Patent ID: 12250955

The detailed description explains the preferred embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.

DETAILED DESCRIPTION OF THE INVENTION

Turning now to the drawings in greater detail, it will be seen that inFIG.1there are illustrated examples of frozen beverage equipment and soft-serve ice cream equipment. The frozen beverage equipment102and soft-serve ice cream equipment104are commonly found in restaurants, quick-serve restaurants, convenience stores, and numerous other locations.

In an exemplary embodiment, each frozen beverage equipment102and soft-serve ice cream equipment104can comprise one or more separate mixing cylinders524that contain a food product302. The mixing cylinders524receive a food portion306from a food portion supply562and a gas portion304that form the food product302. Selectively, in some exemplary embodiment, a water portion308can also be supplied. Each of the food portion306, gas portion304, and water portion308are ratiometrically injected into the mixing cylinder524so that the percentage proportion of each to the other is maintained. The food product306is chilled in the mixing cylinder524and dispensed through a dispense valve526. Such food product302dispensing can be automated and portion-controlled or effectuated by user402or customer404manually.

The term “ratiometrically” or “ratiometric”, in the present invention, is intended to mean two or more ingredients, portions, or other contents being mixed in a continuous predefined ratio regardless of the total volume being mixed forming a ratiometric mixture, such as of the food product302. Such portions can be the food portion306, the gas portion304, water, or other portions. Each ingredient, portion, or other content is mixed in a predefined ratio with respect to each of the other ingredients, portions, or other contents, as may be required and/or desired in a particular embodiment. In this regard, any volume of the final mixture comprising the ingredients, portions, or other contents can be produced. Such gas portions can be air, carbon dioxide, nitrogen, or other gas portion.

The frozen beverage equipment102and soft-serve ice cream equipment104can be configured with any number of mixing cylinders comprising the same or different kinds of food portions306, gas portions304, and thus food products302. Illustrated inFIG.1, as an example and not a limitation, frozen beverage equipment102is shown with two separate mixing cylinders524and dispense valves526. Soft-serve ice cream equipment104is shown with two separate mixing cylinders524and dispense valves526, and one additional dispense valve560that combines food products from both mixing cylinders526into a single dispense stream558. This configuration is common where one mixing cylinder comprises, as an example, chocolate ice cream, the other mixing cylinder comprises, as an example, vanilla ice cream, and the additional dispense valve560dispenses558a mixture of chocolate and vanilla ice cream.

In operation, the food product302is injected into mixing cylinder524as a food portion306, a gas portion304, and selectively a water portion308and then chilled to a predetermined frozen malleable consistency. A user402or customer404can then dispense the food product302by way of a dispense valve526. The gas portion304can be air, carbon dioxide, nitrogen, or other types and kinds of gases, as may be required and/or desired in a particular embodiment. In an exemplary embodiment, gases such as carbon dioxide, and other gasses can be injected into the mixing cylinder at a sufficient pressure to cause the gas to dissolve into the food portion306resulting in the food product302becoming carbonate in the case of dissolved carbon dioxide, or otherwise imbibed, or infused with the gas.

Referring toFIG.2, there is illustrated one example of temperature reference ‘A’, amperage or torque charts reference ‘B’, and a pressure chart reference ‘C’. An advantage, of the present invention, is that in an exemplary embodiment, automatic viscosity control of the food product302is achieved by enabling and disabling the refrigeration system568from chilling the food product306in the mixing cylinder524based on the electrical amperage current draw or the torque214of the auger motor576, or both the temperature204of the food product302and the electrical amperage current draw or the torque214of the auger motor576. In this regard, resultant from the refrigeration system568, as the temperature204of the food product302decreases the food product302begins to chill into a predetermined frozen malleable consistency. This transition to a predetermined frozen malleable consistency increases the viscosity of the food product302. The increased viscosity of the food product306in turn makes it more difficult for the motor502to rotate the auger522through the frozen malleable food product302increasing the amperage draw and the torque214of the auger motor576. In an exemplary embodiment, by controlling the refrigeration system568, ‘ON’ and ‘OFF’, based on at least the amperage draw or torque214of the auger motor576the viscosity of the food product306in the mixing cylinder524can be automatically maintained. For disclosure purposes, with reference toFIG.2reference ‘B’, the chart can represent either amperage draw214or the torque214and can be referred to as amperage draw or the torque214

In an exemplary embodiment, in operation, an automatic viscosity control system for food products302dispensed from frozen beverage equipment102and soft-serve ice cream equipment104can comprise a mixing cylinder524comprising at least one of an auger522, at least one of a product inlet566through which a food portion306is injected into the mixing cylinder524, and at least one gas inlet564through which a gas portion304is injected into the mixing cylinder524. A food product302comprises the food portion306, and the gas portion304. An auger motor576is interconnected with the auger522. The auger is positioned inside the mixing cylinder524and turns stirring the food product302.

A control system500comprises a microcontroller502, a memory504, and a motor sensor530(amperage draw) or528(torque). The motor sensor528/530is operationally related to the auger motor576. The motor sensor528/530measures an amperage draw528or a torque530of the auger motor576resultant from the resistance of rotating the auger522through the food product302. For disclosure purposes, the motor sensor can be one or both of the amperage meter530or torque monitor528referred to as motor sensor528/530.

A refrigeration system568comprises a compressor536. The refrigeration system568is configured to chill, to a predetermined frozen malleable consistency, the food product302inside the mixing cylinder524.

The memory504can be encoded with instructions that when executed by the microcontroller502transition between the steps of starting or speeding up the compressor536when the amperage draw or the torque214of the auger motor576is below a predetermined high motor performance setting218. And, slowing or stopping the compressor536when the amperage draw or the torque of the auger motor576is between234a predetermined low motor performance setting216, and the predetermined high motor performance setting218. In this regard,FIG.2, reference ‘B’, illustrates an amperage draw or the torque curve214electrical current amperages or torque in inch-pounds (or other units) versus time210.

In another exemplary embodiment, the control system500can comprise a temperature sensor542. The temperature sensor542is operationally related to the microcontroller502and the mixing cylinder524. The temperature sensor542measures the temperature of the food product302inside the mixing cylinder524. The memory504can be encoded with instructions that when executed by the microcontroller502perform the steps of starting or speeding up the compressor536when the temperature204of the food product302is above a predetermined high-temperature setting206. And, slowing or stopping the compressor536when temperature204of the food product302is between a predetermined low-temperature setting208and the predetermined high-temperature setting206range232, and the amperage draw or the torque of the auger motor576is between a predetermined low motor performance setting216and the predetermined high motor performance setting218range234.

In this regard,FIG.2, reference ‘A’, illustrates a food product302chilling temperature curve204plotted as temperature202versus time210. A predetermined food product302temperature range232is selected between232a predetermined low-temperature setting208and the predetermined high-temperature setting206. Such food product302predetermined low-temperature setting208and the predetermined high-temperature setting206can be selected in the range228of where the food product302freezes plus or minus a few degrees.

Food product302viscosity plays an important role in the quality of the frozen beverage or soft-serve ice cream. If the food product302viscosity is too low it can make the food product302inconsistent, soft, and/or runny, and if the food product302viscosity is too high can make the food product302thick, or even frozen to the point that it can't easily be dispensed from the dispense valve526.

In operation, several factors can influence food product302freezing and as such optimal food product302viscosity in a predetermined frozen malleable form. Such factors can include the amount of chill time at or near the food product302freezing point, the rotational speed of the auger522, ambient conditions such as humidity, external temperature, and other ambient conditions, and the composition of the food product302such as the type, kind, and/or amount of sugar content, and other factors can influence the progression of freezing and the viscosity of the food product302as it freezes.

An advantage, in the present invention, is that in addition to closely monitoring and controlling the temperature of the food product302, the viscosity of the food product is also closely monitored and controlled. In this regard,FIG.2, reference ‘B’, illustrates an auger motor576amperage draw or torque curve214plotted as electrical amperage or torque212versus time210.

In operation, as the food product302chills and begins to freeze the viscosity of the food product302increases as it thickens, transitioning the food product302into a predetermined frozen malleable form. As the food product302thickens as it is chilled the viscosity increases applying more force to the auger522which in turn causes the auger motor576to draw more electrical current amperage and the torque214on the auger motor576increases too. For motor control systems that can determine torque, torque determination or measurements can be used along with or instead of using electrical amperage draw determination or measurements. One example of a motor control system that determines torque can be a variable frequency drive (VFD) that can be used as the auger motor576. Other types and kinds of auger motors can also be used, as may be required and/or desired in a particular embodiment.

In another exemplary embodiment, torque can be measured mechanically by having a force of the food product302mixed in the mixing cylinder524applied to a lever that increasingly displaces as the food product302transitions to a predetermined frozen malleable consistency. The amount of displacement of the lever can be measured by the torque monitor528automatically electronically to determine a relative torque reading that can then be used in the methods of the present invention.

To achieve optimal food product302viscosity, a predetermined low motor performance setting216and a predetermined high motor performance setting218range234can be predetermined and set. The control system500can then disable the refrigeration system568when the amperage draw or torque214reaches the predetermined high motor performance setting218allowing the food product302to warm reducing the food product302viscosity. Similarly, if the amperage draw or torque214reaches the predetermined low motor performance setting216and the refrigeration system568is in the disabled state then the control system500can enable the refrigeration system568to chill the food product302which in turn increases the viscosity of the food product302.

