Information
-
Patent Grant
-
6301908
-
Patent Number
6,301,908
-
Date Filed
Friday, October 8, 199924 years ago
-
Date Issued
Tuesday, October 16, 200122 years ago
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Inventors
-
Original Assignees
-
Examiners
Agents
-
CPC
-
US Classifications
Field of Search
US
- 062 71
- 062 137
- 062 233
- 062 158
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International Classifications
-
Abstract
An ice making device including a control system to regulate the dispensing of manufactured ice to a hopper for subsequent dispensing into a container such as a cup. The control system senses a low level of ice in the hopper and initiates a signal that is sent to a controller. The controller initiates a time delay that prevents discharge of ice from the ice making device to the hopper until a monitored variable about the ice meets a predetermined value. When the value is reached, additional ice is dispensed to the hopper. Such an ice making device has use in combination with a beverage dispensing device.
Description
BACKGROUND OF THE INVENTION
The present invention relates to an ice making apparatus and method particularly adapted for use in conjunction with automatic beverage dispensers or other devices requiring frequent dispensing of small quantities of ice. It is also particularly adapted for ice makers utilizing small hoppers relative to the total amount of ice dispensed which typically make ice continuously during an ice making cycle.
Automatic ice makers are well known in the art and are available in many forms and typically have hoppers for temporary storage of manufactured ice. Beverage dispensers of the coin operated type, dispense both ice and beverage when the requisite amount of money is provided and a beverage selection is made. A cup is automatically dispensed, ice is fed to the cup and then beverage is dispensed to the cup. Such vending machines are commonly used in cafeterias and break rooms. A typical vending machine is a model 328 from Crane National Vendors. Many ice makers have control systems to improve their operation and/or efficiency. Typically, the ice maker will cease making ice when the ice bin is full and commence ice making when the ice level in the hopper reaches a low level. Such a control system does not readily adapt itself to ice makers having small hoppers, for example, a four pound capacity hopper, relative to the amount of ice dispensed, like ice makers associated with coin operated beverage dispensers. Nor is such a control system well adapted for ice makers where the amount of dispensed ice varies, sometimes significantly, throughout a day or by day of week. Ice makers using such control systems can produce poor quality ice and present operational problems such as ice clumping. When ice is retained in a hopper for an extended period, it tends to clump together forming large blocks of ice that cannot be dispensed requiring its removal sometimes leaving an empty or nearly empty hopper and thereby potentially unable to meet demand. Also, the ice feeder in the hopper may break the clumped ice and unclumped ice degrading its quality by leaving pieces that are too large or small and may also warm the ice.
Clumping can occur at night, over weekends or during other periods when the rate of ice dispensing is reduced. Generally, ice makers associated with vending machines function such that ice in the hopper is not being moved or mixed unless dispensing is occurring or ice is being made which lack of movement can also encourage clumping. Clumping can be due to the temperature in the hopper rising during periods of non-dispensing and non-mixing allowing localized melting of the ice followed by refreezing. Additionally, the weight of the ice itself can cause localized melting also followed by refreezing. Further, continued mixing, as discussed above, can warm the ice, providing conditions which can lead to later clumping and can also degrade the ice quality through breakage.
The ice quality problem is exacerbated by current control systems operating in a manner such that when the low ice level is attained, the ice maker is activated and makes ice until the high level sensor turns off the ice maker. No accommodation is provided with such a control method to accommodate fluctuating ice demand during extended operating periods. Lack of ice and poor quality ice presents consumer acceptance problems.
Ice makers are many times part of vending machines that are on service routes. Should an ice maker become non-functional, e.g., because of ice clumping, it may be several days between visits by a service person to remedy the situation. A vending machine may then be out of service for extended periods of time causing consumer inconvenience.
The apparatus of the present invention includes a control system that is operable to commence ice making upon two or more operating conditions being met with one of the operating conditions being a low ice level in the hopper. The use of two or more operating conditions for control of ice making accommodates fluctuating ice demand and thereby improves operation and ice quality.
SUMMARY OF THE INVENTION
Among the several objects and features of the present invention may be noted the provision of a device for making ice that utilizes at least two operating parameters to control commencement of ice making; the provision of such a device that is effective for ice makers having small storage hoppers; the provision of such a device that continuously makes ice during an ice making portion of an operating cycle; the provision of such an ice making device that is automatic in operation; and the provision of such an ice making device that provides quality ice.
