Portion optimized dispensing system

Abstract

Systems, apparatuses, and methods are disclosed herein for automated cup dispensing and filling. An automated portion cup dispensing system comprises a conveyor belt; a cup dispensing station positioned along the conveyor belt that dispenses cups onto the conveyor belt using a servo motor connected to a rack and pinion gear; a filling station positioned along the conveyor belt that fills the cups with a liquid or semi-liquid food product using a servo motor connected to a cam that actuates a dispenser; a lid dispensing station positioned along the conveyor belt that dispenses lids onto the filled cups using a servo motor that drives a planetary gear system; and a sealing station positioned along the conveyor belt that seals the lids to the cups using a servo motor connected to a pinion gear that drives a press.

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This application claims priority to U.S. Provisional App. No. 63 / 781,210, titled “Portion Optimized Dispensing System,” filed Mar. 31, 2025, which is hereby incorporated by reference in its entirety.TECHNICAL FIELD

[0002] Embodiments of the present disclosure relate to robotic solutions for restaurant kitchens, and specifically, relate to automating the process of preparing portion cups.BACKGROUND

[0003] Increased levels for take-out and delivery food from restaurants has led to a need for more pre-packaged foods such as condiments provided in portion cups. In some cases, restaurants need to produce hundreds of these cups each day, a time-consuming process when done manually. Manual preparation of portion cups requires employees to individually dispense cups, fill each cup with the appropriate amount of condiment, place lids on the filled cups, and seal the lids securely. This repetitive process diverts valuable labor resources from other critical kitchen tasks and customer service activities.

[0004] Furthermore, manual filling introduces variability in portion sizes, which can lead to inconsistent customer experiences and increased food waste when cups are overfilled. Improper sealing of lids during manual preparation can result in spillage, contamination, and reduced product shelf life. The physical demands of repetitive cup filling motions can also contribute to employee fatigue and potential repetitive strain injuries over extended periods. Additionally, during peak service hours, the time required for manual portion cup preparation can create bottlenecks in kitchen operations, potentially delaying order fulfillment and negatively impacting customer satisfaction.SUMMARY

[0005] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0006] In an embodiment, an automated portion cup dispensing system comprises a conveyor belt; a cup dispensing station positioned along the conveyor belt that dispenses cups onto the conveyor belt using a servo motor connected to a rack and pinion gear; a filling station positioned along the conveyor belt that fills the cups with a liquid or semi-liquid food product using a servo motor connected to a cam that actuates a dispenser; a lid dispensing station positioned along the conveyor belt that dispenses lids onto the filled cups using a servo motor that drives a planetary gear system; and a sealing station positioned along the conveyor belt that seals the lids to the cups using a servo motor connected to a pinion gear that drives a press.

[0007] In some embodiments, the automated portion cup dispensing system further comprises distance measuring sensors positioned along the conveyor belt that detect when cups are in correct positions at each station.

[0008] In some embodiments, the automated portion cup dispensing system further comprises a control interface that allows a user to specify how many cups to make.

[0009] In some embodiments, the automated portion cup dispensing system further comprises a finished cup inventory system that holds completed cups.

[0010] In some embodiments, the automated portion cup dispensing system further comprises built-in software that alerts operators when the system is running low on materials or has a fault.

[0011] In some embodiments, the automated portion cup dispensing system has a weight of less than 30 pounds, or in other embodiments less than 25 pounds, less than 20 pounds, less than 15 pounds, or less than 10 pounds, depending on the materials selected for the frame and components, and fits on a 2-foot table.

[0012] In some embodiments, the automated portion cup dispensing system further comprises components manufactured using additive manufacturing, injection molding, CNC machining, or other suitable manufacturing processes, wherein the components are coated or otherwise treated to be food safe and dishwasher safe.

[0013] In another embodiment, a method of automatically dispensing portion cups comprises dispensing a cup onto a conveyor belt using a rack and pinion mechanism driven by a servo motor; moving the cup along the conveyor belt to a filling station; filling the cup with a food product using a cam mechanism driven by a servo motor that actuates a dispenser; moving the filled cup along the conveyor belt to a lid dispensing station; dispensing a lid onto the filled cup using a planetary gear system driven by a servo motor; moving the cup with lid along the conveyor belt to a sealing station; and sealing the lid to the cup using a press mechanism driven by a servo motor connected to a pinion gear.

[0014] In some embodiments, the method further comprises detecting when cups are in correct positions at each station using distance measuring sensors positioned along the conveyor belt.

[0015] In some embodiments, the method further comprises receiving user input specifying how many cups to make through a control interface.

[0016] In some embodiments, the method further comprises moving completed cups to a finished cup inventory system that holds completed cups.

[0017] In some embodiments, the method further comprises alerting operators when the system is running low on materials or has a fault using built-in software.

[0018] In some embodiments, the method further comprises using a dispenser that is certified food safe for filling the cup with the food product.

[0019] In some embodiments, the method further comprises automatically stopping the dispensing process when the specified number of cups has been reached.

[0020] In another embodiment, a tabletop automated food portion dispensing apparatus weighing less than 30 pounds comprises a frame supporting a linear conveyor system; a cup magazine holding a stack of portion cups and a dispensing mechanism that separates individual cups from the stack using a motorized rack and pinion system; a food dispensing assembly that deposits food into cups using a motorized cam system that actuates a food-safe dispenser; a lid magazine holding a stack of lids and a dispensing mechanism that releases individual lids using a motorized planetary gear assembly; a sealing mechanism that secures lids to cups using a motorized press system; and distance measuring sensors positioned at each station to detect cup presence.

[0021] In some embodiments, the tabletop automated food portion dispensing apparatus further comprises a control interface that allows a user to specify how many cups to make.

[0022] In some embodiments, the tabletop automated food portion dispensing apparatus further comprises built-in software that alerts operators when the system is running low on materials or has a fault.

[0023] In some embodiments, the tabletop automated food portion dispensing apparatus further comprises a finished cup inventory system that holds completed cups.

[0024] In some embodiments, the tabletop automated food portion dispensing apparatus further comprises components manufactured using additive manufacturing, injection molding, CNC machining, or other suitable manufacturing processes, and the components are coated or otherwise treated to be food safe and dishwasher safe.

[0025] In some embodiments, the tabletop automated food portion dispensing apparatus further comprises a frame made from stainless steel sheet metal.

[0026] The foregoing general description of the illustrative embodiments and the following detailed description thereof are merely exemplary aspects of the teachings of this disclosure and are not restrictive.BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The accompanying drawings, which are incorporated into and constitute a part of this specification, illustrate various exemplary embodiments and together with the description, serve to explain the principles of the disclosed embodiments.

[0028] FIG. 1 is a process diagram for an embodiment of a method of filling a portion container, in accordance with one or more embodiments of this disclosure.

[0029] FIG. 2A is an isometric view of an embodiment of a cup dispensing assembly, in accordance with one or more embodiments of this disclosure.

[0030] FIG. 2B is a process diagram of an embodiment of dispensing a cup from an apparatus, in accordance with one or more embodiments of this disclosure.

[0031] FIG. 2C is a top view of an embodiment of the cup dispensing apparatus, in accordance with one or more embodiments of this disclosure.

[0032] FIG. 3A is an isometric view of an embodiment of a sauce dispenser assembly, in accordance with one or more embodiments of this disclosure.

[0033] FIG. 3B is an side view of an embodiment of the sauce dispenser assembly, in accordance with one or more embodiments of this disclosure.

[0034] FIG. 4A is an isometric view of an embodiment of a lid dispenser assembly, in accordance with one or more embodiments of this disclosure.

[0035] FIG. 4B is a view of an embodiment of a multi-level flange, in accordance with one or more embodiments of this disclosure.

[0036] FIG. 4C is a side-by-side view of the positions for an embodiment of the lid dispenser assembly, in accordance with one or more embodiments of this disclosure.

[0037] FIG. 4D is a process diagram illustrating an embodiment of the steps of lid dispensing, in accordance with one or more embodiments of this disclosure.

[0038] FIG. 5A is an isometric view of an embodiment of a lid press assembly, in accordance with one or more embodiments of this disclosure.

[0039] FIG. 5B is a series of side views of an embodiment of a lid press assembly, in accordance with one or more embodiments of this disclosure.

[0040] FIG. 6 is an isometric view of an embodiment of a conveyor assembly, in accordance with one or more embodiments of this disclosure.

[0041] FIG. 7 is a block diagram of an embodiment of a computing node.DETAILED DESCRIPTION

[0042] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0043] Reference will now be made in detail to the exemplary embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

[0044] The systems, devices, and methods disclosed herein are described in detail by way of examples and with reference to the figures. The examples discussed herein are examples only and are provided to assist in the explanation of the apparatuses, devices, systems, and methods described herein. None of the features or components shown in the drawings or discussed below should be taken as mandatory for any specific implementation of any of these devices, systems, or methods unless specifically designated as mandatory.

[0045] Also, for any methods described, regardless of whether the method is described in conjunction with a flow diagram, it should be understood that unless otherwise specified or required by context, any explicit or implicit ordering of steps performed in the execution of a method does not imply that those steps must be performed in the order presented but instead may be performed in a different order or in parallel.

[0046] As used herein, the term “exemplary” is used in the sense of “example,” rather than “ideal.” Moreover, the terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of one or more of the referenced items.

[0047] To efficiently automate the process for dispensing a food product into a portion cup, a modular portion cup dispensing system may be used. In some embodiments, the automated dispensing system for portion cups includes a conveyor belt and a series of stations where a portion cup is moved down the conveyor belt and stops at each station. For example, a cup dispensing station is positioned along the conveyor belt, such that cups are dispensed onto the conveyor belt, for example by using a servo motor connected to a rack and pinion gear. The dispensed cup is then transported along the conveyor belt to a filling station, where the cup is filled with a liquid or semi-liquid food product, using a servo motor connected to a cam that actuates a dispenser. Once the cup is determined to be filled, for example by a series of sensors placed along the conveyor belt, it is moved to a lid dispensing station that dispenses lids onto the filled cup using a servo motor that drives a planetary gear system, and then to a sealing station positioned along the conveyor belt that seals the lids to the cups using a servo motor connected to a pinion gear that drives a press.

[0048] Creating a portion container thereby comprises four general steps: dispensing a cup, filling the cup, dispensing a lid, and sealing the cup with the lid. FIG. 1 is a process diagram illustrating an embodiment of an exemplary method 100 of this workflow. Steps 104, 106, 108, and 110 of method 100 may be automated (e.g., by a portion optimized dispensing system (“PODS”), as indicated by the dotted line around steps 104-110), leaving only the jobs of restocking lids, cups, food items, and storing the finished cups to human employees. In some embodiments, a conveyor belt lined with a variety of process checking sensors may move the cups between stations.

[0049] The method 100 may begin at the start 102. The method 100 may start automatically or in response to a request by a user. In step 104, the method may include dispensing a cup onto a designated filling location, such as on a conveyor belt, or as indicated by sensors. The cup may be dispensed onto the conveyor belt, for example, by a rack and pinion mechanisms driven by a servo motor. Once the cup has been dispensed onto the designated filling location, the cup is moved on the conveyor belt to a filling station, where the cup will be filled in step 106.

[0050] In step 106, the cup may be filled with any food product or condiment suitable for dispensing, such as ketchup, salsa, mustard, mayonnaise, ranch dressing, barbecue sauce, hot sauce, soy sauce, teriyaki sauce, honey mustard, tartar sauce, cocktail sauce, aioli, sriracha, buffalo sauce, cheese sauce, nacho cheese, queso, guacamole, sour cream, hummus, tzatziki, pesto, marinara sauce, alfredo sauce, gravy, au jus, hollandaise sauce, béarnaise sauce, chimichurri, tahini, ponzu sauce, hoisin sauce, sweet and sour sauce, duck sauce, plum sauce, chili garlic sauce, gochujang, sambal, harissa, romesco sauce, mole sauce, adobo sauce, green goddess dressing, blue cheese dressing, thousand island dressing, Italian dressing, balsamic vinaigrette, Caesar dressing, honey, maple syrup, chocolate sauce, caramel sauce, fruit compote, jam, jelly, preserves, marmalade, Nutella, peanut butter, almond butter, cream cheese, butter, whipped cream, custard, pudding, yogurt, fruit puree, applesauce, cranberry sauce, relish, pickle relish, olive tapenade, bruschetta topping, guacamole, salsa verde, pico de gallo, mango salsa, corn salsa, bean dip, spinach artichoke dip, onion dip, French onion dip, crab dip, buffalo chicken dip, garlic butter, herb butter, compound butter, olive oil, infused oils, flavored vinegars, lemon curd, lime curd, passion fruit curd, coconut cream, dulce de leche, condensed milk, evaporated milk, half-and-half, heavy cream, sour cream, crème fraîche, mascarpone, ricotta, cottage cheese, or any other liquid, semi-liquid, viscous, or pourable food product suitable for dispensing into portion cups.

[0051] The cup is filled with the food product by using a cam mechanism driven by a servo motor that in turn actuates a dispenser. In alternative embodiments, the actuation mechanism for the dispenser may comprise various configurations beyond the cam-driven servo motor arrangement. For example, the dispenser may be actuated by a linear actuator, such as a pneumatic cylinder, hydraulic cylinder, or electric linear actuator, that directly depresses the dispenser handle or valve. In some embodiments, a solenoid-driven mechanism may be employed to actuate the dispenser, wherein an electromagnetic solenoid provides rapid, precise actuation of the dispensing mechanism. The dispenser may alternatively be actuated by a stepper motor connected to a lead screw assembly, providing fine control over the displacement and force applied to the dispenser handle.

