Refrigerated display counter with ice cream quantity control system

Abstract

A refrigerated display counter (100) comprises a plurality of tubs (1) for containing ice cream (2), a cooling system (3) for cooling the ice cream (2) in the tubs (1), and a monitoring system (M) configured to detect the type of ice cream and a quantity of ice cream contained in each tub (1); the monitoring system (M) comprises a vision sensor unit (5) arranged to detect images (I) of 5 the ice cream (2) contained in the tubs (1), and a control unit (6) operatively connected to the vision sensors (6) and configured to process the images (I) detected by the vision sensors and extract data from said images to detect the type of ice cream and a quantity of ice cream contained in each tub (1).

Description

[0001] REFRIGERATED DISPLAY COUNTER WITH ICE CREAM QUANTITY CONTROL SYSTEM

[0002] DESCRIPTION

[0003] The present invention relates to the display and sale of confectionery products, such as ice cream, and in particular to a refrigerated display counter with ice cream quantity control system.

[0004] Although specific reference will be made hereinafter to ice cream, the invention extends to any type of product equivalent to ice cream that can be contained in a tub, such as Icecream, Frozen Custard, mousse, yogurt, cream, and the like.

[0005] Artisanal ice cream is made starting from an ice cream mixture containing various ingredients. The preparation of ice cream generally comprises three phases:

[0006] - pasteurization and aging,

[0007] - batch freezing, and

[0008] - blast chilling and storage.

[0009] The ice cream mixture is prepared using pasteurization machines that mix the ingredients and incorporate air at a temperature comprised between 4°C and 5°C. The pasteurization phase allows the mixture to acquire greater density, so that the air can be incorporated more easily during the subsequent batch freezing process, allowing the water to be absorbed more readily by the solid components. The pasteurization and aging phase lasts approximately 6-12 hours.

[0010] The pasteurized product is placed in batch freezing machines that continuously mix the mixture, refrigerating and cooling it until it reaches a uniform consistency at a temperature comprised between -8°C and -10°C.

[0011] The batch freezing temperature must be maintained throughout the batch freezing period, which lasts a few minutes, depending on the type of ingredients and thickeners used. This allows the ingredients to achieve a correct homogeneity and density. Once the required homogeneity and densityhave been achieved, the batch frozen product is poured into stainless steel containers of various shapes, typically used by ice cream makers and commonly called tubs.

[0012] After the batch freezing phase, the ice cream in the tubs must be further cooled because the temperature at which it leaves the batch freezer is too high and the product does not have the right hardness to be used in the final preparation of an ice cream cone.

[0013] In order to achieve such a cooling condition, the product must be brought to a temperature comprised between -15°C and -18°C. To do this, the tubs are stored in the workshop in refrigerators or blast chillers if there is a need to reduce the time required to reach the ideal processing conditions for the preparation phase prior to sale. Such blast chilling and storage phase generally lasts 4-6 hours.

[0014] The ice cream product is then placed in refrigerated display counters that are used by ice cream makers to display the product for sale and maintain at the same time an ideal storage and scooping temperature comprised between -12°C and -14°C.

[0015] As described, ice cream preparation goes through several processing phases (pasteurization and aging; batch freezing, blast chilling and storage) which have a relatively long total duration of 9-19 hours.

[0016] Therefore, the ice cream preparation time is an important factor in order to organize the processing of the product in advance, in such a way to have the ice cream available for sale at the right time. High-quality artisan ice cream parlors must organize the ice cream preparation activities in the workshop, trying to avoid overproduction that would require storing the product for long periods of time at a storage temperature comprised between -18°C and -20°C, causing it to lose its freshness and quality. Furthermore, in the latter case, it is necessary to wait for a tempering time of the product inside the refrigerated display counter in order to raise the temperature to values comprised between -12°C and -14°C, in such a way to obtain ice cream that is suitable for scooping and final processing.Obviously, the ice cream production process could be reduced only to the batch freezing phase, which causes a liquid prepared in various ways to become creamy and reach a negative temperature.

[0017] In artisan chains, laboratories can be centralized so that they can serve multiple ice cream parlors, or they can be located in premises adjacent to the point of sale. Since the demand for ice cream is determined by sales and by the availability of the product in the refrigerated display counter, the ice cream maker must check or have information in advance regarding a possible request for new ice cream supplies.

[0018] Furthermore, consumers generally do not like to see half-empty tubs and tend to choose the ice cream from fuller tubs, as they assume that this ice cream is fresher (newer). Therefore, in refrigerated display counters, it is important to create a visual effect that presents the product in the tubs in an attractive way. Obviously, such a visual effect cannot be guaranteed when there is a small amount of ice cream in a tub.