The present invention involves the provision of an ice dispenser having an ice former with an outlet. Ice is discharged from the outlet on command into a hopper positioned for receiving ice discharged from the outlet. A low ice level sensor is operatively associated with the hopper and is operable to monitor a first parameter of the ice dispenser, the first parameter being indicative of a low ice level in the hopper. A controller is operably connected to the ice former and the low ice level sensor and is operable to monitor a second parameter of the ice dispenser, the second parameter being indicative of an operating condition of the ice dispenser. The controller is also operable to reenable the ice former for full discharge of ice by the ice former to the hopper in response to the first and second parameters.
The present invention also involves the provision of an ice making device comprising an ice dispenser having an ice former. The ice former has an outlet and is adapted for discharging ice from the outlet on command. The ice dispenser also has a hopper positioned for receiving ice discharged from the outlet and a feeder associated with the hopper operable to feed ice to a discharge for dispensing ice from the hopper. A low ice level sensor is operatively associated with the hopper and operable to monitor a first parameter of the ice dispenser, the first parameter being indicative of a low ice level in the hopper. The low ice level sensor is operable to generate a low ice level signal. A high ice level sensor is operatively associated with the hopper and operable to monitor a second parameter of the ice dispenser. The second parameter is indicative of a high ice level in the hopper and the high ice level sensor is operable to generate a high ice level signal. A controller is operably connected to the ice former, the low ice level sensor and the high ice level sensor and is operable to monitor third parameters of the ice dispenser. The third parameters are indicative of operating conditions of the ice dispenser and include the number of times ice has been dispensed from the hopper and a time period. The controller is operable to reenable the ice former for full discharge of ice by the ice former to the hopper in response to the first parameter and at least one of the third parameters meeting a respective predetermined value.
Additionally, the present invention involves the provision of a method of making ice in an ice making device having a hopper and dispensing ice from the hopper. The method includes making ice and discharging the ice at a full discharge rate to the hopper. At least two ice making parameters are monitored, one of which is ice level in the hopper. Full discharge of ice to the hopper is terminated when the ice level reaches a predetermined high ice level. Full discharge of ice to the hopper is reenabled when at least two ice making parameters each meet a respective predetermined value.
Other objects and features will be in part apparent and in part pointed out hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1
is an operation flowchart of a controller for an ice making device; and
FIG. 2
is side elevation sectional view of an ice making device with control elements shown schematically.
Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION
The reference numeral
10
designates generally an ice making device (
FIG. 2
) comprising an ice storage hopper
12
, ice former
14
and ice dispenser
16
. A preferred ice making device is model 638090900004 from IMI Cornelius. The ice former
14
includes an auger shaft
18
rotatably mounted in a tube
20
. The auger
18
is driven by a motor
21
operably connected thereto. A freezer section
19
includes refrigeration coils
22
surrounding the tube
20
and operably connected to a refrigeration unit
25
that includes a compressor
23
. Insulation
24
in a housing
26
surrounds the coils
22
. A water inlet tube
27
communicates with the interior
31
of tube
20
. Preferably water flow in the inlet tube
27
is controlled by a water flow control valve arrangement preferably of the float valve type having a water flow control valve
28
and a float chamber
30
. One or more switches
29
are operably connected to the valve
28
signaling high and low water levels in the chamber to control the valve
28
. Preferably the valve
28
is a solenoid operated valve. Water flows into the space
31
between the auger
18
and the interior surface
32
of the tube
20
and freezes and is fed to a discharge
34
at the upper end of the auger
18
. The formed ice
35
breaks into pieces on its own after exiting the tube
20
and is then fed through a bottom opening
36
into the hopper
12
. An ice breaker (not shown)could be provided in the tube
20
to assist in ice breakage if desired. The bottom wall
38
of the hopper
12
is frustoconically shaped, sloping downwardly to its outer perimeter. An ice outlet opening
40
is positioned in a sidewall
42
of the hopper
12
and is operable for dispensing ice to a beverage cup or the like. A door
43
is movably mounted on the sidewall
42
and selectively opens and closes the opening
40
upon command. The command includes a dispensing signal generated by a consumer initiating operation by inserting money and making a selection in the case of an automatic beverage dispenser by actuating a switch
41
or the like. Preferably, the door
43
closes after a predetermined elapsed time of dispensing. The auger
18
has an upper end
44
with a shaft
45
secured thereto. A plurality of paddles
46
are secured to and extend laterally outwardly from the shaft
45
. Rotation of the auger
18
and the shaft
45
with the paddles
46
induces ice flow from the hopper
12
through the outlet
40
. If the auger
18
is not already rotating because of ice making, the signal from the switch
41
will start the motor
21
to achieve ice dispensing and also open the door
43
. After a predetermined time, the door
43
closes and the motor
21
will stop, unless the device
10
is in ice making mode, terminating the dispensing of ice
35
through the opening
40
.