[0052] In further embodiments, the cam mechanism may comprise various cam profiles, including eccentric cams, heart-shaped cams, or conjugate cams, each providing different motion characteristics suited to the viscosity and flow properties of the food product being dispensed. The cam may be fabricated from materials including hardened steel, stainless steel, brass, bronze, aluminum alloy, acetal polymer, nylon, PEEK (polyether ether ketone), or UHMW (ultra-high molecular weight) polyethylene, selected based on wear resistance, food safety requirements, and operational environment considerations.

[0053] In some embodiments, the servo motor may be replaced with alternative motor types, including brushless DC motors, stepper motors, or AC servo motors, depending on the torque requirements, speed control precision, and duty cycle demands of the application. The motor may be coupled to the cam through various transmission mechanisms, including direct drive coupling, belt and pulley systems, chain and sprocket assemblies, or gear trains with reduction ratios ranging from 1:1 to 100:1 or greater.

[0054] In certain embodiments, the dispenser actuation system may incorporate a force feedback mechanism, such as a load cell or strain gauge, to monitor the force applied during dispensing and ensure consistent product delivery regardless of variations in product viscosity or dispenser resistance. The actuation system may further include position sensors, such as encoders, potentiometers, or Hall effect sensors, to provide closed-loop control of the dispensing stroke and enable precise metering of the food product.

[0055] In alternative configurations, the filling station may employ a peristaltic pump mechanism, a positive displacement pump, a gear pump, or a diaphragm pump to dispense the food product, eliminating the need for mechanical actuation of an external dispenser handle. The filling station may also utilize gravity-fed dispensing with an electronically controlled valve, such as a pinch valve, ball valve, butterfly valve, or gate valve, to regulate product flow. In some embodiments, the dispenser may be actuated by a rack and pinion mechanism, a scotch yoke mechanism, a toggle linkage, or a four-bar linkage driven by a rotary motor.

[0056] The dispensing mechanism may be configured to operate at actuation speeds ranging from 0.1 seconds to 10 seconds per dispensing cycle, with dispensing volumes adjustable from 0.125 fluid ounces to 8 fluid ounces or more, depending on the portion cup size and food product requirements. In some embodiments, the actuation speed may be dynamically adjusted based on the viscosity of the food product being dispensed, with faster actuation speeds employed for low-viscosity products such as soy sauce, vinegar, or thin dressings, and slower actuation speeds employed for high-viscosity products such as honey, caramel sauce, peanut butter, or thick cheese sauces. The dispensing volume may be user-configurable through the control interface in increments of 0.1 fluid ounces, 0.25 fluid ounces, 0.5 fluid ounces, or 1 fluid ounce, allowing operators to precisely match portion sizes to menu specifications and cost control requirements. In certain embodiments, the system may store multiple dispensing volume presets corresponding to different menu items, enabling rapid changeover between portion sizes without manual recalibration.

[0057] The actuation force applied to the dispenser may range from 1 Newton to 100 Newtons, calibrated based on the specific dispenser type and product viscosity. In some embodiments, the actuation force may range from 1 Newton to 25 Newtons for low-resistance dispensers and thin products, from 25 Newtons to 50 Newtons for medium-viscosity products such as ketchup, mustard, or ranch dressing, and from 50 Newtons to 100 Newtons or greater for high-viscosity products such as thick sauces, nut butters, or cream cheese. The actuation force may be automatically adjusted by the control system based on feedback from force sensors, current sensors on the servo motor, or empirical calibration data stored in the system memory for each food product type. In further embodiments, the system may employ adaptive force control algorithms that monitor dispensing performance in real-time and incrementally adjust actuation force to compensate for changes in product viscosity due to temperature variations, product settling, or depletion of the product reservoir.

[0058] In some embodiments, the dispensing cycle timing may be configured with variable acceleration and deceleration profiles to minimize splashing, dripping, or product waste. The servo motor may execute trapezoidal velocity profiles, S-curve velocity profiles, or custom motion profiles optimized for the rheological properties of specific food products. The dispensing mechanism may incorporate a dwell time at the end of the dispensing stroke, ranging from 0.05 seconds to 2 seconds, to allow complete product separation from the dispensing nozzle before the mechanism returns to the neutral position. In certain embodiments, the dispensing mechanism may execute a reverse stroke or anti-drip retraction motion following the primary dispensing stroke to draw back residual product and prevent dripping between dispensing cycles.

[0059] The dispensing parameters may be stored in non-volatile memory and associated with specific product identifiers, allowing the system to automatically recall optimal actuation speed, dispensing volume, actuation force, and motion profile settings when a particular food product is selected through the control interface. In some embodiments, the system may include a calibration mode wherein operators dispense test portions and provide feedback to fine-tune dispensing parameters for new or custom food products not included in the default product library. The calibration data may be uploaded to a cloud-based database, enabling sharing of optimized dispensing parameters across multiple PODS units deployed at different locations within a restaurant chain or franchise network.

[0060] The dispenser may be certified to be food safe for filling the cup with the food product. Sensors within the PODS may detect the level of food product within the cup, and / or determine when the cup is adequately filled. In some embodiments, the sensors comprise optical sensors, such as infrared sensors, laser-based distance sensors, or camera-based vision systems that capture images of the cup interior and employ image processing algorithms to determine fill level. In other embodiments, the sensors comprise capacitive sensors that detect changes in capacitance as the food product level rises within the cup, or inductive sensors suitable for detecting metallic or conductive food products. In further embodiments, ultrasonic sensors emit sound waves and measure the time-of-flight of reflected signals to determine the distance to the food product surface, thereby calculating the fill level. Weight-based sensing may also be employed, wherein load cells or strain gauges positioned beneath the cup measure the mass of dispensed product and compare it against a target weight threshold. In some embodiments, the system employs time-based fill detection, wherein the dispenser operates for a predetermined duration calibrated to dispense a specific volume of product based on the product's viscosity and flow characteristics. In certain embodiments, flow meters, such as positive displacement flow meters, turbine flow meters, or Coriolis flow meters, are positioned in the dispensing pathway to measure the volume of product dispensed directly. The sensors may operate in combination, wherein multiple sensor modalities provide redundant measurements that are fused algorithmically to improve accuracy and reliability of fill level detection. In some embodiments, the fill level threshold is user-configurable through the control interface, allowing operators to specify target fill volumes ranging from 25% to 100% of cup capacity, or to specify absolute volumes in fluid ounces or milliliters. The system may employ closed-loop feedback control, wherein sensor readings are continuously monitored during dispensing and the dispensing mechanism is automatically stopped when the target fill level is reached, rather than relying on open-loop timed dispensing. In some embodiments, the sensors detect overfill conditions and trigger an immediate stop of the dispensing mechanism, followed by an alert to the operator. The sensors may be positioned above the cup looking downward, positioned at the side of the cup measuring through transparent or translucent cup walls, or integrated into the dispensing nozzle assembly. In embodiments employing camera-based detection, machine learning models trained on images of properly filled cups may be used to classify fill levels and detect anomalies such as air bubbles, uneven surfaces, or contamination. Once the cup is filled, the cup can be moved along the conveyor belt to a lid dispensing station.

[0061] In step 108, a lid sealable to the top of the cup is dispensed to the cup at the lid dispensing station.

[0062] The lid is dispensed to the filled cup using a planetary gear system driven by a servo motor. In alternative embodiments, the lid dispensing mechanism may employ various gear configurations and drive systems beyond the planetary gear arrangement. For example, the lid dispensing station may utilize a spur gear train, a worm gear assembly, a bevel gear system, or a harmonic drive mechanism to achieve the rotational motion required for lid separation and dispensing. In some embodiments, the planetary gear system comprises a sun gear, a ring gear, and a plurality of planet gears, wherein the number of planet gears ranges from two to eight, with each planet gear connected to a shaft supporting a multi-level flange that engages the lid stack. The planet gears may be fabricated from materials including hardened steel, stainless steel, brass, bronze, aluminum alloy, acetal polymer, nylon, PEEK (polyether ether ketone), Delrin, HDPE, or UHMW (ultra-high molecular weight) polyethylene, selected based on wear resistance, food safety requirements, noise reduction, and operational environment considerations.

[0063] In further embodiments, the servo motor may be replaced with alternative motor types, including brushless DC motors, stepper motors, AC servo motors, or direct drive motors, depending on the torque requirements, positional accuracy, speed control precision, and duty cycle demands of the application. The motor may be coupled to the planetary gear system through various transmission mechanisms, including direct drive coupling, flexible couplings, belt and pulley systems, chain and sprocket assemblies, or intermediate gear trains with reduction ratios ranging from 1:1 to 50:1 or greater.

[0064] In some embodiments, the lid dispensing mechanism employs a linear actuation system rather than a rotary planetary gear system. For example, the lid dispensing station may utilize a pneumatic cylinder, hydraulic cylinder, electric linear actuator, or solenoid-driven mechanism to actuate retractable fingers, pins, or blades that selectively release individual lids from the stack. In certain embodiments, a rack and pinion mechanism driven by a rotary motor provides linear motion to lid-engaging elements that separate the bottom lid from the stack. In other embodiments, a lead screw assembly driven by a stepper motor or servo motor provides precise linear displacement of lid release mechanisms.

[0065] In alternative configurations, the lid dispensing mechanism may employ a vacuum-assisted system, wherein a vacuum cup or suction head engages the bottom lid of the stack and transports it to the filled cup below. The vacuum may be generated by a venturi device, a diaphragm pump, a rotary vane pump, or a regenerative blower. In some embodiments, the lid dispensing mechanism utilizes a rotary carousel or turret system that indexes individual lids from a magazine to a dispensing position above the filled cup.

[0066] In some embodiments, the multi-level flange attached to each planet gear shaft comprises two, three, or four support levels, each level having a different radial extension to engage lids at different heights within the stack. The flanges may be fabricated as integral components with the planet gear shafts or as separate modular components that are press-fit, threaded, or fastened to the shafts. The flange geometry may be configured to accommodate various lid diameters ranging from 1 inch to 6 inches, and various lid thicknesses ranging from 0.5 millimeters to 3 millimeters.

[0067] In certain embodiments, the lid dispensing station incorporates position sensors, such as optical encoders, magnetic encoders, Hall effect sensors, or limit switches, to provide closed-loop feedback control of the planetary gear system position and ensure accurate lid dispensing. The system may further include presence sensors, such as optical sensors, capacitive sensors, or mechanical switches, positioned within the lid magazine to detect the presence and quantity of lids remaining in the stack and to trigger alerts when the lid supply is low.

[0068] In some embodiments, the lid dispensing mechanism operates at dispensing speeds ranging from 0.5 seconds to 5 seconds per lid, with positional accuracy of the planetary gear system within 0.1 degrees to 2 degrees of the target position. The torque applied by the servo motor may range from 0.1 Newton-meters to 10 Newton-meters, calibrated based on the lid stack weight, friction characteristics, and mechanism geometry.

[0069] Upon the lid being dispensed to the cup, the cup and lid are moved down the conveyor belt to a sealing station.

[0070] The dispensed lid is then sealed onto the filled cup in step 110. Sealing the cup may comprise applying pressure to the dispensed lid to snap onto the cup, clipping the lid onto the cup, or any other suitable means of sealing the cup.

[0071] The lid may also be sealed to the cup using a press mechanism driven by a servo motor connected to a pinion gear. In alternative embodiments, the sealing mechanism may employ various motor types and transmission configurations beyond the servo motor and pinion gear arrangement. For example, the press mechanism may be driven by a brushless DC motor, a stepper motor, an AC servo motor, or a direct drive motor, depending on the torque requirements, positional accuracy, speed control precision, and duty cycle demands of the sealing application. The motor may be coupled to the press mechanism through various transmission systems, including direct drive coupling, belt and pulley systems, chain and sprocket assemblies, worm gear assemblies, bevel gear systems, or gear trains with reduction ratios ranging from 1:1 to 100:1 or greater.

[0072] In some embodiments, the press mechanism may be actuated by a linear actuator rather than a rotary motor with gear transmission. For example, the sealing station may utilize a pneumatic cylinder, hydraulic cylinder, electric linear actuator, or solenoid-driven mechanism to drive the press downward onto the lid. In certain embodiments, a lead screw assembly driven by a stepper motor or servo motor provides precise linear displacement of the press with fine control over the applied sealing force. In other embodiments, a rack and pinion mechanism, a scotch yoke mechanism, a toggle linkage, a four-bar linkage, or a cam-follower mechanism may be employed to convert rotary motor motion into the linear pressing motion required for lid sealing.

[0073] The press mechanism may apply sealing forces ranging from 5 Newtons to 500 Newtons, calibrated based on the lid material, cup material, and interference fit requirements of the specific portion cup and lid combination. The press may operate at sealing speeds ranging from 0.2 seconds to 3 seconds per sealing cycle, with positional accuracy within 0.1 millimeters to 2 millimeters of the target position. In some embodiments, the press mechanism incorporates a force feedback system, such as a load cell, strain gauge, or current sensing on the motor, to monitor the sealing force applied and ensure consistent lid attachment regardless of variations in lid or cup dimensions.

[0074] The press may comprise a contact surface fabricated from materials including aluminum alloy, stainless steel, brass, acetal polymer, nylon, PEEK (polyether ether ketone), UHMW (ultra-high molecular weight) polyethylene, silicone rubber, or food-grade elastomers, selected based on durability, food safety requirements, and the desired pressure distribution characteristics. In some embodiments, the press contact surface includes a compliant layer, such as a silicone pad or rubber gasket, to distribute sealing pressure evenly across the lid surface and accommodate minor variations in lid geometry. The press may have a modular bottom topography with interchangeable contact surfaces configured to optimize pressure distribution for various lid types, including flat lids, domed lids, vented lids, and lids with raised features or embossing.