[0019] Therefore, monitoring ice cream sales is a key factor in choosing the preparation time of the product. In addition, such monitoring also provides information on consumer flavor trends. A lack of this information in real time creates difficulties in managing the cold chain, which in most cases is broken, thus storing and stocking ice cream, with consequent problems in terms of possible overproduction, quality, and costs due to unsold stock.

[0020] EP3834672A1 , in the name of the same applicant, discloses a refrigerated display counter for ice cream tubs, wherein each tub is provided with a dish suitable for being gradually raised towards the opening of the tub to keep the ice cream loaded in the tub always close to the opening, even in case of a progressive level reduction suffered by said ice cream in view of the ordinary distribution to customers.

[0021] However, Jingang et al.: “Improved Ice Cream Detection Algorithm Based on YOLOv5” discloses a flow alignment module to improve the detection of the ice cream features.

[0022] The purpose of the present invention is to eliminate the drawbacks of the prior art by providing a refrigerated display counter with ice cream quantitycontrol system that is capable of continuously monitoring the quantity of ice cream in the refrigerated display counter in real time.

[0023] Another purpose is to provide such a refrigerated display counter with ice cream quantity control system that is accurate and reliable.

[0024] Another purpose is to provide such a refrigerated display counter with ice cream quantity control system that is versatile and easy to install and manage.

[0025] These purposes are achieved in accordance with the invention with the characteristics of the attached independent claims.

[0026] Advantageous embodiments of the invention are apparent from the dependent claims.

[0027] Further features of the invention will become clearer from the following detailed description, which refers to a purely exemplary and therefore nonlimiting embodiment, illustrated in the attached drawings, wherein:

[0028] Fig. 1 is a diagrammatic view, partially in cross-section, illustrating a refrigerated display counter according to the invention;

[0029] Fig. 2 is a perspective rendering view illustrating a refrigerated display counter according to the invention;

[0030] Fig. 3 is a block diagram schematically illustrating a monitoring system of the refrigerated display counter according to the invention;

[0031] Fig. 4 is a block diagram illustrating in greater detail the control unit of the monitoring system of the refrigerated display counter according to the invention;

[0032] Fig. 5 is a sectional view of a tub containing ice cream; and

[0033] Fig. 6 is a block diagram illustrating in greater detail two algorithms of the control unit of the monitoring system of the refrigerated display counter according to the invention.

[0034] With the aid of the Figures, a refrigerated display counter according to the invention, which is generally indicated with reference numeral 100, is described.With reference to Fig. 1 , the refrigerated display counter (100) is suitable for containing tubs (1 ) for ice cream (2). Hereinafter, the terms “front” and “rear” refer to a user standing in front of the refrigerated display counter (100).

[0035] The refrigerated display counter (100) comprises a cooling system (3) for cooling the ice cream (2) in the tubs (1). The cooling system (3) comprises a refrigeration circuit and a ventilation system (32). The refrigeration circuit comprises a compressor (30), a condenser, an expansion valve, and an evaporator (31). The ventilation system (32) comprises a fan that forces a circulation of cooled air through the evaporator (31) up to the ice cream (2) contained in the tubs (1).

[0036] A temperature control is carried out by means of a temperature sensor (33) located at the inlet of the evaporator (31) to detect a temperature inside the refrigerated display counter. The desired temperature range is given between a minimum value and a maximum value. When the temperature detected by the temperature sensor (33) reaches the minimum value, the compressor (30) is stopped. When the temperature detected by the temperature sensor (33) reaches the maximum value, the compressor is started.

[0037] The refrigerated display counter (100) normally comprises a cover (4) made of transparent material to let the users see the ice cream in the tubs (1). The cover (4) has a rear opening (40) to let the operator access the tubs (1).

[0038] To minimize the operation of the compressor (30), the refrigerated display counter (100) comprises a closure system (41), either a curtain or sliding door, suitable for closing the rear opening (40) of the cover. The closure system (41) is kept closed when ice cream is not being sold. Such a closure system (41) reduces the heat loss by preventing ambient air from entering the refrigerated display counter, which would increase the temperature of the air inside the refrigerated display counter. As a result, closing the closure system (41 ) increases the stop times (thermostat control) of the compressor (30) of the refrigeration circuit, reducing both the energy consumption and lack of temperature uniformity in the refrigerated display counter.The refrigerated display counter (100) comprises a monitoring system (M) suitable for detecting the type of ice cream and a quantity of ice cream contained in each tub (1).

[0039] With reference to Fig. 3, the monitoring system (M) comprises a vision sensor unit (5) and a control unit (6) operatively connected to the vision sensor unit (5).