An advantage, in the present invention, is that automate viscosity control of the food product302can be controlled by controlling the temperature around the food product302freezing point228between a predetermined low-temperature setting208and a predetermined high-temperature setting206range232, and between234a predetermined low motor performance setting216and a predetermined high motor performance setting218. The result is that the present invention delivers the food product302in an optimum frozen malleable form at a consistent viscosity automatically without a technician having to change equipment configurations manually.

In an exemplary embodiment, an alarm condition can be communicated by way of a display506or data communicated with a remote data processing resource604when a predetermined refrigeration chill period230elapses and the food product302has not sufficiently increased in viscosity to cause an increase in the amperage or torque214to reach the desired range234. The control system500comprises the display506and the display506is operationally related to the microcontroller502. In operation, the predetermined refrigeration chill period230is the amount of time allotted for the food product302to reach a predetermined frozen malleable consistency. Failure to achieve the desired predetermined frozen malleable consistency of the food product302in the allotted predetermined refrigeration chill period230can indicate equipment failures such as a refrigeration system568failure or other equipment failures.

In another exemplary embodiment, referring toFIG.2reference ‘C’ chart, pressure222within the mixing cylinder524can be determined over time210. The pressure222is resultant from a gas portion304and a food portion306being initially injected in a predetermined ratio into the mixing cylinder524. Food product302comprises the gas portion304and the food portion306. The pressure222can also increase as the food product302transitions to a predetermined frozen malleable form.

In this regard, a product pump552is operationally related to the microcontroller502and interconnected between the product inlet566and the supply of the food portion306stored in package562such as a bag-in-the-box type or kind of packaging, or other types and kinds of packaging as may be required and/or desired in a particular embodiment. A gas metering device548is operationally related to the microcontroller502and interconnected with a gas inlet564. The mixing cylinder524further comprises the gas inlet564, and the product inlet566. A pressure sensor520is operationally related to the microcontroller502. The pressure sensor520is configured to measure a food product302pressure inside the mixing cylinder524.

In operation, the memory504is encoded with instructions that when executed by the microcontroller502perform the step of filling the mixing cylinder, by way of the gas metering device and the product pump, with a predetermined ratio of the gas portion to the food portion until the food product pressure is between236a predetermined low-pressure setting and a predetermined high-pressure setting.

In another exemplary embodiment, a portion control system for food products302dispensed from frozen beverage equipment102and soft-serve ice cream equipment104can comprise a mixing cylinder524that comprises at least one auger522, at least one product inlet574, and at least one dispense valve526. An auger motor can be interconnected with the auger522. The auger522is positioned inside the mixing cylinder524and turns through and stirs the food product302.

A control system comprises a microcontroller502, a memory504, a temperature sensor542, and a motor sensor528/530. The temperature sensor is operationally related to the mixing cylinder524. The temperature sensor measures the temperature204of the food product302inside the mixing cylinder524. The motor sensor528/530is operationally related to the auger motor576. The motor sensor528/530measures an amperage draw or a torque214of the auger motor576resultant from the resistance of rotating the auger522through the food product302.

The memory504is encoded with instructions that when executed by the microcontroller502perform the steps of injecting a food product302into the mixing cylinder524and chilling the food product302into a predetermined frozen malleable consistency. Receiving a portion-controlled dispense amount volume indicating the volume of the food product302to dispense. Determining a product temperature204of the food product by way of the temperature sensor542. Determining the amperage draw or the torque214of the auger motor522by way of the motor sensor528/530. Determining by querying a dispense time from the memory504or a remote data processing resource604based on the portion-controlled dispense amount volume. The product temperature204, and the amperage draw or the torque214. And, opening the dispense valve526for the dispense time, allowing the food product302, in a predetermined frozen malleable consistency to be dispensed in a portion-control manner.

In an exemplary embodiment, the step of receiving referenced above the portion-controlled dispense amount volume can be effectuated by a data communication from a point-of-sale device, a quick-serve restaurant data processing device, a customer404or the user402initiated data communication from a digital communication device, a remote data communication from the remote data processing resource, manual data entry by the user at the portion control system, or by other methods or techniques as may be required and/or desired in a particular embodiment.

In an exemplary embodiment, the step of determining by querying reference above the dispense time is effectuated by a lookup table or a database encoded in the memory504, the lookup table and the database correlates a plurality of the dispense time based on a plurality of the portion-controlled dispense amount volume, a plurality of the product temperature, a plurality of the amperage draw or the torque, and other factors, as may be required and/or desired in a particular embodiment.

In an exemplary embodiment, a product pump552is operationally related to the microcontroller502and interconnected between the product inlet566and the supply of the food portion306. A gas metering device548is operationally related to the microcontroller502and interconnected with a gas inlet564. The mixing cylinder524further comprises the gas inlet564, and the product inlet566. A pressure sensor520is operationally related to the microcontroller502. The pressure sensor520is configured to measure a food product pressure inside the mixing cylinder524. The memory504can be encoded with instructions that when executed by the microcontroller502perform the step of filling the mixing cylinder, by way of the gas metering device and the product pump, with a predetermined ratio of the gas portion to the food portion until the food product pressure is between a predetermined low-pressure setting and a predetermined high-pressure setting.

When the dispense valve526is first opened the food product pressure forces a surge of food product302also called overrun to dispense out of the dispense valve526. When the food product pressure drops it is then the auger522that pushes the food product302out of the dispense valve526.

In another exemplary embodiment, a pressure sensor520is operationally related to the microcontroller502. The memory504is encoded with instructions that when executed by the microcontroller502perform the steps of determining, by way of the pressure sensor520, a food product pressure222inside the mixing chamber524. Determining, based on the food product pressure222, a surge dispense amount of food product302also called overrun will initially be dispensed resultant from the food product pressure222when the dispense valve526is opened. And, adjusting the portion-controlled dispense amount volume desired, for purposes of determining the dispense time, by subtracting from the portion-controlled dispense amount volume the surge dispense amount.

In an exemplary embodiment, the food product pressure222is sufficient to force a surge dispense amount of food product302out the dispense valve526when opened. Once the food product pressure222drops resultant from the surge dispense amount egress through the dispense valve526it is the auger522that pushes the remaining desired food portion through the dispense valve526. In a portion-controlled application, the surge dispense amount should be subtracted from the portion-controlled dispense amount volume before the dispense time is determined to better ensure food product302dispense accuracy.

As an example and not a limitation, at a predetermined temperature204, amperage draw or torque214, and food product pressure222the surge dispense amount is one ounce of food product302, and the food product dispense flow rate is two ounces per second. Therefore if the desired portion-controlled dispense amount volume is nine ounces then the adjusted portion-controlled dispense amount volume is nine ounces minus the surge dispense amount or nine ounces minus one ounce which equals eight ounces. The dispense time then becomes the adjusted portion-controlled dispense amount volume divided by the food product dispense flow rate or eight ounces divide by two ounces per second which equals four seconds. The dispense time is then four seconds. In a plurality of embodiments, as temperature204, amperage draw or torque214, and food product pressure222change so will the surge dispense amount, and the food product dispense flow rate. In operation, an accessible lookup table or database in memory504or on a remote data processing resource604can correlate variables that change such as temperature204, amperage draw of torque214, food product pressure222, the surge dispense amount, and the food product dispense flow rate, and other variables with the desired portion-controlled dispense amount to determine a dispense time to achieve an accurate portion-controlled food product302dispense.

In an exemplary embodiment, the auger motor576can be stopped and thus the auger522stopped during the surge period, this allows the surge amount to be predictably dispensed without the aid of the auger522. Once the surge amount has been dispensed the auger522by way of the auger motor576can be restarted and it is then the action of the auger522that causes the food product302to be dispensed.

In an exemplary embodiment, during dispense of the food product302, the auger motor576speed can be reduced proportionally as the temperature of the food product increases, the amperage draw decreases, or the torque decreases. In this regard, as the viscosity of the food product302decreases (thins) the auger motor speed502can be decreased to maintain a constant flow rate of the food product302during dispense. In an exemplary embodiment, the auger motor576can a variable frequency drive (VFD) motor, or other type or kind of motor as may be required and/or desired in a particular embodiment.

Referring toFIG.3, there is illustrated one example of a system block diagram for frozen beverage equipment102or a soft-serve ice cream equipment104using air304as the gas portion. In an exemplary embodiment, a mixing cylinder524comprises at least one auger522, at least one product inlet566through which a food portion306is injected into the mixing cylinder524, and at least one gas inlet564through which a gas portion304such as air, in this exemplary embodiment, is injected into the mixing cylinder52. A food product302comprises the food portion306, and the gas portion304.

The gas inlet564can be interconnected with a pump/air tube548. The pump/air tube548supplies air to the mixing cylinder524at a predetermined airflow rate so that the ratio of food portion306, gas portion304, the air in this exemplary embodiment, and optionally water portion308(in embodiments when needed) can be preset, ratiometrically mixed, and maintained each time the mixing cylinder524needs to replenish the food product, such as in an initial fill, and after a dispense.

Such air injection, by way of pump/air tube548, can be under pump conditions wherein the air304is mechanically or otherwise forced into the mixing cylinder524up to the desired pressure, or the air304can be drawn into the mixing cylinder524absent a pump through an air tube as the food product302is dispensed. The diameter of the air tube can be selected, larger or smaller diameter, to effectuate the ratio of air to food portion306, and optionally water portion308, as may be required and/or desired in a particular embodiment.