[0075] In certain embodiments, the sealing station incorporates position sensors, such as optical encoders, magnetic encoders, Hall effect sensors, limit switches, or proximity sensors, to provide closed-loop feedback control of the press position and ensure accurate and repeatable sealing operations. The system may further include presence sensors positioned at the sealing station to detect the presence of a cup with lid prior to initiating the sealing cycle, preventing damage to the press mechanism or incomplete sealing operations.

[0076] In alternative configurations, the sealing mechanism may employ a rotary sealing approach rather than a vertical press, wherein a rotating element applies circumferential pressure around the lid perimeter to snap the lid onto the cup. In some embodiments, the sealing station utilizes a crimping mechanism with multiple radially-arranged fingers or jaws that simultaneously engage the lid edge and press it onto the cup rim. In further embodiments, the sealing mechanism may incorporate heat sealing, ultrasonic welding, or induction sealing capabilities for use with compatible lid and cup materials that require thermal bonding rather than mechanical snap-fit attachment.

[0077] The method 100 may also comprise detecting when cups are in a correct position at each station, such as by using distance measuring sensors positioned along the conveyor belt. In some embodiments, the distance measuring sensors comprise ultrasonic sensors that emit sound waves and measure the time-of-flight of reflected signals to determine the distance to objects. In other embodiments, the distance measuring sensors comprise time-of-flight (TOF) sensors that use infrared light pulses to measure distances with high precision. In further embodiments, the distance measuring sensors comprise laser distance sensors, such as laser triangulation sensors or laser rangefinders, that provide accurate distance measurements using focused laser beams. In some embodiments, the distance measuring sensors comprise infrared proximity sensors that detect the presence and distance of objects based on reflected infrared radiation. In certain embodiments, the distance measuring sensors comprise capacitive proximity sensors, inductive proximity sensors, or photoelectric sensors configured to detect cup presence and position. The distance measuring sensors may operate individually or in combination, wherein multiple sensor modalities provide redundant measurements to improve accuracy and reliability of cup position detection at each station

[0078] After the cup is sealed in step 110, the cup may be advanced to a storage site in step 112. Once the cup's arrival has been noted, either by sensors or some other suitable means of indication, the method may reach its end 114. In some embodiments, the system is automatically stopped once a specified number of cups have been filled.

[0079] A human employee may restock cups for dispensing as needed, or to ensure that enough cups are present for dispensing, as indicated by step 116. The same or another human employee may also ensure that there is enough condiment for filling the cup, and may restock the condiment supply as needed, as indicated by step 118.

[0080] The user controls the device from a control interface to specify how many cups to make and how much of the product to dispense.

[0081] In some embodiments, PODS has the capacity to hold a number of containers (such as ten) and some volume of food or beverage, determined by the capacities of modular hoppers to be attached or replaced by the user. The cup magazine may be configured to hold stacks of portion cups ranging from 25 cups to 200 cups or more, depending on the cup size and magazine dimensions. Similarly, the lid magazine may accommodate corresponding quantities of lids to match the cup supply. The food dispensing assembly may include a reservoir or hopper with a capacity ranging from 0.5 gallons to 5 gallons or more, allowing for extended operation between refills. In some embodiments, the modular hoppers are designed with quick-release mechanisms, such as twist-lock fittings, snap-fit connections, or magnetic attachments, enabling rapid replacement or swapping of hoppers without tools. The hoppers may be fabricated from food-safe materials including stainless steel, food-grade polycarbonate, polypropylene, high-density polyethylene (HDPE), or other FDA-approved polymers suitable for contact with food products. In certain embodiments, the hoppers include transparent or translucent sections that allow visual inspection of remaining material levels. The system may further include level sensors, such as optical sensors, capacitive sensors, ultrasonic sensors, or weight-based sensors integrated into the hopper mounting locations, to automatically detect and report the quantity of cups, lids, or food product remaining in each hopper. In some embodiments, the modular hopper system allows users to configure PODS for different portion cup sizes by swapping cup and lid magazines designed for specific cup diameters, such as 2-ounce, 4-ounce, or 5.5-ounce souffle cups. The food hopper capacity may be selected based on the anticipated production volume and the viscosity of the food product being dispensed, with larger capacity hoppers suitable for high-volume operations and smaller hoppers suitable for products that require more frequent changeover or have limited shelf life once opened.

[0082] Once a cup is finished (i.e., step 114 is reached), PODS dispenses it into a finished cup inventory system at the end of line, which may comprise a tray, storage area, or bin depending on the desired capacity. Once a cup is finished, it may be held in a finished cup inventory system. In some embodiments, the finished cup inventory system comprises an inventory area that can hold up to 10 cups for easy user access. In other embodiments, the finished cup inventory system comprises a bin that can hold 50 or more completed cups for higher volume operations. In some embodiments, the PODS system includes built in software to alert a user when it is running low on material or a fault has occurred.

[0083] At the end of line, PODS may perform a quality check that determines whether the cup was sealed successfully and notified the user if a cup did not seal correctly.

[0084] In some embodiments, the PODS fits onto a two foot tabletop within a restaurant kitchen, and weighs less than 20 pounds, or in some embodiments, less than 30 pounds. Due to its small size and light weight, the PODS device is easy to move around and store, as well as comprising modular mechanisms for rapid repair.

[0085] The tabletop PODS can comprise a frame, supporting a linear conveyor system; a cup magazine for holding a stack of portion cups and for dispensing cups using a motorized rack and pinion system; a food dispensing assembly for depositing food into cups using a motorized cam system that actuates a food-safe dispenser; a lid magazine that holds a stack of lids and a dispensing mechanism that releases individual lids using a motorized planetary gear assembly; a sealing mechanism that secures lids to cups using a motorized press system; and distance measuring sensors positioned at each assembly station to detect cup presence. In some embodiments, the frame is made from stainless steel sheet metal.

[0086] Components of the PODS system may be manufactured using various processes depending on production volume, material requirements, and cost considerations. In some embodiments, components are manufactured using additive manufacturing processes, such as fused deposition modeling (FDM), stereolithography (SLA), selective laser sintering (SLS), or other 3D printing technologies. In other embodiments, components are manufactured using injection molding, which may be preferred for higher production volumes. In further embodiments, components are manufactured using CNC machining, die casting, thermoforming, or other suitable manufacturing processes. The manufactured components may be coated or otherwise treated to ensure they are food safe and dishwasher safe.

[0087] FIGS. 2A-C illustrate an embodiment of an assembly 200 for dispensing cups. FIG. 2A is an isometric view of an embodiment of the assembly 200. The cup dispensing assembly 200 comprises a servo motor 204 connected to a rack and pinion gear (as shown in FIG. 2C) to separate a bottom cup from a stack of cups. The stack of cups may be stored in cylinder 202. The rack and pinion mechanism moves a slider back and forth to thereby separate a bottom cup 216a from the stack, using two separate supports. The bottom support 220 of the two separate supports is in a neutral position, holding a full stack of cups. As the slider moves to a rear position, the top support of the two separate supports holds up the top cup 216a and bottom cup 216b in cylinder 202 while also allowing the bottom cup 216b to then fall onto the conveyor belt system. A partial funnel attached to the bottom of the assembly 200 guides the falling bottom cup 216b to a repeatable position on the conveyor belt below. A spirit level vial is also mounted to the body of the apparatus to ensure that the mechanism is level and operating optimally.

[0088] FIG. 2B is a section view of an embodiment of the slider mechanism 218 and displays three steps in cup dispensing. In the first step 210, top cup 216a and bottom cup 216b are resting on the bottom support 220 in a neutral position. In step 212, the slider moves to the rear position, where the top cup 216a is still supported by the upper support and the bottom cup 216b is free to fall to the conveyor. In step 214, the slider mechanism 218 returns to the rear position and drops the top cup 216a to the lower level. The cycle repeats as long as the system detects cups in the stack.

[0089] FIG. 2C is a top view of an embodiment of the cup dispensing apparatus 200. The lefthand diagram illustrates the slider mechanism 218 in the neutral position, where all cups are supported. As the motor moves the slider mechanism 218 to the rear position, the slider separates the bottom cup 216b from the rest of the stack, allowing the bottom cup to fall. The rack and pinion gear 222 is also displayed in each diagram, as the rack and pinion gear 222 moves the slider mechanism 218 from the neutral to the rear position.

[0090] FIGS. 3A-B illustrate an embodiment of the steps of filling the cup. FIG. 3A is an isometric view of an embodiment of a sauce dispenser assembly 300. The sauce dispenser assembly 300 uses a servo motor 302 connected to a cam 304, where the motor 302 and cam 304 press a handle 306 of a sauce dispenser 308 (sauce dispenser 308 and handle 306 not shown in FIG. 3A). The sauce dispenser 308 can be a commercially available sauce dispenser, such as any one of the commercially available sauce dispensers manufactured by Asept International AB of Mölndal, Sweden listed below:Asept designation onNSF listingDescriptionSS6L-1DISingle drop-in dispenser for 1.5-gal (6-qt) fitmented pouches; adjustableportion up to 1 oz; stainless, low-profile look that locks into counter.SS6L-2DIDouble drop-in dispenser; same portion-control and 1.5-gal pouch spec.SS6L-3DITriple drop-in dispenser; same system and features.SS6L-4DIQuadruple drop-in dispenser; same system and features.SS6L-5DIQuintuple drop-in dispenser; same system and features.Portion PumpHandheld portion-control pump dispenser; adjustable portion sizes;designed for use with fitmented pouches; food-safe construction.

[0091] The electronics within the sauce dispenser 308 are configurable, to thereby adjust the exact amount of sauce dispensed. To ensure the system minimizes spillage, a distance measuring sensor (not pictured) is used to ensure a cup is present beneath the dispenser. If the sensors do not detect a cup, the sauce dispenser 308 will not activate.

[0092] FIG. 3B is a section view of an embodiment of the sauce dispenser 308. The lefthand view illustrates the neutral position, where the cam 304 is oriented parallel to the sauce dispenser 308. The righthand view illustrates the press position, where the cam 304 is oriented perpendicular to the dispenser 308, thereby pressing the handle 306 of the dispenser 308 and dispensing the sauce into the cup.

[0093] FIGS. 4A-4D illustrate an embodiment of the steps of dispensing the lid to the cup. FIG. 4A is an isometric view of an embodiment of the lid dispenser assembly 400. The lid dispenser assembly 400 uses a servo motor 402 to rotate a ring gear 404 connected to four planet gears 404a-404d (as shown in FIG. 4C). Each planet gear 404a-404d has a shaft connected to a rotating flange 406 with two support levels: a high level 406a and a low support level 406b. In the neutral position, the ring gear 404 is rotated to the far left of the dispenser and the low support level 406b is exposed to the inside of the assembly supporting the entire stack of lids, as is shown in FIG. 2B-2C. In the drop position, the ring gear 404 is rotated to the far right, thereby exposing the high support 406a inside the assembly. The exposed high support 406a catches the stack of lids above, while allowing the lid at the bottom of the stack to fall without the support of the lower support 406b.

[0094] In FIG. 4B, an embodiment of an exemplary rotating multi-level flange 406 is shown connected to a ring gear shaft. The flange 406 has two support levels. In the neutral position, the bottom level 406b is exposed in the inside of the assembly, supporting the entire stack of lids. In the far right position, the high support level 406a is exposed, allowing the bottom lid to fall.

[0095] FIG. 4C illustrates a side-by-side view of the two positions for an embodiment of the lid dispenser assembly 400. On the left hand side, the neutral position is shown, where the ring gear 404 is rotated to the far left side. On the right hand side, the drop position is illustrated. In the drop position, the ring gear 404 is rotated to the far right. The four planet gears 404a-404d are shown to rotate as the ring gear 404 rotates.

[0096] FIG. 4D illustrates an embodiment of an exemplary method 410 of lid dispensing. In step 412, two lids 418a and 418b are seen resting on the bottom support 406b of the flange in the neutral position. In step 414, the ring gear rotates and moves the flange to the bottom position, where the top lid is supported only by the upper support, and the bottom lid 418b is able to fall to the conveyor belt. In step 416, the ring gear moves back to the neutral position, dropping the lid 418a to the lower level. The cycle repeats for any lid remaining in the stack.

[0097] FIG. 5A is an isometric view of an embodiment of the lid press mechanism 500. The lid sealer 502 uses a servo motor 504 to operate a rack and pinion mechanism 508 (illustrated in FIG. 5B), which moves a press 506 up and down. In the neutral position, the press 506 is retracted allowing the cup to enter the station. In the seal position, the gear will rotate to move the press 506 down sealing the lid onto the filled cup. The press 506 has a modular bottom topography to optimize the pressure distribution on a variety of different lid types.

[0098] FIG. 5B is a side sectional view of an embodiment of the lid press mechanism 500. The lefthand view illustrates the neutral position, where the press 506 is oriented up. The righthand view illustrates the seal position, where the press 506 is oriented down, thereby sealing a lid onto the cup.

[0099] FIG. 6 is an isometric view of an embodiment of the conveyor assembly 600. For clarity, the belt 602 is displayed as a transparent part to show the internal mechanisms. A custom conveyor assembly 600 transports cups between different assembly stations. The conveyor assembly 600 uses a high friction belt, brushed DC motor, and PID control to move the same amount every time. The motor transmits rotation to the belt via a belt transmission. This transmission is enclosed in order to ensure operator safety and cleanliness.