[0040] With reference to Fig. 2, the vision sensor unit (5) comprises at least one vision sensor (5a, 5b, 5b). By way of example, three vision sensors (5a, 5b, 5b) may be provided above the tubs (1) along a longitudinal direction of the refrigerated display counter.

[0041] Each vision sensor (5a, 5b, 5b) may be of “Vision Al” type, i.e. suitable for working with artificial intelligence algorithms configured to detect the type of ice cream and a quantity of ice cream contained in each tub, for example, in the form of the filling level of the tub expressed as a percentage. The artificial intelligence algorithms are installed in the control unit (6).

[0042] Each vision sensor (5a, 5b, 5b) is centrally located in an upper part of the cover (4), so as to be at a distance of approximately 40-60 cm from the upper surface of the ice cream (2) contained in the tubs. Each vision sensor (5a, 5b, 5b) has a viewing angle (a) of approximately 60°-80° so as to frame the upper surface of the ice cream contained in more than one tub (1).

[0043] With reference to Fig. 3, using the images captured by the vision sensor unit (5) and the data obtained from the images and processed by the algorithms of the vision sensors, the monitoring system (M) is able to dynamically detect the type of ice cream contained in each tub and the availability status of each type of ice cream. The monitoring system (M) is able to detect the type of ice cream contained in each tub, regardless of the position of the tubs (1 ) by means of a 3D detection with high-resolution 3D image acquisition performed by the vision sensor unit (5).

[0044] With reference to Fig. 4, the control unit (6) has an image processor (60) configured to process the 3D images (I) detected by the vision sensor unit (5).

[0045] In addition, the control unit (6) comprises:- a recognition algorithm (7) configured to receive the images processed by the image processor (60), divide them into sub-images (In) indicative of the ice cream in each tub, and classify the type (T) of ice cream in each tub; and - a filling algorithm (8) configured to receive said sub-images (Im) and the type of ice cream (T) in each tub from the recognition algorithm (7) and calculate filling levels (Lr) and consumption levels (Lc) for each tub (1) contained in the refrigerated display counter.

[0046] The recognition algorithm (7) and the filling algorithm (8) are based on artificial intelligence.

[0047] During the setup, the monitoring system (M) is trained by acquiring sample images of various types of ice cream with different ingredients. In this way, during the subsequent use, the monitoring system (M) is able to recognize the type of ice cream contained in any position in a tub. In particular, each sample image is divided into sample pixels (Pm) of different colors based on the ingredients.

[0048] The acquisition of images by means of the vision sensor unit (5) requires a calibration of the sensors made on the tubs (1 ). With reference to Fig. 5, each tub (1) has an upper edge (10) and the ice cream (2) contained in the tub has an upper surface (20).

[0049] The vision sensor unit (5) is calibrated based on a planar detection surface (S) at the upper edge (10) of the tubs (1) contained in the refrigerated display counter. So, when the vision sensor unit (5) detects an image (I) of the tub, the image processor (60) traces the contours of the upper edge (10) of the tub that are positioned on the same level as the planar detection surface (S).

[0050] When a 3D image of the ice cream (2) contained in a tub (1 ) is acquired, the image processor (60) processes said image and the recognition algorithm (7) is able to distinguish each ice cream in each tub.

[0051] With reference to Fig. 6, the recognition algorithm (7) comprises:

[0052] - a subdivision sub-algorithm (70) configured to subdivide the image (I) processed by the image processor (60) into a plurality of sub-images (In) representing the ice cream in each tub;- a pixel extraction sub-algorithm (71 ) configured to extract the pixels (P) of each sub-image (In) representing the ice cream in a tub;

[0053] - a comparison sub-algorithm (72) configured to compare the pixels (P) of each sub-image with sample pixels (Pm) indicative of ice cream ingredients, and identify the ingredients (G) contained in the ice cream captured by the vision sensor unit (5), and

[0054] - a classification sub-algorithm (73) configured to receive the ingredients (G) identified by the comparison sub-algorithm (72) and classify the type (T) of ice cream.

[0055] Having at its disposal a sub-image (In) representing the ice cream in a tub, the filling algorithm (8) is able to calculate an emptiness depth (Hv) given by the distance between the planar detection surface (S) and the upper surface (20) of the ice cream. Knowing the total depth (H) of the tub, the filling algorithm (8), also calculates a full depth (Hp) of the tub, which is given by the difference between the total depth (H) and the emptiness depth (Hv). The filling algorithm (8) then calculates a filling level (Lr) of the tub based on the full depth (Hp) of the tub and a consumption level (Lc) based on the emptiness depth (Hv).

