Patent Description:
The present invention relates to the field of metered food dispensers that dispense a metered quantity of food product from a hopper. More particularly, the invention relates to a dispenser for frozen food, which can be, for example, French fries, that are dispensed from a bulk storage hopper in metered batch sizes to a fry basket.

Applicant has developed and markets metered food dispensers, particularly for frozen foods such as French fries or chicken nuggets, that dispense bulk food product from a storage hopper into a receptacle, such as a fry basket. A product dispenser of the applicant is described for example in <CIT>. The frozen food is dispensed in specific metered quantities as the amount of the frozen food that is dispensed at one time can affect quality of the finished (cooked) food product, for example, based on the temperature change imparted by the food product to the cooking oil as well as the necessary fry time in the cooking oil. Currently, the frozen food product is removed from a bottom of the storage hopper via a rotating drum having paddles or fins on a periphery thereof by rotating the drum so that the food product that is released/displaced by the paddles fall onto a weighing/dispensing assembly, and when the appropriate weight of food product is detected by the weighing/dispensing assembly, the rotation of the drum stops, and the accumulated food product that was dispensed is delivered to the receptacle, for example, the fry basket.

In the known equipment, the weighing/dispensing assembly includes or is connected to one or more dump doors on which the dispensed food product accumulates. A first motor operates these dump doors to open when the appropriate amount of food product is accumulated in order to dispense a metered amount or batch of food product. Additionally, the dump doors are supported via a support assembly that is movable into and out of contact with a load cell that forms part of the weighing/dispensing assembly in order to determine the weight of the product that has been dispensed onto the dump doors. Here, a second motor is used to move the support assembly relative to the load cell so that the weight of the support assembly and the dump doors is not constantly on the load cell when the dispenser is not in active use. <CIT>shows weighing and dispensing mechanism of the applicant with a food container, a motor to open and close a discharge port of the food container, and a moving part that moves the food container in contact with a load cell. <CIT> shows another weighing and dispensing mechanism of the applicant. A drive motor opens and closes a pair of weighing doors, which are connected to a movable block that exerts downward pressure onto a load cell. A food dispensing apparatus with a refrigerated cabinet, a hopper, an accumulator assembly, a weighing system, and a flap door is also known from <CIT>.

Although the known arrangement has been very successful in operation, it would be desirable to maintain or improve the function and reliability of the system while reducing cost.

The present disclosure is directed to a product dispenser, preferably for frozen food product, having a storage hopper, a rotatable drum having paddles on a periphery thereof located at a bottom of the storage hopper, and a drive motor connected to the rotatable drum. Rotation of the drum causes the paddles to engage with and move product from the open bottom of the hopper to a position in the drum housing where the product can then fall through the open bottom of the drum housing. A weighing/dispensing assembly is located beneath the rotatable drum and includes a load cell and further includes or is connected to one or more dump doors on which product to be dispensed is adapted to accumulate. The one or more dump doors are connected to a support assembly that is movable into and out of contact with the load cell. A single weighing/dispensing motor drives a gearbox that includes an actuator shaft such that upon rotation of the actuator shaft in a first direction, the support assembly is raised out of contact with the load cell and the one or more dump doors are opened such that accumulated product is dispensed. Upon rotation of the actuator shaft in a second, opposite direction, the one or more dump doors are closed, and upon further rotation, the support assembly moves into contact with the load cell. The dispenser is then in a position to receive a next batch of food product from the hopper.

A controller is provided and is configured to actuate the drive motor to rotate the rotatable drum at a start of a dispensing cycle, and to receive a signal from the load cell and determine a weight of the product accumulating on the dump doors. The controller is further configured to deactivate the drive motor upon a target weight being detected, and to activate the single weighing/dispensing motor to drive the actuator shaft in the first direction to raise the support assembly out of contact with the load cell and open the one or more dump doors such that accumulated product is dispensed. The controller is then configured to activate the single weighing/dispensing motor to rotate the actuator shaft in the second direction to close the one or more dump doors. The controller is further configured to activate the single weighing/dispensing motor to further rotate the actuator shaft in the second direction to move the support assembly back into contact with the load cell upon a new dispensing cycle being initiated.