[0100] A series of distance measuring sensors are placed along the conveyor belt, to detect when cups are in the correct position for each station. In some embodiments, the distance measuring sensors comprise ultrasonic sensors, time-of-flight (TOF) sensors, laser distance sensors, infrared sensors, or other suitable distance measurement technologies. In some embodiments, a plurality of distance measuring sensors are positioned along the conveyor belt, with at least one sensor located at each station to independently detect cup presence and position at that station. In alternative embodiments, a single distance measuring sensor may be employed to detect cup positions at multiple stations along the conveyor belt. For example, a single sensor may be mounted on a movable carriage that traverses the length of the conveyor belt, sequentially measuring cup positions at each station. In other embodiments, a single sensor may be positioned at a fixed location with a field of view sufficient to monitor cup positions across multiple stations, such as a laser scanner or camera-based vision system that captures distance measurements across an extended area. In further embodiments, a single time-of-flight sensor or ultrasonic sensor may be positioned at a central location along the conveyor belt and configured to detect cups as they pass through its detection zone, with the control system correlating sensor readings with conveyor belt position data to determine cup locations at each station. In certain embodiments, a single sensor positioned at the end of the conveyor belt may be used in conjunction with conveyor belt encoder data to track cup positions throughout the system, wherein the sensor detects when a cup is dispensed and the control system calculates expected cup positions based on belt movement. The single sensor implementation may reduce system cost and complexity while maintaining adequate position detection accuracy for proper system operation. The user is notified when the cups are in the correct position, or if the cups fail to reach the correct position, by a control interface that allows the user to specify how many cups to make.

[0101] To ensure every step is completed successfully, error handling is built into each step of the filling and sealing process. Table 1 shows an exemplary list of different failure modes and built in error handling procedures for PODS.TABLE 1Failure ModeDescriptionFailure HandlingSystem Not LevelPODS must be level toPODS has a built- in level that shows the operator whether the system is level.operate properly. If theTo further assist operators with leveling the system, Pinto also uses a number ofsystem is not level,inertial measurement units (IMU) to determine whether the system is level. Ifcups and lids can getthe system is not level a visual warning will be displayed and the system willjammed in thenot allow the operator to begin a cup filling cycle. The display instructs the usermechanism.which leveling leg to adjust to ensure the system is within a proper operatingstate. Once the system is level, PODS will be capable of running a cup cycle.Empty CupCup dispenser fails toThe system uses a time of flight (TOF) or other obstruction sensor under theHopper / Cupproperly dispense asauce dispenser to determine whether a cup is present. If no cup is present,Dispensing JamcupPODS will try to dispense another cup. After three attempts where the systemdoes not detect a cup, the system will pause and alert the operator with a visualand audible warming. The system will not continue the process until prompted.No / LowNo sauce left in theThe system uses multiple sensors including current sensing, a camera, andQuantity ofdispenser, or a lowother modalities to determine whether the proper amount of product is beingProductamount of saucedispensed. If the level is too low, the system will pause and alert the operatorDispenseddispensedwith a visual and audible warming.OverfillToo much sauceThe system uses visual feedback such as a camera to determine whether there isdispensedtoo much sauce in the cup. If the sauce level is too high the system will pauseand alert the operator with a visual and audible warming prompting them toadjust the amount of sauce being dispensed.Empty LidLid dispenser fails toThe system uses a number of force detecting sensors such as a current sensorHopper / properly dispense a lidon the lid press combined with a neural network to determine whether a lid isLid Dispenserpresent on the cup when the press activates. If no lid is detected, the system willJammedpause and alert the operator with a visual and audible warming.Failure to SealCases where the lid isTo ensure each cup is filled and sealed correctly, Pinto developed an end of linenot correctly sealedtest that uses different sensor modalities such as a microphone, camera, and / orcurrent sensor, to determine whether the cup was sealed successfully followingthe activation of the lid press.Motor FailuresCases where systemThe system uses a smart time out function that alerts user what stage of thecommands a motor toprocess PODS is failing. Will alert user with an audible and visual notificationmove but the motor isof which motor is failing.unresponsive

[0102] Referring now to FIG. 7, a schematic of an example of a computing node is shown. Computing node 10 is only one example of a suitable computing node and is not intended to suggest any limitation as to the scope of use or functionality of embodiments described herein. Regardless, computing node 10 is capable of being implemented and / or performing any of the functionality set forth hereinabove.

[0103] In computing node 10 there is a computer system / server 12, which is operational with numerous other general purpose or special purpose computing system environments or configurations. Examples of well-known computing systems, environments, and / or configurations that may be suitable for use with computer system / server 12 include, but are not limited to, personal computer systems, server computer systems, thin clients, thick clients, handheld or laptop devices, multiprocessor systems, microprocessor-based systems, set top boxes, programmable consumer electronics, network PCs, minicomputer systems, mainframe computer systems, and distributed cloud computing environments that include any of the above systems or devices, and the like.

[0104] Computer system / server 12 may be described in the general context of computer system-executable instructions, such as program modules, being executed by a computer system. Generally, program modules may include routines, programs, objects, components, logic, data structures, and so on that perform particular tasks or implement particular abstract data types. Computer system / server 12 may be implemented using various computing platforms, including but not limited to single-board computers such as Raspberry Pi (manufactured by Raspberry Pi Ltd, headquartered in Cambridge, United Kingdom), NVIDIA Jetson (manufactured by NVIDIA Corporation, headquartered in Santa Clara, California, United States), Arduino (manufactured by Arduino S.r.l., headquartered in Monza, Italy), BeagleBone (manufactured by BeagleBoard.org Foundation, headquartered in Oakland Township, Michigan, United States), Intel NUC (manufactured by Intel Corporation, headquartered in Santa Clara, California, United States), or Odroid (manufactured by Hardkernel Co., Ltd., headquartered in Anyang, South Korea). Computer system / server 12 may be practiced in distributed cloud computing environments where tasks are performed by remote processing devices that are linked through a communications network. In a distributed cloud computing environment, program modules may be located in both local and remote computer system storage media including memory storage devices.

[0105] As shown in FIG. 7, computer system / server 12 in computing node 10 is shown in the form of a general-purpose computing device. The components of computer system / server 12 may include, but are not limited to, one or more processors or processing units 16, a system memory 28, and a bus 18 that couples various system components including system memory 28 to processor 16.

[0106] Bus 18 represents one or more of any of several types of bus structures, including a memory bus or memory controller, a peripheral bus, an accelerated graphics port, and a processor or local bus using any of a variety of bus architectures. By way of example, and not limitation, such architectures include Industry Standard Architecture (ISA) bus, Micro Channel Architecture (MCA) bus, Enhanced ISA (EISA) bus, Video Electronics Standards Association (VESA) local bus, Peripheral Component Interconnect (PCI) bus, Peripheral Component Interconnect Express (PCIe), and Advanced Microcontroller Bus Architecture (AMBA).

[0107] Computer system / server 12 typically includes a variety of computer system readable media. Such media may be any available media that is accessible by computer system / server 12, and it includes both volatile and non-volatile media, removable and non-removable media.

[0108] System memory 28 can include computer system readable media in the form of volatile memory, such as random access memory (RAM) 30 and / or cache memory 32. Computer system / server 12 may further include other removable / non-removable, volatile / non-volatile computer system storage media. By way of example only, storage system 34 can be provided for reading from and writing to a non-removable, non-volatile magnetic media (not shown and typically called a “hard drive”). Although not shown, a magnetic disk drive for reading from and writing to a removable, non-volatile magnetic disk (e.g., a “floppy disk”), and an optical disk drive for reading from or writing to a removable, non-volatile optical disk such as a CD-ROM, DVD-ROM or other optical media can be provided. In such instances, each can be connected to bus 18 by one or more data media interfaces. As will be further depicted and described below, memory 28 may include at least one program product having a set (e.g., at least one) of program modules that are configured to carry out the functions of embodiments of the disclosure.

[0109] Program / utility 40, having a set (at least one) of program modules 42, may be stored in memory 28 by way of example, and not limitation, as well as an operating system, one or more application programs, other program modules, and program data. Each of the operating systems, one or more application programs, other program modules, and program data or some combination thereof, may include an implementation of a networking environment. Program modules 42 generally carry out the functions and / or methodologies of embodiments as described herein.

[0110] Computer system / server 12 may also communicate with one or more external devices 14 such as a keyboard, a pointing device, a display 24, etc.; one or more devices that enable a user to interact with computer system / server 12; and / or any devices (e.g., network card, modem, etc.) that enable computer system / server 12 to communicate with one or more other computing devices. Such communication can occur via Input / Output (I / O) interfaces 22. Still yet, computer system / server 12 can communicate with one or more networks such as a local area network (LAN), a general wide area network (WAN), and / or a public network (e.g., the Internet) via network adapter 20. As depicted, network adapter 20 communicates with the other components of computer system / server 12 via bus 18. It should be understood that although not shown, other hardware and / or software components could be used in conjunction with computer system / server 12. Examples, include, but are not limited to: microcode, device drivers, redundant processing units, external disk drive arrays, RAID systems, tape drives, and data archival storage systems, etc.

[0111] The present disclosure may be embodied as a system, a method, and / or a computer program product. The computer program product may include a computer readable storage medium (or media) having computer readable program instructions thereon for causing a processor to carry out aspects of the present disclosure.

[0112] The computer readable storage medium can be a tangible device that can retain and store instructions for use by an instruction execution device. The computer readable storage medium may be, for example, but is not limited to, an electronic storage device, a magnetic storage device, an optical storage device, an electromagnetic storage device, a semiconductor storage device, or any suitable combination of the foregoing. A non-exhaustive list of more specific examples of the computer readable storage medium includes the following: a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), a static random access memory (SRAM), a portable compact disc read-only memory (CD-ROM), a digital versatile disk (DVD), a memory stick, a floppy disk, a mechanically encoded device such as punch-cards or raised structures in a groove having instructions recorded thereon, and any suitable combination of the foregoing. A computer readable storage medium, as used herein, is not to be construed as being transitory signals per se, such as radio waves or other freely propagating electromagnetic waves, electromagnetic waves propagating through a waveguide or other transmission media (e.g., light pulses passing through a fiber-optic cable), or electrical signals transmitted through a wire.

[0113] Computer readable program instructions described herein can be downloaded to respective computing / processing devices from a computer readable storage medium or to an external computer or external storage device via a network, for example, the Internet, a local area network, a wide area network and / or a wireless network. The network may comprise copper transmission cables, optical transmission fibers, wireless transmission, routers, firewalls, switches, gateway computers and / or edge servers. A network adapter card or network interface in each computing / processing device receives computer readable program instructions from the network and forwards the computer readable program instructions for storage in a computer readable storage medium within the respective computing / processing device.

[0114] Computer readable program instructions for carrying out operations of the present disclosure may be assembler instructions, instruction-set-architecture (ISA) instructions, machine instructions, machine dependent instructions, microcode, firmware instructions, state-setting data, or either source code or object code written in any combination of one or more programming languages, including an object oriented programming language such as Smalltalk, C++ or the like, and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The computer readable program instructions may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider). In some embodiments, electronic circuitry including, for example, programmable logic circuitry, field-programmable gate arrays (FPGA), or programmable logic arrays (PLA) may execute the computer readable program instructions by utilizing state information of the computer readable program instructions to personalize the electronic circuitry, in order to perform aspects of the present disclosure.

[0115] Aspects of the present disclosure are described herein with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the disclosure. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer readable program instructions.

[0116] These computer readable program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions / acts specified in the flowchart and / or block diagram block or blocks. These computer readable program instructions may also be stored in a computer readable storage medium that can direct a computer, a programmable data processing apparatus, and / or other devices to function in a particular manner, such that the computer readable storage medium having instructions stored therein comprises an article of manufacture including instructions which implement aspects of the function / act specified in the flowchart and / or block diagram block or blocks.

[0117] The computer readable program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other device to cause a series of operational steps to be performed on the computer, other programmable apparatus or other device to produce a computer implemented process, such that the instructions which execute on the computer, other programmable apparatus, or other device implement the functions / acts specified in the flowchart and / or block diagram block or blocks.

[0118] The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present disclosure. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of instructions, which comprises one or more executable instructions for implementing the specified logical function(s). In some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and / or flowchart illustration, and combinations of blocks in the block diagrams and / or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts or carry out combinations of special purpose hardware and computer instructions.

[0119] The descriptions of the various embodiments of the present disclosure have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein.

[0120] The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 wt. %” is intended to mean “about 40 wt. %”.

[0121] A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. Accordingly, other implementations are within the scope of the following claims.

Examples

Embodiment Construction

[0042]This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0043]Reference will now be made in detail to the exemplary embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

[0044]The systems, devices, and methods disclosed herein are described in detail by way of examples and with reference to the figures. The examples discussed herein are examples only and are provided to assist in the explanation of the apparatuses, devices, systems, and methods described herein. None of the features or components shown in the drawings or discus...

CROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This application claims priority to U.S. Provisional App. No. 63 / 781,210, titled “Portion Optimized Dispensing System,” filed Mar. 31, 2025, which is hereby incorporated by reference in its entirety.TECHNICAL FIELD

[0002] Embodiments of the present disclosure relate to robotic solutions for restaurant kitchens, and specifically, relate to automating the process of preparing portion cups.BACKGROUND

[0003] Increased levels for take-out and delivery food from restaurants has led to a need for more pre-packaged foods such as condiments provided in portion cups. In some cases, restaurants need to produce hundreds of these cups each day, a time-consuming process when done manually. Manual preparation of portion cups requires employees to individually dispense cups, fill each cup with the appropriate amount of condiment, place lids on the filled cups, and seal the lids securely. This repetitive process diverts valuable labor resources from other critical kitchen tasks and customer service activities.

[0004] Furthermore, manual filling introduces variability in portion sizes, which can lead to inconsistent customer experiences and increased food waste when cups are overfilled. Improper sealing of lids during manual preparation can result in spillage, contamination, and reduced product shelf life. The physical demands of repetitive cup filling motions can also contribute to employee fatigue and potential repetitive strain injuries over extended periods. Additionally, during peak service hours, the time required for manual portion cup preparation can create bottlenecks in kitchen operations, potentially delaying order fulfillment and negatively impacting customer satisfaction.SUMMARY

[0005] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0006] In an embodiment, an automated portion cup dispensing system comprises a conveyor belt; a cup dispensing station positioned along the conveyor belt that dispenses cups onto the conveyor belt using a servo motor connected to a rack and pinion gear; a filling station positioned along the conveyor belt that fills the cups with a liquid or semi-liquid food product using a servo motor connected to a cam that actuates a dispenser; a lid dispensing station positioned along the conveyor belt that dispenses lids onto the filled cups using a servo motor that drives a planetary gear system; and a sealing station positioned along the conveyor belt that seals the lids to the cups using a servo motor connected to a pinion gear that drives a press.

