Frozen Beverage Dispenser Viscosity Control Using Auger Motor Feedback
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Solution Overview
Problem
Existing frozen beverage and soft-serve ice cream machines lack automatic viscosity control, leading to inconsistent product quality and difficulty in reliably dispensing exact portion sizes due to manual setting adjustments and environmental factors.
Innovation Solution
An automatic viscosity control system using a mixing cylinder with an auger, gas inlet, and refrigeration system controlled by a microcontroller to maintain optimal product consistency based on amperage draw and torque measurements, along with a portion control method to dispense precise amounts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual control settings are used for temperature and spring tension, then the machine can operate with simple controls, but product viscosity and consistency vary widely between consecutive dispenses
Solution Approach 1:
The system uses a motor sensor to measure amperage draw or torque of the auger motor, which varies with product viscosity. This feedback signal is sent to the microcontroller, which automatically adjusts the refrigeration system to maintain consistent product consistency, eliminating the need for manual adjustments while ensuring reliable product quality
Solution Approach 2:
The system performs self-adjustment by automatically controlling the refrigeration system based on real-time viscosity measurements from the motor sensor. The microcontroller modulates the refrigeration system without human intervention, allowing the machine to self-regulate product consistency and eliminate manual control requirements
2Reliability
If the refrigeration system runs continuously to maintain product consistency, then product viscosity remains stable, but energy consumption increases
Solution Approach 1:
The refrigeration system operates periodically rather than continuously. The microcontroller receives feedback from the motor sensor and cycles the refrigeration system on and off to maintain product viscosity within the desired range, reducing energy consumption while maintaining product consistency
Solution Approach 2:
The system dynamically changes the refrigeration system's operational parameters (on/off timing, intensity) based on real-time viscosity measurements. The microcontroller adjusts refrigeration input as a variable parameter to match actual product viscosity conditions, optimizing energy efficiency while maintaining consistent product quality
3Adaptability or versatility
If ambient temperature and humidity are not controlled, then the machine operates in varying environmental conditions, but product consistency changes requiring manual intervention
Solution Approach 1:
The motor sensor continuously monitors viscosity changes caused by environmental factors. When ambient temperature or humidity changes affect product consistency, the feedback signal triggers automatic refrigeration adjustments, compensating for environmental variations without requiring manual intervention or controlled environmental conditions
4Reliability
If automatic viscosity control is implemented using motor sensor feedback, then product consistency is maintained, but device complexity increases
Solution Approach 1:
The microcontroller serves multiple functions: it processes feedback from the motor sensor, controls the refrigeration system, and manages the auger motor. By making the control system multi-functional, the patent reduces the need for separate dedicated components for each function, thereby limiting the increase in overall device complexity while achieving automatic viscosity control
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Ensures consistent product viscosity and accurate portioning by automatically adjusting refrigeration and dispensing, independent of ambient conditions, thereby improving product quality and reliability.
Implementation Method 1
The motor sensor measures an amperage draw or a torque of the auger motor resultant from the resistance of rotating the auger through the food product
Implementation Method 2
The refrigeration system is configured to chill, to a predetermined frozen malleable consistency, the food product inside the mixing cylinder
Implementation Method 3
A refrigeration system comprises a compressor. The refrigeration system is configured to chill, to a predetermined frozen malleable consistency, the food product inside the mixing cylinder
Data Source
AI summary
The present invention relates to an automatic viscosity control system and method for food products dispensed from frozen beverage and soft-serve ice cream equipment. A mixing cylinder includes an auger interconnected with an auger motor. A refrigeration system chills the food product in the mixing cylinder to a predetermined frozen malleable consistency. A motor sensor measures amperage draw or torque of the auger motor resultant from resistance of rotating the auger through the food product. By transitioning between starting or speeding up a compressor when the amperage draw or the torque of the auger motor is below a predetermined high motor performance setting, and slowing or stopping the compressor when the amperage draw or the torque of the auger motor is between a predetermined low motor performance setting and the predetermined high motor performance setting the viscosity of the food product is automatically controlled.