COFFEE ROASTING SYSTEM HAVING ROAST AND COOLING SUBSYSTEMS AND METHOD THEREOF

Abstract

The bean roasting system includes a roasting subsystem, a cooling subsystem, an air outlet subsystem fluidly coupled to the cooling subsystem, and a controller. The cooling subsystem includes an outer housing including a holding chamber, a cooling platform defining a lower limit of the holding chamber, a vibration actuator coupled to the cooling platform, and a platform actuator coupled to the cooling platform. The controller is configured to operate the air outlet subsystem to maintain an upward flow of air through the holding chamber, operate the roasting subsystem to transfer a batch of beans from the roasting subsystem to the holding chamber, operate the vibration actuator to vibrate the cooling platform, operate the air outlet subsystem and operate the vibration actuator to accelerate cooling of the batch of beans, and operate the platform actuator to transport the batch of beans from the cooling subsystem.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to and is a continuation-in-part of U.S. patent application Ser. No. 17 / 391,579, entitled "Coffee Roasting System with Roasting and Cooling Subsystems, and Methods for the Same," filed on August 2, 2021, which is a continuation-in-part of U.S. patent application Ser. No. 17 / 391,581, entitled "Coffee Roasting System with Roasting and Cooling Subsystems, and Methods for the Same," filed on August 2, 2021, which is a continuation-in-part of U.S. patent application Ser. No. 17 / 391,581, entitled "Coffee Roasting System with Roasting and Cooling Subsystems," filed on September 23, 2021, which is a continuation-in-part of U.S. patent application Ser. No. 17 / 482,858, entitled "Coffee Roasting System with Roasting and Cooling Subsystems," filed on September 23, 2021, which is a continuation-in-part of U.S. patent application Ser. "Subsystems, and Methods for the Same" and is a continuation-in-part of U.S. patent application Ser. No. 17 / 482,862, filed Sep. 23, 2021, the contents of each of which are incorporated by reference in their entireties herein.

[0002] The present disclosure relates to roasting food products, such as beans, for example coffee beans. In one or more embodiments, the present disclosure describes a roasting system having an improved system for roasting and cooling beans. In one or more embodiments, the present disclosure describes a roasting system having a compact and thermally efficient heating system. In one or more embodiments, the present disclosure describes an automated roasting system having a compact roasting subsystem that maximizes roast uniformity and allows for visibility of the roasting process. In one or more embodiments, the present disclosure describes a roasting system having an improved system for removing heat, moisture, and emissions from an exhausted fluid stream. [Background technology]

[0003] Food roasters are widely used. One particularly common roaster is utilized to package or grind coffee beans and prepare them for brewing. A typical roaster includes a roasting chamber for supporting, stirring, and roasting the beans. It is desirable to provide an automated method of roasting, cooling, and removing the beans that minimizes the overall cycle time. Another challenge is to provide a highly productive, yet compact, roasting system. Heaters are used to provide a roasting temperature profile inside the roasting chamber. Known heaters contain bulky insulation or give off undesirable amounts of excess heat. Another challenge is to provide a compact roasting system while providing a very uniform roast and allowing visibility of the roasting process. In a typical roaster, a bean cooler is used to cool the beans after they are roasted. The roasting process occurs at high temperatures. During this process, water vapor, particulates, and harmful gases are generated and may be carried from the bean cooler by the fluid flow passing through the roasting chamber. A portion of the fluid flow needs to be vented. There is a further need to efficiently treat the discharged fluid stream. [Brief description of the drawings]

[0004] [Figure 1]1 is a schematic diagram of an embodiment of a roasting system for processing a batch of coffee beans, FIG 1 shows the connections between elements that are fluid connections or that are involved in the physical transport of the batch of beans; [Diagram 2] Fig. 2 is a simplified electrical block diagram of the roasting system of Fig. 1. Fig. 2 shows the electrical or wireless connections between the elements, including the controller. [Diagram 3] 1 is a flow chart of an embodiment of a roasting process for a batch of beans. [Figure 4] FIG. 2 is an isometric view of an embodiment of a portion of a bean cooling subsystem, otherwise referred to as a "bean cooler." [Diagram 5] FIG. 2 is a vertical cross-sectional view of an embodiment of a bean cooler. [Figure 6A] FIG. 13 is a side view of an embodiment of a single cooling platform. [Figure 6B] FIG. 1 illustrates a top down isometric view of an embodiment of a single cooling platform. [Figure 7A] FIG. 2 is a vertical cross-sectional view of a portion of an embodiment of a bean cooler with the platform in a closed configuration for supporting a batch of beans during cooling. [Figure 7B] FIG. 2 is a vertical cross-sectional view of a portion of an embodiment of the bean cooler with the platform in an open configuration to allow a cooled batch of beans to exit the bean cooler. [Figure 8] 1 is a flow chart illustrating an embodiment of a method for cooling and discharging or ejecting a batch of beans. [Figure 9] 1 is a flow chart illustrating an embodiment of a method for roasting and cooling a batch of beans. [Figure 10] FIG. 1 is a schematic diagram of a portion of a roasting system highlighting the (main) heater and cyclone separator. The heater includes a heater power supply and a heater winding. The heater winding includes a resistive heating coil for converting electrical energy to thermal energy. The heater winding is integrated with a portion of the cyclone separator. [Figure 11A] FIG. 2 is an isometric view of an example cyclone separator including an integral heater winding. [Figure 11B]FIG. 11B is a cross-sectional view of the cyclone separator of FIG. 11A including an integral heater winding. [Figure 12] FIG. 11B is an isometric view of a portion of the cyclone separator of FIG. 11A highlighting the electrodes and insulating substrate that supports and insulates the heater winding. [Figure 13] FIG. 1 illustrates an isometric view of an embodiment of a roasting subsystem. [Figure 14] FIG. 1 illustrates a cross-sectional view of an embodiment of a roasting subsystem. [Figure 15] FIG. 13 is a side view of an embodiment of an agitator coupled solely to a bearing. [Figure 16] FIG. 13 is an isometric view of an embodiment of an agitator coupled solely to an agitator actuator. [Figure 17] 1 is a flow chart of an embodiment of a method of operating a roasting system. [Figure 18] 1 is a schematic diagram of a portion of a roasting system to highlight an embodiment of an air outlet subsystem, the purpose of which is to remove heat, water vapor, and harmful emissions generated during the roasting and cooling process. [Figure 19] FIG. 2 is a "front" isometric view showing an embodiment of a heat sink coupled to a filter. [Figure 20] FIG. 2 is a "back" isometric view showing an embodiment of a heat sink coupled to a filter. [Figure 21] FIG. 2 is a horizontal cross-sectional view of the heat sink. [Figure 22] FIG. 1 is an isometric view of a top portion of the air outlet subsystem highlighting the housing that provides a fluid coupling between the heat sink and the filter. [Figure 23] FIG. 13 is an isometric cross-sectional view looking down on an embodiment of an air outlet subsystem. Summary of the Invention

[0005] In a first aspect of the disclosure, a bean roasting system includes a roasting subsystem configured to receive and thermally roast beans, a cooling subsystem, an air outlet subsystem fluidly coupled to the cooling subsystem, and a controller. The cooling subsystem includes an outer housing including a holding chamber, a cooling platform defining a lower limit of the holding chamber, a vibration actuator coupled to the cooling platform, and a platform actuator coupled to the cooling platform. The controller is configured to operate the air outlet subsystem to maintain an upward air flow through the holding chamber, operate the roasting subsystem to transfer a batch of beans from the roasting subsystem to the holding chamber, operate the vibration actuator to vibrate the cooling platform, operate the air outlet subsystem and operate the vibration actuator to accelerate cooling of the batch of beans, and operate the platform actuator to transport the batch of beans in a downward direction and out of the cooling subsystem.

[0006] In one implementation, the cooling subsystem includes an upper subunit, a middle subunit, and a lower subunit. The middle subunit includes a cooling platform. The upper subunit defines a chute for receiving the batch of beans from the roasting subsystem. The upper subunit can further define an air conduit coupled to the air outlet subsystem and receiving the flow of air from the holding chamber. The air outlet can include an outlet fan coupled to the air conduit and configured to maintain the flow of air.

[0007] In another implementation, the cooling platform can include a plurality of resilient supports coupling the cooling platform to the outer housing. A vibration actuator is coupled between the outer housing and the cooling platform and imparts relative vibratory motion between the cooling platform and the outer housing that flexes the resilient supports. The relative vibratory motion is primarily lateral motion generally parallel to a top surface of the cooling platform.

[0008] In yet another implementation, the cooling platform includes a plurality of rotatable moving parts. The platform actuator is configured to rotate the plurality of rotatable moving parts to transport the batch of beans from the bean cooler. The cooling platform may include a generally rectangular frame. The plurality of rotatable moving parts are individually rotatably mounted to the rectangular frame having an axis of rotation along the generally rectangular frame. The rotatable moving parts define at least one line where the moving parts intersect. During rotation, the moving parts rotate about the axis of rotation downward and away from the at least one line. The plurality of rotatable moving parts may include four moving parts, and the at least one line may include two intersecting lines. The rectangular frame may have a generally square shape.