[0007] In some embodiments, the automated portion cup dispensing system further comprises distance measuring sensors positioned along the conveyor belt that detect when cups are in correct positions at each station.

[0008] In some embodiments, the automated portion cup dispensing system further comprises a control interface that allows a user to specify how many cups to make.

[0009] In some embodiments, the automated portion cup dispensing system further comprises a finished cup inventory system that holds completed cups.

[0010] In some embodiments, the automated portion cup dispensing system further comprises built-in software that alerts operators when the system is running low on materials or has a fault.

[0011] In some embodiments, the automated portion cup dispensing system has a weight of less than 30 pounds, or in other embodiments less than 25 pounds, less than 20 pounds, less than 15 pounds, or less than 10 pounds, depending on the materials selected for the frame and components, and fits on a 2-foot table.

[0012] In some embodiments, the automated portion cup dispensing system further comprises components manufactured using additive manufacturing, injection molding, CNC machining, or other suitable manufacturing processes, wherein the components are coated or otherwise treated to be food safe and dishwasher safe.

[0013] In another embodiment, a method of automatically dispensing portion cups comprises dispensing a cup onto a conveyor belt using a rack and pinion mechanism driven by a servo motor; moving the cup along the conveyor belt to a filling station; filling the cup with a food product using a cam mechanism driven by a servo motor that actuates a dispenser; moving the filled cup along the conveyor belt to a lid dispensing station; dispensing a lid onto the filled cup using a planetary gear system driven by a servo motor; moving the cup with lid along the conveyor belt to a sealing station; and sealing the lid to the cup using a press mechanism driven by a servo motor connected to a pinion gear.

[0014] In some embodiments, the method further comprises detecting when cups are in correct positions at each station using distance measuring sensors positioned along the conveyor belt.

[0015] In some embodiments, the method further comprises receiving user input specifying how many cups to make through a control interface.

[0016] In some embodiments, the method further comprises moving completed cups to a finished cup inventory system that holds completed cups.

[0017] In some embodiments, the method further comprises alerting operators when the system is running low on materials or has a fault using built-in software.

[0018] In some embodiments, the method further comprises using a dispenser that is certified food safe for filling the cup with the food product.

[0019] In some embodiments, the method further comprises automatically stopping the dispensing process when the specified number of cups has been reached.

[0020] In another embodiment, a tabletop automated food portion dispensing apparatus weighing less than 30 pounds comprises a frame supporting a linear conveyor system; a cup magazine holding a stack of portion cups and a dispensing mechanism that separates individual cups from the stack using a motorized rack and pinion system; a food dispensing assembly that deposits food into cups using a motorized cam system that actuates a food-safe dispenser; a lid magazine holding a stack of lids and a dispensing mechanism that releases individual lids using a motorized planetary gear assembly; a sealing mechanism that secures lids to cups using a motorized press system; and distance measuring sensors positioned at each station to detect cup presence.

[0021] In some embodiments, the tabletop automated food portion dispensing apparatus further comprises a control interface that allows a user to specify how many cups to make.

[0022] In some embodiments, the tabletop automated food portion dispensing apparatus further comprises built-in software that alerts operators when the system is running low on materials or has a fault.

[0023] In some embodiments, the tabletop automated food portion dispensing apparatus further comprises a finished cup inventory system that holds completed cups.

[0024] In some embodiments, the tabletop automated food portion dispensing apparatus further comprises components manufactured using additive manufacturing, injection molding, CNC machining, or other suitable manufacturing processes, and the components are coated or otherwise treated to be food safe and dishwasher safe.

[0025] In some embodiments, the tabletop automated food portion dispensing apparatus further comprises a frame made from stainless steel sheet metal.

[0026] The foregoing general description of the illustrative embodiments and the following detailed description thereof are merely exemplary aspects of the teachings of this disclosure and are not restrictive.BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The accompanying drawings, which are incorporated into and constitute a part of this specification, illustrate various exemplary embodiments and together with the description, serve to explain the principles of the disclosed embodiments.

[0028] FIG. 1 is a process diagram for an embodiment of a method of filling a portion container, in accordance with one or more embodiments of this disclosure.

[0029] FIG. 2A is an isometric view of an embodiment of a cup dispensing assembly, in accordance with one or more embodiments of this disclosure.

[0030] FIG. 2B is a process diagram of an embodiment of dispensing a cup from an apparatus, in accordance with one or more embodiments of this disclosure.

[0031] FIG. 2C is a top view of an embodiment of the cup dispensing apparatus, in accordance with one or more embodiments of this disclosure.

[0032] FIG. 3A is an isometric view of an embodiment of a sauce dispenser assembly, in accordance with one or more embodiments of this disclosure.

[0033] FIG. 3B is an side view of an embodiment of the sauce dispenser assembly, in accordance with one or more embodiments of this disclosure.

[0034] FIG. 4A is an isometric view of an embodiment of a lid dispenser assembly, in accordance with one or more embodiments of this disclosure.

[0035] FIG. 4B is a view of an embodiment of a multi-level flange, in accordance with one or more embodiments of this disclosure.

[0036] FIG. 4C is a side-by-side view of the positions for an embodiment of the lid dispenser assembly, in accordance with one or more embodiments of this disclosure.

[0037] FIG. 4D is a process diagram illustrating an embodiment of the steps of lid dispensing, in accordance with one or more embodiments of this disclosure.

[0038] FIG. 5A is an isometric view of an embodiment of a lid press assembly, in accordance with one or more embodiments of this disclosure.

[0039] FIG. 5B is a series of side views of an embodiment of a lid press assembly, in accordance with one or more embodiments of this disclosure.

[0040] FIG. 6 is an isometric view of an embodiment of a conveyor assembly, in accordance with one or more embodiments of this disclosure.

[0041] FIG. 7 is a block diagram of an embodiment of a computing node.DETAILED DESCRIPTION

[0042] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0043] Reference will now be made in detail to the exemplary embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

[0044] The systems, devices, and methods disclosed herein are described in detail by way of examples and with reference to the figures. The examples discussed herein are examples only and are provided to assist in the explanation of the apparatuses, devices, systems, and methods described herein. None of the features or components shown in the drawings or discussed below should be taken as mandatory for any specific implementation of any of these devices, systems, or methods unless specifically designated as mandatory.

[0045] Also, for any methods described, regardless of whether the method is described in conjunction with a flow diagram, it should be understood that unless otherwise specified or required by context, any explicit or implicit ordering of steps performed in the execution of a method does not imply that those steps must be performed in the order presented but instead may be performed in a different order or in parallel.

[0046] As used herein, the term “exemplary” is used in the sense of “example,” rather than “ideal.” Moreover, the terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of one or more of the referenced items.

[0047] To efficiently automate the process for dispensing a food product into a portion cup, a modular portion cup dispensing system may be used. In some embodiments, the automated dispensing system for portion cups includes a conveyor belt and a series of stations where a portion cup is moved down the conveyor belt and stops at each station. For example, a cup dispensing station is positioned along the conveyor belt, such that cups are dispensed onto the conveyor belt, for example by using a servo motor connected to a rack and pinion gear. The dispensed cup is then transported along the conveyor belt to a filling station, where the cup is filled with a liquid or semi-liquid food product, using a servo motor connected to a cam that actuates a dispenser. Once the cup is determined to be filled, for example by a series of sensors placed along the conveyor belt, it is moved to a lid dispensing station that dispenses lids onto the filled cup using a servo motor that drives a planetary gear system, and then to a sealing station positioned along the conveyor belt that seals the lids to the cups using a servo motor connected to a pinion gear that drives a press.

[0048] Creating a portion container thereby comprises four general steps: dispensing a cup, filling the cup, dispensing a lid, and sealing the cup with the lid. FIG. 1 is a process diagram illustrating an embodiment of an exemplary method 100 of this workflow. Steps 104, 106, 108, and 110 of method 100 may be automated (e.g., by a portion optimized dispensing system (“PODS”), as indicated by the dotted line around steps 104-110), leaving only the jobs of restocking lids, cups, food items, and storing the finished cups to human employees. In some embodiments, a conveyor belt lined with a variety of process checking sensors may move the cups between stations.

[0049] The method 100 may begin at the start 102. The method 100 may start automatically or in response to a request by a user. In step 104, the method may include dispensing a cup onto a designated filling location, such as on a conveyor belt, or as indicated by sensors. The cup may be dispensed onto the conveyor belt, for example, by a rack and pinion mechanisms driven by a servo motor. Once the cup has been dispensed onto the designated filling location, the cup is moved on the conveyor belt to a filling station, where the cup will be filled in step 106.

[0050] In step 106, the cup may be filled with any food product or condiment suitable for dispensing, such as ketchup, salsa, mustard, mayonnaise, ranch dressing, barbecue sauce, hot sauce, soy sauce, teriyaki sauce, honey mustard, tartar sauce, cocktail sauce, aioli, sriracha, buffalo sauce, cheese sauce, nacho cheese, queso, guacamole, sour cream, hummus, tzatziki, pesto, marinara sauce, alfredo sauce, gravy, au jus, hollandaise sauce, béarnaise sauce, chimichurri, tahini, ponzu sauce, hoisin sauce, sweet and sour sauce, duck sauce, plum sauce, chili garlic sauce, gochujang, sambal, harissa, romesco sauce, mole sauce, adobo sauce, green goddess dressing, blue cheese dressing, thousand island dressing, Italian dressing, balsamic vinaigrette, Caesar dressing, honey, maple syrup, chocolate sauce, caramel sauce, fruit compote, jam, jelly, preserves, marmalade, Nutella, peanut butter, almond butter, cream cheese, butter, whipped cream, custard, pudding, yogurt, fruit puree, applesauce, cranberry sauce, relish, pickle relish, olive tapenade, bruschetta topping, guacamole, salsa verde, pico de gallo, mango salsa, corn salsa, bean dip, spinach artichoke dip, onion dip, French onion dip, crab dip, buffalo chicken dip, garlic butter, herb butter, compound butter, olive oil, infused oils, flavored vinegars, lemon curd, lime curd, passion fruit curd, coconut cream, dulce de leche, condensed milk, evaporated milk, half-and-half, heavy cream, sour cream, crème fraîche, mascarpone, ricotta, cottage cheese, or any other liquid, semi-liquid, viscous, or pourable food product suitable for dispensing into portion cups.

[0051] The cup is filled with the food product by using a cam mechanism driven by a servo motor that in turn actuates a dispenser. In alternative embodiments, the actuation mechanism for the dispenser may comprise various configurations beyond the cam-driven servo motor arrangement. For example, the dispenser may be actuated by a linear actuator, such as a pneumatic cylinder, hydraulic cylinder, or electric linear actuator, that directly depresses the dispenser handle or valve. In some embodiments, a solenoid-driven mechanism may be employed to actuate the dispenser, wherein an electromagnetic solenoid provides rapid, precise actuation of the dispensing mechanism. The dispenser may alternatively be actuated by a stepper motor connected to a lead screw assembly, providing fine control over the displacement and force applied to the dispenser handle.

[0052] In further embodiments, the cam mechanism may comprise various cam profiles, including eccentric cams, heart-shaped cams, or conjugate cams, each providing different motion characteristics suited to the viscosity and flow properties of the food product being dispensed. The cam may be fabricated from materials including hardened steel, stainless steel, brass, bronze, aluminum alloy, acetal polymer, nylon, PEEK (polyether ether ketone), or UHMW (ultra-high molecular weight) polyethylene, selected based on wear resistance, food safety requirements, and operational environment considerations.

[0053] In some embodiments, the servo motor may be replaced with alternative motor types, including brushless DC motors, stepper motors, or AC servo motors, depending on the torque requirements, speed control precision, and duty cycle demands of the application. The motor may be coupled to the cam through various transmission mechanisms, including direct drive coupling, belt and pulley systems, chain and sprocket assemblies, or gear trains with reduction ratios ranging from 1:1 to 100:1 or greater.

[0054] In certain embodiments, the dispenser actuation system may incorporate a force feedback mechanism, such as a load cell or strain gauge, to monitor the force applied during dispensing and ensure consistent product delivery regardless of variations in product viscosity or dispenser resistance. The actuation system may further include position sensors, such as encoders, potentiometers, or Hall effect sensors, to provide closed-loop control of the dispensing stroke and enable precise metering of the food product.

[0055] In alternative configurations, the filling station may employ a peristaltic pump mechanism, a positive displacement pump, a gear pump, or a diaphragm pump to dispense the food product, eliminating the need for mechanical actuation of an external dispenser handle. The filling station may also utilize gravity-fed dispensing with an electronically controlled valve, such as a pinch valve, ball valve, butterfly valve, or gate valve, to regulate product flow. In some embodiments, the dispenser may be actuated by a rack and pinion mechanism, a scotch yoke mechanism, a toggle linkage, or a four-bar linkage driven by a rotary motor.

[0056] The dispensing mechanism may be configured to operate at actuation speeds ranging from 0.1 seconds to 10 seconds per dispensing cycle, with dispensing volumes adjustable from 0.125 fluid ounces to 8 fluid ounces or more, depending on the portion cup size and food product requirements. In some embodiments, the actuation speed may be dynamically adjusted based on the viscosity of the food product being dispensed, with faster actuation speeds employed for low-viscosity products such as soy sauce, vinegar, or thin dressings, and slower actuation speeds employed for high-viscosity products such as honey, caramel sauce, peanut butter, or thick cheese sauces. The dispensing volume may be user-configurable through the control interface in increments of 0.1 fluid ounces, 0.25 fluid ounces, 0.5 fluid ounces, or 1 fluid ounce, allowing operators to precisely match portion sizes to menu specifications and cost control requirements. In certain embodiments, the system may store multiple dispensing volume presets corresponding to different menu items, enabling rapid changeover between portion sizes without manual recalibration.