In another aspect, the product dispenser includes an actuating arm connected to the actuator shaft, and the one or more dump doors are connected to one or more rotatable support shafts that are supported by the support assembly, and the actuating arm contacts a lever connected to at least one of the one or more rotatable support shafts to open the one or more dump doors as the single weighing/dispensing motor drives the actuator shaft in the first direction.

In a preferred arrangement, the one or more dump doors include first and second ones of the dump doors that are connected to respective first and second ones of the rotatable support shafts, and a linkage arm extends between the lever connected to the first rotatable shaft and a second lever connected to the second rotatable shaft, such that as the actuating arm contacts the lever connected to the first rotatable support shaft to open the first dump door, the linkage arm acts on the second lever to open the second dump door.

In one preferred aspect of the product dispenser, the support assembly is slidably mounted on guides affixed to a mounting plate, and the mounting plate includes elongated openings through which the one or more rotatable support shafts extend. The elongated openings allow enough space for upward and downward travel of the rotatable support shafts as the support assembly is moved up and down as part of the dispensing and weighing cycle in order to discharge a specific amount of food product.

In a preferred embodiment, a lifting cam is connected to the actuator shaft, and the lifting cam is configured to raise the support assembly as the single weighing/dispensing motor drives the actuator shaft in the first direction. This removes the combined weight of the support assembly, rotatable support shaft(s), dump door(s), and product that is accumulated on the dump door(s) from the load cell prior to opening the dump doors to discharge the product accumulated thereon.

Further, the lifting cam is configured to lower the support assembly as the single weighing/dispensing motor drives the actuator shaft in the second direction. This is done at the start of a next dispensing cycle so that the load cell is not under load when the product dispenser is not in use.

Preferably, the lifting cam is configured to come out of contact with the support assembly as the support assembly reaches a weighing position in contact with the load cell.

In another aspect, the product dispenser includes a position indicator connected to the actuator shaft and a sensor that detects a position of the position indicator and signals the controller. This is used so that the controller can detect a position of the actuator shaft before or during each dispensing cycle. The position sensor is a break-beam sensor, and the position indicator is a "flag" connected to the actuator shaft.

In a preferred application, the product dispenser is for dispensing frozen food product, such as French fires of chicken nuggets into a fry basket that is arranged below the dump doors. A refrigerated housing surrounds the hopper and the rotatable drum. Placement of the fry basket below the dispenser activates a dispensing cycle by the fry basket pressing a switch or otherwise being detected, which signals the controller to begin a dispensing cycle. The dispensing cycle can include:.

The various features noted above can be used alone or in various combination to provide for metered dispensing of food products in an accurate manner using a simplified weighing and dispensing arrangement.

Further advantages and characteristics of the invention will become apparent by the below description of embodiments making reference to the accompanying drawings, in which:.

Certain terminology is used in the following description for convenience only and is not limiting. The words "right," "left," "top," and "bottom" designate directions in the drawings to which reference is made. The words "a" and "one," as used in the claims and in the corresponding portions of the specification, are defined as including one or more of the referenced item unless specifically stated otherwise. This terminology includes the words above specifically mentioned, derivatives thereof, and words of similar import. The phrase "at least one" followed by a list of two or more items, such as "A, B, or C," means any individual one of A, B or C as well as any combination thereof. The terms approximately or generally mean within +/-<NUM>% of a specified value unless otherwise noted, and within +/- <NUM>° of a specified angle or direction.

Referring to <FIG>, a prior art product dispenser <NUM>, in particular a dispenser for frozen food such as french fries or chicken nuggets, is shown. The product dispenser <NUM> includes a housing <NUM> with a refrigeration unit <NUM> located on top of the housing <NUM> as well as an access door <NUM> to the refrigerated portion of the product dispenser <NUM>. Product receiving spaces <NUM> are located beneath the enclosed area and are configured to receive a receptacle, such as a fry basket <NUM>, into which a metered amount of product is to be dispensed.

