In one embodiment, a proximity sensor has a field of proximity detection  128  that is wide enough to enable a proximity sensor to detect items located anywhere on one side of the ice merchandiser compartment. For example, the field of proximity detection can be thirty-five degrees, though other angles may be used. One or more further sensors may be included in a sensor compartment disposed within the ice merchandiser compartment  112 . For example, a temperature sensor may be coupled to the system to provide signals representative of the temperature within the ice merchandiser. In another example, a contact switch sensor may be coupled to the system to provide signals to indicate whether a chest door is open. Sensor compartment  130  may also include multiple sensors to sense further parameters, such as humidity. 
         [0020]    In some embodiments, multiple proximity sensors may be used in the chest to measure the proximity of different sized bags of ice placed within the ice merchandiser compartment  112 . For example, in an ice merchandiser with two doors, one door may be used for bags of one weight having a first proximity sensor, and the other door may be used for bags of a different weight having a second proximity sensor. Thus, two proximity measurements are provided to the system for publishing via the network connection. In some embodiments, the system may provide alerts regarding a need for restocking one side or the other of the ice merchandiser when the ice level falls below a predetermined threshold. In various embodiments, the alerts may be provided via text messages, email, voicemail, or other mechanisms including various social media. Information regarding the ice merchandiser may be accessible from at least mobile devices, computer systems, and other devices capable of providing information. 
         [0021]      FIG. 2  is a top view block diagram  200  of components in the compressor enclosure  140  for the ice merchandiser of  FIGS. 1A-1B , according to an example embodiment. The compressor enclosure  140  may include a compressor electrical enclosure  210 , where the compressor electrical enclosure  210  may contain circuitry for controlling the compressor and fan, as in standard compressor designs. The compressor electrical enclosure  210  may include a signal conditioner that takes voltage signals entering the system on the lower part of the picture and converts them to a zero to five-volt range. In some embodiments, sensors may be provided within the compressor electrical enclosure  140  to sense internal temperature, external temperature, and compressor power draw. Still further sensors may be included in further embodiments. The compressor electrical enclosure  210  may include condenser tubing, and wires from the sensors may follow the path of the condenser tubing. 
         [0022]    A communications enclosure  215  may be included, which may contain circuitry for controlling sensors that have been added to the ice merchandiser  110  in various embodiments. The communications enclosure  215  may receive compatible voltage signals from the signal conditioner in the electrical controller  210 . The circuitry may include an IP address and modem, which may provide data to a network such as the internet. The data may be representative of the sensed parameters, which may indicate the amount of ice within the ice merchandiser compartment  112 . For example, sensed parameters may include proximity measurements, temperature, humidity, or other parameters. While the communications enclosure  215  is shown located within the compressor electrical enclosure  140 , the communications enclosure  215  may be positioned in any other location that allows it to receive sensed parameters. 
         [0023]    A communications enclosure  215  may include a web-enabled sensor appliance  144 . The web-enabled sensor appliance  144  may include an internet communication device, analog/digital inputs, or relay outputs. The web-enabled sensor appliance  144  may include a microcontroller, such as an Arduino microcontroller. The web-enabled sensor appliance  144  may operate with a power source, such as a nine-volt DC transformer. The internet communication device may send data to a webserver on the internet, and a web browser may be used to view the data collected by the webserver. The web-enabled sensor appliance  144  may include an antenna extending out of the container to facilitate communication. 
         [0024]      FIGS. 3A-3B  are side block diagrams  300 A and  300 B illustrating further details of sensor enclosures  115 A or  115 B within the ice merchandiser compartment  112  of  FIGS. 1A-1B , according to example embodiments. A circuit board  310  can have one or more proximity sensors  315  mounted on it, along with one or more light emitting diodes (LEDs)  320  near the proximity sensors. In an embodiment, two proximity sensors may be housed in one or two enclosures. For example,  FIG. 3A  depicts a sensor enclosure  115 A that includes two proximity sensors  315 , and  FIG. 3B  depicts a sensor enclosure  115 B that includes a single proximity sensor  315 . In one embodiment, the proximity sensors  315  and LED  320  may be enclosed in a transparent proximity sensor enclosure  325 . The proximity sensor enclosure  325  may be made of polycarbonate materials in one embodiment, and the volume enclosed may be heated sufficiently by the LED  320  to remove or prevent moisture from condensing or freezing on the proximity sensors  315 , enabling increased accuracy of the proximity measurements of the items stocked in the ice merchandiser  110 . In further embodiments, the LED  320  may be positioned very close to the proximity sensors  315 , and the LED  320  may heat the proximity sensors  315  sufficiently to obviate the need for the enclosure  325 . The proximity of the LED  320  to the proximity sensors  315  may thus vary in different embodiments, but should be within a distance to allow it to perform the function of enabling increased accuracy of the proximity measurements. In still further embodiments, a heater substrate  400  can be attached to the inside or outside of the enclosure  325 , which can heat the enclosure to remove or prevent moisture from condensing or freezing on the proximity sensors  315 . 