[0009] In a further implementation, the cooling subsystem includes a lower subunit below the cooling platform, the lower subunit generally converging in a downward direction to facilitate discharging the batch of beans into a container or bag, and a platform actuator coupled between the lower subunit and the cooling platform.

[0010] In yet a further implementation, the bean roasting system includes a "ventless" air handling system. "Ventless" means that the air handling system recirculates heated air through the roasting subsystem and other components including at least one heater and at least one component for removing particles and gaseous emissions from the heated air. The air handling system may include two airflow branches (or loops) joined by a bypass. The air handling system may include two or more heaters including a main heater and an auxiliary heater. Other components may include a cyclone for removing particulates and a catalytic converter for removing gaseous emissions. All components of the bean roasting system may be electrically powered.

[0011] In a second aspect of the disclosure, a method of producing roasted beans includes providing and operating components of a bean roasting system. The bean roasting system includes a roasting subsystem configured to receive and thermally roast beans, a cooling subsystem, and an air outlet subsystem fluidly coupled to the cooling subsystem. The cooling subsystem includes an outer housing including a holding chamber, a cooling platform defining a lower limit of the holding chamber, a vibration actuator coupled to the cooling platform, and a platform actuator coupled to the cooling platform. The method includes operating the air outlet subsystem to maintain an upward air flow through the holding chamber, operating the roasting subsystem to transfer a batch of beans from the roasting subsystem to the holding chamber, operating the vibration actuator to vibrate the cooling platform, operating the air outlet subsystem and operating the vibration actuator to accelerate cooling of the batch of beans, and operating the platform actuator to transport the batch of beans in a downward direction and out of the cooling subsystem.

[0012] In another aspect of the disclosure, a bean roasting system includes a roasting subsystem and an air treatment subsystem. The roasting subsystem is configured to receive and thermally roast a batch of beans. The air treatment subsystem is coupled to the roasting subsystem and includes a blower, a cyclone separator, and a heater. The blower is configured to impart air motion. Air passes through the air treatment subsystem. The cyclone separator is configured to remove particulates from the air treatment subsystem. The heater is configured to heat air passing through the air treatment subsystem. The heater includes a heater portion integrated into the cyclone separator. The heater portion generates heat and heats the air passing through the cyclone separator. The heater can generate heat and hot air based on resistive heating through a heater winding, ignition of a fuel such as natural gas, or generation of high temperature plasma, to name a few examples.

[0013] In one implementation, the cyclone separator includes an air outlet, an air inlet, and a particulate outlet. The heater portion is integrated into the air outlet. If the heater is based on resistive heating, the heater portion can be or include a heater winding integrated into the air outlet.

[0014] In another implementation, the cyclone separator has a vertical cyclone axis that is centered about a helical rotation of the particulates as they pass from the top portion of the cyclone separator to the particulate outlet. The heater portion can include a heater winding that surrounds the cyclone axis.

[0015] In yet another implementation, the cyclone separator includes a cyclone housing including an upper housing and a lower housing. The heater portion extends vertically from above the upper housing into the upper housing. The cyclone separator includes an air outlet having an outlet housing extending into the upper housing and defining a vertical air outlet passage. The heater portion is disposed within the outlet housing and within the air outlet passage. The upper housing defines a vertical axis. The heater portion can include a heater winding spiraling about the vertical axis.

[0016] In a further implementation, the heater provides a majority of the thermal energy for roasting the batch of beans. The bean roasting system can also include an auxiliary heater that is physically separate from the cyclone separator.

[0017] In yet a further implementation, the bean roasting system also includes a controller coupled to the blower and the heater and other components of the bean roasting system, the controller configured to operate the blower, the heater and other components of the bean roasting system to provide a predetermined temperature profile in the roasting subsystem to roast the batch of beans.

[0018] In yet another aspect of the present disclosure, a method of producing roasted beans includes providing and operating a bean roasting system as described.

[0019] In a further aspect of the disclosure, a bean roasting system includes a roasting subsystem and an air handling subsystem. The roasting subsystem includes a housing, an agitator actuator, an agitator, a bearing, and a door. The housing has an inner surface defining an inner chamber for holding a batch of beans during a thermal roasting process. The inner chamber has a horizontal axis. The agitator is coupled to the agitator actuator and includes a central shaft and a blade set attached to the central shaft. The bearing is disposed at a rear end portion of the housing. The bearing is configured to support the central shaft and prevent the blade set from contacting an inner surface of the housing. The door has a transparent window disposed at a front end portion of the housing. The transparent window is configured to allow viewing of the inner chamber during the thermal roasting process. The air handling system is coupled to the roasting subsystem and includes a blower and a heater and is configured to circulate heated air through the roasting subsystem during the thermal roasting process. The roasting subsystem provides a highly uniform roast of the batch of beans that can be viewed through the transparent window. The roasting subsystem is very compact while still holding large batches of beans.

[0020] In one implementation, the housing includes a first conduit defining an air inlet and a second conduit defining an air outlet and a bean inlet. The first conduit may be located adjacent a rear end portion of the housing and configured to receive a heated air flow in a vertically downward direction from the air treatment subsystem. The second conduit may be located adjacent a front end portion of the housing and configured to output an air flow in a vertically upward direction to the air treatment subsystem. The second conduit may have a larger cross-sectional area than the first conduit and may be configured to slow the velocity of the air flow into the air treatment subsystem in the upward direction to reduce the intake of the batch of beans into the air treatment subsystem. The second conduit is also configured to receive the batch of unroasted beans from the hopper.

[0021] In another implementation, the housing includes a hatch. The blade set can be configured to impart an agitating motion to the batch of beans as the batch is removed from the chamber to facilitate exiting the batch of beans through the hatch. The agitating motion can include a back and forth horizontal component.

[0022] In yet another implementation, the blade set can include an inner helical auger and an outer set of blades. The inner helical auger is configured to impart horizontal motion of the batch of beans along a first horizontal direction. The outer set of blades is configured to impart horizontal motion of the beans along a second horizontal direction opposite the first horizontal direction to enhance mixing of the batch of beans during the thermal roasting process. The blade set can include a number of radial spokes supporting the outer set of blades on the outside of the inner helical auger. This blade configuration and imparted motion also increases efficiency and completeness in removing the beans.

[0023] In a further implementation, the central shaft is a hollow cylindrical shaft. The bearings radially surround the hollow cylindrical shaft at the rear end portion of the housing. This configuration allows the blade set to be fully supported without a separate support bearing at the front end portion of the housing.

[0024] In yet a further implementation, the agitator actuator includes a motor and a power coupling mounted behind the rear end portion of the housing. The power coupling is configured to transfer rotational power from the motor to the agitator. The motor extends in a forward direction from the power coupling and overlaps with the housing along a horizontal axis. This configuration provides efficient rotational power delivery to the agitator in a compact configuration of the roasting subsystem.

[0025] In another implementation, a bean roasting system includes a hopper, a bean cooling subsystem, and a controller configured to operate the hopper to discharge a batch of beans from the hopper into the inner chamber, operate the agitator actuator to rotate the actuator and agitate the batch of beans in the inner chamber, operate the air handling subsystem to circulate heated air through the inner chamber according to a thermal roasting process, and operate the bean discharge actuator and the agitator actuator to discharge beans from the inner chamber to the bean cooling subsystem.

[0026] In yet a further aspect of the disclosure, a bean roasting system includes a roasting drum, an air handling system, a bean cooler, and an air outlet subsystem. The roasting drum is configured to receive and thermally roast beans. The air handling system is configured to circulate a fluid flow through the roasting drum. The bean cooler is configured to receive and cool the beans from the roasting drum. The air outlet subsystem is configured to receive and process a first fluid flow from the air handling system and a second fluid flow from the bean cooler. The air outlet subsystem includes a heat sink and a filter. The heat sink defines two parallel fluid paths including a first fluid path and a second fluid path. The air outlet subsystem includes a metal body configured to receive heat from the first fluid path and the second fluid path. The first fluid path is fluidly coupled to receive the first fluid flow from the air handling system. The second fluid path is fluidly coupled to receive the second fluid flow from the bean cooler. The filter is fluidly coupled to the first and second air flow paths. The bean roasting system can be described in terms of mutually perpendicular X, Y, and Z axes. The X and Y axes are generally horizontal transverse axes. The Z axis is vertical and generally aligned with a gravity reference.