[0057] The actuation force applied to the dispenser may range from 1 Newton to 100 Newtons, calibrated based on the specific dispenser type and product viscosity. In some embodiments, the actuation force may range from 1 Newton to 25 Newtons for low-resistance dispensers and thin products, from 25 Newtons to 50 Newtons for medium-viscosity products such as ketchup, mustard, or ranch dressing, and from 50 Newtons to 100 Newtons or greater for high-viscosity products such as thick sauces, nut butters, or cream cheese. The actuation force may be automatically adjusted by the control system based on feedback from force sensors, current sensors on the servo motor, or empirical calibration data stored in the system memory for each food product type. In further embodiments, the system may employ adaptive force control algorithms that monitor dispensing performance in real-time and incrementally adjust actuation force to compensate for changes in product viscosity due to temperature variations, product settling, or depletion of the product reservoir.

[0058] In some embodiments, the dispensing cycle timing may be configured with variable acceleration and deceleration profiles to minimize splashing, dripping, or product waste. The servo motor may execute trapezoidal velocity profiles, S-curve velocity profiles, or custom motion profiles optimized for the rheological properties of specific food products. The dispensing mechanism may incorporate a dwell time at the end of the dispensing stroke, ranging from 0.05 seconds to 2 seconds, to allow complete product separation from the dispensing nozzle before the mechanism returns to the neutral position. In certain embodiments, the dispensing mechanism may execute a reverse stroke or anti-drip retraction motion following the primary dispensing stroke to draw back residual product and prevent dripping between dispensing cycles.

[0059] The dispensing parameters may be stored in non-volatile memory and associated with specific product identifiers, allowing the system to automatically recall optimal actuation speed, dispensing volume, actuation force, and motion profile settings when a particular food product is selected through the control interface. In some embodiments, the system may include a calibration mode wherein operators dispense test portions and provide feedback to fine-tune dispensing parameters for new or custom food products not included in the default product library. The calibration data may be uploaded to a cloud-based database, enabling sharing of optimized dispensing parameters across multiple PODS units deployed at different locations within a restaurant chain or franchise network.

[0060] The dispenser may be certified to be food safe for filling the cup with the food product. Sensors within the PODS may detect the level of food product within the cup, and / or determine when the cup is adequately filled. In some embodiments, the sensors comprise optical sensors, such as infrared sensors, laser-based distance sensors, or camera-based vision systems that capture images of the cup interior and employ image processing algorithms to determine fill level. In other embodiments, the sensors comprise capacitive sensors that detect changes in capacitance as the food product level rises within the cup, or inductive sensors suitable for detecting metallic or conductive food products. In further embodiments, ultrasonic sensors emit sound waves and measure the time-of-flight of reflected signals to determine the distance to the food product surface, thereby calculating the fill level. Weight-based sensing may also be employed, wherein load cells or strain gauges positioned beneath the cup measure the mass of dispensed product and compare it against a target weight threshold. In some embodiments, the system employs time-based fill detection, wherein the dispenser operates for a predetermined duration calibrated to dispense a specific volume of product based on the product's viscosity and flow characteristics. In certain embodiments, flow meters, such as positive displacement flow meters, turbine flow meters, or Coriolis flow meters, are positioned in the dispensing pathway to measure the volume of product dispensed directly. The sensors may operate in combination, wherein multiple sensor modalities provide redundant measurements that are fused algorithmically to improve accuracy and reliability of fill level detection. In some embodiments, the fill level threshold is user-configurable through the control interface, allowing operators to specify target fill volumes ranging from 25% to 100% of cup capacity, or to specify absolute volumes in fluid ounces or milliliters. The system may employ closed-loop feedback control, wherein sensor readings are continuously monitored during dispensing and the dispensing mechanism is automatically stopped when the target fill level is reached, rather than relying on open-loop timed dispensing. In some embodiments, the sensors detect overfill conditions and trigger an immediate stop of the dispensing mechanism, followed by an alert to the operator. The sensors may be positioned above the cup looking downward, positioned at the side of the cup measuring through transparent or translucent cup walls, or integrated into the dispensing nozzle assembly. In embodiments employing camera-based detection, machine learning models trained on images of properly filled cups may be used to classify fill levels and detect anomalies such as air bubbles, uneven surfaces, or contamination. Once the cup is filled, the cup can be moved along the conveyor belt to a lid dispensing station.

[0061] In step 108, a lid sealable to the top of the cup is dispensed to the cup at the lid dispensing station.

[0062] The lid is dispensed to the filled cup using a planetary gear system driven by a servo motor. In alternative embodiments, the lid dispensing mechanism may employ various gear configurations and drive systems beyond the planetary gear arrangement. For example, the lid dispensing station may utilize a spur gear train, a worm gear assembly, a bevel gear system, or a harmonic drive mechanism to achieve the rotational motion required for lid separation and dispensing. In some embodiments, the planetary gear system comprises a sun gear, a ring gear, and a plurality of planet gears, wherein the number of planet gears ranges from two to eight, with each planet gear connected to a shaft supporting a multi-level flange that engages the lid stack. The planet gears may be fabricated from materials including hardened steel, stainless steel, brass, bronze, aluminum alloy, acetal polymer, nylon, PEEK (polyether ether ketone), Delrin, HDPE, or UHMW (ultra-high molecular weight) polyethylene, selected based on wear resistance, food safety requirements, noise reduction, and operational environment considerations.

[0063] In further embodiments, the servo motor may be replaced with alternative motor types, including brushless DC motors, stepper motors, AC servo motors, or direct drive motors, depending on the torque requirements, positional accuracy, speed control precision, and duty cycle demands of the application. The motor may be coupled to the planetary gear system through various transmission mechanisms, including direct drive coupling, flexible couplings, belt and pulley systems, chain and sprocket assemblies, or intermediate gear trains with reduction ratios ranging from 1:1 to 50:1 or greater.

[0064] In some embodiments, the lid dispensing mechanism employs a linear actuation system rather than a rotary planetary gear system. For example, the lid dispensing station may utilize a pneumatic cylinder, hydraulic cylinder, electric linear actuator, or solenoid-driven mechanism to actuate retractable fingers, pins, or blades that selectively release individual lids from the stack. In certain embodiments, a rack and pinion mechanism driven by a rotary motor provides linear motion to lid-engaging elements that separate the bottom lid from the stack. In other embodiments, a lead screw assembly driven by a stepper motor or servo motor provides precise linear displacement of lid release mechanisms.

[0065] In alternative configurations, the lid dispensing mechanism may employ a vacuum-assisted system, wherein a vacuum cup or suction head engages the bottom lid of the stack and transports it to the filled cup below. The vacuum may be generated by a venturi device, a diaphragm pump, a rotary vane pump, or a regenerative blower. In some embodiments, the lid dispensing mechanism utilizes a rotary carousel or turret system that indexes individual lids from a magazine to a dispensing position above the filled cup.

[0066] In some embodiments, the multi-level flange attached to each planet gear shaft comprises two, three, or four support levels, each level having a different radial extension to engage lids at different heights within the stack. The flanges may be fabricated as integral components with the planet gear shafts or as separate modular components that are press-fit, threaded, or fastened to the shafts. The flange geometry may be configured to accommodate various lid diameters ranging from 1 inch to 6 inches, and various lid thicknesses ranging from 0.5 millimeters to 3 millimeters.

[0067] In certain embodiments, the lid dispensing station incorporates position sensors, such as optical encoders, magnetic encoders, Hall effect sensors, or limit switches, to provide closed-loop feedback control of the planetary gear system position and ensure accurate lid dispensing. The system may further include presence sensors, such as optical sensors, capacitive sensors, or mechanical switches, positioned within the lid magazine to detect the presence and quantity of lids remaining in the stack and to trigger alerts when the lid supply is low.

[0068] In some embodiments, the lid dispensing mechanism operates at dispensing speeds ranging from 0.5 seconds to 5 seconds per lid, with positional accuracy of the planetary gear system within 0.1 degrees to 2 degrees of the target position. The torque applied by the servo motor may range from 0.1 Newton-meters to 10 Newton-meters, calibrated based on the lid stack weight, friction characteristics, and mechanism geometry.

[0069] Upon the lid being dispensed to the cup, the cup and lid are moved down the conveyor belt to a sealing station.

[0070] The dispensed lid is then sealed onto the filled cup in step 110. Sealing the cup may comprise applying pressure to the dispensed lid to snap onto the cup, clipping the lid onto the cup, or any other suitable means of sealing the cup.

[0071] The lid may also be sealed to the cup using a press mechanism driven by a servo motor connected to a pinion gear. In alternative embodiments, the sealing mechanism may employ various motor types and transmission configurations beyond the servo motor and pinion gear arrangement. For example, the press mechanism may be driven by a brushless DC motor, a stepper motor, an AC servo motor, or a direct drive motor, depending on the torque requirements, positional accuracy, speed control precision, and duty cycle demands of the sealing application. The motor may be coupled to the press mechanism through various transmission systems, including direct drive coupling, belt and pulley systems, chain and sprocket assemblies, worm gear assemblies, bevel gear systems, or gear trains with reduction ratios ranging from 1:1 to 100:1 or greater.

[0072] In some embodiments, the press mechanism may be actuated by a linear actuator rather than a rotary motor with gear transmission. For example, the sealing station may utilize a pneumatic cylinder, hydraulic cylinder, electric linear actuator, or solenoid-driven mechanism to drive the press downward onto the lid. In certain embodiments, a lead screw assembly driven by a stepper motor or servo motor provides precise linear displacement of the press with fine control over the applied sealing force. In other embodiments, a rack and pinion mechanism, a scotch yoke mechanism, a toggle linkage, a four-bar linkage, or a cam-follower mechanism may be employed to convert rotary motor motion into the linear pressing motion required for lid sealing.

[0073] The press mechanism may apply sealing forces ranging from 5 Newtons to 500 Newtons, calibrated based on the lid material, cup material, and interference fit requirements of the specific portion cup and lid combination. The press may operate at sealing speeds ranging from 0.2 seconds to 3 seconds per sealing cycle, with positional accuracy within 0.1 millimeters to 2 millimeters of the target position. In some embodiments, the press mechanism incorporates a force feedback system, such as a load cell, strain gauge, or current sensing on the motor, to monitor the sealing force applied and ensure consistent lid attachment regardless of variations in lid or cup dimensions.

[0074] The press may comprise a contact surface fabricated from materials including aluminum alloy, stainless steel, brass, acetal polymer, nylon, PEEK (polyether ether ketone), UHMW (ultra-high molecular weight) polyethylene, silicone rubber, or food-grade elastomers, selected based on durability, food safety requirements, and the desired pressure distribution characteristics. In some embodiments, the press contact surface includes a compliant layer, such as a silicone pad or rubber gasket, to distribute sealing pressure evenly across the lid surface and accommodate minor variations in lid geometry. The press may have a modular bottom topography with interchangeable contact surfaces configured to optimize pressure distribution for various lid types, including flat lids, domed lids, vented lids, and lids with raised features or embossing.

[0075] In certain embodiments, the sealing station incorporates position sensors, such as optical encoders, magnetic encoders, Hall effect sensors, limit switches, or proximity sensors, to provide closed-loop feedback control of the press position and ensure accurate and repeatable sealing operations. The system may further include presence sensors positioned at the sealing station to detect the presence of a cup with lid prior to initiating the sealing cycle, preventing damage to the press mechanism or incomplete sealing operations.

[0076] In alternative configurations, the sealing mechanism may employ a rotary sealing approach rather than a vertical press, wherein a rotating element applies circumferential pressure around the lid perimeter to snap the lid onto the cup. In some embodiments, the sealing station utilizes a crimping mechanism with multiple radially-arranged fingers or jaws that simultaneously engage the lid edge and press it onto the cup rim. In further embodiments, the sealing mechanism may incorporate heat sealing, ultrasonic welding, or induction sealing capabilities for use with compatible lid and cup materials that require thermal bonding rather than mechanical snap-fit attachment.

[0077] The method 100 may also comprise detecting when cups are in a correct position at each station, such as by using distance measuring sensors positioned along the conveyor belt. In some embodiments, the distance measuring sensors comprise ultrasonic sensors that emit sound waves and measure the time-of-flight of reflected signals to determine the distance to objects. In other embodiments, the distance measuring sensors comprise time-of-flight (TOF) sensors that use infrared light pulses to measure distances with high precision. In further embodiments, the distance measuring sensors comprise laser distance sensors, such as laser triangulation sensors or laser rangefinders, that provide accurate distance measurements using focused laser beams. In some embodiments, the distance measuring sensors comprise infrared proximity sensors that detect the presence and distance of objects based on reflected infrared radiation. In certain embodiments, the distance measuring sensors comprise capacitive proximity sensors, inductive proximity sensors, or photoelectric sensors configured to detect cup presence and position. The distance measuring sensors may operate individually or in combination, wherein multiple sensor modalities provide redundant measurements to improve accuracy and reliability of cup position detection at each station

[0078] After the cup is sealed in step 110, the cup may be advanced to a storage site in step 112. Once the cup's arrival has been noted, either by sensors or some other suitable means of indication, the method may reach its end 114. In some embodiments, the system is automatically stopped once a specified number of cups have been filled.

[0079] A human employee may restock cups for dispensing as needed, or to ensure that enough cups are present for dispensing, as indicated by step 116. The same or another human employee may also ensure that there is enough condiment for filling the cup, and may restock the condiment supply as needed, as indicated by step 118.