In operation, it is the ratio of the air304to the food portion306and optionally to the water portion308that is important to preset and maintain as the ratio impacts the food product302quality. In other embodiments, the radiometric mixture of the air304, food portion306, and optionally the water portion308can be preset such that the ratio is maintained each time the mixing cylinder524is refilled thus maintaining product quality.

The product inlet566can be interconnected with a pump552and the pump552can be interconnected with a food portion306such that the pump552can pump the food portion306into the mixing cylinder524. When energized, the pump552supplies the food portion306to the mixing cylinder524at a predetermined flow rate so that the ratio of food portion306, gas portion304, and water portion308(in embodiments when needed) can be preset, ratiometrically mixed, and maintained each time the mixing cylinder524needs to replenish the food product, such as in an initial fill, and after a dispense.

In an exemplary embodiment, a water inlet574can be interconnected with a pump572and the pump572can be interconnected with a water supply308such that the pump572can pump water308into the mixing cylinder542. When energized, the pump552supplies the water308to the mixing cylinder524at a predetermined flow rate so that the ratio of water308, food portion306, and gas portion304can be preset, ratiometrically mixed, and maintained each time the mixing cylinder524needs to replenish the food product, such as in an initial fill, and after a dispense. In an exemplary embodiment, when water is needed such as in diluting food portion306syrup, other for other needs it can be supplied and mixed in ration with the food portion306and the gas portion304.

In an exemplary embodiment, the pumps548,552, and572can each be interconnected with and operationally related to the pump controller546. The pump controller546can independently control each of the pumps548,552, and548. Such pumps548,552, and572types and kinds can be selected such that accurate metering of the respective gas portion304, food portion306, and when needed water portion572for recipe mixing purposes can be effectuated.

An auger motor576is interconnected with the auger522. The auger522is positioned inside the mixing cylinder524. The auger522can be a fan-style configuration, blade-style configuration, paddle-style configuration, spiral-spatula configuration, or other types and kinds of styles and configurations as may be required and/or desired in a particular embodiment.

A dispensing valve526can be operated automatically by way of the control500or manually by way of a user402. When the dispense valve526is opened the food product302is dispensed from the mixing cylinder524. The dispensed food product302is replaced by an equivalent portion of the food portion306, the gas portion304, and selectively the water portion308.

A dispense lock556is operationally related to a lockout controller550. The lockout controller550is operationally related to the microcontroller502.

The control system500comprises the microcontroller502, the pump controller546, the temperature sensor542, and the lockout controller550.

In an automated viscosity control exemplary embodiment, a dispense lock556is operationally related to the microcontroller502. The memory504is encoded with instructions that when executed by the microcontroller502transition between the steps of unlocking the dispense lock556, allowing a user402or a customer404to dispense the food product302when the temperature of the food product302is between the predetermined low-temperature setting208and the predetermined high-temperature setting206, and the amperage draw or the torque214of the auger motor576is between a predetermined low motor performance setting216and the predetermined high motor performance setting218. And, locking the dispense lock556, preventing the user402or the customer404from dispensing the food product302, when the temperature of the food product302is below the predetermined low-temperature setting208or above the predetermined high-temperature setting206, or the amperage draw or the torque214of the auger motor576is below the predetermined low motor performance setting216or above the predetermined high motor performance setting218. The dispense lock556can comprise a solenoid, or other mechanisms as may be required and/or desired in a particular embodiment.

In a portion-controlled exemplary embodiment, a dispense lock556is operationally related to the microcontroller502. The memory504is encoded with instructions that when executed by the microcontroller502transition between the steps of unlocking the dispense lock556, allowing the food product302to be dispensed, when the temperature204of the food product302is between a predetermined low-temperature setting208and a predetermined high-temperature setting206, and the amperage draw or the torque214of the auger motor576is between a predetermined low motor performance setting216and a predetermined high motor performance setting218. And, locking the dispense lock556and queuing the portion-controlled dispense amount volume, preventing the food product302from being dispensed, when the temperature of the food product302is below the predetermined low-temperature setting208or above the predetermined high-temperature setting206, or the amperage draw or the torque214of the auger motor576is below the predetermined low motor performance setting216or above the predetermined high motor performance setting218. The dispense lock556can comprise a solenoid, or other mechanisms as may be required and/or desired in a particular embodiment.

In the present invention “ideal consistency” is related to food product302viscosity and intended to mean the predetermined frozen malleable consistency of the food product302which can be easily dispensed from the dispense valve526yet frozen enough to be non-runny and user402and/or customer404desirable for consumption. In this regard, the predetermined frozen malleable consistency can be selected by the user configuring the frozen beverage equipment102and soft-serve ice cream equipment104.

In operation, the memory504can be encoded with instructions that when executed by the microcontroller perform the steps of allowing the user doing equipment configuration to change the ratio of the food portion306with respect to the gas or air304portions. Then at least one of the predetermined low-temperature setting, the predetermined high-temperature setting, the predetermined low motor performance setting, or the predetermined high motor performance setting can be adjusted to maintain the predetermined frozen malleable consistency. In this manner, the ideal consistency of the food product302also called the predetermined frozen malleable consistency can be maintained even when the ratio of the food portion306with respect to the gas portion or air304changes. Noting that desirable mouth feel and other desirable customer consumption benefits of the frozen beverage or soft-serve ice cream can be obtained by changing the ratio of the food portion306with respect to the gas or air portion304.

As an example, and not a limitation, a food product302with a food portion306and a gas or air portion304ratios of 60/40, 50/50, 40/60, or other ratios will all have different mouth feels and different customer consumption benefits at the predetermined frozen malleable consistency which can also be called the ideal consistency. To maintain the predetermined frozen malleable consistency across various food portion304and a gas portion306ratio changes at least one of the predetermined low-temperature setting, the predetermined high-temperature setting, the predetermined low motor performance setting, or the predetermined high motor performance setting can be adjusted. The present invention will then automatically maintain the desired predetermined frozen malleable consistency for the ratio of food portion306to gas or air portion304.

An advantage, in the present invention, is that food product302ideal consistency can be achieved by maintaining the food product302between a temperature range defined by a predetermined low-temperature setting208and a predetermined high-temperature setting206, and between a motor performance range defined by a predetermined low motor performance setting216and a predetermined high motor performance setting218. Such food product302ideal consistency is automatically maintained by holding the food product302within the predetermined ranges of temperature206/208and motor performance216/218and such ranges can be adjusted manually or automatically in response to variances such as environmental conditions, equipment variances, food product302type or kind changes or variance, and other variances, as may be required and/or desired in a particular embodiment.

In an exemplary embodiment, in the present invention, by automatically maintaining the ideal consistency of the food product302even with variances in operating conditions the ability to determine a dispense time to dispense a desired portion-controlled dispense amount volume is effectuated. To increase the accuracy of the desired portion-controlled dispense amount volume a surge dispense amount must be taken into consideration. Since the ideal consistency can be relied on, the present invention uses food product pressure222to determine and control the surge dispense amount.

In this regard, the surge dispense amount of the food product302occurs during the initial dispense when the dispense valve526is first opened. With the temperature range232and motor performance range234established creating the desired food product30ideal consistency, the food product pressure222can be adjusted by establishing a food product302pressure range236defined by a predetermined low-pressure setting226and a predetermined high-pressure setting224. Once established the food product pressure222is maintained within the range resulting in a predictable and known surge dispense amount that can be used to adjust the dispense time so that the desired portion-controlled dispense amount volume is more accurately achieved.

In operation, while the food product302ideal consistency is maintained between the predetermined ranges of temperature232and motor performance range234the surge dispense amount can be adjustably changed by changing the food product pressure range236and then repeatably maintained when the food product pressure222, within the mixing chamber524, is maintained between the predetermined low-pressure setting226and the predetermined high-pressure setting224. Such food product pressure222is controlled by the amount of the food portion306and gas portion304that is injected into the mixing chamber524. Changing the food product pressure222predictably changes the surge dispense amount.

In combination, the temperature range232and motor performance range234automatically control the viscosity of the food product302creating the ideal consistency while the pressure range236controls the amount of the surge dispense amount that is dispensed when the dispense valve526is first opened. Together, maintaining ranges in temperature232, motor performance range234, and food product pressure range236effectuate the ability to dispense the food product302in a repeatably accurate portion-controlled manner.

Referring toFIG.4, there is illustrated one example of a control system500. In an exemplary embodiment, control system500can be integrated into and control frozen beverage equipment102and soft-serve ice cream equipment104. In addition, control system500can be a web-enabled control system.

The term “web-enabled” or “web-enabled control system” or “web-enabled control system500” in the present invention is intended to mean an Internet-of-things device. In this regard, a device that is capable of connecting a physical device such as the frozen beverage equipment102and soft-serve ice cream equipment104to the digital world. Stated differently, web-enabling is equipping a device with the necessary electronics to be monitored, controlled, and data communicate locally and remotely with other data communicating devices. Such other data communicating devices can be smartphones, tablets, laptops, mobile communication devices, other web-enabled devices, servers, and similar devices.

In addition, such data communicating devices606can data communicate with remote data processing resources604and utilize data storage resources602. Laptops, smartphones, smartwatches, tablets, desktop computers, servers, mobile communication devices, and other types and kinds of data communication devices can all be data communicating devices606.

