ICE DISTRIBUTION SYSTEM AND METHOD

• US 20080295462A1
• Filed: 05/30/2008
• Published: 12/04/2008
• Est. Priority Date: 05/31/2007
• Status: Active Grant

• Current Assignee: Reddy Ice LLC
• Original Assignee: Reddy Ice Corporation (Stone Canyon Industries Holdings LLC)
• Inventors: Metzger, Mark C.
• Granted Patent: US 8,381,534 B2
• Time in Patent Office: Days
• US Class Current: 53/469
• CPC Class Codes: B65B 1/04 Methods of, or means for, filling the material into the containers or receptacles
• CPC Class Codes: B65B 1/30 Devices or methods for controlling or determining the quantity or quality or the material fed or filled
• CPC Class Codes: B65B 39/007 Guides or funnels for introducing articles into containers or wrappers
• CPC Class Codes: B65B 43/52 using roller-ways or endless conveyors
• CPC Class Codes: B65G 47/32 Applications of transfer devices such devices per se B65G47/74
• CPC Class Codes: F25C 1/00 Producing ice F25C3/00 takes precedence
• CPC Class Codes: F25C 5/187 with ice level sensing means
• CPC Class Codes: F25C 5/24 for storing bins ice bins F25C5/182

Abstract

An ice distribution system and method according to which ice-filled bags are distributed within a unit such as, for example, an ice merchandiser.

Claims

1. An apparatus comprising:

a temperature-controlled storage unit defining an internal region in which a plurality of ice-filled bags are adapted to be stored, a portion of the internal region being an available space in which a first ice-filled bag is adapted to be disposed;

one or more tracks extending within the internal region;

and

one or more of the following;

a first kicker assembly coupled to the one or more tracks and movable therealong within the internal region, the first kicker assembly comprising a first basket sized to receive the first ice-filled bag before the first ice-filled bag is disposed in the available space; and

a push arm coupled to the one or more tracks and movable therealong within the internal region, the push arm being configured to engage the first ice-filled bag to thereby dispose the first ice-filled bag in the available space.

2. The apparatus of claim 1 further comprising:

a drive motor operably coupled to the one or more tracks for driving the one or more tracks to thereby cause the first kicker assembly and/or the push arm to move along the one or more tracks;

an ice maker for making the ice;

a hopper operably coupled to the ice maker for receiving the ice from the ice maker;

a measurement and delivery assembly operably coupled to the hopper for measuring and delivering an amount of the ice into an empty bag used to produce the first ice-filled bag;

a bagging mechanism operably coupled to the measurement and delivery assembly for providing the empty bag used to produce the first ice-filled bag;

and

a control system operably coupled to one or more of the storage unit, the first kicker assembly, the push arm, the drive motor, the ice maker, the hopper, the measurement and delivery assembly, and the bagging mechanism, the control system comprising;

a computer comprising;

a processor; and

a memory accessible to the processor for storing instructions executable by the processor;

and

one or more sensors operably coupled to the computer and adapted to monitor one or more of the storage unit, the first kicker assembly, the push arm, the drive motor, the ice maker, the hopper, the measurement and delivery assembly, and the bagging mechanism.

3. The apparatus of claim 1, comprising the first kicker assembly;

wherein the apparatus further comprises;

a drive motor operably coupled to the one or more tracks for driving the one or more tracks to thereby cause the first kicker assembly to move along the one or more tracks within the internal region;

a first sensor coupled to the first kicker assembly for searching for the available space; and

a second sensor coupled to the storage unit and vertically positioned below the first kicker assembly for determining whether the first kicker assembly will be blocked as it moves along the one or more tracks;

wherein the first kicker assembly further comprises a first rotator motor operably coupled to the first basket for rotating the first basket to thereby discharge the first ice-filled bag from the first kicker assembly and dispose the first ice-filled bag in the available space.

