Metered iced dispenser system utilizing a brushless direct current gearmotor
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Solution Overview
Problem
Current ice dispensing systems in vending applications suffer from unreliable human reaction time and high costs associated with high-accuracy servo motor and encoder systems, leading to inconsistent ice dispensing.
Innovation Solution
The use of low-cost brushless direct current (DC) motors integrated with hall effect sensors to accurately control ice dispensing by monitoring motor rotation and dispensing a predefined amount using a processor and microcontroller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If high-accuracy servo motor and encoder systems are used, then ice dispensing precision is improved, but system cost increases significantly
Solution Approach 1:
The patent replaces expensive servo motors and encoders with inexpensive brushless DC motors and hall effect sensors. The hall effect sensors provide sufficient rotational position feedback at a fraction of the cost of encoder systems, enabling accurate ice dispensing measurement without high-precision (and high-cost) components.
Solution Approach 2:
The system changes the control approach by using pulse width modulation (PWM) to control motor speed and using hall effect sensor pulses to measure rotational displacement. This parameter-based control method achieves accurate dispensing measurement through software processing of sensor signals rather than through expensive hardware encoders.
2Extent of automation
If timer-based systems are used for ice dispensing, then automation is improved, but dispensing accuracy deteriorates due to machine-to-machine variations
Solution Approach 1:
The patent implements a feedback control system where hall effect sensors continuously monitor motor rotational position and provide real-time feedback to the microcontroller. The system counts hall effect pulses to precisely track ice wheel rotation and dispensed ice volume, automatically adjusting to maintain accurate dispensing across different machines without requiring manual calibration.
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
Achieves precise and consistent ice dispensing by controlling the amount of ice dispensed through the integration of hall effect sensors with brushless DC motors, reducing costs and improving accuracy.
Implementation Method 1
The motor includes at least one integrated hall sensor configured to monitor a rotation of the motor
Data Source
AI summary
Metered ice dispenser systems utilizing a brushless DC gearmotor are disclosed. In one form, an ice dispenser system includes a brushless DC gearmotor, an ice wheel, a system interface and a processor. The ice wheel is coupled with the brushless DC gearmotor such that rotation of the gearmotor rotates the ice wheel, wherein ice dispenses from the metered ice dispenser system as the ice wheel rotates. The processor is configured to: receive information from the system interface identifying an input, and transmit control information to the brushless DC gearmotor based on the user input. A microcontroller of the brushless DC gearmotor is configured to: start the motor; monitor pulses received from at least one integrated hall sensor indicating a rotation of the motor; and stop the motor after a number of pluses as indicated in the control information is received from the at least one integrated hall sensor.