In operation, a user402, or a customer404can use data communicating devices606to interact with the frozen beverage equipment102and soft-serve ice cream equipment104. In this regard, a user402can be a person who operates, maintains, cleans, configures, repairs, and performs other functions on or with the frozen beverage equipment102or soft-serve ice cream equipment104. A customer404can be a person who self-serve dispenses food product302. The digital experience and interaction with the frozen beverage equipment102and soft-serve ice cream equipment104by the user402, and customer404can be different and suited for their various roles and requirements, as may be required and/or desired in a particular embodiment.

Such data processing resources can be a server or other types and kinds of data processing resources. Furthermore, data communicating devices606, remote data processing resources604, data storage resources602, and other types and kinds of data communicating devices can data communicate over a global network700. The Internet is a global network700.

In an exemplary embodiment, the frozen beverage equipment102and soft-serve ice cream equipment104can be equipped with a web-enabled control system500. Such a web-enabled control system can comprise a microcontroller502which is operationally related to a plurality of communication interfaces508, a power supply514, a pump controller546, a display506, motor controller530, a memory504, a torque monitor528, an amperage meter530, a refrigeration controller540, a temperature sensor542, and a lockout controller550.

The microcontroller502can be INTEL, ZILOG, MICROCHIP, AMD, ARM, and/or other types or kinds of microcontrollers.

The memory614can be combinations of RAM, ROM, flash, hard drives, solid-state drives, USB flash drives, and/or other types and kinds of memory.

The display610can be an LCD, OLED, LED, as well as have touch input capabilities and/or other types and kinds of displays and user inputs as may be required and/or desired in a particular embodiment.

The communication interface508can be LAN, WAN, USB, Ethernet, RS232, RS485, serial, WiFi, 802.11abgn and similar, 2G 3G 4G 5G compatible, Bluetooth, TCP, UDP, Mesh Network, Zigbee, Pico Network, LORAN, and/or other types and kinds of communication interfaces and protocols.

In an exemplary embodiment, the communication interface508is operationally related to the microcontroller502. The control system by way of the communication interface508data communicates with the remote data processing resource604, data communication devices606, remote service provider406networks, quick-server restaurant networks, other frozen beverage equipment102and soft-serve ice cream equipment104, in a local area network environment or a wide area network environment across a global network700in a wired or wireless manner as may be required and or desired in a particular embodiment. The Internet is a global network700.

The power supply514can be AC, DC, battery, solar, and/or other types and kinds of power supplies.

The pump controller546can be a relay, MOSFET, or other types and kinds of controlling devices.

The motor controller530can be a relay, MOSFET, variable frequency drive controller (VFD), or other types and kinds of motor control devices.

The torque monitor528can be a communication interface that communicates with a motor controller such as a VFD motor controller or other motor controllers that provides information about the motor performance that includes a torque metric determination or other motor performance data such that the control system500can calculate the torque of the auger motor576. In an exemplary embodiment, analog-type sensor determinations can be converted to digital values so that the microcontroller502can process the data. Alternatively, the microcontroller502can perform the analog-to-digital conversions if equipped to perform such functions.

In another exemplary embodiment, torque can be measured mechanically by having a force of the food product302mixed in the mixing cylinder524applied to a lever that increasingly displaces as the food product302transitions to a predetermined frozen malleable consistency. The amount of displacement of the lever can be measured by the torque monitor528automatically electronically to determine a relative torque reading that can then be used in the methods of the present invention.

The amperage meter530can be a current transformer such as a torrid coil winding having one of the auger motor electrical wires running through the center of the torrid coil, or other types and kinds of electrical current sensing techniques and/or devices. In an exemplary embodiment, analog-type sensor determinations can be converted to digital values so that the microcontroller502can process the data. Alternatively, the microcontroller502can perform the analog-to-digital conversions if equipped to perform such functions.

A refrigeration system568comprises the refrigeration controller540. The refrigeration controller540can be a relay, MOSFET, or other types and kinds of refrigeration controlling devices. In an exemplary embodiment and better illustrated in at leastFIG.7, a compressor536is interconnected with and operationally related to the refrigeration controller540. The compressor536circulates the refrigerant through a condenser coil538, a refrigerant metering device534such as an expansion valve, and an evaporate coil532. In operation, the refrigeration system568chills the food product302in the mixing cylinder524to a predetermined frozen malleable consistency. The refrigeration system568can use a variety of refrigerant types including for example thermoelectric such as Peltier and others, vapor-compression, non-vapor-compression, and other types and kinds of refrigeration system, as may be required and/or desired in a particular embodiment.

The temperature sensor542can be positioned and configured to measure the temperature of the food product302within the mixing cylinder524. Such a temperature sensor542can be a resistive temperature (RTD), thermistor, infrared, integrated silicon-based, or other types and kinds of temperature sensors as may be required and/or desired in a particular embodiment. In an exemplary embodiment, analog-type sensor determinations can be converted to digital values so that the microcontroller502can process the data. Alternatively, the microcontroller502can perform the analog-to-digital conversions if equipped to perform such functions.

In an exemplary embodiment, a user interface comprises at least one of the following a display506, a display506with touchscreen, a communication interface508configured to data communicate with a data communication device606, a plurality of button input capabilities by way of the GPIO510, or other user interfaces. The user interface is operationally related to the microcontroller502, a user402or customer404can enter the portion-controlled dispense amount volume by way of the user interface.

Referring toFIG.5, there is illustrated one example of a system block diagram for frozen beverage equipment102or a soft-serve ice cream equipment104configured to use a variety of gases as the gas portion304. With reference toFIG.5, in an exemplary embodiment, the system block diagram inFIG.3can be adapted to provide for varying types or kinds of the gas portion304in addition to air. In this regard, a gas metering device548can be interconnected between a gas portion304supply of a gas and the gas inlet564. In operation, the gas portion can be air, carbon dioxide, nitrogen, or other types and kinds of gases, as may be required and/or desired in a particular embodiment. In an exemplary embodiment, gases such as carbon dioxide, and other gasses can be injected into the mixing cylinder524at a sufficient pressure to cause the gas to dissolve into the food portion resulting in the food product324becoming carbonate in the case of dissolved carbon dioxide, or otherwise imbibed, or infused with the gas.

With reference toFIG.5, in an exemplary embodiment, the system block diagram inFIG.3can be adapted to provide for a pressure sensor520. The pressure sensor520is operationally related to the microcontroller502. The pressure sensor520is configured to measure the food product pressure222of the food product302inside the mixing cylinder524.

In an exemplary embodiment, an automatic viscosity control system for food products dispensed from frozen beverage equipment and soft-serve ice cream equipment can comprise a mixing cylinder524which comprises at least one of an auger522, at least one of a product inlet566through which a food portion306is injected into the mixing cylinder524, and at least one of a gas inlet564through which a gas portion304is injected into the mixing cylinder524.

A food product302comprises the food portion306and the gas portion304. An auger motor576is interconnected with the auger522. The auger522is positioned inside the mixing cylinder524.

A control system500comprises a microcontroller502, and a memory504. A motor sensor528/530is operationally related to the microcontroller502and interconnected with the auger motor576. The motor sensor528/530measures an amperage draw or a torque of the auger motor576resultant from the resistance of rotating the auger522through the food product302. A gas metering device548is operationally related to the microcontroller502and interconnected with a gas inlet564. The mixing cylinder524further comprises the gas inlet564, and the product inlet566. A pressure sensor520is operationally related to the microcontroller502. The pressure sensor520is configured to measure the pressure of the food product302inside the mixing cylinder524.

A refrigeration system568comprises a compressor536. The compressor536is operationally related to the microcontroller502and configured to chill, into the predetermined frozen malleable consistency, the food product302inside the mixing cylinder524.

The memory504is encoded with instructions that when executed by the microcontroller502perform the steps of filling the mixing cylinder524, by way of the gas metering device548and the product pump552, with a predetermined ratio of the gas portion304to the food portion306until the food product pressure222is between a predetermined low-pressure setting226and a predetermined high-pressure setting224.

The method continues by starting or speeding up the compressor536when the temperature of the food product302is above a predetermined high-temperature setting208or when the amperage draw or the torque of the auger motor576is below a predetermined high motor performance setting218. And, slowing or stopping the compressor536when the temperature of the food product302is between a predetermined low-temperature setting206and the predetermined high-temperature setting208, and the amperage draw or the torque of the auger motor576is between a predetermined low motor performance setting216and the predetermined high motor performance setting218.

Referring toFIG.6, there is illustrated an example of a control system500. In an exemplary embodiment, the control system500ofFIG.4can be enhanced with the following features illustrated inFIG.6.

The defrost system516can be resistive heat518, thermoelectric, and/or other types and kinds of defrosting systems. In operation, the defrost system516, as needed, can warm the mixing cylinder524to prevent the food product324from freezing into a solid mass.

The pressure sensor520can be diagram displacement-based, strain gauge, variable capacitance, resistive, piezoelectric, micro-electrical mechanical system (MEMS), and/or other types and kinds of pressure sensors. In an exemplary embodiment, analog-type sensor determinations can be converted to digital values so that the microcontroller502can process the data. Alternatively, the microcontroller502can perform the analog-to-digital conversions if equipped to perform such functions.

The GPIO510can be TTL, CMOS, transistors, buffers, relays, pushbutton, switch, and/or other types and kinds of GPIO circuits.