[0056] The filling algorithm (8) comprises:

[0057] - an identification sub-algorithm (80) configured to receive the subimages (In) representing the ice cream in each tub and the type (T) of ice cream from the recognition algorithm (7);

[0058] - a distance calculation sub-algorithm (81) that receives the sub-images (In) representing the ice cream in each tub and calculates an emptiness depth (Hv) given by the distance between the planar detection surface (S) and the upper surface (20) of the ice cream;

[0059] - a subtractor (82) that subtracts the emptiness depth (Hv) from the total depth (H) of the tub to detect the full depth (Hp);

[0060] - a filling level calculation sub-algorithm (83) that receives the emptiness depth (Hv) and calculates a filling level (Lr) of the tub; and

[0061] - a consumption level calculation sub-algorithm (84) that receives the full depth (Hp) and calculates a consumption level (Lc) of the ice cream in the tub.Returning to Fig. 4, the recognition algorithm (7) outputs the types (T) of ice cream contained in the tubs. Instead, the filling algorithm (8) outputs the filling level (Lr) and the consumption level (Lc) for each tub containing a specific type of ice cream.

[0062] The control unit (6) comprises:

[0063] - a type database (63), wherein the types (T) of ice cream classified by the recognition algorithm (7) are stored;

[0064] - a filling database (64), wherein the filling levels (Lr) for each tub containing a specific type of ice cream, calculated by the filling algorithm (8), are stored; and

[0065] - a consumption database (65), wherein the consumption levels (Lc) for each tub containing a specific type of ice cream, calculated by the filling algorithm (8), are stored.

[0066] The control unit (6) further comprises a graph generator (66) connected to the filling database (64) to generate graphs (dashboard) (Gh) indicating the filling level of the tubs for each type of ice cream.

[0067] Furthermore, the control unit (6) comprises a comparator (67) that compares the filling level (Lr) calculated by the filling algorithm with a minimum filling level (Lm) set by the user, indicative of the fact that said particular type of ice cream is about to finish.

[0068] When the filling level (Lr) is lower than the minimum filling level (Lm), the comparator (67) outputs an alarm signal (A) that is sent to a user device (D) provided in an ice cream workshop, which can then start producing the type of ice cream that is about to finish.

[0069] It should be noted that the monitoring system (M) classifies according to the type (T) of ice cream and not according to the position of the tubs; therefore, the position of the tubs (1) in the refrigerated display counter can be changed freely.

[0070] With reference to Fig. 3, the monitoring system (M) comprises a Wi-Fi or Internet of Things (loT) connection system (9) for connecting to the Internet. In this way, a user device (D) of a user, such as a mobile device, can connect to the monitoring system (M) via the Internet and view the data collected by themonitoring system (M) in streaming. In particular, by means of the user device (D), the user can view the graph (Gh) showing the data indicating the filling level of the tubs for each type of ice cream and the contents of the databases (63, 64, 65).

[0071] In addition, the data collected by the monitoring system (M) can be downloaded and saved on a cloud (C). In such a case, a user can access the data saved in the cloud (C) via the user device (D).

[0072] The data acquired by the monitoring system (M) during the use of the refrigerated display counter (100) and the sale of ice cream can be consulted directly on a user device (D) connected via Wi-Fi, or transferred with an loT system to a central database in the cloud (C) in such a way to be consulted remotely by directly accessing a web portal for statistical sale analysis and ice cream replenishment analysis in real time.

[0073] The monitoring system (M) is able to inform an ice cream workshop by means of alarm signals (A) based on minimum filling levels (Lm) of the tubs (1 ). In this way, the workshop can organize in advance the preparation and replenishment times of the ice cream that is about to finish, with advantages in terms of reducing stocks, freshness and quality of the product, customer service, and costs for overproduction of stocks.

[0074] It should be noted that the monitoring of the full level (Lp) is a measure of the residual quantity of ice cream in the tubs. Therefore, such a monitoring is both a way of optimizing the availability of fresh product (for example, avoiding stock shortages because the blast-chilled and stored product may be too cold to be served immediately) and a way of optimizing excessive stock (flavors that sell less on certain days or at certain times of the day).

[0075] The monitoring system (M) allows for effectively monitoring the correct presentation of the product and provides guidance to the operators on filling the tubs, especially before peak sales times. In fact, sales peaks often occur in a few hours.

[0076] Numerous variations and detailed modifications can be made to the present embodiment of the invention, within the reach of a person skilled in theart, however falling within the scope of the invention as expressed by the appended claims.