         [0025]    The circuit board  310  may further include control circuitry  330  that may control the proximity sensors  315  and LED  320 , and may communicate with the circuitry in the electrical enclosure  210  in various embodiments. The processing of data may be split between such circuitry in various embodiments, or only one set of circuitry may perform all the functions. In still further embodiments, one or more sensors, such as temperatures sensor  335  may be included on the circuitry board  310 . 
         [0026]      FIG. 4  is a block schematic diagram of an example heater  400 , according to an example embodiment. The example heater  400  may be used to provide a clear field of proximity detection for the proximity sensor. The example heater  400  may include a substrate  340  having fine resistive heating wires  410  to provide heat when powered via circuitry. The substrate  340  may be adhesive, with the wires on or embedded, similar to add-on rear windshield heaters for automobiles. The example heater  400  can be positioned proximate the proximity sensor, in the field of proximity detection of the proximity sensor, such as on or embedded within the transparent proximity sensor enclosure  325 . The heater may be positioned outside the field of proximity detection on the proximity sensor enclosure  325  if it provides sufficient heat to create a clear field of proximity detection when proximity measurements are obtained. 
         [0027]      FIG. 5  is a block flow diagram  500  illustrating sensed parameters and components involved in data flow, according to an example embodiment. Internal conditions  510  represent conditions inside of the ice merchandiser  110  in one embodiment. Internal conditions may include measurements from two proximity sensors  512  and  514 , and an internal temperature sensor  518 . External conditions  520  may include compressor enclosure or hood temperature  522 , compressor power draw  524 , a maintenance log  526 , and power loss indications  528 . 
         [0028]    The connection module  215  may receive the information corresponding to these conditions at  530 . The connection module  215  may be a 3G, 4G, WIFI, or other type of wireless communications module in various embodiments that is coupled to the internet represented at  532 . The information may be provided to server  534 , and then via network  536 , such as the internet, to a provider of the items at  538 . The provider  538  may be an ice company in one embodiment responsible for restocking the ice merchandiser. One or more user interfaces may be provided on a personal computer, smart phone, tablet, or other device enabling a person responsible for restocking to determine whether an ice merchandiser needs restocking, and with what types of items. The information may distinguish between different sized bags of ice, such as 10 lbs or 20 lbs. 
         [0029]      FIG. 6  is an example interface  600  to interact with the system of  FIGS. 1A-1B , according to an example embodiment. In one embodiment, the server  534  processes the information and creates a user interface allowing viewing of the information in various forms. Multiple different parameters may be published and viewable via interface  600 . A web-enabled interface, or any number of other media, such as social media, including email and other forms of electronic communication may be used. Still further, the system may provide visible and audible alerts proximate the ice merchandiser. 
         [0030]    In example interface  600 , proximity measurements are shown at  610 ,  612 , and  614 . The newest proximity measurement is indicated at  614 , with prior proximity measurements available to the left side of the display. In one embodiment, clicking on the latest proximity measurement may initiate communications back to the system  100 A or  100 B to provide a real time proximity measurement. In another embodiment, the proximity measurement may be represented by a diagram (e.g., bar graph, pie chart, etc.) or a series of diagrams indicating how much ice is left in the ice merchandiser. 
         [0031]    A graph  620  illustrates desired parameters over time. In some embodiments, the period may be selected by the user. Illustrated on graph  620  are internal ice merchandiser temperature  622  and ambient temperature  624 , which varies significantly over the few days that are shown. As desired, the internal temperature  622  may be constant. Note that a winter environment is occurring in this representation as the ambient temperature dips below the internal temperature. While temperature is shown on the graph, other parameters may be shown in further embodiments. In addition, a link to multiple settings  630  may be provided to enable the user to change timing of when data is periodically provided, or change any other control points used to control the system  100 A or  100 B, including the compressor and fan in some embodiments. 
         [0032]    Some example control points and corresponding notes are shown in the following TABLE 1: 
         [0000]    
       
