SYSTEM AND METHOD FOR DISTRIBUTING AND STACKING BAGS OF ICE

• US 20110185749A1
• Filed: 10/28/2010
• Published: 08/04/2011
• Est. Priority Date: 02/02/2010
• 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 8,739,557 B2
• Time in Patent Office: Days
• US Class Current: 62/60
• CPC Class Codes: B65B 1/06 by gravity flow
• CPC Class Codes: B65B 43/123 Feeding flat bags connected to form a series or chain
• CPC Class Codes: B65B 43/267 Opening of bags interconnected in a web
• CPC Class Codes: B65B 43/34 by internal pressure
• CPC Class Codes: B65B 51/146 Closing bags
• CPC Class Codes: B65B 61/06 by cutting
• CPC Class Codes: B65B 63/08 for heating or cooling articles or materials to facilitate packaging
• CPC Class Codes: F25C 5/18 Storing ice
• CPC Class Codes: F25C 5/20 Distributing ice

Abstract

A system and method according to which ice is automatically disposed in respective bags and the bags of ice are distributed and stacked within a temperature-controlled storage unit, such as an ice merchandiser.

Claims

1. A method comprising:

providing a temperature-controlled storage unit, the temperature-controlled storage unit defining a region, the region comprising a plurality of disposal zones, each disposal zone defining a stacking level;

selecting a disposal zone from the plurality of disposal zones, wherein the stacking level of the selected disposal zone is equal to or lower than the respective stacking levels of the other disposal zones in the plurality of disposal zones; and

disposing an ice-filled bag in the selected disposal zone.

2. The method of claim 1, wherein selecting the disposal zone from the plurality of disposal zones comprises:

determining the stacking level of each of the disposal zones in the plurality of disposal zones; and

determining the lowest stacking level of the respective stacking levels of the disposal zones in the plurality of disposal zones, wherein the lowest stacking level is generally equal to the stacking level of the selected disposal zone.

3. The method of claim 2, wherein determining the stacking level of each of the disposal zones in the plurality of disposal zones comprises:

measuring the respective stacking level of each of the disposal zones using at least one sensor.

4. The method of claim 3, wherein measuring the respective stacking level of each of the disposal zones using the at least one sensor comprises:

moving the at least one sensor across the disposal zone while the at least one sensor is positioned above the disposal zone; and

taking a plurality of stacking level measurements using the at least one sensor during moving the at least one sensor across the disposal zone.

5. The method of claim 1, further comprising:

before disposing the ice-filled bag in the selected disposal zone, filling a bag with a measured amount of ice to thereby produce the ice-filled bag, comprising;

at least partially disposing the bag in a basket; and

filling the bag with the measured amount of ice while the bag is at least partially disposed in the basket;

wherein disposing the ice-filled bag in the selected disposal zone comprises;

moving the basket, and thus the ice-filled bag, along a first axis to a position that is generally aligned with the selected disposal zone along the first axis; and

rotating the basket about a second axis to thereby discharge the ice-filled bag from the basket and dispose the ice-filled bag in the selected disposal zone, the second axis being coaxial with, or generally parallel to, the first axis.

6. The method of claim 5, wherein the temperature-controlled storage unit comprises at least one door movable between an open position in which access to the region is permitted, and a closed position;

wherein the ice-filled bag has a length and a width; and

wherein, in response to the rotation of the basket about the second axis and the resulting disposal of the ice-filled bag in the selected disposal zone, the ice-filled bag is positioned so that the length of the ice-filled bag is generally perpendicular to the door when the door is in the closed position.

7. The method of claim 5, further comprising:

rotating the basket, and thus the ice-filled bag, about a third axis that is generally perpendicular to each of the first and second axes, wherein the basket is rotated about the third axis after the bag is filled with ice but before the basket is rotated about the second axis.

8. The method of claim 1, further comprising:

determining whether the region is full of ice-filled bags; and

if the region is not full of ice-filled bags, then;

selecting another disposal zone from the plurality of disposal zones, wherein the stacking level of the another selected disposal zone is equal to or lower than the respective stacking levels of the other disposal zones in the plurality of disposal zones; and

disposing another ice-filled bag in the another selected disposal zone.