The sensors512can be PIR motion sensors, infrared, thermal, Doppler radar, ultrasonic, capacitance, touch-type, optical, Hall effect, switch, fingerprint, and other types of biometric sensors, and/or other types and kinds of sensors. In an exemplary embodiment, analog-type sensor determinations can be converted to digital values so that the microcontroller502can process the data. Alternatively, the microcontroller502can perform the analog-to-digital conversions if equipped to perform such functions.

The ambient condition sensors544can be temperature, moisture, humidity, sunlight, time, date, and/or other types and kinds of sensors. In an exemplary embodiment, analog-type sensor determinations can be converted to digital values so that the microcontroller502can process the data. Alternatively, the microcontroller502can perform the analog-to-digital conversions if equipped to perform such functions.

Referring toFIG.7, there is illustrated one example of a refrigeration system568. In an exemplary embodiment, the refrigeration system568comprises the refrigeration controller540. The refrigeration controller540can be a relay, MOSFET, or other types and kinds of refrigeration controlling devices. The refrigeration controller540is operationally related to the microcontroller502. The compressor536is interconnected with and operationally related to the refrigeration controller540. The compressor536circulates the refrigerant through a condenser coil538, a refrigerant metering device534such as an expansion valve, and an evaporate coil532. In operation, the refrigeration system568chills the food product302in the mixing cylinder524to a predetermined frozen malleable consistency. The refrigeration system568can use a variety of refrigerant types including for example thermoelectric, vapor-compression, non-vapor-compression, and other types and kinds of refrigeration system, as may be required and/or desired in a particular embodiment.

In a plurality of exemplary embodiments, the compressor536can be a standard conventional compressor that can be turned ‘ON’ and ‘OFF’ or a variable speed compressor that can be turned ‘ON’ and ‘OFF’ as well as have variable speed controls to allow the compressors to be operated at different rotational speeds. Such variable speed compressors, used properly, can have the benefit of lower overall energy usage requirements, as well as having other benefits. Other types and kinds of compressors can be used as well as other types and kinds of the refrigeration system568configurations can be effectuated, as may be required and or desired in a particular embodiment.

Referring toFIG.8, there is illustrated one example of a global network-based system block diagram. In an exemplary embodiment, by way of control system500communication interface508, frozen beverage equipment102and soft-serve ice cream equipment104can data communicate over a global network700with one or more remote data processing resources604, databases602that are operationally related to a remote data processing resource604, one or more data communication device606operated by user402or customer404, and one or more remote service provider406. The Internet is one example of a global network700. Database602is operationally related to the remote data processing resource604. In addition, there can be any number of remote data processing resources604, and/or database602, as well as other global network-based computing devices as may be required and/or desired in a particular embodiment.

Such data communication devices606can include smartphones, tablets, laptops, other web-enabled devices, mobile communication devices, and other data communication devices, as may be required and/or desired in a particular embodiment.

Such remote data processing resource604can be a server, network appliance, or other types and kinds of remote data processing resources, as may be required and or desired in a particular embodiment.

Such remote service provider406can be a technical service network, a call center, a customer service organization, an alarm/equipment service monitoring company, or other types and kinds of remote service providers.

Referring toFIG.9, there is illustrated one example of an automatic viscosity control method for frozen food products302dispensed from frozen beverage equipment102and soft-serve ice cream equipment104. In an exemplary embodiment, a refrigeration system568can comprise a compressor536. The refrigeration system568is configured to chill, into the predetermined frozen malleable consistency, the food product302inside the mixing cylinder524. The memory504is encoded with instructions that when executed by the microcontroller502transitions between steps1002and1004.

In step1002, the compressor536is started or speeded up when the amperage draw or the torque214of the auger motor576is below a predetermined high motor performance setting218. And, in step1004, the compressor536is slowed or stopped when the amperage draw or the torque214of the auger motor576is between234a predetermined low motor performance setting216, and the predetermined high motor performance setting218.

In a plurality of exemplary embodiments, the compressor536can be a standard conventional compressor that can be turned ‘ON’ and ‘OFF’ or a variable speed compressor that can be turned ‘ON’ and ‘OFF’ as well as have variable speed controls to allow the compressors to be operated at different rotational speeds.

Referring toFIG.10, there is illustrated one example of an automatic viscosity control method for frozen food products302dispensed from frozen beverage equipment102and soft-serve ice cream equipment104. In an exemplary embodiment, the control system500further comprises a temperature sensor542. The temperature sensor542is operationally related to the microcontroller502and the mixing cylinder524. The temperature sensor542measures the temperature of the food product302inside the mixing cylinder524. The memory504is encoded with instructions that when executed by the microcontroller502transitions between steps1004and1006.

In step1004, the compressor536is started or speeded up when the temperature204of the food product302is above a predetermined high-temperature setting206. And, in step1006, the compressor536is slowed or stopped when temperature204of the food product302is between232a predetermined low-temperature setting208and the predetermined high-temperature setting206, and the amperage draw or the torque214of the auger motor576is between234a predetermined low motor performance setting216and the predetermined high motor performance setting218.

Referring toFIG.11, there is illustrated one example of an automatic viscosity control method for frozen food products302dispensed from frozen beverage equipment102and soft-serve ice cream equipment104. In an exemplary embodiment, a product pump552is operationally related to the microcontroller502and interconnected between the product inlet566and a supply of the food portion306. A gas metering device548is operationally related to the microcontroller502and interconnected with a gas inlet564. The mixing cylinder524further comprises the gas inlet548, and the product inlet566. A pressure sensor520is operationally related to the microcontroller502. The pressure sensor502is configured to measure the food product302pressure222inside the mixing cylinder524. The memory is encoded with instructions that when executed by the microcontroller502perform step1008.

In step1008, filling the mixing cylinder524, by way of the gas metering device548and the product pump552, with a predetermined ratio of the gas portion304to the food portion306until the food product pressure222is between236a predetermined low-pressure setting226and a predetermined high-pressure setting224.

In an exemplary embodiment, the food product302can comprise a food portion306, and a gas portion304. The food product302can also comprise a water portion308, or other dilutants as may be required and or desired in a particular embodiment. Additionally, the gas portion304can be air, carbon dioxide, nitrogen, or other gas. In operation, the food portion306, gas portion304, and water or dilutant portion308can be precisely ratiometrically mixed in a predetermined manner by way of the pumps548/552/572, gas metering devices548, and other various valves in the system. Such ratiometric mixing can be changed to control viscosity, portion dispensed control, and other factors, as may be required and or desired in a particular embodiment.

In step1010, the ratio of the food portion306to the gas portion can be changed. The method then moves to step1012.

In step1020, at least one of the predetermined low-temperature setting, the predetermined high-temperature setting, the predetermined low motor performance setting, or the predetermined high motor performance setting can be adjusted to maintain the predetermined frozen malleable consistency. As an example, and not a limitation, a food product302with a food portion306and a gas or air portion304ratios of 60/40, 50/50, 40/60, or other ratios will all have different mouth feels and different customer consumption benefits at the predetermined frozen malleable consistency which can also be called the ideal consistency. To maintain the predetermined frozen malleable consistency across various food portion304and a gas portion306ratio changes at least one of the predetermined low-temperature setting, the predetermined high-temperature setting, the predetermined low motor performance setting, or the predetermined high motor performance setting can be adjusted. The present invention will then automatically maintain the desired predetermined frozen malleable consistency for the ratio of food portion306to gas or air portion304.

Referring toFIG.12, there is illustrated one example of an automatic viscosity control method for frozen food products302dispensed from frozen beverage equipment102and soft-serve ice cream equipment104. In an exemplary embodiment, a dispense lock550/556is operationally related to the microcontroller502. The memory is encoded with instructions that when executed by the microcontroller502transition between steps1014and1016.

In step1014, the dispensing lock550/556is unlocked, allowing a user402to dispense the food product302when the temperature204of the food product302is between the predetermined low-temperature setting208and the predetermined high-temperature setting206, and the amperage draw or the torque214of the auger motor576is between234a predetermined low motor performance setting216and the predetermined high motor performance setting218. And, in step1016, locking the dispensing lock550/556, preventing the user402from dispensing the food product302, when the temperature204of the food product302is below the predetermined low-temperature setting208or above the predetermined high-temperature setting206, or the amperage draw or the torque214of the auger motor576is below the predetermined low motor performance setting216or above the predetermined high motor performance setting218.

Referring toFIG.13, there is illustrated one example of an automatic viscosity control method for frozen food products302dispensed from frozen beverage equipment102and soft-serve ice cream equipment104. In an exemplary embodiment, a defroster516/518is operationally related to the microcontroller502. The memory504is encoded with instructions that when executed by the microcontroller502transition between steps1018and1020.

In step1018, turning ‘ON’ the defroster516/518when temperature204of the food product302is below the predetermined low-temperature setting208or the amperage draw or the torque214of the auger motor576is above the predetermined high motor performance setting218. And, in step1020, turning ‘OFF’ the defroster516/518when temperature204of the food product302is above the predetermined low-temperature setting208and the amperage draw or the torque214of the auger motor576is below the predetermined high motor performance setting218.

Referring toFIG.14, there is illustrated one example of an automatic viscosity control method for frozen food products302dispensed from frozen beverage equipment102and soft-serve ice cream equipment104. In an exemplary embodiment, an automatic viscosity control system for food products dispensed from frozen beverage equipment and soft-serve ice cream equipment can comprise a mixing cylinder524which comprises at least one of an auger522, at least one of a product inlet566through which a food portion306is injected into the mixing cylinder524, and at least one of a gas inlet564through which a gas portion304is injected into the mixing cylinder524.