[0027] The function of the air outlet subsystem is to remove heat, water vapor, and harmful emissions from the fluid streams, including the first and second fluid streams. This design has the following advantages: (A) Heat transferred from the fluid streams is transferred to the metal body of the heat sink. Having a single metal body coupled to both parallel fluid paths provides better heat capacity for each. This is advantageous because the operations are asynchronous. The first fluid stream passes through the heat sink during the operation of roasting a batch of beans. The second fluid stream then passes through the heat sink as the batch of beans is cooling. Thus, a larger heat capacity heat sink is utilized by both fluid streams. (B) Both fluid streams utilize a single filter. This allows for a single larger capacity and more effective filtration of each fluid stream.

[0028] In one implementation, the air outlet subsystem includes a housing defining a housing fluid path. The housing fluid path combines a first fluid stream and a second fluid stream to provide a combined fluid stream. The housing fluid path also fluidly couples the combined fluid stream to a filter. The housing includes an outlet fan disposed within the housing fluid path. The combined fluid stream generally traverses the housing fluid path along a lateral Y-axis. The combined fluid stream then passes downward (-Z) into the filter along a vertical Z-axis. Finally, the combined fluid path passes through the filter within the filter along the X-axis.

[0029] In another implementation, the air outlet subsystem includes a housing. A first fluid flow enters the housing along a Y axis and then traverses a first fluid path primarily along a Z axis. The first fluid path directs the first fluid flow in a downward (-Z) direction and then an upward (+Z) direction relative to the Z axis before the first fluid flow re-enters the housing.

[0030] In yet another implementation, the air outlet subsystem includes a housing, the second fluid flow entering the second fluid path upward along the Z axis (+Z) before entering the housing.

[0031] In a further implementation, the heat sink further includes a first plurality of fins extending from the metal body into the first fluid path and a second plurality of fins extending from the metal body into the second fluid path.

[0032] In yet a further implementation, the bean roasting system includes a controller. The controller is configured to operate the roasting drum, the air handling system, and the bean cooler. The controller is configured to operate the roasting drum and the air handling system to receive and thermally roast a batch of beans. The controller is configured to operate the bean cooler to cool the batch of beans. The controller is configured to operate the air outlet subsystem to receive and process a first fluid stream and a second fluid stream. Operating the air outlet subsystem includes passing the first fluid stream through a first fluid path, passing the second fluid stream through a second fluid path, and passing the first fluid stream and the second fluid stream through a filter. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0033] Figure 1 is a schematic diagram of an embodiment of a roasting system 2. Figure 1 discloses the fluid paths between the various functional elements. The fluid paths tend to conduct gaseous fluids such as air, water vapor, and gaseous emissions from the beans being roasted or cooled. Additionally, particulates from the roasting process can also be transported or entrained through the fluid paths. Figure 1 also discloses the path of a batch of beans from the bean input to the bean outlet.

[0034] The roasting system 2 includes a hopper 4 for inputting and receiving a quantity or batch of unroasted beans. The hopper 4 feeds the unroasted beans into a roasting drum 6 or roasting subsystem 6, where the batch of beans is heated and roasted, for example, according to a preprogrammed roasting process. Adjacent to or below the roasting drum 6 is a bean cooling subsystem 8 or bean cooler 8 for receiving the batch of beans when the beans are in a just-roasted state (still hot), holding the batch of beans until the beans have cooled, and then discharging the batch of beans into a receiving container such as a bag (not shown).

[0035] The roasting drum 6 is coupled to an air handling system 10, which includes a main heater 12, a catalytic converter 14, a blower 16, an auxiliary heater 17, a bypass 18, a speed reducer 20, a cyclone separator 22, and a chaff collector 24. The air handling system 10 determines the temperature versus time roasting profile through the controlled operation of the main heater 12, the blower 16, the auxiliary heater 17, the bypass 18, and possibly other components of the air handling system 10. An air flow (indicated by arrows) recirculates through the air handling system 10. The air handling system 10 receives and removes particles and gaseous emissions released during the roasting process. The particles are captured by the cyclone 22, which deposits the particles in the chaff collector 24, which is periodically emptied. The gaseous emissions are collected by the catalytic converter 14.

[0036] The air treatment system 10 defines two distinct branches or loops of airflow that are joined by a bypass 18. One branch circulates from the bypass 18 to a reducer 20, through a cyclone 22, the main heater 12, the catalytic converter 14, the blower 16, and the auxiliary heater 17, before returning to the bypass 18. The other branch passes from the bypass 18 to the roasting drum 6, through the reducer 20, the cyclone 22, the main heater 12, the catalytic converter 14, the blower 16, and the auxiliary heater 17, before returning to the bypass 18.

[0037] A portion of the airflow generated by blower 16 passes through air outlet subsystem 19, which includes heat sink 26, outlet fan 28, and filter 30, before passing to ambient air (labeled "air outlet" in FIG. 1). Heat sink 26 has the effect of cooling the outlet airflow as well as condensing water vapor from the outlet airflow. The condensed water vapor drips into water collection receptacle 32. Exchange air from ambient air (labeled "air inlet" in FIG. 1) enters blower 16. The overall effect is to remove water vapor from air handling system 10 and cause the water to condense in water collection receptacle 26.

[0038] The bean cooler 8 is also coupled to the air outlet subsystem 19. Thus, the outlet fan 28 draws air from the bean cooler 8 through the heat sink 26. This has the effect of accelerating the cooling of the batch of beans.

[0039] Figure 2 is a simplified electrical block diagram of a roasting system 2. Like element numbers refer to like components with reference to Figure 1. However, while Figure 1 focuses on the fluid dynamics and physical movement of the beans, Figure 2 focuses on the electrical or wireless connections between components.

[0040] The controller 34 includes a processor 36 coupled to an information storage device 38. The information storage device 38 is a non-volatile or non-transitory information storage device 38 that stores software instructions. When executed by the processor 36, the software instructions can control the portions of the roasting system 2 that the controller 34 is configured to control. For example, the controller 34 can control any of the hopper 4, drum 6, bean cooler 8, main heater 12, blower 16, auxiliary heater 17, bypass 18, outlet fan(s) 28, and other portions of the roasting system 2. The controller 34 can receive information from one or more sensors 40 to monitor the status of the portions of the roasting system 2. The controller 34 is configured to control various actuators, including an agitator actuator 42, a bean release actuator 44, a vibration actuator 46, and a platform actuator 48.

[0041] The agitator actuator 42 is configured to agitate the batch of beans in the drum 6 during the roasting process. The bean ejection actuator 44 is configured to eject the batch of beans after roasting so that the beans can enter the bean cooler 8. The vibration actuator 46 is configured to vibrate the batch of beans to increase the uniformity and cooling rate of the batch of beans. The platform actuator 48 is configured to eject the batch of beans after cooling for discharge into a container or bag.

[0042] In an embodiment, the agitator actuator 42 is configured to rotate the agitator. The agitator may include an agitator blade set supported by a central shaft. The agitator actuator may include a motor and a power coupling coupling the motor to the central shaft. The power coupling may include a gearbox and / or a belt providing a rotational coupling between the motor and the central shaft. In an embodiment, the bean release actuator 44 includes a pneumatic cylinder configured to open and close a hatch formed in the underside of the drum 6.

[0043] In an embodiment, the vibration actuator 46 may include a motor coupled to an oval cam or gear that couples to and vibrates with the cooling platform, which supports the batch of beans during cooling. In other embodiments, the vibration actuator 46 may take other forms, such as a motor with an oval weight or a piezoelectric transducer stack. In an embodiment, the platform actuator 48 may include one or more pneumatic cylinders configured to open and close an opening in the cooling platform.

[0044] 3 is a flow chart of an embodiment of a roasting process 50 controlled by controller 34. According to 52, controller 34 receives roast parameters and a start signal. The roast parameters may indicate a temperature versus time profile for a roast. The roast parameters may include a temperature profile before and after a bean cracking event is detected.

[0045] According to 54, a batch of beans is automatically or manually dumped into hopper 4. Step 54 is shown in dashed outline to emphasize that it can be performed before or after step 52.

[0046] According to step 56, the roasting system 10 is operated to agitate and heat the batch of beans to initiate and carry out the roasting process of the beans. Carrying out the roasting process includes more specific processes including (1) operating the hopper to discharge the batch of beans into the drum, (2) operating the agitator actuator 42 to begin stirring and agitating the batch of beans, and (3) operating the air handling system 10 to heat the drum and remove by-products of the roasting process. The temperature of the drum increases and then stabilizes at the roasting temperature.

[0047] According to 58, the power used by the air handling system 10 to maintain the roasting temperature (by heating the drum) is monitored. The power is used to compensate for heat loss from the air handling system and the phase change that occurs as water is released from the batch of beans. Power usage is fairly stable and tends to drop initially during the roast. However, as the beans begin to crack, the exposure of water from within the beans will cause the air handling system 10 to use more power to compensate for the phase change of the water from liquid to gas phase. The controller then detects an increase in the power input at step 58. This increase in power is referred to as the "inflection point" of the monitored power level.

