Automated Ice Bag Filling and Distribution in Merchandisers
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Solution Overview
Problem
Existing ice distribution systems in units like ice storage units, freezers, and ice merchandisers lack efficient automation for filling and managing ice-filled bags, leading to manual intervention and potential overfilling or underfilling, which can result in inefficiencies and increased operational costs.
Innovation Solution
A system comprising an ice maker, a hopper, a measurement and delivery assembly, a bagging mechanism, and a control system that uses sensors and motors to automate the filling and distribution of ice-filled bags within a freezer, ensuring optimal filling and preventing overfilling by monitoring the availability of space and ice levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual intervention is used for filling and managing ice-filled bags, then operational flexibility is maintained, but productivity is reduced and overfilling or underfilling occurs
Solution Approach 1:
The system enables self-service automation where the ice distribution system automatically fills bags with ice, monitors ice levels, and manages distribution without human intervention. The control system autonomously operates the ice maker, measurement assembly, and delivery mechanisms to maintain optimal ice supply.
Solution Approach 2:
Manual mechanical operations are replaced with an automated control system that uses sensors, motors, and electronic controllers to manage the ice filling and distribution process. The system substitutes human-operated mechanical actions with automated electromechanical systems including the ice maker mechanism, measurement assembly, and bagging system.
2Productivity
If automated filling is implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The control system serves multiple functions simultaneously: it controls the ice maker operation, monitors ice levels in the hopper, operates the measurement and delivery assembly, manages the bagging mechanism, and tracks distribution status. This multi-functionality consolidates what would otherwise require separate systems into a single integrated control unit.
Solution Approach 2:
The patent combines the ice maker, hopper, measurement and delivery assembly, bagging mechanism, and control system into an integrated automated distribution system. These previously separate components are merged into a unified system where the control system coordinates all operations, reducing overall system complexity while maintaining automation benefits.
3Manufacturing precision
If sensors and monitoring are added to prevent overfilling, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The system incorporates sensors that continuously monitor ice levels in the hopper and provide feedback to the control system. This feedback mechanism enables the control system to adjust the ice making and filling operations in real-time, ensuring precise filling amounts and preventing overfilling or underfilling conditions.
Solution Approach 2:
The measurement assembly is designed to deliver a predetermined amount of ice to each bag, using a controlled filling process that stops at the optimal point. This partial action approach ensures each bag receives the exact required amount without excessive filling, while the sensor monitoring provides the precision needed to stop at the correct level.
Data Source
AI summary
An ice distribution system and method according to which ice-filled bags are distributed within a unit such as, for example, an ice merchandiser.