A food product302comprises the food portion306and the gas portion304. An auger motor576is interconnected with the auger522. The auger522is positioned inside the mixing cylinder524.

A control system500comprises a microcontroller502, and a memory504. A motor sensor528/530is operationally related to the microcontroller502and interconnected with the auger motor576. The motor sensor528/530measures an amperage draw or a torque of the auger motor576resultant from the resistance of rotating the auger522through the food product302. A gas metering device548is operationally related to the microcontroller502and interconnected with a gas inlet564. The mixing cylinder524further comprises the gas inlet564, and the product inlet566. A pressure sensor520is operationally related to the microcontroller502. The pressure sensor520is configured to measure the pressure of the food product302inside the mixing cylinder524.

A refrigeration system568comprises a compressor536. The compressor536is operationally related to the microcontroller502and configured to chill, into the predetermined frozen malleable consistency, the food product302inside the mixing cylinder524.

The memory504is encoded with instructions that when executed by the microcontroller502perform steps that begin in step1402by filling the mixing cylinder524, by way of the gas metering device548and the product pump552, with a predetermined ratio of the gas portion304to the food portion306until the food product pressure222is between236a predetermined low-pressure setting226and a predetermined high-pressure setting224. The method then moves to step1404.

In step1404, the compressor536is started or sped up when the temperature of the food product302is above a predetermined high-temperature setting208or when the amperage draw or the torque of the auger motor576is below a predetermined high motor performance setting218. The method then moves to step1406.

In step1406, the compressor536is slowed or stopped when the temperature of the food product302is between a predetermined low-temperature setting206and the predetermined high-temperature setting208, and the amperage draw or the torque of the auger motor576is between a predetermined low motor performance setting216and the predetermined high motor performance setting218.

Referring toFIG.15, there is illustrated one example of a portion control method for food products302dispensed from frozen beverage equipment102and soft-serve ice cream equipment104. In an exemplary embodiment, a mixing cylinder524comprises at least one of an auger522, at least one of a product inlet566, and at least one of a dispense valve526. An auger motor576is interconnected with the auger522. The auger522is positioned inside the mixing cylinder524. A control system500comprises a microcontroller502, a memory504, a temperature sensor542, and a motor sensor528(torque monitoring)/530(electrical current sensing). The temperature sensor542is operationally related to the mixing cylinder524. The temperature sensor542measures the temperature204of the food product302inside the mixing cylinder524. The motor sensor528/530is operationally related to the auger motor576. The motor sensor528/530measures a torque528or an amperage draw530of the auger motor576resultant from the resistance of rotating the auger522through the food product302. The memory504is encoded with instructions that when executed by the microcontroller502perform the following steps beginning in step1102.

In step1102, a food product302is injected into the mixing cylinder524and chilled to a predetermined frozen malleable consistency. The method then moves to step1104.

In step1104, a portion-controlled dispense amount volume indicating the volume of the food product to dispense is received, In an exemplary embodiment, the step of receiving the portion-controlled dispense amount volume is effectuated by a data communication from a point-of-sale device, a quick-serve restaurant data processing device, a customer404or user402initiated data communication from a data communication device606, a remote data communication from the remote data processing resource604, manual data entry by the user402or the customer404at the portion control system500, or by other methods or techniques. The method then moves to step1106.

In step1106, a product temperature204of the food product302is determined by way of the temperature sensor542. The method then moves to step1108.

In step1108, the amperage draw or the torque214of the auger motor576is determined by way of the motor sensor528/530. The method then moves to step1110.

In step1110, a dispense time is determined by a query from the memory504or from a remote data processing resource604based on the portion-controlled dispense amount volume, the product temperature204, and the amperage draw or the torque214. In an exemplary embodiment, the step of determining by querying the dispense time is effectuated by way of a lookup table or a database encoded in the memory504, the lookup table and/or the database correlates a plurality of the dispense times210based on a plurality of the portion-controlled dispense amounts volume, a plurality of the product temperatures204, and a plurality of the amperage draw or the torque214measurements, or effectuated by other methods or techniques. The method then moves to step1112.

In step1112, the dispense valve526is opened for the dispense time allowing the food product302, in a predetermined frozen malleable consistency, to be dispensed in a portion-controlled manner. The method is then exited.

In an exemplary embodiment, the food product302can comprise a food portion306, and a gas portion304. The food product302can also comprise water308, or other dilutants as may be required and or desired in a particular embodiment. Additionally, the gas portion304can be air, carbon dioxide, nitrogen, or other gas. In operation, The food portion306, gas portion304, and water or dilutant portion308can be precisely ratiometrically mixed in a predetermined manner by way of the pumps548/552/572, gas metering devices548, and other various valves in the system. Such ratiometric mix can be changed to control viscosity, portion dispenses control, and other factors, as may be required and or desired in a particular embodiment.

Referring toFIG.16, there is illustrated one example of a portion control method for food products302dispensed from frozen beverage equipment102and soft-serve ice cream equipment104. In an exemplary embodiment, a product pump552is operationally related to the microcontroller502and interconnected between the product inlet566and the supply of the food portion306. A gas metering device548is operationally related to the microcontroller502and interconnected with a gas inlet564. The mixing cylinder524further comprises the gas inlet564, and the product inlet566. A pressure sensor520is operationally related to the microcontroller502. The pressure sensor520is configured to measure a food product pressure222inside the mixing cylinder524. The memory504is encoded with instructions that when executed by the microcontroller502transition between steps1202and1204.

In step1202, decreasing the food product pressure222inside the mixing cylinder524to decrease a surge dispense amount of the food product302when the dispense valve526is initially opened. And, in step1204, increasing the food product pressure222inside the mixing cylinder524to increase the surge dispense amount of the food product302when the dispense valve526is initially opened.

Referring toFIG.17, there is illustrated one example of a portion control method for food products302dispensed from frozen beverage equipment102and soft-serve ice cream equipment104. In an exemplary embodiment, a pressure sensor520is operationally related to the microcontroller502. The memory504is encoded with instructions that when executed by the microcontroller502perform steps1206,1208, and1210.

In step1206, a food product pressure222inside the mixing chamber524is determined, by way of the pressure sensor520. In an exemplary embodiment, the ratio of the gas portion304, food portion306, and if necessary the water portion308influences the food product pressure222when it reaches the desired predetermined frozen malleable consistency. When the dispense valve526is first opened the food product pressure222forces a surge of food product to dispense out of the dispense valve526. When the food product pressure222drops it is then the auger522that pushes the food product302out of the dispense valve526. The method then moves to step1208.

In step1208, a surge dispense amount of food product that will initially be dispensed resultant from the food product pressure222when the dispense valve is opened is determined, based on the food product pressure222. The method then moves to step1210.

In step1210, the portion-controlled dispense amount volume desired is adjusted, for purposes of determining the dispense time, by subtracting from the portion-controlled dispense amount volume the surge dispense amount.

In an exemplary embodiment, the food product pressure222is sufficient to force a surge dispense amount of food product302out the dispense valve526when opened. Once the food product pressure222drops resultant from the surge dispense amount egress through the dispense valve526it is the auger522that pushes the remaining desired food portion through the dispense valve526. In a portion-controlled application, the surge dispense amount should be subtracted from the portion-controlled dispense amount volume before the dispense time is determined to better ensure food product302dispense accuracy.

As an example and not a limitation, at a predetermined temperature204, amperage draw or torque214, and food product pressure222the surge dispense amount is one ounce of food product302, and the food product dispense flow rate is two ounces per second. Therefore if the desired portion-controlled dispense amount volume is nine ounces then the adjusted portion-controlled dispense amount volume is nine ounces minus the surge dispense amount or nine ounces minus one ounce which equals eight ounces. The dispense time can then be determined by the adjusted portion-controlled dispense amount volume divided by the food product dispense flow rate or eight ounces divide by two ounces per second which equals four seconds. The dispense time is then four seconds. In a plurality of embodiments, as temperature204, amperage draw or torque214, and food product pressure222change so will the surge dispense amount, and the food product dispense flow rate. In operation, an accessible lookup table or database in memory504or on a remote data processing resource604can correlate variables that change such as temperature204, amperage draw of torque214, food product pressure222, the surge dispense amount, and the food product dispense flow rate, and other variables with the desired portion-controlled dispense amount to determine a dispense time to achieve an accurate portion-controlled food product302dispense.

Referring toFIG.18, there is illustrated one example of a portion control method for food products302dispensed from frozen beverage equipment102and soft-serve ice cream equipment104. In an exemplary embodiment, the portion control system can be trained by encoding the memory504instructions that when executed by the microcontroller502performs the following step beginning in step1302.

In step1302, the food product302can be dispensed in a predetermined frozen malleable consistency form. The method then moves to step1304.

In step1304, the volume of food product dispensed is then determined. In this regard, since training is an iterative process, the amount of dispense can very to create an array of different data points. The method then moves to step1306.

In step1306, a training dispense time is determined in which the volume of food product was dispensed. In this regard, the dispense is timed so that a volume per second determination can be determined. The method then moves to step1308.

In step1308, the product temperature204of the food product is determined by way of the temperature sensor542. The method then moves to step1310.

In step1310, the amperage draw or the torque214of the auger motor576can be determined by way of the motor sensor528/530. The method then moves to step1312.