[0048] According to 60, detection of an inflection point in the power level causes the process to proceed to step 62. Otherwise, the process returns to steps 56 and 58 to continue maintaining the roasting temperature and monitoring the input power.

[0049] Once the inflection point is determined, the controller 34 calculates or determines the remaining temperature profile (temperature vs. time) to complete the roasting process according to step 62. According to step 64, the controller applies the determined remaining temperature profile to the batch of beans.

[0050] According to 66, the controller controls the drum 6 and bean cooler 8 to cool and discharge the batch of beans. This ends with the discharge of the beans into a container such as a bag at step 68.

[0051] In the examples and descriptions herein, mutually orthogonal axes X, Y, and Z are used. The Z axis is generally vertical and generally aligned with a gravity reference. "Regularly" is by design, but may vary depending on manufacturing tolerances. The X and Y axes are generally horizontal and lateral.

[0052] 4 is an isometric view of an embodiment of a portion of a bean cooling subsystem or bean cooler 8. The bean cooler 8 includes an upper subunit 100, a middle subunit 102, and a lower subunit 104. The upper subunit 100 defines a chute 106 for receiving a batch of beans from the roasting subsystem 6. The middle subunit 102 is for containing the batch of beans during cooling. The lower subunit 104 has a generally tapered shape in the downward (-Z) direction to facilitate ejection of the batch of beans from the bean cooler 8 into a bag or container (not shown).

[0053] Figure 5 is a vertical cross-sectional view of the embodiment of the bean cooler 8 shown in Figure 4. The bean cooler 8 includes an outer housing 108 that forms part of the middle 102 and lower 104 subunits. Within the outer housing 108 (e.g., disposed within an interior of the outer housing 108) is a cooling platform 110. The outer housing 108 also includes (or defines or defines) a retention chamber 112 that is vertically bounded by the upper subunit 100 and the cooling platform 110.

[0054] A plurality of resilient supports 114 couple the cooling platform 110 to the outer housing 108. The resilient supports 114 are formed from a flexible material, such as rubber, to allow the cooling platform 110 to move or vibrate relative to the outer housing 108. Not shown in Figure 5 is the vibration actuator 46 coupled between the outer housing 108 and the cooling platform 110. The vibration actuator 46 is configured to impart primarily lateral vibratory motion (along lateral X and Y axes) of the cooling platform 110 relative to the outer housing 108.

[0055] The platform actuator 48 is coupled between the lower subunit 104 portion of the outer housing 108 and the cooling platform 110. The platform actuator 108 is configured to move the platform actuator 110 to allow a batch of cooled beans to drop through the lower subunit 104 and into a container, such as a bag. Details of the operation of the platform actuator 48 are described with respect to Figures 7A and 7B.

[0056] The bean cooler 8 defines (or forms) an air passage 116 that extends (1) up through the lower subunit 104, (2) up through the cooling platform 110, (3) up through the holding chamber 112, (4) into and through a conduit 118 in the upper subunit 100 (and through a filter chamber 120), and (5) to the heat sink 26 (shown in FIG. 1). The outlet fan 28 (shown in FIGS. 1 and 2), air passage 116, and other components (heat sink 26, filter 30) form an air outlet subsystem 19 for transporting ambient air through the holding chamber 112.

[0057] The vibration actuator 46 and the air outlet subsystem 19 work synergistically to uniformly and quickly cool the batches of beans. The vibrations caused by the vibration actuator 46 combine with the airflow to separate and randomly translate and rotate the batches of beans. Thus, the batches of beans receive individual cooling airflow on all sides providing rapid and more uniform cooling.

[0058] Figure 6A is a side view of the cooling platform 110 shown in Figure 5 without showing some other components of the bean cooler 8 of Figure 5. As previously mentioned, the cooling platform 110 is coupled to the outer housing 108 via four resilient supports 114. Also shown is a coupler 122 that couples the cooling platform 110 to a vibration actuator 46 (not shown in Figures 6A and 6B). The vibration actuator 46 may include a motor having an elliptical cam or gear that connects to and vibrates the coupler 122. The vibration actuator 46 may take other forms, such as a motor having an elliptical weight.

[0059] 6B is an isometric top view of the cooling platform 110 shown in FIG. 5 without showing some other components of the bean cooler 8 of FIG. 5. The cooling platform 110 includes a rectangular or square frame 124 that is directly coupled to the elastic support 114. The cooling platform 110 also includes four rotatable movable parts 126 (also collectively referred to herein as "floors"). The rotatable movable parts 126 each include a proximal side 128 that is coupled to the frame 124 by a flexure or hinge 130. The rotatable movable parts 126 meet along two intersecting lines 132. The rotatable movable parts 126 define an area array of perforations 133 to allow the air flow passage 116 to pass uniformly through the batch of beans being cooled.

[0060] Figures 7A and 7B are vertical cross-sectional views showing the middle 102 and lower sub-units 104 of the bean cooler 8 in two configurations of the cooling platform 110. Figure 7A shows the cooling platform 110 in the upper or holding configuration as previously shown in Figures 5, 6A and 6B. This is a configuration for holding a batch of hot beans during the cooling process.

[0061] The platform actuator 48 includes a pneumatic actuator 134 that is rotatably coupled to a follower 136. The pneumatic actuator 134 is controlled by the controller 34 (shown in FIG. 2 ) and is rotatably coupled to the outer housing 108. The follower 136 is rotatably coupled to the rotatable moving parts 126 and the outer housing 108. In the exemplary embodiment, there are four pneumatic actuators 134, each of which is operatively coupled to one of the four rotatable moving parts 126 (via one follower 136 from the group of four followers 136) and each of which is configured to raise and lower one of the rotatable moving parts 126.

[0062] FIG. 7A illustrates the cooling platform 110 in a closed configuration in which the movable parts 126 are substantially horizontal and intersect along an intersecting line 132. FIG. 7B illustrates the cooling platform 110 in an open configuration in which the movable parts 126 define an oblique angle with respect to horizontal axes X (not shown, but having an orientation into the page) and Y. As shown, the platform actuators 48 are configured to individually rotate the rotatable movable parts 126 between a closed configuration (shown in FIG. 7A) and an open configuration (shown in FIG. 7B). Extension of the pneumatic actuators 134 rotates the movable parts 126 from the closed configuration (shown in FIG. 7A) to the open configuration (shown in FIG. 7B). Retraction of the pneumatic actuators 134 rotates the movable parts 126 from the open configuration (shown in FIG. 7B) to the closed configuration (shown in FIG. 7A).

[0063] Figure 8 illustrates an embodiment of a method 140 for cooling and discharging a batch of beans. Method 140 may correspond, for example, to 66 in Figure 3. According to 142, outlet fan 28 (as part of air outlet subsystem 19) transports air along air flow path 116, including up through holding chamber 112. At 142, movable portion 126 of cooling platform 110 is in a closed configuration (as shown in Figure 7A).

[0064] Per 144, the controller 34 operates and activates the vibration actuator 46. Per 146, the controller 34 operates the bean release actuator 44. In one embodiment, this opens a hatch in the drum 6, which allows the batch of hot, freshly roasted beans to fall from the drum 6, down the chute 106, and into the holding chamber 112 above the cooling platform 110.

[0065] According to 148, the beans can be cooled while the cooling platform 110 is vibrated by the vibration actuators 46 and air rises along the air flow passage 116 through the batch of beans. Once the beans have cooled (according to either a predetermined cooling time and / or a temperature sensor signal), the controller 34 operates the four platform actuators 48, thus rotating the moveable part 126 to the open configuration (shown in FIG. 7A). The batch of beans can then slide and drop out of the holding chamber 112, through the lower subunit 104 and into a container such as a bag.

[0066] The order of the steps of the method 140 may vary. For example, step 146 (dropping the beans into the bean cooler 8) may occur before step 144 (initiating vibration of the vibration actuator 46).

[0067] 9 is a flow chart illustrating an embodiment of a method 160 for roasting and cooling a batch of beans. Method 160 may be performed by roasting system 2 under control of controller 34, for example, when processor 36 executes software instructions stored on non-transitory information storage device 38.

[0068] Per 162, the batch of unroasted beans is thermally roasted in a roasting subsystem (e.g., roasting subsystem 6) to provide a batch of hot roasted beans. Per 164, the batch of thermally roasted beans is transferred from the roasting subsystem to a holding chamber (e.g., holding chamber 112) of a cooling subsystem (e.g., cooling subsystem 8). During cooling, the batch of beans is supported by a cooling platform (e.g., cooling platform 110).

[0069] According to 166, air flow is maintained through the holding chamber to accelerate cooling of the batch of beans. And according to 168, the cooling platform is vibrated to accelerate cooling of the batch of beans. The result of the synergistic aspects of 166 and 168 is that the batch of beans is cooled rapidly to provide a cooled batch of beans. According to 170, the cooled batch of beans is transported in a downward direction and out of the cooling subsystem.