[0080] The user controls the device from a control interface to specify how many cups to make and how much of the product to dispense.

[0081] In some embodiments, PODS has the capacity to hold a number of containers (such as ten) and some volume of food or beverage, determined by the capacities of modular hoppers to be attached or replaced by the user. The cup magazine may be configured to hold stacks of portion cups ranging from 25 cups to 200 cups or more, depending on the cup size and magazine dimensions. Similarly, the lid magazine may accommodate corresponding quantities of lids to match the cup supply. The food dispensing assembly may include a reservoir or hopper with a capacity ranging from 0.5 gallons to 5 gallons or more, allowing for extended operation between refills. In some embodiments, the modular hoppers are designed with quick-release mechanisms, such as twist-lock fittings, snap-fit connections, or magnetic attachments, enabling rapid replacement or swapping of hoppers without tools. The hoppers may be fabricated from food-safe materials including stainless steel, food-grade polycarbonate, polypropylene, high-density polyethylene (HDPE), or other FDA-approved polymers suitable for contact with food products. In certain embodiments, the hoppers include transparent or translucent sections that allow visual inspection of remaining material levels. The system may further include level sensors, such as optical sensors, capacitive sensors, ultrasonic sensors, or weight-based sensors integrated into the hopper mounting locations, to automatically detect and report the quantity of cups, lids, or food product remaining in each hopper. In some embodiments, the modular hopper system allows users to configure PODS for different portion cup sizes by swapping cup and lid magazines designed for specific cup diameters, such as 2-ounce, 4-ounce, or 5.5-ounce souffle cups. The food hopper capacity may be selected based on the anticipated production volume and the viscosity of the food product being dispensed, with larger capacity hoppers suitable for high-volume operations and smaller hoppers suitable for products that require more frequent changeover or have limited shelf life once opened.

[0082] Once a cup is finished (i.e., step 114 is reached), PODS dispenses it into a finished cup inventory system at the end of line, which may comprise a tray, storage area, or bin depending on the desired capacity. Once a cup is finished, it may be held in a finished cup inventory system. In some embodiments, the finished cup inventory system comprises an inventory area that can hold up to 10 cups for easy user access. In other embodiments, the finished cup inventory system comprises a bin that can hold 50 or more completed cups for higher volume operations. In some embodiments, the PODS system includes built in software to alert a user when it is running low on material or a fault has occurred.

[0083] At the end of line, PODS may perform a quality check that determines whether the cup was sealed successfully and notified the user if a cup did not seal correctly.

[0084] In some embodiments, the PODS fits onto a two foot tabletop within a restaurant kitchen, and weighs less than 20 pounds, or in some embodiments, less than 30 pounds. Due to its small size and light weight, the PODS device is easy to move around and store, as well as comprising modular mechanisms for rapid repair.

[0085] The tabletop PODS can comprise a frame, supporting a linear conveyor system; a cup magazine for holding a stack of portion cups and for dispensing cups using a motorized rack and pinion system; a food dispensing assembly for depositing food into cups using a motorized cam system that actuates a food-safe dispenser; a lid magazine that holds a stack of lids and a dispensing mechanism that releases individual lids using a motorized planetary gear assembly; a sealing mechanism that secures lids to cups using a motorized press system; and distance measuring sensors positioned at each assembly station to detect cup presence. In some embodiments, the frame is made from stainless steel sheet metal.

[0086] Components of the PODS system may be manufactured using various processes depending on production volume, material requirements, and cost considerations. In some embodiments, components are manufactured using additive manufacturing processes, such as fused deposition modeling (FDM), stereolithography (SLA), selective laser sintering (SLS), or other 3D printing technologies. In other embodiments, components are manufactured using injection molding, which may be preferred for higher production volumes. In further embodiments, components are manufactured using CNC machining, die casting, thermoforming, or other suitable manufacturing processes. The manufactured components may be coated or otherwise treated to ensure they are food safe and dishwasher safe.

[0087] FIGS. 2A-C illustrate an embodiment of an assembly 200 for dispensing cups. FIG. 2A is an isometric view of an embodiment of the assembly 200. The cup dispensing assembly 200 comprises a servo motor 204 connected to a rack and pinion gear (as shown in FIG. 2C) to separate a bottom cup from a stack of cups. The stack of cups may be stored in cylinder 202. The rack and pinion mechanism moves a slider back and forth to thereby separate a bottom cup 216a from the stack, using two separate supports. The bottom support 220 of the two separate supports is in a neutral position, holding a full stack of cups. As the slider moves to a rear position, the top support of the two separate supports holds up the top cup 216a and bottom cup 216b in cylinder 202 while also allowing the bottom cup 216b to then fall onto the conveyor belt system. A partial funnel attached to the bottom of the assembly 200 guides the falling bottom cup 216b to a repeatable position on the conveyor belt below. A spirit level vial is also mounted to the body of the apparatus to ensure that the mechanism is level and operating optimally.

[0088] FIG. 2B is a section view of an embodiment of the slider mechanism 218 and displays three steps in cup dispensing. In the first step 210, top cup 216a and bottom cup 216b are resting on the bottom support 220 in a neutral position. In step 212, the slider moves to the rear position, where the top cup 216a is still supported by the upper support and the bottom cup 216b is free to fall to the conveyor. In step 214, the slider mechanism 218 returns to the rear position and drops the top cup 216a to the lower level. The cycle repeats as long as the system detects cups in the stack.

[0089] FIG. 2C is a top view of an embodiment of the cup dispensing apparatus 200. The lefthand diagram illustrates the slider mechanism 218 in the neutral position, where all cups are supported. As the motor moves the slider mechanism 218 to the rear position, the slider separates the bottom cup 216b from the rest of the stack, allowing the bottom cup to fall. The rack and pinion gear 222 is also displayed in each diagram, as the rack and pinion gear 222 moves the slider mechanism 218 from the neutral to the rear position.

[0090] FIGS. 3A-B illustrate an embodiment of the steps of filling the cup. FIG. 3A is an isometric view of an embodiment of a sauce dispenser assembly 300. The sauce dispenser assembly 300 uses a servo motor 302 connected to a cam 304, where the motor 302 and cam 304 press a handle 306 of a sauce dispenser 308 (sauce dispenser 308 and handle 306 not shown in FIG. 3A). The sauce dispenser 308 can be a commercially available sauce dispenser, such as any one of the commercially available sauce dispensers manufactured by Asept International AB of Mölndal, Sweden listed below:Asept designation onNSF listingDescriptionSS6L-1DISingle drop-in dispenser for 1.5-gal (6-qt) fitmented pouches; adjustableportion up to 1 oz; stainless, low-profile look that locks into counter.SS6L-2DIDouble drop-in dispenser; same portion-control and 1.5-gal pouch spec.SS6L-3DITriple drop-in dispenser; same system and features.SS6L-4DIQuadruple drop-in dispenser; same system and features.SS6L-5DIQuintuple drop-in dispenser; same system and features.Portion PumpHandheld portion-control pump dispenser; adjustable portion sizes;designed for use with fitmented pouches; food-safe construction.

[0091] The electronics within the sauce dispenser 308 are configurable, to thereby adjust the exact amount of sauce dispensed. To ensure the system minimizes spillage, a distance measuring sensor (not pictured) is used to ensure a cup is present beneath the dispenser. If the sensors do not detect a cup, the sauce dispenser 308 will not activate.

[0092] FIG. 3B is a section view of an embodiment of the sauce dispenser 308. The lefthand view illustrates the neutral position, where the cam 304 is oriented parallel to the sauce dispenser 308. The righthand view illustrates the press position, where the cam 304 is oriented perpendicular to the dispenser 308, thereby pressing the handle 306 of the dispenser 308 and dispensing the sauce into the cup.

[0093] FIGS. 4A-4D illustrate an embodiment of the steps of dispensing the lid to the cup. FIG. 4A is an isometric view of an embodiment of the lid dispenser assembly 400. The lid dispenser assembly 400 uses a servo motor 402 to rotate a ring gear 404 connected to four planet gears 404a-404d (as shown in FIG. 4C). Each planet gear 404a-404d has a shaft connected to a rotating flange 406 with two support levels: a high level 406a and a low support level 406b. In the neutral position, the ring gear 404 is rotated to the far left of the dispenser and the low support level 406b is exposed to the inside of the assembly supporting the entire stack of lids, as is shown in FIG. 2B-2C. In the drop position, the ring gear 404 is rotated to the far right, thereby exposing the high support 406a inside the assembly. The exposed high support 406a catches the stack of lids above, while allowing the lid at the bottom of the stack to fall without the support of the lower support 406b.

[0094] In FIG. 4B, an embodiment of an exemplary rotating multi-level flange 406 is shown connected to a ring gear shaft. The flange 406 has two support levels. In the neutral position, the bottom level 406b is exposed in the inside of the assembly, supporting the entire stack of lids. In the far right position, the high support level 406a is exposed, allowing the bottom lid to fall.

[0095] FIG. 4C illustrates a side-by-side view of the two positions for an embodiment of the lid dispenser assembly 400. On the left hand side, the neutral position is shown, where the ring gear 404 is rotated to the far left side. On the right hand side, the drop position is illustrated. In the drop position, the ring gear 404 is rotated to the far right. The four planet gears 404a-404d are shown to rotate as the ring gear 404 rotates.

[0096] FIG. 4D illustrates an embodiment of an exemplary method 410 of lid dispensing. In step 412, two lids 418a and 418b are seen resting on the bottom support 406b of the flange in the neutral position. In step 414, the ring gear rotates and moves the flange to the bottom position, where the top lid is supported only by the upper support, and the bottom lid 418b is able to fall to the conveyor belt. In step 416, the ring gear moves back to the neutral position, dropping the lid 418a to the lower level. The cycle repeats for any lid remaining in the stack.

[0097] FIG. 5A is an isometric view of an embodiment of the lid press mechanism 500. The lid sealer 502 uses a servo motor 504 to operate a rack and pinion mechanism 508 (illustrated in FIG. 5B), which moves a press 506 up and down. In the neutral position, the press 506 is retracted allowing the cup to enter the station. In the seal position, the gear will rotate to move the press 506 down sealing the lid onto the filled cup. The press 506 has a modular bottom topography to optimize the pressure distribution on a variety of different lid types.

[0098] FIG. 5B is a side sectional view of an embodiment of the lid press mechanism 500. The lefthand view illustrates the neutral position, where the press 506 is oriented up. The righthand view illustrates the seal position, where the press 506 is oriented down, thereby sealing a lid onto the cup.

[0099] FIG. 6 is an isometric view of an embodiment of the conveyor assembly 600. For clarity, the belt 602 is displayed as a transparent part to show the internal mechanisms. A custom conveyor assembly 600 transports cups between different assembly stations. The conveyor assembly 600 uses a high friction belt, brushed DC motor, and PID control to move the same amount every time. The motor transmits rotation to the belt via a belt transmission. This transmission is enclosed in order to ensure operator safety and cleanliness.

[0100] A series of distance measuring sensors are placed along the conveyor belt, to detect when cups are in the correct position for each station. In some embodiments, the distance measuring sensors comprise ultrasonic sensors, time-of-flight (TOF) sensors, laser distance sensors, infrared sensors, or other suitable distance measurement technologies. In some embodiments, a plurality of distance measuring sensors are positioned along the conveyor belt, with at least one sensor located at each station to independently detect cup presence and position at that station. In alternative embodiments, a single distance measuring sensor may be employed to detect cup positions at multiple stations along the conveyor belt. For example, a single sensor may be mounted on a movable carriage that traverses the length of the conveyor belt, sequentially measuring cup positions at each station. In other embodiments, a single sensor may be positioned at a fixed location with a field of view sufficient to monitor cup positions across multiple stations, such as a laser scanner or camera-based vision system that captures distance measurements across an extended area. In further embodiments, a single time-of-flight sensor or ultrasonic sensor may be positioned at a central location along the conveyor belt and configured to detect cups as they pass through its detection zone, with the control system correlating sensor readings with conveyor belt position data to determine cup locations at each station. In certain embodiments, a single sensor positioned at the end of the conveyor belt may be used in conjunction with conveyor belt encoder data to track cup positions throughout the system, wherein the sensor detects when a cup is dispensed and the control system calculates expected cup positions based on belt movement. The single sensor implementation may reduce system cost and complexity while maintaining adequate position detection accuracy for proper system operation. The user is notified when the cups are in the correct position, or if the cups fail to reach the correct position, by a control interface that allows the user to specify how many cups to make.