         
               
               
               
             
           
               
                   
                 TABLE 1 
               
               
                   
                   
               
             
             
               
                   
                 Product 
                 Product Level Measured 
               
               
                   
                 Level 
                 Within ± 5% 
               
               
                   
                   
                 Product Level Differentiation 
               
               
                   
                   
                 by Merchandiser Side 
               
               
                   
                 Compressor Status 
                 Defrost Monitoring and 
               
               
                   
                   
                 Control 
               
               
                   
                   
                 Electric Current Draw 
               
               
                   
                   
                 Monitoring 
               
               
                   
                   
                 Power Outage Monitoring 
               
               
                   
                   
                 Compressor Hood 
               
               
                   
                   
                 Temperature Change 
               
               
                   
                   
                 Monitoring 
               
               
                   
                   
                 Maintenance Tracking and 
               
               
                   
                   
                 Alerts 
               
               
                   
                 Interior Case Temperature 
                 Temperature Change 
               
               
                   
                   
                 Monitoring 
               
               
                   
                 Merchandiser Door Status  
                 Open Door Alarm Set Points 
               
               
                   
                   
               
             
          
         
       
     
         [0033]      FIG. 7  is a block diagram a system for performing functions and communications, according to an example embodiment.  FIG. 7  is a block diagram of a computer system or circuitry that may be used to process and publish sensed data and information according to an example embodiment. In the embodiment shown in  FIG. 7 , a hardware and operating environment is provided that is applicable to any of the circuitry, servers and/or remote clients shown in the other Figures. It should be noted that many devices to provide the functions described herein may be formed with far fewer components than described below. Components may be included or excluded as desired and appropriate for the functions to be provided. 
         [0034]    As shown in  FIG. 7 , one embodiment of the hardware and operating environment includes a general purpose computing device in the form of a computer  700  (e.g., a personal computer, workstation, or server), including one or more processing units  721 , a system memory  722 , and a system bus  723  that operatively couples various system components including the system memory  722  to the processing unit  721 . There may be only one or there may be more than one processing unit  721 , such that the processor of computer  700  comprises a single central-processing unit (CPU), or a plurality of processing units, commonly referred to as a multiprocessor or parallel-processor environment. In various embodiments, computer  700  is a conventional computer, a distributed computer, or any other type of computer. 
         [0035]    The system bus  723  can be any of several types of bus structures including a memory bus or memory controller, a peripheral bus, and a local bus using any of a variety of bus architectures. The system memory can also be referred to as simply the memory, and, in some embodiments, includes read-only memory (ROM)  724  and random-access memory (RAM)  725 . A basic input/output system (BIOS) program  726 , containing the basic routines that help to transfer information between elements within the computer  700 , such as during start-up, may be stored in ROM  724 . The computer  700  further includes a hard disk drive  727  for reading from and writing to a hard disk, not shown, a magnetic disk drive  728  for reading from or writing to a removable magnetic disk  729 , and an optical disk drive  730  for reading from or writing to a removable optical disk  731  such as a CD ROM or other optical media. 
         [0036]    The hard disk drive  727 , magnetic disk drive  728 , and optical disk drive  730  couple with a hard disk drive interface  732 , a magnetic disk drive interface  733 , and an optical disk drive interface  734 , respectively. The drives and their associated computer-readable media provide non-volatile storage of computer-readable instructions, data structures, program modules, and other data for the computer  700 . It should be appreciated by those skilled in the art that any type of computer-readable media which can store data that is accessible by a computer, such as magnetic cassettes, flash memory cards, digital video disks, Bernoulli cartridges, random access memories (RAMs), read only memories (ROMs), redundant arrays of independent disks (e.g., RAID storage devices) and the like, can be used in the exemplary operating environment. 
         [0037]    A plurality of program modules can be stored on the hard disk, magnetic disk  729 , optical disk  731 , ROM  724 , or RAM  725 , including an operating system  735 , one or more application programs  736 , other program modules  737 , and program data  738 . Programming for implementing one or more processes or method described herein may be resident on any one or number of these computer-readable media. 
         [0038]    A user may enter commands and information into computer  700  through input devices such as a keyboard  740  and pointing device  742 . Other input devices (not shown) can include a microphone, joystick, game pad, touch screen, mobile phone, mobile pad, satellite dish, scanner, or the like. These other input devices are often connected to the processing unit  721  through a serial port interface  746  that is coupled to the system bus  723 , but can be connected by other interfaces, such as a parallel port, game port, wireless, or a universal serial bus (USB). A monitor  747  or other type of display device, including a touch screen, can also be connected to the system bus  723  via an interface, such as a video adapter  748 . The monitor  747  can display a graphical user interface for the user. In addition to the monitor  747 , computers typically include other peripheral output devices (not shown), such as speakers and printers. 
         [0039]    The computer  700  may operate in a networked environment using logical connections to one or more remote computers or servers, such as remote computer  749 . These logical connections are achieved by a communication device coupled to or a part of the computer  700 ; the invention is not limited to a particular type of communications device. The remote computer  749  can be another computer, a server, a router, a network PC, a client, a peer device or other common network node, and typically includes many or all of the elements described above I/O relative to the computer  700 , although only a memory storage device  750  has been illustrated. The logical connections depicted in  FIG. 7  include a local area network (LAN)  751  and/or a wide area network (WAN)  752 . Such networking environments are commonplace in office networks, enterprise-wide computer networks, intranets and the internet, which are all types of networks. 
         [0040]    When used in a LAN-networking environment, the computer  700  is connected to the LAN  751  through a network interface or adapter  753 , which is one type of communications device. In some embodiments, when used in a WAN-networking environment, the computer  700  typically includes a modem  754  (another type of communications device) or any other type of communications device, e.g., a wireless transceiver, for establishing communications over the wide-area network  752 , such as the internet. The modem  754 , which may be internal or external, is connected to the system bus  723  via the serial port interface  746 . In a networked environment, program modules depicted relative to the computer  700  can be stored in the remote memory storage device  750  of remote computer, or server  749 . It is appreciated that the network connections shown are exemplary and other means of, and communications devices for, establishing a communications link between the computers may be used including hybrid fiber-coax connections, T1-T3 lines, DSL&#39;s, OC-3 and/or OC-12, TCP/IP, microwave, wireless application protocol, and any other electronic media through any suitable switches, routers, outlets and power lines, as the same are known and understood by one of ordinary skill in the art.