Ice level sensing means is provided and is operable to generate signals indicative of a high ice level and a low ice level in the hopper
12
. Any suitable sensing means can be used. Preferably, a diaphragm
47
is movably mounted in the hopper
12
. The diaphragm
47
has an actuator shaft
48
engageable with a switch
49
such as a limit switch. The diaphragm
47
rests on the ice
35
indicating generally the level of the top surface of the pile of ice in the hopper
12
. When the top surface of the ice pile reaches a predetermined high level in the hopper
12
, ID the switch
49
generates a signal such as by making or breaking a circuit indicative of a high ice level. When the ice level lowers from ice dispensing, the diaphragm
47
moves down in the hopper
12
until it reaches a predetermined low level again activating the switch
49
to generate a second signal such as by breaking or making a circuit (the opposite of the switch generating the high ice level signal) indicative of a predetermined low ice level. The diaphragm
47
and switch
49
form both high and low ice level sensors. Other forms of ice level sensors could be used. For example a swing arm arrangement like those used in home refrigerator ice makers could be used. A two switch arrangement could also be used.
A controller
50
is operably connected to various components of the ice making device
10
to control the operation thereof. The controller
50
operates in a manner shown in FIG.
1
. Preferably, the controller
50
is a programmable logic circuit device as are known in the art. Ice making is commenced by activating the refrigeration unit
25
and feeding water into the space
31
. The motor
21
is also activated driving the auger
18
to move formed ice
35
to and out the outlet
34
and bottom opening
36
. The formed ice
35
is discharged into and fills the hopper
12
until a high ice level signal is generated by ice reaching the high ice level thereby activating the sensor
49
. When the high ice level signal is generated, the manufacture of ice is at least partially and preferably completely terminated stopping full ice discharge to the hopper
12
(i.e. the production of ice at a generally normal rate). The operation of the ice making device
10
will be discussed in terms of ice making being completely temporarily stopped when the ice
35
in the hopper
12
reaches a predetermined high level as sensed by the high ice level sensor
49
. It is to be understood that the making of ice could be, alternatively, slowed down substantially to stop full ice discharge, for example less than about 20% of normal ice production rates. Ice making ceases when the high level sensor
49
is activated.
The high ice level signal, which can be the making or breaking of a circuit, is indicative of a high ice level and is transmitted to the controller
50
and disables the motor
21
and hence the auger
18
and the compressor
23
of the refrigeration unit
25
. Ice
35
is dispensed from the hopper
12
through the opening
40
from time to time. For ice dispensing, the motor
21
is reactivated to drive the auger
18
, shaft
45
and paddles
46
to help move ice to the opening
40
. When the ice
35
reaches a predetermined low level in the hopper
12
, the low level ice sensor
49
generates a signal indicative of the low ice level which could be the making or breaking of a circuit. The controller
50
is further operable to monitor an additional parameter indicative of a second operating condition of the ice making device
10
. The second operating condition can be indicative of current and/or former operating conditions. The controller
50
is operable to reenable the ice forming auger
18
for full discharge of ice
35
by the ice former
14
to the hopper
12
in response to the low level signal and the second operating condition. When the second operating condition reaches a predetermined value and the low ice level signal indicates low ice, the ice former
14
, including the auger
18
, will be reenabled for full discharge of ice to the hopper
12
. The second operating condition can be any suitable operating condition, e.g., elapsed time, the length of time ice has been dispensed, i.e. the total or cumulative amount of elapsed time during which one or more ice has been dispensed since a starting point, number of dispenses of ice from the hopper
12
, etc. Some second operating conditions are monitored from a starting point. Preferably, the starting point is the generation of the low ice level signal, however, it could also be measured from the generation of the full ice level signal. Also, more than one operating condition can be monitored and can be used individually or in combination for reenabling full discharge of ice.