[0070] The transporting at 170 may include moving or configuring the floor of the cooling platform from a closed configuration (shown in FIG. 7A) to an open configuration (shown in FIG. 7B). The batch of beans is transported in a downward direction and out of the cooling subsystem in response to the floor moving from the closed configuration to the open configuration.

[0071] Figure 10 is a schematic diagram of a portion 200 of the roasting system 2 highlighting the main heater 12 and the cyclone separator 22. In the embodiment shown, the main heater 12 includes a heater power supply 202 coupled to a heater portion or winding 204. The heater winding 204 includes one or more coils of resistive material configured to convert electrical energy into thermal energy. Under the control of the controller 34, the heater power supply 202 is configured to apply power to the heater winding 204, which increases in temperature and heats the cyclone separator 22 and the air passing through the cyclone separator 22.

[0072] 10, 11A, and 11B, the heater winding 204 is integral with the cyclone separator 22. Stated another way, the heater winding 204 is physically supported and electrically insulated (insulated to avoid short circuits between portions of the winding) within the cyclone separator 22. The cyclone separator 22 includes a cyclone housing 206 and an air outlet 208 that is coupled to the cyclone housing 206 and contains the heater winding 204.

[0073] 11A and 11B are isometric and cross-sectional views, respectively, of an example of a standalone cyclone separator 22. In the preceding description, mutually orthogonal axes X, Y, and Z are used. The Z axis is generally vertical and generally aligned with a gravity reference. "Regularly" is by design, but may vary depending on manufacturing tolerances. The X and Y axes are generally horizontal and lateral.

[0074] The cyclone housing 206 defines a central axis 210 that is generally parallel to the Z-axis. The cyclone housing 206 includes a cylindrical upper housing 212 and a conical lower housing 214. The conical lower housing 214 tapers in a downward direction from the upper housing 212 to a particulate outlet 216. The upper housing 212 has an annular upper portion 218. The air outlet 208 is generally cylindrical and extends through the annular upper portion 218. A plurality of electrodes 220 extend radially from the air outlet 208 and couple to the heater windings 204 and heater power supply 202 (shown in FIG. 10 ). The upper housing 212 also includes an air inlet 222.

[0075] In the embodiment shown, the central axis 210 is substantially common to the heater winding 204, the air outlet 208, the upper housing 212, and the lower housing 214. The air outlet 208 includes a cylindrical housing 224 that extends from the outside of the cyclone housing 206 through the annular top 218 into the upper housing 212. The heater winding 204 is disposed inside the cylindrical housing 224 and similarly extends from the outside of the cyclone housing 206 through the annular top 218 into the upper housing 212. In other words, the heater winding 204 is disposed such that a portion of the heater winding 204 is disposed above the cyclone housing 206 and another portion of the heater winding 204 is disposed within the cyclone housing 206. The air outlet 208 defines a vertical air outlet flow path 226 for air to be pumped from the air outlet 208 to the blower 16 (shown in FIG. 1 ). The heater winding 204 is helically disposed within a cylindrical housing 224 and within an air outlet passage 226 .

[0076] During roasting operation, air from the roasting drum 6 enters the air inlet 222 along a direction that is substantially or nearly tangential to the circular and cylindrical shape of the upper housing 212. Alternatively, the air from the roasting drum 6 may enter the air inlet 222 along a generally different vector and then be redirected to be nearly tangential to the circular and cylindrical geometry of the upper housing. In use, the air becomes filled with fines from the roasting process. The fines circulate in a downward spiral as they lose velocity and fall towards the fines outlet 216. The fines exit the fines outlet 216 and fall into the chaff collector 24 (shown in FIG. 1). The downward spiral of the fines trajectory is along the inner conical surface of the lower housing 214 and tends to be around the vertical axis 210. The conical surface of the lower housing 214 is configured to direct the spiral movement of the fines from the upper housing 212 to the fines outlet 216 at the lower end portion 217 of the lower housing 214.

[0077] Locating (or disposing or integrating) the heater winding 204 within the interior of the air outlet 208 has various advantages including thermal efficiency and compactness. The addition of the heater winding 204 has a negligible impact on the size of the cyclone separator 22. Furthermore, the heater winding 204 convectively heats the cylindrical housing 224 and the upper housing 212, which increases the metal surface area in contact with the air flow along the air outlet flowpath 226 exiting the cyclone separator 22. As a result, there is a very effective convective heat transfer of thermal energy from the heater winding 204 to the air passing out the air outlet 208.

[0078] The view of the heater windings 204 within the air outlet 208 is schematic in nature. FIG. 12 is an isometric view of a portion of a particular embodiment of the cyclone separator 22. The embodiment shown includes six pairs of electrodes 220 that extend from an outer cylindrical surface of the air outlet 208 into the air outlet flow passage 226, which is a cylindrical space within the air outlet 208. (Some of the electrodes 220 are only partially visible and others are not visible in FIG. 12, but it should be understood that each electrode 220 is partially disposed outside the air outlet 208 and partially disposed inside the air outlet 208.) Within the air outlet flow passage 226 are three intersecting insulating substrates 228. The heater windings 204 (not shown in FIG. 12) include multiple helical coils that extend from the electrodes 220 and are supported by the insulating substrates 228. More specifically, each insulating substrate 228 has a plurality of holes in a substantially vertical arrangement positioned to receive a portion of a heater winding from heater winding 204. Collectively, insulating substrates 228 support and maintain proper spacing and physical separation of the helical coils of heater winding 204. This maximizes (or at least improves) convective heat transfer from heater winding 204 to the airflow passing through air outlet 208 and prevents shorting between heater windings 204.

[0079] Although particular embodiments of the heater 12 are shown in Figures 10, 11A, 11B, and 12, alternative embodiments of the heater 12 can be used. As a first alternative embodiment, the heater 12 can include a plasma generator configured to generate a plasma in the air outlet passage 226. As a second alternative embodiment, the heater 12 can include a natural gas jet device that emits a flame into the air outlet passage 226. Thus, the "heater portion" of the heater 12 can include one or more of a plasma emitter, a gas jet flame, a resistive heater winding, and other heating devices configured to heat air passing through the air outlet passage 226 of the air outlet 208.

[0080] 13 and 14 are isometric and cross-sectional views, respectively, of an embodiment of the roasting subsystem 6. The roasting subsystem 6 includes a housing 300 having an inner surface 302. The inner surface 302 defines a chamber 304 for holding a batch of beans during a thermal roasting process. The housing 300, the inner surface 302, and the chamber 304 have a common horizontal axis 306. The housing 300 has a rear end portion 308 and a front end portion 310 relative to the horizontal axis 306. As shown in FIGS. 13 and 14, the housing 300, the inner surface 302, and the chamber 304 can each have a substantially cylindrical shape.

[0081] The bean roasting subsystem 6 is adjacent the rear end portion 308 of the housing 300 and includes a first conduit 312 that functions as an air inlet. As shown in Figure 1, heated air from the air handling system 10 enters the first conduit 312 and then enters the chamber 304 in a vertically downward (-Z) direction.

[0082] A second conduit 314 is adjacent to the front end portion 310 of the housing 300. The second conduit 314 functions as an air outlet and a bean inlet. Batches of beans are dumped from the hopper 4 through the second conduit 314 into the chamber 304. Air from the chamber 304 exits the second conduit 314 in an upward direction and then passes to the cyclone 22 (see also FIG. 1 ). The second conduit 314 has a larger cross-sectional area than the first conduit 312 to slow the velocity of the upward exiting air, avoiding entraining beans, but with a velocity that entrains smaller discharge particles that are removed by the cyclone 22.

[0083] The housing 300 includes a hatch 316 configured to remove a batch of beans after the roasting process is completed. The hatch 316 is located along a lower portion of the housing 300 and above the bean cooler 8. The hatch 316 is coupled to a bean release actuator 44. The bean release actuator 44 is configured to swing or move the hatch 316 between two positions: a closed position in which the hatch 316 is flush with a lower portion of the inner surface 302, and an open position in which the hatch 316 lowers below the inner surface 302 to allow the beans to drop into the bean cooling subsystem 8.

[0084] A door 318 having a transparent window 320 is attached to the front end portion 310 of the housing 300. The door 318 is configured to open from a closed state to allow front access to the chamber 304. The transparent window 320 is a large circular transparent plate that allows viewing of the chamber 304 during the roasting process. The transparent window 320 can be formed from high temperature glass, quartz, or other high temperature and transparent material.

[0085] Positioned within the chamber 304 is an agitator 322. The agitator 322 includes a central shaft 324 coupled to a set of blades 326. The central shaft 324 is a hollow cylindrical shaft 324 and is configured to rotate about the horizontal axis 306. Attached to the rear end portion 308 of the housing 300 is a bearing 328 that surrounds and rotatably supports a rear portion 330 of the central shaft 324.