Still with reference to <FIG>, hoppers 20a, 20b are located within the refrigerated area and are assembled on top of drum housings 22a, 22b. Frozen food product (indicated by arrow <NUM> in <FIG>) can be loaded into the hoppers 20a, 20b for metered dispensing. As shown in detail in <FIG>, rotatable drums 24a, 24b are located within the respective drum housings 22a, 22b. Flexible paddles or fins (these terms are used interchangeably herein) 26a, 26b are located on the rotatable drums 24a, 24b. Drive motors 28a, 28b, shown schematically, are individually activatable to rotate the respective associated rotatable drum 24a, 24b in order to move product from the open bottom end of the desired associated hopper 20a, 20b into the respective drum housings 22a, 22b so that the product can drop down on to the respective weighing/dispensing assembly 30a, 30b. These are indicated in <FIG> and <FIG>, and shown in detail in <FIG>. Boots <NUM> shown in <FIG> guide the food product <NUM> from the open bottom of the drum housings 22a, 22b to the weighing/dispensing assemblies 30a, 30b.

The weighing/dispensing assemblies 30a, 30b each include a mounting plate <NUM> that is connected to the housing <NUM>. A support assembly <NUM> is slidably connected to the mounting plate <NUM> for up and down movement. Rotatable shafts 34a, 34b are rotatably supported in the support assembly <NUM> and respective dump doors 32a, 32b are connected to the respective rotatable shafts 34a, 34b. A dump motor <NUM> is mounted on the support assembly <NUM> and includes a dump motor gear box <NUM> that is connected to an actuator arm <NUM> that, upon activation of the dump door motor <NUM>, is rotated into contact with a first dump door drive lever 40a, which can be connected via a linkage arm <NUM> to a second dump door drive lever 40b in order to activate and open the dump doors 32a, 32b. This is done when a specific product weight is accumulated on the dump doors 32a, 32b based on rotation of an associated one of the rotatable drums 24a, 24b moving product from the bottom of a respective one of the hoppers 28a, 28b so it falls through the respective drum housing 22a, 22b, on to the respective closed dump doors 32a, 32b.

In order to detect the weight of the product accumulated on the dump doors 32a, 32b, a load cell <NUM> is provided and is in contact with the support assembly <NUM> as the food product is accumulated on the dump doors 32a, 32b while the rotatable drum 24a or 24b is rotated by the respective drive motor 28a or 28b. Once the load cell detects <NUM> that the desired amount of food product is located on the dump doors 32a, 32b, rotation of the rotatable drum 24a or 24b is stopped and the dump door motor <NUM> is activated in order to open the dump doors 32a, 32b. In order to move the support assembly <NUM> out of contact with the load cell <NUM>, a support assembly lift motor <NUM> is provided and is connected to a support assembly lift gear box <NUM>. The support assembly lift motor <NUM> is activated in order to raise the support assembly <NUM> out of contact with the load cell <NUM> when the dispensing cycle is completed so that the load cell <NUM> is not loaded until a next dispensing cycle is initiated and the support assembly lift motor is activated to move the support assembly <NUM> into contact with the load cell <NUM>.

This weighing/dispensing assembly 30a, 30b is complex and includes the dump door motor <NUM> and the dump door gear box <NUM> as well as the support assembly lift motor <NUM> and the support assembly lift gear box <NUM>, all of which increase costs and complexity as well as require additional maintenance.