Claims

CLAIMS1. Refrigerated display counter (100) comprising:- a plurality of tubs (1) suitable for containing ice cream (2),- a cooling system (3) suitable for cooling the ice cream (2) in the tubs (1), and- a monitoring system (M) configured to detect the type of ice cream and a quantity of ice cream contained in each tub (1),wherein said monitoring system (M) comprises:- a vision sensor unit (5) arranged to detect images (I) of the ice cream (2) contained in the tubs (1), and- a control unit (6) operatively connected to said vision sensors (5) and configured to process said images (I) detected by the vision sensors and extract data from said images to detect the type of ice cream and a quantity of ice cream contained in each tub (1).

2. The refrigerated display counter (100) according to claim 1, wherein the vision sensor unit (5) comprises at least one Al Vision sensor (5a, 5b, 5b) that works with artificial intelligence algorithms configured to detect the type of ice cream and a quantity of ice cream contained in each tub.

3. The refrigerated display counter (100) according to claim 1 or 2, wherein said refrigerated display counter has a cover (4) disposed above said tubs (1 ) and said vision sensor unit (5) is centrally disposed in an upper portion of the cover (4) above said tubs (1).

4. The refrigerated display counter (100) according to any of the preceding claims, wherein said control unit (6) comprises:- an image processor (60) configured to receive and process the images (I) taken by said vision sensor unit (5),- a recognition algorithm (7) configured to receive the images processed by the image processor (60), divide them into sub-images (In) indicative of the ice cream in each tub and classify the type (T) of ice cream in each tub; and - a filling algorithm (8) configured to receive said sub-images (Im) and the type of ice cream (T) in each tub from the recognition algorithm (7) andcalculate filling levels (Lr) and consumption levels (Lc) of each tub (1 ) contained in the refrigerated display counter.

5. The refrigerated display counter (100) according to claim 4, wherein said recognition algorithm (7) and said filling algorithm (8) are artificial intelligence-based algorithms.

6. The refrigerated display counter (100) according to claim 5, wherein, during the setup, said monitoring system (M) is trained with the acquisition of sample images of various types of ice cream so that, during the successive use phase, the monitoring system (M) can recognize the type of ice cream contained in a tub.

7. The refrigerated display counter (100) according to claim 6, wherein each of said sample images used in the training phase is divided into sample pixels (Pm) of different color based on the ingredients and the recognition algorithm (7) is configured to extract the pixels (P) of the sub-images (In) and compare them with said sample pixels (Pm) to detect the ingredients (G) of the ice cream.

8. The refrigerated display counter (100) according to claim 7, wherein said recognition algorithm (7) comprises:- a subdivision sub-algorithm (70) configured to divide the image (I) processed by the image processor (60) into a plurality of sub-images (In) representing the ice cream in each tub;- a pixel extraction sub-algorithm (71 ) configured to extract the pixels (P) of each sub-image (In) representing the ice cream in a tub;- a comparison sub-algorithm (72) configured to compare the pixels (P) of each sub-image with the sample pixels (Pm) indicative of the ingredients of an ice cream, and identify the ingredients (G) of the ice cream, and- a classification sub-algorithm (73) configured to receive the ingredients (G) identified by the comparison sub-algorithm (72) and classify the type (T) of ice cream.

9. The refrigerated display counter (100) according to any of the preceding claims, wherein said filling algorithm (8) comprises:- an identification sub-algorithm (80) configured to receive the subimages (In) representing the ice cream in each tub and the type (T) of ice cream from the recognition algorithm (7);- a distance calculation sub-algorithm (81) that receives the sub-images (In) representing the ice cream in each tub and calculates an emptiness depth (Hv) given by the distance between a planar detection surface (S) at an upper edge (10) of the tub and an upper surface (20) of the ice cream;- a subtractor (82) that subtracts the emptiness depth (Hv) from the total depth (H) of the tub to detect a full depth (Hp);- a filling level calculation sub-algorithm (83) that receives the emptiness depth (Hv) and calculates a filling level (Lr) of the tub; and- a consumption level calculation sub-algorithm (84) that receives the full depth (Hp) and calculates a consumption level (Lc) of the ice cream in the tub.

10. The refrigerated display counter (100) according to any of the preceding claims, wherein said monitoring system (M) comprises a Wi-Fi or Internet of Thinking (loT) connection system (9) for connection to the Internet, so that a user device (D) of a user can be connected to the monitoring system (M) over the Internet and display the data detected by the monitoring system (M) in streaming; andsaid control unit (6) comprises a comparator (67) configured to compare the filling level (Lr) calculated by the filling algorithm (8) with a minimum filling level (Lm) and send an alarm signal (A) to said user device (D) when the filling level (Lr) is lower than the minimum filling level (Lm).

Images