[0086] The combination of the bearing 328 and hollow cylindrical shaft 324 is configured to provide support to maintain the spacing between the blade set 326 and the inner surface 302 of the housing 300 without axial bearing support at the front portion 331 of the central shaft 324. For example, the bearing 328 may be sized and configured to support the weight of the hollow cylindrical shaft 324 in a cantilevered position. Thus, in implementations in which the cylindrical shaft 324 presents a larger moment arm (e.g., due to a larger outer radius, a smaller inner radius, a longer length, and / or a larger weight) than other implementations, then the bearing 328 may have a larger length (along the horizontal axis 306) and / or stiffness than in other implementations. It should be understood that although the cylindrical shaft 324 is described as hollow, in different embodiments, the cylindrical shaft may be solid. Whether the cylindrical shaft is hollow or solid, and depending on the material(s) used to form the cylindrical shaft, the cylindrical shaft will present a particular moment arm, and the bearing 328 is sized and configured to support the weight of the cylindrical shaft in a cantilever position.

[0087] In another example, the bearing 328 may be sized and configured as a function of the position of the bearing 328 relative to the rear portion of the housing 300. In particular, the further a portion of the bearing 328 is disposed within the chamber 302, the higher the temperature within the chamber 302 that portion of the bearing 328 will be exposed to. Thus, the bearing 328 may be configured based at least in part on the size of the portion of the bearing 328 within the chamber 302 and the temperature within the chamber 302 to which the bearing 328 will be exposed and the associated time profile of the temperature.

[0088] Although the bearing 328 is shown in FIG. 14 as having substantially uniform inner and outer radii, it should be understood that non-uniform values ​​are possible. For example, in an embodiment, the bearing can have a uniform inner radius and an outer radius of a portion of the bearing outside the chamber 302 that is greater than the outer radius of the portion of the bearing inside the chamber 302. In an alternative embodiment, the bearing can have a uniform inner radius and an outer radius of a portion of the bearing outside the chamber 302 that is less than the outer radius of the portion of the bearing inside the chamber 302. In some embodiments, the inner radius of the bearing can be non-uniform, e.g., to correspond to a non-uniform outer radius of the hollow cylindrical shaft 324. In some embodiments, both the inner and outer radii of the bearing can be non-uniform, e.g., according to one or more of the embodiments described above.

[0089] For the embodiment shown in Figure 14, a horizontal axis 306 is generally common to the housing 300, the cylindrical interior or inner surface 302, and the chamber 304. The horizontal axis 306 is also generally common to the cylindrical shaft 324 of the agitator 322 and is the axis of rotation of the agitator 322. The rear 308 and front 310 portions of the housing 300 are generally opposing circular end portions. The term "front" refers to the side from which a user can view the roasting system 2 when the roasting system 2 is in operation to view the batch of beans being agitated inside the chamber 304. The opposing rear 330 and front 331 ends of the cylindrical shaft correspond to the opposing rear 308 and front 310 ends or portions of the housing 300.

[0090] 15 is a side view of the agitator 322 and bearing 328. The blade set 326 includes an inner helical auger 332. The blade set 326 also includes a set of outer blades 334 supported by radial spokes 336. As the agitator 322 rotates about a horizontal axis, the inner helical auger 332 imparts horizontal motion to the beans in the +Y direction (towards the door 318 or front end portion 310 of the housing). At the same time, the outer blades 334 impart motion to the beans in the Y direction (towards the rear end portion 308 of the housing 300). The opposing directions of motion help mix the beans during the roasting process and provide a more uniform roast. This motion is also useful when the beans are removed from the chamber 304.

[0091] FIG. 16 is an isometric view of the agitator 322 and agitator actuator 42 in isolation. The agitator actuator 42 includes a power coupling 338 and a motor 340. The power coupling 338 is coupled to the rear end portion 308 of the housing 300 (FIG. 13). The power coupling 338 includes a gear train or pulley system (inside the housing 339 shown) to provide a rotational coupling from the motor 340 to the central shaft 324 of the agitator 322. In the embodiment shown, the motor 340 extends from the power coupling 338 in a forward or +Y direction and overlaps with the housing along the horizontal Y-axis. This geometric arrangement allows for a more compact overall geometry of the roasting subsystem 6.

[0092] 17 is a flow chart of an embodiment of a method 350 of operating the bean roasting system 2. The method 350 is implemented by the controller 34. According to 352, the hopper 4 is operated to discharge a batch of beans into the roasting subsystem 6. The batch of beans passes from the hopper 4 through the second conduit 314 and into the inner chamber 304.

[0093] According to 354, the agitator actuator 42 is operated to rotate the actuator 322 about axis 306. According to 356, the air handling system 10, including the heaters 12 and 17 and the blower 16, is operated to provide heated air to the inner chamber 304 according to the roasting temperature versus time profile of the beans. During step 356, the heated air from the air handling system 10 enters the inner chamber 304 via the first conduit 312 at an incoming velocity and then exits the inner chamber via the second conduit 314 at an exit velocity that is an order of magnitude lower than the incoming velocity.

[0094] Once the roasting process is complete, the bean release actuator 44 is actuated to open the hatch 316 and release the beans from the roast subsystem 6 to the bean cooling subsystem 8. While the hatch 316 is open, the agitator 322 continues to rotate. The outer blades 334 impart bean motion along the Y axis to facilitate a more complete transfer of the batch of beans from the roast subsystem 6 to the bean cooling subsystem 8.

[0095] Figure 18 is a schematic diagram of a portion of the roasting system 2 to highlight an embodiment of the air outlet subsystem 19. It should be understood that the roasting system 2 includes additional components shown in Figures 1 and 2, which have been omitted from Figure 18 for simplicity.

[0096] In FIG. 18, two fluid streams are shown, including a first fluid stream 402 and a second fluid stream 404. When referring to a "fluid stream," it is primarily a gaseous air stream that may be filled with various gases, vapors, and / or small particulate components. The first fluid stream 402 comes from the air handling system 10, which circulates the fluid stream through the roasting drum 6. This first fluid stream 402 is very hot and filled with water vapor, particulates, and harmful gaseous emissions. There is a need to effectively and efficiently cool the first fluid stream 402 and remove the gases, vapors, and / or small particulate components. In the illustrated embodiment, the first fluid stream 402 leaves the output of the blower 16 before reaching the air outlet subsystem 19. The second fluid stream 404 is also very hot upon arrival from the cooling subsystem (bean cooler) 8.

[0097] The heat sink 26 is shown in FIG. 18 as having two heat sink portions including a first heat sink portion 26A and a second heat sink portion 26B. The two heat sink portions 26A and 26B are conductively and thermally coupled to one another as one common connected metal body 400. The first heat sink portion 26A receives a first fluid flow 402 from the blower 16. The second heat sink portion 26B receives a second fluid flow 404 from the cooling subsystem (bean cooler) 8. The second heat sink portion 26B is operably coupled to a water collection receptacle 32 (e.g., a container or bottle for receiving water from the second heat sink portion 26B).

[0098] First fluid stream 402 and second fluid stream 404 combine to form combined fluid stream 406. Outlet fan 28 receives combined fluid stream 406 and pushes combined fluid stream 406 through filter 30 before combined fluid stream 406 exits to the ambient environment (the "air outlet").

[0099] 19-23 show an embodiment of the outlet air subsystem 19. In the foregoing figures, mutually orthogonal (vertical) axes X, Y, and Z are used. The X and Y axes are generally (or substantially) horizontal transverse axes. The Z axis is a vertical axis and is generally aligned with the gravity reference. "Regularly" (or "substantially") means that this is designed within manufacturing tolerances, but may not be exact. Furthermore, all references to X, Y, and Z directions are understood to be generally (or substantially) in such directions, with some variation allowed depending on the circumstances. For example, when discussing the direction of a fluid vapor, it should be understood that the fluid vapor may not pass exactly in the discussed direction, but may vary due to pressure and / or temperature differences, etc.

[0100] FIG. 19 is an isometric view showing the heat sink 26 coupled to the filter 30 by the housing 408. From the perspective of FIG. 19, the first heat sink portion 26A faces the viewer. Also shown is the path of the first fluid stream 402. The first fluid stream 402 enters the housing 408 in the +Y direction along the Y axis. The first fluid stream 402 then passes through the first heat sink portion 26A a first time in the -Z direction downward along the Z axis. The first fluid stream 402 then passes through the first heat sink portion 26A a second time in the +Z direction upward along the Z axis. Having the first fluid stream 402 pass through the first heat sink portion 26A a second time maximizes (or improves) the heat transfer from the first fluid stream 402 to the heat sink 26. In alternative embodiments, the first fluid stream 402 can pass through the first heat sink portion 26A three or more times. A water collection trough 403 is coupled to the lower end of the first heat sink portion 26A. The water collection trough 403 forms at least a portion of the water collection receptacle 32 (which may include a bottle (not shown) for receiving water from the water collection trough 403). As the first fluid stream 402 passes through the heat sink portion 26A, it cools and the entrained water vapor condenses on the surfaces of the heat sink portion 26A and then flows into the collection trough 403.