In step1312, storing in a lookup table or a database, in the memory504or accessible on the remote data processing resource604, the training dispense time duration, the volume of food product dispensed, the product temperature204, and the amperage or the torque214of the auger motor. In this regard, then during normal operational use, the lookup table or the database is updated and becomes queryable to determine the dispense time based on a desired portion-controlled dispense amount volume.

In an exemplary embodiment, the food product pressure222can also be correlated with other variables and stored in a lookup table or a database, in the memory504or accessible on the remote data processing resource604.

Referring toFIG.19, there are illustrated exemplary embodiments utilized with the methods of the present invention.

In step1314, the auger motor576can be stopped while the surge dispense amount is being dispensed. In this regard, stopping the auger motor576and thus the auger522during the surge period, allows the surge amount to be predictably dispensed without the aid of the auger522. Once the surge amount has been dispensed the auger522by way of the auger motor576can be restarted and it is then the action of the auger522that causes the food product302to be dispensed.

In step1316, the auger motor576can be slowed or stopped when temperature204of the food product302is above the predetermined high-temperature setting206.

In step1318, reducing, during dispense of the food product302, the auger motor speed502proportionally as temperature204of the food product302increases, or amperage draw214decreases or the torque214decreases. In this regard, as the viscosity of the food product decreases (thins), the auger motor576speed decreases to maintain a constant flow rate of the food product302during dispense.

In step1320, communicating an alarm condition by way of a display506or data communication with a remote data processing resource604when a predetermined refrigeration chill period230elapses. The control system500comprises the display506and the display506is operationally related to the microcontroller502. In this regard, the predetermined refrigeration chill period230is the amount of time allotted for the food product302reaches a predetermined frozen malleable consistency after which a problem with the frozen beverage equipment102and soft-serve ice cream equipment104can be suspected.

Referring toFIG.20, there is illustrated one example of a network and database structure for a portion control system for food products dispensed from frozen beverage equipment and soft-serve ice cream equipment102/104. In an exemplary embodiment, a database602or lookup table can comprise a plurality of dispense table records802. Each of the dispense table records802is a set of dispense condition variables in which a dispense amount volume can be dispensed in a dispense time. In operation, the dispense condition variables of food product302pressure, temperature, viscosity, auger RPM, dispense valve aperture, the geometry in the mixing cylinder522, and other variables all play a role in the volume of food product that can be dispensed in a dispense time.

In a portion-controlled application, in response to receiving a portion-controlled dispense amount volume for a desired food product302, a dispense time to dispense a dispense amount volume can be determined. The dispense time is the amount of time to open the dispense valve526to dispense the desired dispense amount volume. The dispense amount volume of the received portion-controlled dispense amount volume.

In determining the dispense time, one or more dispense table records of similar dispense condition variables values that most closely match the current dispense condition sensor reading and similar dispense amount volumes are used. Since each variable can have an operating range, it is perhaps likely that in a system with a finite number of trained dispense table records that the exact dispense condition variables values and/or the exact dispense amount volume wouldn't exist in a single dispense table record.

An advantage, in the present invention, is that several dispense table records802can be used to interpolate804between the dispense condition variables values stored in the dispense table records802and the current sensor values and conditions. In this regard, responsive to virtually any received portion-controlled dispense amount volume desired across a wide range of dispense condition variables, a dispense time can be determined. This allows portion-controlled dispensing at any preferred dispense amount volume.

In operation, such interpolation804can be between one or more of the plurality of dispense condition variables, the dispense time, and/or the dispense amount volume. If the auger motor is ‘on’ and operating, a single dispense time can be used to dispense in a dispense amount volume that matches the received portion-controlled dispense amount volume. If the auger motor is in the ‘off’ state, a dispense time can be determined for a surge amount. The surge amount is the amount of dispense volume amount that is dispensed when dispense valve526is opened when the auger motor576is not operating and the mixing cylinder pressurized. Once the surge amount has been dispensed the remain amount of the dispense amount volume can be used to determine a final dispense time. The auger motor576is then started at the desired auger motor RPM speed, and the remaining dispense amount volume dispensed. The combination of the surge amount and the final dispense amount total the received a portion-controlled dispense amount volume. In other words, the final dispense amount volume is equal to the received portion-controlled dispense amount volume minus the surge amount volume.

In an exemplary embodiment, a portion control system for food products dispensed from frozen beverage equipment and soft-serve ice cream equipment comprises a mixing cylinder524. The mixing cylinder524comprises at least one of an auger522, at least one of a product inlet564/566/574, and at least one of a dispense valve526.

The portion control system further comprises, an auger motor576that is interconnected with the auger522. The auger522is positioned inside the mixing cylinder524and rotates at an auger motor RPM speed. And, a control system500that comprises a microcontroller502, a memory504, a temperature sensor542, a pressure sensor520, and a motor sensor528/530. The temperature sensor542is operationally related to the mixing cylinder524and measures a product temperature of a food product302inside the mixing cylinder524. The pressure sensor520is operationally related to the mixing cylinder524and measures pressure inside the mixing cylinder524. The motor sensor528/530is operationally related to the auger motor576and measures an amperage draw or a torque of the auger motor576resultant from the resistance of rotating the auger522through the food product302.

In operation, the memory504is encoded with instructions that when executed by the microcontroller502perform the steps of injecting the food product302into the mixing cylinder524through the product inlet564/566/574and chilling the food product302to a predetermined frozen malleable consistency. The method continues by receiving a portion-controlled dispense amount volume indicating the volume of the food product302to dispense.

If initially the auger motor RPM speed is zero, the auger motor576is ‘off’, a dispense time and a dispense amount volume are determined based on the current values of a plurality of dispense condition variables by interpolating between a plurality of a dispense table record802. The dispense table record802comprise a dispense time, a dispense amount, and the auger motor RPM across a range of values of the plurality of dispense condition variables where the auger motor RPM is zero. The dispense amount volume is a surge amount volume. The dispense valve is then opened for the dispense time, allowing the surge amount volume of the food product302, in the predetermined frozen malleable consistency, to be dispensed in a portion control manner. A new dispense time and the dispense amount volume is determined. The new dispense time is determined based on current values of the plurality of dispense condition variables by interpolating between a plurality of the dispense table record. The new dispense amount volume is equal to the portion-controlled dispense amount volume minus the surge dispense amount volume already dispensed. The auger motor576is started rotating, and the dispense valve526is opened for the dispense time, allowing the dispense amount volume of the food product302, in the predetermined frozen malleable consistency, to be dispensed in a portion control manner.

In the alternative, if initially the auger motor RPM speed is greater than zero, the auger motor576is ‘on’, the dispense time and the dispense amount volume are determined. The dispense time is determined based on current values of the plurality of dispense condition variables by interpolating between a plurality of the dispense table record. The dispense amount volume is equal to the portion-controlled dispense amount volume. The dispense valve is then opened for the dispense time, allowing the dispense amount volume of the food product302, in the predetermined frozen malleable consistency, to be dispensed in portion control manner.

An advantage in the present invention is that during normal operation the auger motor576turns ‘on’ and ‘off’ to keep the food product at an optimal viscosity and frozen malleable state. The auger motor576may be ‘on’ or ‘off’ when a portion-controlled dispense request is received at equipment102/104. Since speed to complete the dispense is important in quick serve restaurant environments, there is no need to change the state of the auger motor576‘off’ to ‘on’ in order to initiate a dispense. In this regard, regardless of the state of the auger motor576, the present invention can determine a surge amount plus a final dispenses amount to accommodate an auger motor576initially ‘off’, then turned it ‘on’ to complete the dispense, or start a dispense with the auger motor576‘on’ and dispense in a manner where a surge amount does not apply.

In an exemplary embodiment, the plurality of dispense condition variables can comprise a food product viscosity, a mixing cylinder pressure, a dispense valve aperture size, a geometry of the auger, and other variables, as may be required an/or desired in a particular embodiment.

In an exemplary embodiment, the food product302viscosity can be determined based on the amperage draw or the torque of the auger motor576. Additionally, the step of determining the dispense time further comprises selecting an auger motor RPM speed, and the step of starting the auger motor further comprises starting the auger motor576at the auger motor RPM speed.

In an exemplary embodiment, the step of receiving the portion-controlled dispense amount volume can be effectuated by way of one of the following: a data communication from a point-of-sale devices, a quick-serve restaurant data processing device which can also be referred to as a data communication device606, a customer404or the user402initiated data communication from a digital communication device, a remote data communication from the remote data processing resource604, or manual data entry by the user at the portion control system which is part of equipment102/104.

Referring toFIG.21there is illustrated one example of a portion control method for food products302dispensed from frozen beverage equipment102and soft-serve ice cream equipment104. In an exemplary embodiment, and with reference toFIG.21, the method begins in step1402where a food product302can be injected into a mixing cylinder524and chilling the food product to a predetermined frozen malleable consistency. The mixing cylinder524comprises at least one of an auger522, at least one of a product inlet564/566/574, and at least one of a dispense valve526. An auger motor576is interconnected with the auger522. A control system500comprising a temperature sensor542, a pressure sensor520, and a motor sensor528/530. The temperature sensor542is operationally related to the mixing cylinder524. The temperature sensor542measures the temperature of the food product302inside the mixing cylinder524. The pressure sensor520can be operationally related to the mixing cylinder524and measures the pressure inside the mixing cylinder524. The auger522is positioned inside the mixing cylinder524and rotates at an auger motor RPM speed. The motor sensor528/530can be operationally related to the auger motor576. The motor sensor528/530measures an amperage draw or a torque of the auger motor576resultant from the resistance of rotating the auger522through the food product302. The method then moves to step1404.