Referring to <FIG>, a product dispenser <NUM> in accordance with the present disclosure having the improved features discussed herein is described in detail. The product dispenser <NUM> is similar to the product dispenser <NUM> and the housing <NUM>, refrigeration unit <NUM> as well as the access door <NUM> and fry basket receiving spaces <NUM> are as described above. Additionally, the hoppers 20a, 20b as well as the drum housings 22a, 22b and rotatable drums 24a, 24b are provided as described above in connection with the product dispenser <NUM>. Drive motors 28a, 28b as described above for driving the rotatable drums 24a, 24b are also provided and are used to drive the respective rotatable drums 24a, 24b to engage with and move food product from the open bottom of a respective hopper 20a or 20b to a position in the drum housing 22a, 22b where the food product can then fall through the open bottom of the drum housing 22a, 22b. While the product dispenser is described with a two hopper arrangement as shown in <FIG>, it could also be a single hopper arrangement or include more than two hoppers.

In accordance with the present disclosure, the weighing/dispensing assembly <NUM> is provided instead of each of each of the prior weighing/dispensing assemblies 30a, 30b. The weighing/dispensing assembly <NUM> that is used for each respective hopper/rotating drum in the dispenser <NUM> is shown in detail in <FIG> and includes only a single weighing/dispensing motor <NUM>. Here, the weighing/dispensing assembly <NUM> preferably includes a mounting plate <NUM> on which a support assembly <NUM> is mounted for slidable up and down movement as described further below. The mounting plate <NUM> can be connected to or supported on the housing <NUM>. A weighing/dispensing assembly <NUM> further includes a load cell <NUM> and includes or is connected to one or more dump doors, in the present case two dump doors, 132a, 132b. Here, food product that is dispensed from the hopper via the rotatable drum is accumulated and weighed by the load cell <NUM>. The dump door(s) 132a, 132b are connected to the support assembly <NUM>, preferably by being mounted on respective rotatable shafts 134a, 134b that are rotatably supported in bearings <NUM> located in the support assembly <NUM>. <FIG> show the boot <NUM> that leads from the open bottom of the drum housings 24a, 24b to guide food product <NUM> being dispensed to the dump doors.

As shown in detail in <FIG> and <FIG>, the single weighing/dispensing motor <NUM> is connected to a weighing/dispensing gear box <NUM> from which an actuator shaft <NUM> extends. When the actuator shaft <NUM> is driven in a first direction A (shown in <FIG>), the support arrangement <NUM> is raised out of contact with the load cell <NUM> and the one or more dump doors 132a, 132b are opened such that the accumulated food product is dispensed. Upon rotation of the actuator shaft <NUM> in a second, opposite direction B (shown in <FIG>), the one or more dump doors 132a, 132b are closed. Upon further rotation, the support assembly <NUM> moves into contact with the load cell <NUM> so the next dispensing/weighing cycle can be carried out when a next batch of food product is dispensed from a respective one of the hoppers 20a, 20b.

As shown schematically in <FIG>, a controller <NUM> is provided and is configured to actuate a drive motor 28a or 28b at a start of a dispensing cycle and is further considered to receive a signal from the load cell <NUM> in order to determine a weight of the food product accumulating on the dump doors 132a, 132b. The controller <NUM> is further configured to de-activate the drive motor 28a or 28b upon a target weight being detected and to activate the single weighing/dispensing motor <NUM> to drive the actuator shaft <NUM> via the gearbox <NUM> in the first direction to raise the support arrangement <NUM> out of contact with the load cell <NUM>. Preferably, a lifting cam <NUM>, shown in detail in <FIG> and <FIG> is connected to the actuator shaft <NUM> and the lifting cam <NUM> is configured to raise the support assembly <NUM> as the single weighing/dispensing motor <NUM> drives the actuator shaft <NUM> in the first direction. This removes the combined weight of the support assembly <NUM>, the rotatable support shafts 134a, 134b, the dump doors 132a, 132b, and the food product <NUM> that is accumulated on the dump doors 132a, 132b from the load cell <NUM> prior to the dump doors 132a, 132b opening to discharge the product accumulated thereon. In <FIG>, the lifting cam <NUM> is shown in the position lifting the support assembly <NUM> out of contact with the load cell <NUM>. In <FIG>, the lifting cam <NUM> is shown in the disengaged position such that the support assembly <NUM> is in contact with the load cell <NUM> so that the weight of the product being dispensed can be determined.

