Frozen beverage machine control system and method
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Solution Overview
Problem
Existing frozen beverage machines face issues with maintaining consistent liquid levels, pressures, and carbon dioxide content, leading to inconsistent product quality due to unpredictable expansion and contraction within the freezing chamber, resulting in problems like inconsistent ice crystal size, fluctuating barrel pressure, and 'wet' or 'cold' drinks.
Innovation Solution
A dynamic charge control system is introduced, comprising an expansion tank, pressure sensors, and solenoids to actively control the pressure of the expansion tank, ensuring the desired pressure range is maintained by supplying or exhausting gas, thereby regulating the freezing chamber pressure and improving drink consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If torque-based control is used to trigger refreeze cycles, then the system can operate with simple control logic, but the product temperature becomes unstable and drink quality becomes inconsistent
Solution Approach 1:
The patent replaces the mechanical torque-based control system with a pressure-based control system. Instead of using the beater motor's torque to detect freezing state, the system uses a pressure sensor to monitor chamber pressure and control refreeze cycles, eliminating the mechanical coupling between the beater and control logic while improving temperature and product consistency control.
2Device complexity
If the freezing chamber pressure is not actively controlled, then the system structure remains simple, but the liquid level and carbon dioxide content become unpredictable leading to wet or cold drinks
Solution Approach 1:
The patent introduces a feedback control system where a pressure sensor continuously monitors the freezing chamber pressure and sends signals to the controller. The controller adjusts the refreeze cycles based on pressure deviations from the setpoint, creating a closed-loop system that actively maintains pressure within the optimal range to prevent wet or cold drinks.
Solution Approach 2:
The patent introduces an expansion tank as an intermediary component between the freezing chamber and the external environment. This expansion tank acts as a pressure buffer, absorbing pressure fluctuations and providing more stable pressure conditions in the freezing chamber, which improves liquid level and carbon dioxide content control.
3Reliability
If refreeze cycles are triggered frequently to maintain product temperature, then the product stays frozen, but the barrel pressure fluctuates and energy consumption increases
Solution Approach 1:
The pressure-based feedback control system triggers refreeze cycles only when pressure deviations indicate actual freezing state changes, rather than using fixed-time or torque-based triggers. This reduces unnecessary refreeze cycles while maintaining product frozen state, thereby reducing energy consumption and pressure fluctuations.
4Manufacturing precision
If the system uses pressure sensor feedback control, then the freezing chamber pressure is maintained within a tighter range, but the device complexity increases
Solution Approach 1:
The expansion tank serves as a mechanical intermediary that provides inherent pressure stabilization through its gas-liquid interface. This passive pressure buffering reduces the burden on the active control system, allowing tighter pressure control without proportionally increasing control system complexity.
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
This solution maintains freezing chamber pressure within a tighter range, enhances drink consistency, reduces over/under pressurization issues, and ensures better gas solubility, resulting in a more consistent and high-quality frozen beverage product.
Implementation Method 1
The expansion tank may be configured to contain a gas and a solution. The charge pressure sensor may be to determine an active pressure of the at least one expansion tank.
Implementation Method 2
a supply solenoid coupled to at least one the expansion tank; a exhaust solenoid coupled to at least one the expansion tank
Implementation Method 3
a freezing chamber; a refrigeration system coupled to the freezing chamber... The mixture freezes on the inner surface of the chamber
Implementation Method 4
The temperature of the liquid within the chamber is maintained below the freezing point of water at atmospheric pressure
Implementation Method 5
The pressure of the carbon dioxide within the chamber is maintained above atmospheric pressure... ensuring better gas solubility
Data Source
AI summary
The inventions disclosed and taught herein relate generally to frozen beverage machines; and more specifically relate to improved methods of and apparatuses for controlling the consistency and quality of the dispensed beverage product.