[0101] To ensure every step is completed successfully, error handling is built into each step of the filling and sealing process. Table 1 shows an exemplary list of different failure modes and built in error handling procedures for PODS.TABLE 1Failure ModeDescriptionFailure HandlingSystem Not LevelPODS must be level toPODS has a built- in level that shows the operator whether the system is level.operate properly. If theTo further assist operators with leveling the system, Pinto also uses a number ofsystem is not level,inertial measurement units (IMU) to determine whether the system is level. Ifcups and lids can getthe system is not level a visual warning will be displayed and the system willjammed in thenot allow the operator to begin a cup filling cycle. The display instructs the usermechanism.which leveling leg to adjust to ensure the system is within a proper operatingstate. Once the system is level, PODS will be capable of running a cup cycle.Empty CupCup dispenser fails toThe system uses a time of flight (TOF) or other obstruction sensor under theHopper / Cupproperly dispense asauce dispenser to determine whether a cup is present. If no cup is present,Dispensing JamcupPODS will try to dispense another cup. After three attempts where the systemdoes not detect a cup, the system will pause and alert the operator with a visualand audible warming. The system will not continue the process until prompted.No / LowNo sauce left in theThe system uses multiple sensors including current sensing, a camera, andQuantity ofdispenser, or a lowother modalities to determine whether the proper amount of product is beingProductamount of saucedispensed. If the level is too low, the system will pause and alert the operatorDispenseddispensedwith a visual and audible warming.OverfillToo much sauceThe system uses visual feedback such as a camera to determine whether there isdispensedtoo much sauce in the cup. If the sauce level is too high the system will pauseand alert the operator with a visual and audible warming prompting them toadjust the amount of sauce being dispensed.Empty LidLid dispenser fails toThe system uses a number of force detecting sensors such as a current sensorHopper / properly dispense a lidon the lid press combined with a neural network to determine whether a lid isLid Dispenserpresent on the cup when the press activates. If no lid is detected, the system willJammedpause and alert the operator with a visual and audible warming.Failure to SealCases where the lid isTo ensure each cup is filled and sealed correctly, Pinto developed an end of linenot correctly sealedtest that uses different sensor modalities such as a microphone, camera, and / orcurrent sensor, to determine whether the cup was sealed successfully followingthe activation of the lid press.Motor FailuresCases where systemThe system uses a smart time out function that alerts user what stage of thecommands a motor toprocess PODS is failing. Will alert user with an audible and visual notificationmove but the motor isof which motor is failing.unresponsive

[0102] Referring now to FIG. 7, a schematic of an example of a computing node is shown. Computing node 10 is only one example of a suitable computing node and is not intended to suggest any limitation as to the scope of use or functionality of embodiments described herein. Regardless, computing node 10 is capable of being implemented and / or performing any of the functionality set forth hereinabove.

[0103] In computing node 10 there is a computer system / server 12, which is operational with numerous other general purpose or special purpose computing system environments or configurations. Examples of well-known computing systems, environments, and / or configurations that may be suitable for use with computer system / server 12 include, but are not limited to, personal computer systems, server computer systems, thin clients, thick clients, handheld or laptop devices, multiprocessor systems, microprocessor-based systems, set top boxes, programmable consumer electronics, network PCs, minicomputer systems, mainframe computer systems, and distributed cloud computing environments that include any of the above systems or devices, and the like.

[0104] Computer system / server 12 may be described in the general context of computer system-executable instructions, such as program modules, being executed by a computer system. Generally, program modules may include routines, programs, objects, components, logic, data structures, and so on that perform particular tasks or implement particular abstract data types. Computer system / server 12 may be implemented using various computing platforms, including but not limited to single-board computers such as Raspberry Pi (manufactured by Raspberry Pi Ltd, headquartered in Cambridge, United Kingdom), NVIDIA Jetson (manufactured by NVIDIA Corporation, headquartered in Santa Clara, California, United States), Arduino (manufactured by Arduino S.r.l., headquartered in Monza, Italy), BeagleBone (manufactured by BeagleBoard.org Foundation, headquartered in Oakland Township, Michigan, United States), Intel NUC (manufactured by Intel Corporation, headquartered in Santa Clara, California, United States), or Odroid (manufactured by Hardkernel Co., Ltd., headquartered in Anyang, South Korea). Computer system / server 12 may be practiced in distributed cloud computing environments where tasks are performed by remote processing devices that are linked through a communications network. In a distributed cloud computing environment, program modules may be located in both local and remote computer system storage media including memory storage devices.

[0105] As shown in FIG. 7, computer system / server 12 in computing node 10 is shown in the form of a general-purpose computing device. The components of computer system / server 12 may include, but are not limited to, one or more processors or processing units 16, a system memory 28, and a bus 18 that couples various system components including system memory 28 to processor 16.

[0106] Bus 18 represents one or more of any of several types of bus structures, including a memory bus or memory controller, a peripheral bus, an accelerated graphics port, and a processor or local bus using any of a variety of bus architectures. By way of example, and not limitation, such architectures include Industry Standard Architecture (ISA) bus, Micro Channel Architecture (MCA) bus, Enhanced ISA (EISA) bus, Video Electronics Standards Association (VESA) local bus, Peripheral Component Interconnect (PCI) bus, Peripheral Component Interconnect Express (PCIe), and Advanced Microcontroller Bus Architecture (AMBA).

[0107] Computer system / server 12 typically includes a variety of computer system readable media. Such media may be any available media that is accessible by computer system / server 12, and it includes both volatile and non-volatile media, removable and non-removable media.

[0108] System memory 28 can include computer system readable media in the form of volatile memory, such as random access memory (RAM) 30 and / or cache memory 32. Computer system / server 12 may further include other removable / non-removable, volatile / non-volatile computer system storage media. By way of example only, storage system 34 can be provided for reading from and writing to a non-removable, non-volatile magnetic media (not shown and typically called a “hard drive”). Although not shown, a magnetic disk drive for reading from and writing to a removable, non-volatile magnetic disk (e.g., a “floppy disk”), and an optical disk drive for reading from or writing to a removable, non-volatile optical disk such as a CD-ROM, DVD-ROM or other optical media can be provided. In such instances, each can be connected to bus 18 by one or more data media interfaces. As will be further depicted and described below, memory 28 may include at least one program product having a set (e.g., at least one) of program modules that are configured to carry out the functions of embodiments of the disclosure.

[0109] Program / utility 40, having a set (at least one) of program modules 42, may be stored in memory 28 by way of example, and not limitation, as well as an operating system, one or more application programs, other program modules, and program data. Each of the operating systems, one or more application programs, other program modules, and program data or some combination thereof, may include an implementation of a networking environment. Program modules 42 generally carry out the functions and / or methodologies of embodiments as described herein.

[0110] Computer system / server 12 may also communicate with one or more external devices 14 such as a keyboard, a pointing device, a display 24, etc.; one or more devices that enable a user to interact with computer system / server 12; and / or any devices (e.g., network card, modem, etc.) that enable computer system / server 12 to communicate with one or more other computing devices. Such communication can occur via Input / Output (I / O) interfaces 22. Still yet, computer system / server 12 can communicate with one or more networks such as a local area network (LAN), a general wide area network (WAN), and / or a public network (e.g., the Internet) via network adapter 20. As depicted, network adapter 20 communicates with the other components of computer system / server 12 via bus 18. It should be understood that although not shown, other hardware and / or software components could be used in conjunction with computer system / server 12. Examples, include, but are not limited to: microcode, device drivers, redundant processing units, external disk drive arrays, RAID systems, tape drives, and data archival storage systems, etc.

[0111] The present disclosure may be embodied as a system, a method, and / or a computer program product. The computer program product may include a computer readable storage medium (or media) having computer readable program instructions thereon for causing a processor to carry out aspects of the present disclosure.

[0112] The computer readable storage medium can be a tangible device that can retain and store instructions for use by an instruction execution device. The computer readable storage medium may be, for example, but is not limited to, an electronic storage device, a magnetic storage device, an optical storage device, an electromagnetic storage device, a semiconductor storage device, or any suitable combination of the foregoing. A non-exhaustive list of more specific examples of the computer readable storage medium includes the following: a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), a static random access memory (SRAM), a portable compact disc read-only memory (CD-ROM), a digital versatile disk (DVD), a memory stick, a floppy disk, a mechanically encoded device such as punch-cards or raised structures in a groove having instructions recorded thereon, and any suitable combination of the foregoing. A computer readable storage medium, as used herein, is not to be construed as being transitory signals per se, such as radio waves or other freely propagating electromagnetic waves, electromagnetic waves propagating through a waveguide or other transmission media (e.g., light pulses passing through a fiber-optic cable), or electrical signals transmitted through a wire.

[0113] Computer readable program instructions described herein can be downloaded to respective computing / processing devices from a computer readable storage medium or to an external computer or external storage device via a network, for example, the Internet, a local area network, a wide area network and / or a wireless network. The network may comprise copper transmission cables, optical transmission fibers, wireless transmission, routers, firewalls, switches, gateway computers and / or edge servers. A network adapter card or network interface in each computing / processing device receives computer readable program instructions from the network and forwards the computer readable program instructions for storage in a computer readable storage medium within the respective computing / processing device.

[0114] Computer readable program instructions for carrying out operations of the present disclosure may be assembler instructions, instruction-set-architecture (ISA) instructions, machine instructions, machine dependent instructions, microcode, firmware instructions, state-setting data, or either source code or object code written in any combination of one or more programming languages, including an object oriented programming language such as Smalltalk, C++ or the like, and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The computer readable program instructions may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider). In some embodiments, electronic circuitry including, for example, programmable logic circuitry, field-programmable gate arrays (FPGA), or programmable logic arrays (PLA) may execute the computer readable program instructions by utilizing state information of the computer readable program instructions to personalize the electronic circuitry, in order to perform aspects of the present disclosure.

[0115] Aspects of the present disclosure are described herein with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the disclosure. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer readable program instructions.

[0116] These computer readable program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions / acts specified in the flowchart and / or block diagram block or blocks. These computer readable program instructions may also be stored in a computer readable storage medium that can direct a computer, a programmable data processing apparatus, and / or other devices to function in a particular manner, such that the computer readable storage medium having instructions stored therein comprises an article of manufacture including instructions which implement aspects of the function / act specified in the flowchart and / or block diagram block or blocks.

[0117] The computer readable program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other device to cause a series of operational steps to be performed on the computer, other programmable apparatus or other device to produce a computer implemented process, such that the instructions which execute on the computer, other programmable apparatus, or other device implement the functions / acts specified in the flowchart and / or block diagram block or blocks.

[0118] The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present disclosure. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of instructions, which comprises one or more executable instructions for implementing the specified logical function(s). In some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and / or flowchart illustration, and combinations of blocks in the block diagrams and / or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts or carry out combinations of special purpose hardware and computer instructions.

[0119] The descriptions of the various embodiments of the present disclosure have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein.

[0120] The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 wt. %” is intended to mean “about 40 wt. %”.

[0121] A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. Accordingly, other implementations are within the scope of the following claims.

Examples

Embodiment Construction

[0042]This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0043]Reference will now be made in detail to the exemplary embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

[0044]The systems, devices, and methods disclosed herein are described in detail by way of examples and with reference to the figures. The examples discussed herein are examples only and are provided to assist in the explanation of the apparatuses, devices, systems, and methods described herein. None of the features or components shown in the drawings or discus...

Claims

1. An automated portion cup dispensing system, comprising:a conveyor belt;a cup dispensing station positioned along the conveyor belt that dispenses cups onto the conveyor belt using a servo motor connected to a rack and pinion gear;a filling station positioned along the conveyor belt that fills the cups with a liquid or semi-liquid food product using a servo motor connected to a cam that actuates a dispenser;a lid dispensing station positioned along the conveyor belt that dispenses lids onto the filled cups using a servo motor that drives a planetary gear system; anda sealing station positioned along the conveyor belt that seals the lids to the cups using a servo motor connected to a pinion gear that drives a press.

2. The automated portion cup dispensing system of claim 1, further comprising distance measuring sensors positioned along the conveyor belt that detect when cups are in correct positions at each station.

3. The automated portion cup dispensing system of claim 2, further comprising a control interface that allows a user to specify how many cups to make.

4. (canceled)5. The automated portion cup dispensing system of claim 1, further comprising built-in software that alerts operators when the system is running low on materials or has a fault.

6. The automated portion cup dispensing system of claim 1, having a weight of less than 30 pounds and fitting on a 2-foot table.

7. The automated portion cup dispensing system of claim 1, further comprising components coated or otherwise treated to be food safe and dishwasher safe.

8. A method of automatically dispensing portion cups, comprising:dispensing a cup onto a conveyor belt using a rack and pinion mechanism driven by a servo motor;moving the cup along the conveyor belt to a filling station;filling the cup with a food product using a cam mechanism driven by a servo motor that actuates a dispenser;moving the filled cup along the conveyor belt to a lid dispensing station;dispensing a lid onto the filled cup using a planetary gear system driven by a servo motor;moving the cup with lid along the conveyor belt to a sealing station; andsealing the lid to the cup using a press mechanism driven by a servo motor connected to a pinion gear.

9. The method of claim 8, further comprising detecting when cups are in correct positions at each station using distance measuring sensors positioned along the conveyor belt.

10. The method of claim 9, further comprising receiving user input specifying how many cups to make through a control interface.

11. The method of claim 8, further comprising moving completed cups to a finished cup inventory system that holds completed cups.

12. The method of claim 8, further comprising alerting operators when the system is running low on materials or has a fault using built-in software.

13. The method of claim 8, further comprising using a dispenser that is certified food safe for filling the cup with the food product.

14. The method of claim 10, further comprising automatically stopping the dispensing process when the specified number of cups has been reached.

15. (canceled)16. (canceled)17. (canceled)18. (canceled)19. (canceled)20. (canceled)21. The automated portion cup dispensing system of claim 1, further comprising an end-of-line quality check system configured to determine whether a cup was sealed successfully and to notify a user if a cup did not seal correctly.

22. The automated portion cup dispensing system of claim 1, further comprising a partial funnel positioned below the cup dispensing station that guides dispensed cups to a repeatable position on the conveyor belt.

23. The automated portion cup dispensing system of claim 1, further comprising one or more inertial measurement units configured to determine whether the system is level, and a display configured to instruct a user which leveling leg to adjust to ensure the system is within a proper operating state.

24. The automated portion cup dispensing system of claim 1, wherein the conveyor belt is driven by a brushed DC motor using PID control to move a consistent distance for each cup.

25. The automated portion cup dispensing system of claim 1, wherein the filling station comprises adaptive force control that monitors dispensing performance in real-time and incrementally adjusts actuation force to compensate for changes in product viscosity.

26. The automated portion cup dispensing system of claim 1, further comprising a camera-based detection system employing machine learning models trained on images of filled cups to classify fill levels and detect anomalies.

27. The method of claim 8, further comprising determining whether a cup was sealed successfully at an end-of-line quality check, and notifying a user if a cup did not seal correctly.

Images