The controller <NUM> is further configured to activate the single weighing/dispensing motor <NUM> to rotate the actuator shaft <NUM> in the second direction to close the one or more dump doors 132a, 132b once the product has been dispensed for example into the fry basket <NUM> or other receptacle, for example as shown in <FIG>. The controller <NUM> is further configured to activate the single weighing/dispensing motor <NUM> to rotate the actuator shaft <NUM> in the second direction to move the support assembly <NUM> back into contact with the load cell <NUM> upon a new dispensing cycle being initiated.

As shown in detail in <FIG> and <FIG>, the weighing/dispensing assembly <NUM> further includes an actuating arm <NUM> connected to the actuator shaft <NUM>, and the one or more dump doors 132a, 132b are connected to the respective rotatable shafts 134a, 134b that are supported by the support assembly <NUM>. The actuating arm <NUM> contacts a dump door lever 140a connected to one of the rotatable shafts 134a or 134b in order to open the dump door(s) 132a, 132b as the single weighing/dispensing motor <NUM> drives the actuator shaft <NUM> in the first direction. In a preferred embodiment, a roller <NUM> is provided at an end of the actuating arm <NUM> and contacts a surface of the dump door drive lever 140a.

In the case of two dump doors 132a, 132b, a second dump door drive lever 140b is connected to the second rotatable shaft 134b for the second dump door 132b. A linkage arm <NUM> extends between the dump door drive levers 140a, 140b such that upon the first dump door lever 140a being acted upon by the actuating arm <NUM>, the linkage arm <NUM> also transfers the movement to the second dump door drive lever 140b such that the first and second dump doors 132a, 132b are opened at the same time. A return spring <NUM> assists in closing the dump doors 132a, 132b.

While the preferred embodiment of the weighing/dispensing assembly <NUM> includes two dump doors 132a, 132b, it is possible that only a single dump door 132a could be utilized, which would eliminate the need for the linkage arm <NUM> that extends to the second dump door drive lever 140b.

Still with reference to <FIG> and <FIG>, the support assembly <NUM> is preferably slidably mounted on guides on <NUM> so that it is constrained to move only up and down. The support assembly <NUM> can be lifted up by the lifting cam <NUM> so that it is out of contact with the load cell <NUM> or, if the lifting cam <NUM> is disengaged from the support assembly <NUM>, the weight of the product being dispensed upon the dump doors 132a, 132b (along with the weight of the support assembly <NUM> and connected components) causes the support assembly <NUM> to move downwardly against the load cell <NUM>. In a preferred embodiment, a weight transfer pin <NUM> is located between the load cell <NUM> and the support assembly <NUM>.

As shown in <FIG>, elongated openings <NUM> are provided in the support plate <NUM> through which the one or more rotatable support shafts 134a, 134b extend. These elongated openings <NUM> allow enough space for upward and downward travel for rotatable support shafts 134a, 134b as the support assembly <NUM> is moved up and down as part of the dispensing and weighing cycle.

The lifting cam <NUM> is shown in the upper, raised position of the support assembly <NUM> in <FIG>, and upon the single weighing/dispensing motor <NUM> driving the actuator shaft <NUM> in the second direction, the lifting cam <NUM> rotates to the position shown in <FIG> so that the support assembly <NUM> is in contact with the load cell <NUM>. This is only done at the start of a dispensing cycle so that the load cell <NUM> is not under load when the product dispenser <NUM> is not in use. As shown in <FIG>, the lifting cam <NUM> comes out of contact with the support assembly <NUM> as it reaches a weighing position in contact, via the weight transfer pin <NUM>, with the load cell <NUM>.