4. The apparatus of claim 1, comprising the push arm;

wherein the apparatus further comprises;

a drive motor operably coupled to the one or more tracks for driving the one or more tracks to thereby cause the push arm to move along the one or more tracks within the internal region;

a second kicker assembly, at least a portion of which is fixedly positioned within the internal region, the second kicker assembly comprising;

a second basket sized to receive the first ice-filled bag before the first ice-filled bag is disposed in the available space; and

a second rotator motor operably coupled to the second basket for rotating the second basket to thereby discharge the first ice-filled bag from the second kicker assembly before the push arm engages the first ice-filled bag;

and

an amperage measuring device operably coupled to the drive motor for controlling the drive motor to thereby control the push arm.

5. The apparatus of claim 1, comprising the first kicker assembly;

wherein the first kicker assembly further comprises a first rotator motor operably coupled to the first basket for rotating the first basket to thereby discharge the first ice-filled bag from the first kicker assembly and dispose the first ice-filled bag in the available space;

and

wherein the apparatus further comprises;

a drive motor operably coupled to the one or more tracks for driving the one or more tracks to thereby cause the first kicker assembly to move along the one or more tracks within the internal region;

a first sensor coupled to the first kicker assembly for searching for the available space;

a second sensor coupled to the storage unit and vertically positioned below the first kicker assembly for determining whether the first kicker assembly will be blocked as it moves along the one or more tracks;

an ice maker for making the ice;

a hopper operably coupled to the ice maker for receiving the ice from the ice maker;

a measurement and delivery assembly operably coupled to the hopper for measuring and delivering an amount of the ice into an empty bag used to produce the first ice-filled bag;

a bagging mechanism operably coupled to the measurement and delivery assembly for providing the empty bag used to produce the first ice-filled bag;

and

a control system operably coupled to one or more of the storage unit, the first kicker assembly, the push arm, the drive motor, the ice maker, the hopper, the measurement and delivery assembly, and the bagging mechanism, the control system comprising;

a computer comprising;

a processor; and

a memory accessible to the processor for storing instructions executable by the processor;

the first and second sensors;

and

one or more other sensors operably coupled to the computer and adapted to monitor one or more of the storage unit, the first kicker assembly, the push arm, the drive motor, the ice maker, the hopper, the measurement and delivery assembly, and the bagging mechanism.

6. A method comprising:

distributing a first ice-filled bag within an internal region defined by a temperature-controlled storage unit, comprising;

providing a first kicker assembly comprising a first basket;

disposing the first ice-filled bag in the first basket of the first kicker assembly;

searching for a first available space in the internal region in which to dispose the first ice-filled bag; and

disposing the first ice-filled bag in the first available space in the internal region, comprising;

discharging the first ice-filled bag from the first kicker assembly.

7. The method of claim 6 further comprising:

determining whether the temperature-controlled storage unit is full of bags filled with ice after distributing the first ice-filled bag within the internal region defined by the temperature-controlled storage unit; and

if the temperature-controlled storage unit is not full of bags filled with ice after distributing the first ice-filled bag within the internal region defined by the temperature-controlled storage unit, then;

(a) filling another bag with ice to thereby produce another ice-filled bag;

(b) distributing the another ice-filled bag within the internal region defined by the temperature-controlled storage unit; and

(c) if the temperature-controlled storage unit is not full of bags filled with ice after distributing the another ice-filled bag within the internal region defined by the temperature-controlled storage unit, then repeating steps (a) and (b) until the temperature-controlled storage unit is full of bags filled with ice.

8. The method of claim 7 further comprising:

making the ice;

before distributing the first ice-filled bag within the internal region defined by the temperature-controlled storage unit, filling a first bag with the ice to thereby produce the first ice-filled bag, comprising;

providing the first bag used to produce the first ice-filled bag;

measuring a first amount of the ice;

disposing the first amount of the ice in the first bag;

if the first bag in which the first amount of the ice is disposed is not filled with ice, then;

(d) measuring another amount of the ice;

(e) disposing the another measured amount of the ice in the first bag in which the first amount of ice is disposed; and

(f) if the first bag in which the first and another amounts of ice are disposed is not filled with ice, then repeating steps (d) and (e) until the first bag is filled with ice to thereby produce the first ice-filled bag.

9. The method of claim 7 wherein disposing the first ice-filled bag in the first available space in the internal region further comprises:

extending one or more tracks within the internal region;

coupling the first kicker assembly to the one or more tracks;

operably coupling a drive motor to the one or more tracks; and

driving the one or more tracks using the drive motor to thereby move the first kicker assembly and thus the first ice-filled bag.