[0101] 20 is an isometric view showing the heat sink 26 coupled to the filter 30 from the perspective of the second heat sink portion 26B facing the viewer. The second fluid stream 404 passes through the second heat sink portion 26B in an upward +Z direction along the Z axis until it reaches the housing 408. In an alternative embodiment, the second fluid stream passes through the heat sink portion 26B more than once. The first fluid stream then passes laterally in the +Y direction until it merges with the first fluid stream 402, resulting in a merged fluid stream 406.

[0102] FIG. 21 is a horizontal cross-sectional view of the heat sink 26. More specifically, FIG. 21 is a cross-sectional view taken from a horizontal plane cut through the heat sink 26 shown in FIGS. 19 and 20, looking down (-Z direction). The heat sink 26 defines two internal and "parallel" fluid paths, including a first fluid path 410 and a second fluid path 412. The two internal fluid paths (410 and 412) are referred to as "parallel" because the fluid flows 402 and 404 flow primarily along the Z axis as they pass through the heat sink 26. More specifically, the fluid flow 402 (shown in FIG. 19) can travel along the internal fluid path 410 (shown in FIG. 21), which flows downward in the -Z direction into the page (shown in the lower left quadrant of FIG. 21) and then upward out of the page in the +Z direction (shown in the upper left quadrant of FIG. 21). Similarly, fluid flow 404 (shown in FIG. 20) can travel along an internal fluid path 412 (shown in FIG. 21) that runs up in the +Z direction from the page (shown in the upper right and lower right quadrants of FIG. 21).

[0103] As also shown in FIG. 19, the first fluid flow 402 first flows up through the internal fluid path 410 and then down. As also shown in FIG. 20, the second fluid flow 404 flows up through the second fluid path 412. Returning to FIG. 21, the heat sink 26 includes a first plurality of fins 414 extending from the metal body 400 into the first fluid path 410. The heat sink 26 includes a second plurality of fins 416 extending from the metal body 400 into the second fluid path 412. As shown, the "down / up" first fluid path 410 is defined in the first heat sink portion 26A. The "up" second fluid path 412 is defined in the second heat sink portion 26B.

[0104] In the embodiment shown, the metal body 400 and the fins 414 and 416 are monolithically formed from cast aluminum. This provides very high conductive heat transfer from the fins to the metal body 400. The metal body 400, which is common to both sets of fins 414 and 416, provides a large heat sink capacity to remove heat from the fluid streams 402 and 404. In other implementations, the metal body 400 and the fins 414 and 416 can be formed by techniques other than monolithically formed (e.g., parts formed separately and then connected together) and from materials other than cast aluminum (e.g., aluminum, steel, cast iron, etc.).

[0105] In the embodiment shown, the fluid path 410 has lower and upper segments with a vertical extent of 33 inches counting the lower and upper segment sequence or a total of 66 inches. This provides a significant structural length exposure to maximize (or improve) heat transfer. In the embodiment shown, the UP fluid path 412 has a vertical extent of 42 inches. Because the bean roasting system 2 may be located in a small facility, such as a coffee shop facility, it is typically desirable to maximize (or improve) heat transfer from the fluid streams 410 and 412. This ensures that the majority of the heat is transferred to the metal body 400 and not to the local atmosphere so as not to overwhelm the facility's air conditioning when the combined fluid stream 406 is output. Cooling also helps improve the life of replaceable components in the filter 30.

[0106] 22 is an isometric view of a top portion of air outlet subsystem 19 with portions of housing 408 highlighted. Housing 408 defines a housing fluid path 418 through which fluid streams 402, 404, and 406 flow. Housing fluid path 418 combines first fluid stream 402 and second fluid stream 404 to provide combined fluid stream 406. Housing 408 includes outlet fan 28. Combined fluid stream 406 flows along the Y-axis and then into filter 30.

[0107] 23 is an isometric cross-sectional view looking down on the air outlet subsystem 19. The filter 30 includes an input fluid path 420, a high efficiency air permeable (HEPA) filter 422, a carbon treatment filter 424, and an outlet opening 426. Driven by the outlet fan 28, the combined fluid flow 408 flows downward (-Z) along the Z axis along the input fluid path 420, then laterally in the +X direction along the X axis through the HEPA filter 422, the carbon treatment (activated charcoal) filter 424, and the outlet opening 426.

[0108] The above specific embodiments and applications thereof are for illustrative purposes only and are not intended to exclude modifications and variations encompassed by the following claims. More specifically, although a bean roasting system is shown and described herein as including a particular combination or subcombination of components, features, and the like, other suitable combinations or subcombinations of such features are contemplated. For example, a bean roasting system described herein as including a roasting subsystem and a cooling subsystem, or including a roasting subsystem and an air handling subsystem, in some embodiments, such a bean roasting system may also optionally include one or more of a hopper, a cooling subsystem, an air handling system (or at least one component thereof), an air outlet subsystem (or at least one component such as a heat sink as described herein), a controller, and / or a filter as described herein, or any suitable combination thereof. Similarly, although a method of roasting beans is described herein as including certain steps, in other embodiments, such a method may include any suitable combination of method steps as described herein. For example, a bean roasting method according to an embodiment includes providing a bean roasting system, operating an air outlet subsystem, operating the roasting subsystem, operating a vibration actuator, and operating a platform actuator, while in other embodiments, a method according to another embodiment includes thermally roasting a batch of beans, transporting the batch of beans, maintaining an air flow through the holding chamber to accelerate cooling of the batch of beans, vibrating the cooling platform, and transporting the batch of beans after the beans are cooled, while in some embodiments the method may include any suitable combination of the foregoing steps. Additionally, while some embodiments are disclosed as including certain features or components, some embodiments may omit certain features or components.For example, although a bean roasting system is described herein as including a hopper, a roasting drum, an air handling system, a bean cooler, an air outlet subsystem (e.g., having a heat sink and a filter), and a controller, in other embodiments, one or more of the hopper, roasting drum, air handling system, bean cooler, air outlet subsystem, and / or controller may be omitted.

[0109] Those skilled in the art will appreciate that the drawings are primarily for illustrative purposes and are not intended to limit the scope of the subject matter described herein. The drawings are not necessarily to scale, and in some instances, various aspects of the subject matter disclosed herein may be shown exaggerated or enlarged in the drawings to facilitate an understanding of different features. In the drawings, like reference numbers generally indicate identical, functionally similar, and / or structurally similar elements.

[0110] In order to address various problems and advance the art, the entirety of this application (including the cover page, title, headings, background, abstract, brief description of drawings, detailed description, embodiments, abstract, drawings, appendix, and others) illustrates, by way of example, various embodiments in which the embodiments may be practiced. The advantages and features of the present application are only a representative sample of embodiments and are not exhaustive and / or exclusive. Rather, they are presented to aid in the understanding and teaching of the embodiments and are not representative of all embodiments. Thus, certain aspects of the present disclosure are not described herein. The fact that alternative embodiments may not be presented for certain parts of the invention, or that alternative embodiments not described may be available for some, is not to be considered as excluding such alternative embodiments from the scope of the present disclosure. It will be understood that many of these undescribed embodiments incorporate the same principles of the invention and that other embodiments are equivalent. Thus, it is to be understood that other embodiments may be utilized and functional, logical, organizational, structural and / or topological modifications may be made without departing from the scope of the present disclosure. Thus, all examples and / or embodiments are considered non-limiting throughout this disclosure.

[0111] Also, for purposes of reducing space and repetition, no inferences should be drawn with respect to embodiments described herein compared to those embodiments not described herein. For example, it should be understood that the logical and / or topological structure of any combination of any program components (component collections), other components, and / or any present feature set as described in the figures is not limited to a fixed order and / or arrangement of operations, but rather that any disclosed order is exemplary and all equivalents regardless of order are contemplated by this disclosure.

[0112] Various concepts may be embodied as one or more methods, at least one example of which is provided. Acts performed as part of a method may be ordered in any suitable manner. Thus, although shown as sequential operations in an exemplary embodiment, embodiments may be constructed in which operations are performed in an order different from that illustrated, which may include performing some operations simultaneously. In other words, it should be understood that such features are not necessarily limited to a particular order of execution, but rather, may be limited to any number of threads, processes, services, servers, and / or the like, which may be performed serially, asynchronously, simultaneously, in parallel, simultaneously, synchronously, and / or the like, in a manner consistent with the present disclosure. Thus, some of these features may be mutually incompatible in that they cannot exist simultaneously in a single embodiment. Similarly, some features may be applicable to some aspects of the innovation and not to other aspects.