It has been found desirable to initiate a time delay (as described below) when the low ice level signal is generated. When ice storage hoppers have small storage capacities, as is typically the case for automated beverage dispensers which can have a full capacity on the order of four lbs., it has been found desirable to generate the low ice level signal when the hopper
12
has ice in the range of about 40% through about 80%, preferably in the range of about 50% through about 70% and most preferably about 60% of the capacity at the full ice level as indicated by the high ice level sensor
49
. The degree of ice fill in the hopper
12
to initiate the low ice level signal will depend on the size of hopper relative to the rate of ice dispensing. Having a significant amount of ice in the hopper
12
provides for the use of a small hopper and dispensing of high quality ice while being able to meet demand for ice. The initiation of a predetermined time delay period with a significant amount of ice in the hopper
12
allows the hopper to be further emptied without jeopardizing the ability to meet demand. typical time delay would be in the range of about ½ hour through about 4 hours, preferably in the range of about 1 hour through about 3 hours and most preferably about 2 hours of elapsed time since the most recent low ice level signal (starting point).
Other second operating conditions that can be monitored include the amount of time ice
35
is dispensed and the number of times ice has been dispensed through the opening
40
since the last low ice level signal (starting point). Both are indicative of the quantity of ice that has been dispensed. Preferably, the amount of time of ice dispensing is used as a second operating condition. The ice dispensing time is measured by measuring the length of time the door
43
is open. In a preferred embodiment, the aforementioned time delay period is initiated by the low ice level signal during which time period full ice discharge is disabled until another operating condition is met. As seen in
FIG. 1
, full ice discharge is reenabled when either the time delay period has elapsed, as described above, or within the time delay period upon meeting another operating condition as described above. When the operating conditions are met, the controller
50
effects commencement of operation of the ice former
14
for full ice discharge to the hopper
12
by activating the compressor
23
and powering the motor
21
to drive the auger
18
. Full discharge of ice is continued until the ice reaches and activates the high ice level sensor
49
. When the high ice level sensor
49
is activated, the full discharge of ice is again ceased. In the described preferred embodiment, the ice making cycle starts again upon receipt of the low ice level signal. It is to be understood that the controller
50
can be programmed for a variety of operating modes, for example, cycle initiation could be the high ice level signal. Rate of ice dispenses could be monitored instead of or in addition to the number of dispenses or total time of dispensing. If the ice making device
10
is used in an environment where there are regular periods of non operation, the controller
50
could be programmed for preselected time periods of stand-by mode such as date, e.g., weekends, holidays, e.g., Thanksgiving, day of week, e.g., weekends, and/or time of day, e.g., early morning hours, when consumers would not normally be present. During such stand-by periods, the ice former
14
would be disabled from full discharge of ice irrespective of the other operating parameters and control functions effected by the controller
50
for normal operation. The controller
50
operates on an ice making cycle basis. A cycle of ice making is between common operating points in successive cycles, e.g., the period between two successive high ice level signals, which is a preferable operating mode, or between two low ice level signals. When an ice making cycle is completed, the controller
50
resets itself for another cycle. The monitoring of the operating conditions will be reinitiated at the appropriate signal and the monitored operating conditions will be remeasured.
The operation of the controller
50
is illustrated in FIG.