10. The method of claim 9 wherein discharging the first ice-filled bag from the first kicker assembly comprises:

rotating the first basket to thereby cause the first ice-filled bag to fall out of the first basket;

wherein searching for the first available space in the internal region comprises;

coupling a first sensor to the first kicker assembly; and

searching for the first available space in the internal region using the first sensor during driving the one or more tracks using the drive motor;

and

wherein determining whether the temperature-controlled storage unit is full of bags filled with ice after distributing the first ice-filled bag within the internal region defined by the temperature-controlled storage unit comprises;

disposing a second sensor within the internal region defined by the temperature-controlled storage unit.

11. The method of claim 7 wherein disposing the first ice-filled bag in the first available space in the internal region further comprises:

extending one or more tracks within the internal region;

coupling a push arm to the one or more tracks;

operably coupling a drive motor to the one or more tracks;

after discharging the first ice-filled bag from the first kicker assembly, driving the one or more tracks using the drive motor to thereby engage the first ice-filled bag with the push arm; and

continuing to drive the one or more tracks using the drive motor to thereby move the push arm and thus the first ice-filled bag.

12. The method of claim 11 wherein discharging the first ice-filled bag from the first kicker assembly comprises:

rotating the first basket to thereby cause the first ice-filled bag to fall out of the first basket;

wherein searching for the first available space in the internal region comprises;

coupling an amperage measuring device to the drive motor;

using the amperage measuring device to measure the amperage draw by the drive motor during continuing to drive the one or more tracks using the drive motor; and

comparing the measured amperage draw with a predetermined amperage amount;

and

wherein determining whether the temperature-controlled storage unit is full of bags filled with ice after distributing the first ice-filled bag within the internal region defined by the temperature-controlled storage unit comprises;

determining the amount of travel the push arm underwent during the steps of driving the one or more tracks and continuing to drive the one or more tracks.

13. A system comprising:

means for distributing a first ice-filled bag within an internal region defined by a temperature-controlled storage unit, comprising;

means for providing a first kicker assembly comprising a first basket;

means for disposing the first ice-filled bag in the first basket of the first kicker assembly;

means for searching for a first available space in the internal region in which to dispose the first ice-filled bag; and

means for disposing the first ice-filled bag in the first available space in the internal region, comprising;

means for discharging the first ice-filled bag from the first kicker assembly.

14. The system of claim 13 further comprising:

means for determining whether the temperature-controlled storage unit is full of bags filled with ice after distributing the first ice-filled bag within the internal region defined by the temperature-controlled storage unit; and

means for if the temperature-controlled storage unit is not full of bags filled with ice after distributing the first ice-filled bag within the internal region defined by the temperature-controlled storage unit, then;

(a) filling another bag with ice to thereby produce another ice-filled bag;

(b) distributing the another ice-filled bag within the internal region defined by the temperature-controlled storage unit; and

(c) if the temperature-controlled storage unit is not full of bags filled with ice after distributing the another ice-filled bag within the internal region defined by the temperature-controlled storage unit, then repeating steps (a) and (b) until the temperature-controlled storage unit is full of bags filled with ice.

15. The system of claim 14 further comprising:

means for making the ice;

means for before distributing the first ice-filled bag within the internal region defined by the temperature-controlled storage unit, filling a first bag with the ice to thereby produce the first ice-filled bag, comprising;

means for providing the first bag used to produce the first ice-filled bag;

means for measuring a first amount of the ice;

means for disposing the first amount of the ice in the first bag;

means for if the first bag in which the first amount of the ice is disposed is not filled with ice, then;

(d) measuring another amount of the ice;

(e) disposing the another measured amount of the ice in the first bag in which the first amount of ice is disposed; and

(f) if the first bag in which the first and another amounts of ice are disposed is not filled with ice, then repeating steps (d) and (e) until the first bag is filled with ice to thereby produce the first ice-filled bag.