[0113] Furthermore, the present disclosure may include other innovations not currently described. The applicants reserve all rights in such innovations, including the right to implement such innovations and to file additional applications, continuations, continuations in part, divisions, and / or the like. As such, it should be understood that the advantages, embodiments, examples, functions, features, logical, operational, organizational, structural, topological, and / or other aspects of the present disclosure should not be considered as limitations of the present disclosure as defined by the embodiments or limitations of equivalents of the embodiments. Depending on the particular desires and / or characteristics of individual and / or enterprise users, database configurations and / or relational models, data types, data transmission and / or network frameworks, syntax structures, etc., various embodiments of the technology disclosed herein may be implemented in a manner that allows for great flexibility and customization, as described herein.

[0114] All definitions, as defined and used herein, shall be understood to control over dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meaning of the defined terms.

[0115] As used herein, in certain embodiments, the term "about" or "approximately" when preceding a numerical value indicates a range of the value plus or minus 10%. When a range of values ​​is provided, it is understood that each intervening value between the upper and lower limits of that range, to the tenth of the unit of the lower limit, and any other stated or intervening value within that stated range, is encompassed within the disclosure, unless the context clearly dictates otherwise. The upper and lower limits of these smaller ranges may be independently included in the smaller ranges, subject to any specifically excluded limit of the stated range, and are encompassed within the disclosure. Where a stated range includes one or both of the limits, ranges excluding one or both of those included limits are also included in the disclosure.

[0116] As used in the specification and embodiments, unless clearly indicated to the contrary, the indefinite articles "a" and "an" should be understood to mean "at least one."

[0117] As used herein in the specification and embodiments, the term "and / or" should be understood to mean "either or both" of the elements so conjoined, i.e., elements that are sometimes conjunctive and other times disjunctive. Multiple elements listed with "and / or" should be interpreted in the same manner, i.e., "one or more" of the elements so conjoined. Other elements, whether related or unrelated to those elements specifically identified, other than the elements specifically identified may be optionally present. Thus, as a non-limiting example, a reference to "A and / or B," when used in conjunction with open-ended language such as "comprising," may refer in one embodiment to only A (optionally including elements other than B), in another embodiment to only B (optionally including elements other than A), and in yet another embodiment to both A and B (optionally including other elements), etc.

[0118] As used herein and in the embodiments, "or" should be understood to have the same meaning as "and / or" as defined above. For example, when separating items in a list, "or" or "and / or" should be interpreted as inclusive, i.e., including at least one of, but more than one of, a number or list of elements, and, optionally, including additional unlisted items. Only terms clearly indicated to the contrary, such as "only one of" or "exactly one of," or, when used in the embodiments, "consisting of," will refer to the inclusion of exactly one element of a number or list of elements. In general, when used herein, the term "or" should be interpreted as indicating exclusive alternatives (i.e., "one or the other, but not both") only when preceded by a term of exclusivity, e.g., "either," "one of," "only one of," or "exactly one of." "Consisting essentially of," when used in the embodiments, shall have its ordinary meaning as used in the field of patent law.

[0119] As used herein and in embodiments herein, the phrase "at least one" should be understood in reference to a list of one or more elements to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each element specifically listed in the list of elements, and not excluding any combination of elements in the list of elements. This definition also allows for the optional presence of elements other than those specifically identified in the list of elements to which the phrase "at least one" refers, whether or not related to the specifically identified element. Thus, as a non-limiting example, "at least one of A and B" (or, equivalently, "at least one of A or B" or, equivalently, "at least one of A and / or B") can refer, in one embodiment, to at least one, optionally, two or more A, and no B (and optionally including elements other than B); in another embodiment, to at least one, optionally, two or more B, and no A (and optionally including elements other than A); in yet another embodiment, to at least one, optionally, two or more A, and at least one, optionally, two or more B (and optionally including other elements).

[0120] In the embodiments, as well as in the above specification, all transitional phrases such as "comprising," "including," "carrying," "having," "containing," "involving," "holding," "consisting of," and the like, are understood to be open-form, i.e., to mean "including, but not limited to." Only the transitional phrases "consisting of" and "consisting essentially of" must be closed or semi-closed transitional phrases, respectively, as set forth in Section 2111.03 of the United States Patent Office Manual of Patent Examining Procedures.

[0121] Some embodiments and / or methods may be implemented by software (executed on hardware), hardware, or a combination thereof. A hardware module (e.g., a controller) may include, for example, a processor, a field programmable gate array (FPGA), and / or an application specific integrated circuit (ASIC). A software module (executed on hardware) may include instructions stored in a memory operatively coupled to a processor, and may be expressed in a variety of software languages ​​(e.g., computer code), including C, C++, Java™, Ruby, Visual Basic™, and / or other object-oriented, procedural, or other programming languages ​​and development tools. Examples of computer code include, but are not limited to, microcode or microinstructions, machine instructions such as those generated by a compiler, code used to generate a web service, and files containing higher level instructions executed by a computer using an interpreter. For example, embodiments may be implemented using an imperative programming language (e.g., C, Fortran, etc.), a functional programming language (Haskell, Erlang, etc.), a logic programming language (e.g., Prolog), an object-oriented programming language (e.g., Java, C++, etc.), or other suitable programming language and / or development tools. Additional examples of computer code include, but are not limited to, control signals, encryption code, and compression code.

[0122] The term "processor" should be interpreted broadly to encompass a general purpose processor, a central processing unit (CPU), a microprocessor, a digital signal processor (DSP), a controller, a microcontroller, a state machine, etc. Under some circumstances, a "processor" may refer to an application specific integrated circuit (ASIC), a programmable logic device (PLD), a field programmable gate array (FPGA), etc. The term "processor" may also refer to a combination of processing devices, e.g., a combination of a DSP and a microprocessor, multiple microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration.

[0123] The term "memory" (or "information storage") should be interpreted broadly to encompass any electronic component capable of storing electronic information. The term memory may refer to various types of processor-readable media, such as random access memory (RAM), read-only memory (ROM), non-volatile random access memory (NVRAM), programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), electrically erasable PROM (EEPROM), flash memory, magnetic or optical data storage devices, registers, etc. Memory is said to be in electronic communication with a processor if the processor can read information from the memory and / or write information to the memory. Memory that is integral to a processor is in electronic communication with the processor.

[0124] The terms "instructions" and "code" should be interpreted broadly to include any type of computer-readable statement(s). For example, the terms "instructions" and "code" may refer to one or more programs, routines, subroutines, functions, procedures, etc. "Instructions" and "code" may include a single computer-readable statement or many computer-readable statements.

[0125] While specific embodiments of the present disclosure have been outlined above, many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, the embodiments, as described herein, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the present disclosure.

Claims

1. 1. A bean roasting system comprising: a roasting drum configured to receive and thermally roast the beans; an air handling system configured to circulate a first fluid stream through the roasting drum; a bean cooler configured to receive and cool the beans from the roasting drum; an air outlet subsystem configured to receive and process the first fluid flow from the air handling system and the second fluid flow from the bean cooler, a heat sink defining the first and second fluid paths, the heat sink including a metal body and being substantially parallel to the first fluid path; the metal body configured to receive heat from the first fluid path and the second fluid path; a first fluid path fluidly coupled to the air handling system for receiving the first fluid flow from the air handling system; a second fluid path fluidly coupled to the bean cooler for receiving the second fluid stream from the bean cooler; and an air outlet subsystem including a filter fluidly coupled to the first fluid path and the second fluid path.

2. 10. The bean roasting system of claim 1, further comprising a housing defining a housing fluid path fluidly coupling the first fluid path and the second fluid path to the filter and combining the first fluid stream and the second fluid stream to provide a combined fluid stream.

3. The bean roasting system of claim 2 , wherein the housing includes an outlet fan disposed within the housing fluid path.

4. 4. The bean roasting system of claim 3, wherein during operation, the combined fluid flow generally traverses the housing fluid path along a transverse Y-axis, then passes into the filter along a vertical Z-axis, and then passes through a filter within the filter along a transverse X-axis, the X-axis, the Y-axis, and the Z-axis being mutually orthogonal.

5. 3. The bean roasting system of claim 2, wherein during operation, the first fluid flow enters the housing along a Y-axis and then traverses along the first fluid path along the Z-axis, the Y-axis and the Z-axis being mutually orthogonal.

6. 10. The bean roasting system of claim 1, wherein during operation, the first fluid path and the second fluid path direct airflow along a vertical Z-axis.

7. 7. The bean roasting system of claim 6, wherein during operation, the first fluid path directs the first fluid flow first in a downward direction and then in an upward direction along the Z-axis.

8. 8. The bean roasting system of claim 7, wherein during operation, the first fluid flow enters the air outlet subsystem along a lateral Y-axis before entering the first fluid path, the lateral Y-axis being orthogonal to the vertical Z-axis.

9. 7. The bean roasting system of claim 6, wherein during operation, the second fluid path directs the second fluid flow in an upward direction along the vertical Z-axis.

10. The heat sink is a first plurality of fins extending from the metal body into the first fluid path; and 10. The bean roasting system of claim 1, further comprising a second plurality of fins extending from the metal body into the second fluid path.

Images