1
. The operation of the ice making device
10
is described below using a time delay period and the amount of elapsed time of ice dispensing as monitored operating parameters for control of the ice making device. The ice making device
10
is powered up, control box
80
, and the compressor
23
and motor
21
are off, control box
51
. The controller
50
is preprogrammed with initial operating parameter data, control box
82
, with the total cumulative elapsed time of ice dispensing required to disable the time delay period and the time delay period are set. Ice making commences by activating the compressor
23
and the motor
21
, control box
84
. The controller
50
checks the ice level signal, control box
86
, and evaluates the signal for whether or not the hopper
12
is full, control box
88
. If the hopper
12
is not full, ice making continues and if it is full, the compressor
23
and motor
21
are disabled from producing full discharge of ice
35
, control box
90
. After the motor
21
and compressor
23
are disabled, the controller
50
checks the signal from the ice level switch
49
and determines if the hopper
12
is full, control box
94
. If the hopper
12
is fill, the compressor
23
and motor
21
are maintained disabled, control box
96
. If a signal from the switch
41
is received, control box
98
, the controller
50
rechecks the level of ice in the hopper
12
, control boxes
92
,
94
. If the hopper
12
is not full, control box
94
, the total time of ice dispensing is set to zero and the time delay period is also set to zero, control box
100
. The controller
50
evaluates whether or not the time delay period, after resetting to zero now exceeds the predetermined time delay period, control box
101
. The elapsed time of the time delay period, control box
102
, is summed or monitored, control box
103
. If the predetermined time delay period is exceeded, the compressor
23
and motor are reenabled for full discharge of ice
35
, control box
84
. If the time delay period has not expired or been exceeded, the controller
50
determines the total time of dispensing of ice
35
from multiple dispenses through the opening
40
, control box
104
. The value of the time of ice dispensing is provided by measuring the total time the door
43
is open for multiple ice dispenses, control box
106
, as initiated by a signal generated by activating the switch
41
, control box
108
. The controller
50
determines if the amount of time of ice dispensing exceeds a predetermined value, control box
110
. If the cumulative time of ice dispensing exceeds the predetermined value, the time delay is disabled and the compressor
23
and motor
21
are reenabled for full ice discharge, control box
84
. If the time of ice dispensing does not reach the predetermined value set therefor, the compressor
23
and motor remain disabled, control box
112
.
When introducing elements of the present invention or the preferred embodiment(s) thereof, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
Claims
- 1. An ice making device comprising:an ice dispenser, said ice dispenser having an ice former, said ice former having an outlet and being adapted for discharging ice from the outlet on command, said ice dispenser further having a hopper positioned for receiving ice discharged from the outlet and a feeder associated with the hopper operable to feed ice to a discharge for dispensing ice from the hopper; a low ice level sensor operatively associated with the hopper and operable to monitor a first parameter of the ice dispenser, said first parameter being indicative of a low ice level in the hopper and said low ice level sensor being operable to generate a low ice level signal; a high ice level sensor operatively associated with the hopper and operable to monitor a second parameter of the ice dispenser, said second parameter being indicative of a high ice level in the hopper and said high ice level sensor being operable to generate a high ice level signal; a controller operably connected to the ice former and the low ice level sensor and the high ice level sensor and operable to monitor third parameters of the ice dispenser, said third parameters being indicative of operating conditions of the ice dispenser, said third parameters including a time period and a quantity of ice dispensed from the hopper and, said controller being operable to reenable the ice former for full discharge of ice by the ice former to the hopper in response to the first parameter being met and at least one of the third parameters meeting a respective predetermined value.
- 2. An ice making device as set forth in claim 1 wherein the third parameter being met when a predetermined time delay period expires.
- 3. An ice making device as set forth in claim 2 wherein said time delay period commences upon generation of the low level signal.
- 4. An ice making device as set forth in claim 2 wherein said time delay period commences upon generation of the high ice level signal generated by the high ice level sensor.
- 5. An ice making device as set forth in claim 1 wherein ice is dispensed from the hopper a number of times during an operating cycle of the ice making device and said third parameter is met when a predetermined number of dispenses is met.
- 6. An ice making device as set forth in claim 5 wherein the number of dispenses being counted commences with the low ice level signal being generated.
- 7. An ice making device as set forth in claim 5 wherein the number of dispenses being counted commences with the high ice level signal being generated.
- 8. An ice making device as set forth in claim 1 wherein ice is dispensed multiple times from the hopper for a period of total time of multiple ice dispenses during an operating cycle of the ice making device and said third parameter is met when a predetermined period of total time of ice dispenses is met.
- 9. An ice making device as set forth in claim 8 wherein the period of time of ice dispensing commences with the low ice level signal being generated.
- 10. An ice making device as set forth in claim 8 wherein the period of time of ice dispensing commences with the high ice level signal being generated.
US Referenced Citations (11)