16. The system of claim 14 wherein means for disposing the first ice-filled bag in the first available space in the internal region further comprises:

means for extending one or more tracks within the internal region;

means for coupling the first kicker assembly to the one or more tracks;

means for operably coupling a drive motor to the one or more tracks; and

means for driving the one or more tracks using the drive motor to thereby move the first kicker assembly and thus the first ice-filled bag.

17. The system of claim 16 wherein means for discharging the first ice-filled bag from the first kicker assembly comprises:

means for rotating the first basket to thereby cause the first ice-filled bag to fall out of the first basket;

wherein means for searching for the first available space in the internal region comprises;

means for coupling a first sensor to the first kicker assembly; and

means for searching for the first available space in the internal region using the first sensor during driving the one or more tracks using the drive motor;

and

wherein means for determining whether the temperature-controlled storage unit is full of bags filled with ice after distributing the first ice-filled bag within the internal region defined by the temperature-controlled storage unit comprises;

means for disposing a second sensor within the internal region defined by the temperature-controlled storage unit.

18. The system of claim 14 wherein means for disposing the first ice-filled bag in the first available space in the internal region further comprises:

means for extending one or more tracks within the internal region;

means for coupling a push arm to the one or more tracks;

means for operably coupling a drive motor to the one or more tracks;

means for after discharging the first ice-filled bag from the first kicker assembly, driving the one or more tracks using the drive motor to thereby engage the first ice-filled bag with the push arm; and

means for continuing to drive the one or more tracks using the drive motor to thereby move the push arm and thus the first ice-filled bag.

19. The system of claim 18 wherein means for discharging the first ice-filled bag from the first kicker assembly comprises:

means for rotating the first basket to thereby cause the first ice-filled bag to fall out of the first basket;

wherein means for searching for the first available space in the internal region comprises;

means for coupling an amperage measuring device to the drive motor;

means for using the amperage measuring device to measure the amperage draw by the drive motor during continuing to drive the one or more tracks using the drive motor; and

means for comparing the measured amperage draw with a predetermined amperage amount;

and

wherein means for determining whether the temperature-controlled storage unit is full of bags filled with ice after distributing the first ice-filled bag within the internal region defined by the temperature-controlled storage unit comprises;

means for determining the amount of travel the push arm underwent during the steps of driving the one or more tracks and continuing to drive the one or more tracks.

20. A computer readable medium comprising a plurality of instructions stored therein, the plurality of instructions comprising:

instructions for distributing a first ice-filled bag within an internal region defined by a temperature-controlled storage unit, comprising;

instructions for disposing the first ice-filled bag in a first basket of a first kicker assembly;

instructions for searching for a first available space in the internal region in which to dispose the first ice-filled bag; and

instructions for disposing the first ice-filled bag in the first available space in the internal region, comprising;

instructions for discharging the first ice-filled bag from the first kicker assembly;

instructions for determining whether the temperature-controlled storage unit is full of bags filled with ice after distributing the first ice-filled bag within the internal region defined by the temperature-controlled storage unit;

instructions for if the temperature-controlled storage unit is not full of bags filled with ice after distributing the first ice-filled bag within the internal region defined by the temperature-controlled storage unit, then;

(a) filling another bag with ice to thereby produce another ice-filled bag;

(b) distributing the another ice-filled bag within the internal region defined by the temperature-controlled storage unit; and

(c) if the temperature-controlled storage unit is not full of bags filled with ice after distributing the another ice-filled bag within the internal region defined by the temperature-controlled storage unit, then repeating steps (a) and (b) until the temperature-controlled storage unit is full of bags filled with ice;

instructions for making the ice;

and

instructions for before distributing the first ice-filled bag within the internal region defined by the temperature-controlled storage unit, filling a first bag with the ice to thereby produce the first ice-filled bag, comprising;

instructions for measuring a first amount of the ice;

instructions for disposing the first amount of the ice in the first bag;

instructions for if the first bag in which the first amount of the ice is disposed is not filled with ice, then;

(d) measuring another amount of the ice;

(e) disposing the another measured amount of the ice in the first bag in which the first amount of ice is disposed; and

(f) if the first bag in which the first and another amounts of ice are disposed is not filled with ice, then repeating steps (d) and (e) until the first bag is filled with ice to thereby produce the first ice-filled bag.