In step1404, a portion-controlled dispense amount volume is received indicating a volume of the food product302to dispense. In operation, such portion-controlled dispense amount volume can be received by manual input from a user, data communication between the dispenser102/104and a data communicating device, or by other methods, as may be required and/or desired in a particular embodiment.

In an exemplary embodiment, the step of receiving the portion-controlled dispense amount volume can be effectuated by way of one of the following: a data communication from a point-of-sale devices, a quick-serve restaurant data processing device, a customer or the user initiated data communication from a digital communication device, a remote data communication from the remote data processing resource, or manual data entry by the user at the portion control system.

In an exemplary embodiment, a communication interface510is operationally related to the microcontroller502. The control system500by way of the communication interface510data communicates with the remote data processing resource604in a local area network environment or a wide area network environment across a global network700.

The method then moves to step1406if initially the auger motor RPM speed is zero indicated that the auger motor was ‘off’ when the portion-control dispense was initiated and step1412if initially the auger motor RPM speed is greater than zero indicating that the auger motor576was ‘on’ when the portion-control dispense was initiated.

With the portion-control dispense initiated when the auger motor576was ‘off’, the auger motor RPM speed equals zero, in step1406, a dispense time and a dispense amount volume are determined. The dispense time is determined based on current values of a plurality of dispense condition variables by interpolating804between plurality of a dispense table record802. The dispense table records802comprise a dispense time, a dispense amount, and the auger motor RPM across a range of values of the plurality of dispense condition variables stored in more than one of the dispense table records802where the auger motor RPM is zero indicating the record is for a plurality of dispense condition variables in which the auger motor576was ‘off’. In this step the dispense amount volume is a surge amount of volume. Such a surge amount volume is the amount of food product302dispenses when the auger motor576is ‘off’ and the dispense valve526is opened. It is the pressure inside the mixing cylinder that causes the food product302to surge out of the dispense valve526when opened.

In an exemplary embodiment, the plurality of dispense condition variables can comprise a food product viscosity, a mixing cylinder pressure, a dispense valve aperture size, and a geometry of the auger. Additionally, determining the food product viscosity can be based on the amperage draw or the torque of the auger motor576. The method then moves to step1408.

In step1408, the dispense valve526is opened for the dispense time, allowing the surge amount of volume of the food product302, in the predetermined frozen malleable consistency, to be dispensed in a portion-controlled manner.

In an exemplary embodiment, the step of opening the dispense valve, such as in step1408,1414,1418, and other steps in the present invention, for the dispense time further comprise the step of maintaining constant pressure within the mixing cylinder524by varying amount of the food product302that is injected into the mixing cylinder524during the dispense time. The method then moves to step1410.

In step1410, the dispense time and the dispense amount volume is determined again. The dispense time is determined based on current values of the plurality of dispense condition variables by interpolating804between the plurality of the dispense table record802. The dispense amount volume this time is equal to the original portion-controlled dispense amount volume requested minus the surge dispense amount volume already dispensed. The method then moves to step1416.

In step1416, the auger motor is started rotating. In an exemplary embodiment, the step of determining the dispense time can further comprise selecting an auger motor RPM speed, and the step of starting the auger motor can further comprise starting the auger motor at the auger motor RPM speed. The method then moves to step1418.

In step1418, the dispense valve is opened for the dispense time, allowing the dispense amount volume of the food product302, in the predetermined frozen malleable consistency, to be dispensed in a portion control manner. The method is then exited.

With the portion-control dispense initiated when the auger motor576was ‘on’, the auger motor RPM speed is greater than zero, in step1412, the dispense time and the dispense amount volume are determined. The dispense time is determined based on current values of the plurality of dispense condition variables by interpolating804between plurality of the dispense table record802, The dispense amount volume is equal to the portion-controlled dispense amount volume. The method then moves to step1414.

In step1414, the dispense valve is opened for the dispense time, allowing the dispense amount volume of the food product302, in the predetermined frozen malleable consistency, to be dispensed in portion control manner. The method is then exited.

Referring toFIG.22there is illustrated one example of a portion control method for food products302dispensed from frozen beverage equipment102and soft-serve ice cream equipment104. In an exemplary embodiment, the method begins in step1502where the portion control system is trained by varying dispense condition and created a plurality of dispense tables record of dispense time and dispense amounts volume based on those dispense conditions.

In this regard, a food product302can be injected into a mixing cylinder and chilling the food product to a predetermined frozen malleable consistency, the mixing cylinder comprising at least one of an auger522, at least one of a product inlet564/566/574, and at least one of a dispense valve526. An auger motor576is interconnected with the auger522. A control system500can comprise a memory504, a temperature sensor542, a pressure sensor520, and a motor sensor528/530. The temperature sensor542can be operationally related to the mixing cylinder524. The temperature sensor542measures the temperature of the food product302inside the mixing cylinder524. The pressure sensor520can be operationally related to the mixing cylinder524and measures pressure inside the mixing cylinder524. The auger522is positioned inside the mixing cylinder524and rotates at an auger motor RPM speed. The motor sensor528/530can be operationally related to the auger motor576. The motor sensor528/530measures an amperage draw or a torque of the auger motor resultant from resistance of rotating the auger522through the food product302. The method then moves to step1504.

In step1504, at least one of a plurality of dispense condition variables is varied. The plurality of dispense condition variables comprise a dispense time, a dispense amount volume, a food product viscosity, a mixing cylinder pressure, a dispense valve aperture size, a geometry of the auger, and an auger motor RPM speed. The method then moves to step1506.

In step1506, the food product302is dispensed in the predetermined frozen malleable consistency form. The method then moves to step1508.

In step1508, a volume of food product302dispensed and a training dispense time in which the volume of food product was dispensed is determined. The method then moves to step1510.

In step1510, stored in at least one of the dispense table records which can be in the memory or accessible to the dispenser102/104on a remote data processing resource are the training dispense time duration as the dispense time, the volume of food product dispensed as the dispense amount volume, the product temperature, the mixing cylinder pressure, the auger motor RPM speed, and a food product viscosity based in part on an amperage draw or a torque of the auger motor. In this regard, the dispense table record is updated. The method is then exited or the plurality of dispense condition variables varied and the test rerun to create additional dispense table records.

Referring toFIGS.23and24, there are illustrated examples of exemplary embodiments that can be interchangeably used with the methods of the present invention

In step1602, at least one of a plurality of dispense condition variables is varied. The plurality of dispense condition variables comprise a dispense time, a dispense amount volume, a food product viscosity, a mixing cylinder pressure, a dispense valve aperture size, a geometry of the auger, and an auger motor RPM speed. The method then moves to step1604.

In step1604, the food product302is dispensed in the predetermined frozen malleable consistency form. The method then moves to step1606.

In step1606, a volume of food product302dispensed and a training dispense time in which the volume of food product was dispensed is determined. The method then moves to step1608.

In step1608, stored in at least one of the dispense table records which can be in the memory or accessible to the dispenser102/104on a remote data processing resource are the training dispense time duration as the dispense time, the volume of food product dispensed as the dispense amount volume, the product temperature, the mixing cylinder pressure, the auger motor RPM speed, and a food product viscosity based in part on an amperage draw or a torque of the auger motor. In this regard, the dispense table record is updated.

In step1610, one or more of the dispense table record data communicated in a local area network environment or a wide area network environment across a global network with at least one of the data processing resource.

With reference toFIG.24, in step1702, the dispensing lock550/556is unlocked, allowing a user402to dispense the food product302when the temperature204of the food product302is between the predetermined low-temperature setting208and the predetermined high-temperature setting206, and the amperage draw or the torque214of the auger motor576is between234a predetermined low motor performance setting216and the predetermined high motor performance setting218. And, in step1704, locking the dispensing lock550/556, and queuing the portion-controlled dispense amount, preventing the user402from dispensing the food product302, when the temperature204of the food product302is below the predetermined low-temperature setting208or above the predetermined high-temperature setting206, or the amperage draw or the torque214of the auger motor576is below the predetermined low motor performance setting216or above the predetermined high motor performance setting218.

In step1706, the food product302viscosity is determined based on the amperage draw or the torque of the auger motor576.

In step1708, constant pressure is maintained within the mixing cylinder524by varying amount of the food product302that is injected into the mixing cylinder524during the dispense time.

The capabilities of the present invention can be implemented in software, firmware, hardware, or some combination thereof.

As one example, one or more aspects of the present invention can be included in an article of manufacture (e.g., one or more computer program products) having, for instance, computer usable media. The media has embodied therein, for instance, computer-readable program code means for providing and facilitating the capabilities of the present invention. The article of manufacture can be included as a part of a computer system or sold separately.

Additionally, at least one program storage device readable by a machine, tangibly embodying at least one program of instructions executable by the machine to perform the capabilities of the present invention can be provided.

The flow diagrams depicted herein are just examples. There may be many variations to these diagrams or the steps (or operations) described therein without departing from the spirit of the invention. For instance, the steps may be performed in a differing order, or steps may be added, deleted, or modified. All of these variations are considered a part of the claimed invention.

While the preferred embodiment of the invention has been described, it will be understood that those skilled in the art, both now and in the future, may make various improvements and enhancements which fall within the scope of the claims which follow. These claims should be construed to maintain the proper protection for the invention first described.