Referring again to <FIG> and <FIG>, a position indicator <NUM> is preferably connected to the actuator shaft <NUM> and a sensor, such as a break-beam sensor <NUM>, detects a position of the position indicator <NUM> and signals the controller <NUM>. In a preferred embodiment, the position indicator <NUM> is a flag <NUM> that includes two sections which interrupt the break-beam sensor, depending upon a position of the actuator shaft <NUM>. In <FIG>, the position indicator is shown in a ready position. Here, the support assembly <NUM> is out of contact with the load cell <NUM> prior to a dispensing operation being initiated. Once the dispensing operation is initiated, the actuator shaft <NUM> rotates in the second direction so that the lifting cam <NUM> is moved into the position shown in <FIG> and the support assembly <NUM> is in contact with the load cell <NUM>, for example via the weight transfer pin <NUM>, so that food product that is dispensed can be weighed. A second portion of the flag <NUM> detects when the actuator shaft <NUM> rotates in the first direction to a position in which the lifting cam <NUM> has moved the support assembly <NUM> out of contact with the load cell <NUM> and the dump doors 132a, 132b have been opened via the actuating arm <NUM> contacting the dump door drive lever 140a.

The product dispenser <NUM> is preferably used for dispensing frozen food product, such as French fries or chicken nuggets into a receptacle, such as a fry basket <NUM>, that is arranged below the dump doors. A sensor, such as a contact switch, proximity sensor, or break beam sensor, is positioned in each said receiving space <NUM> in order to detect when a fry basket <NUM> or other receptacle is placed into a or the respective receiving space so that the dispensing cycle can be initiated by the controller <NUM>.

In a preferred arrangement, two of the hoppers 20a, 20b, rotatable drums 24a, 24b, and weighing/dispensing assemblies <NUM> are provided in the dispenser <NUM>. However, the dispenser <NUM> could include only a single hopper 20a, rotatable drum 24a, and weighing assembly <NUM>, if desired. Additionally, more than two of the dispensing arrangements including the hoppers, rotating drums, and weighing/dispensing assemblies could also be provided.

Claim 1:
A product dispenser (<NUM>), comprising:
a storage hopper (20a, 20b);
a rotatable drum (24a, 24b) having paddles (26a, 26b) on a periphery thereof located at a bottom of the storage hopper (20a, 20b), and a drive motor (28a, 28b) connected to the rotatable drum (24a, 24b);
a weighing/dispensing assembly (<NUM>) located beneath the rotatable drum (24a, 24b), the weighing/dispensing assembly (<NUM>) includes a load cell (<NUM>) and further includes or is connected to one or more dump doors (132a, 132b) on which product to be dispensed is adapted to accumulate, the one or more dump doors (132a, 132b) are connected to a support assembly (<NUM>) that is movable into and out of contact with the load cell (<NUM>), and;
a controller (<NUM>) configured to actuate the drive motor (28a, 28b) to rotate the rotatable drum (24a, 24b) at a start of a dispensing cycle, to receive a signal from the load cell (<NUM>) and determine a weight of the product accumulating on the dump doors (132a, 132b) and deactivate the drive motor upon a target weight being detected;
characterized by
a single weighing/dispensing motor (<NUM>) that drives a gearbox (<NUM>) that includes an actuator shaft (<NUM>) that upon rotation in a first direction, raises the support assembly (<NUM>) out of contact with the load cell (<NUM>) and opens the one or more dump doors (132a, 132b) such that accumulated product is dispensed, and upon rotation in a second direction, closes the one or more dump doors (132a, 132b) and upon further rotation moves the support assembly (<NUM>) into contact with the load cell (<NUM>); wherein
the controller (<NUM>) is further configured to activate the single weighing/dispensing motor (<NUM>) to drive the actuator shaft (<NUM>) in the first direction to raise the support assembly (<NUM>) out of contact with the load cell (<NUM>) and open the one or more dump doors (132a, 132b) such that the accumulated product is dispensed, and to then rotate the actuator shaft (<NUM>) in the second direction to close the one or more dump doors (132a, 132b), and the controller (<NUM>) is further configured to rotate the actuator shaft (<NUM>) in the second direction to move the support assembly (<NUM>) back into contact with the load cell (<NUM>) at a start of a next dispensing cycle.