9. The method of claim 8, wherein determining whether the region is full of ice-filled bags comprises:

determining the degree to which the region is filled with ice-filled bags; and

determining whether the degree to which the region is filled with ice-filled bags is equal to or greater than a predetermined percentage.

10. The method of claim 1, further comprising:

determining the degree to which the region is filled with ice-filled bags.

11. The method of claim 10, wherein the degree to which the region is filled with ice-filled bags is determined using at least a computer, the computer being operably coupled to the temperature-controlled storage unit;

and

wherein the method further comprises;

transmitting data from the computer to a remote user device via a network, the data corresponding to the degree to which the region is filled with ice-filled bags, wherein the remote user device is positioned at a location that is remote from the temperature-controlled storage unit.

12. The method of claim 11, further comprising:

transmitting from the remote user device to the computer via the network a request to determine the degree to which the region is filled with ice-filled bags;

wherein the degree to which the region is filled with ice-filled bags is determined in response to the transmitted request.

13. The method of claim 10, wherein determining the degree to which the region is filled with ice-filled bags comprises:

measuring the respective stacking level of each of the disposal zones, comprising;

moving at least one sensor across the disposal zone while the at least one sensor is positioned above the disposal zone; and

taking a plurality of stacking level measurements using the at least one sensor during moving the at least one sensor across the disposal zone.

14. The method of claim 1, wherein the storage unit comprises front and back inside walls spaced in a parallel relation;

wherein the ice-filled bag has a length and a width; and

wherein, in response to disposing the ice-filled bag in the selected disposal zone, the ice-filled bag is positioned in the selected disposal zone so that;

the length is generally perpendicular to each of the front and back inside walls; and

the width is generally parallel to each of the front and back inside walls.

15. A method comprising:

providing a basket and an ice-filled bag initially disposed therein;

providing a temperature-controlled storage unit, the temperature-controlled storage unit defining a region, the region comprising a plurality of disposal zones; and

disposing the ice-filled bag in one of the disposal zones, comprising;

rotating the basket, and thus the ice-filled bag disposed therein, about a first axis;

moving the basket, and thus the ice-filled bag disposed therein, along a second axis to a position that is generally aligned with the one disposal zone along the second axis, the second axis being generally perpendicular to the first axis; and

rotating the basket about a third axis, the third axis being generally perpendicular to the first axis and coaxial with, or generally parallel to, the second axis;

wherein, in response to the rotation of the basket about the third axis, the ice-filled bag is discharged from the basket and disposed in the one of the disposal zones.

16. The method of claim 15, wherein the temperature-controlled storage unit comprises at least one door movable between an open position in which access to the region is permitted, and a closed position;

wherein the ice-filled bag has a length and a width; and

wherein, in response to the rotation of the basket about the third axis and the resulting disposal of the ice-filled bag in the one of the disposal zones, the ice-filled bag is positioned so that;

the width of the ice-filled bag is generally parallel to the door when the door is in the closed position, and

the length of the ice-filled bag is generally perpendicular to the door when the door is in the closed position.

17. The method of claim 16, wherein, when the ice-filled bag is initially disposed in the basket:

the width of the ice-filled bag is generally perpendicular to the door when the door is in the closed position, and

the length of the ice-filled bag is generally parallel to the door when the door is in the closed position; and

wherein, in response to the rotation of the basket, and thus the ice-filled bag disposed therein, about the first axis;

the width of the ice-filled bag is generally parallel to the door when the door is in the closed position; and

the length of the ice-filled bag is generally parallel to the door when the door is in the closed position.

18. The method of claim 15, wherein each of the disposal zones defines a stacking level;

and

wherein the method further comprises selecting the one of the disposal zones, comprising;

determining the stacking level of each of the disposal zones in the plurality of disposal zones; and

determining the lowest stacking level of the respective stacking levels of the disposal zones in the plurality of disposal zones, wherein the lowest stacking level is generally equal to the stacking level of the one of the disposal zones.

19. An apparatus comprising:

a temperature-controlled storage unit, the temperature-controlled storage unit defining a region in which a plurality of ice-filled bags are adapted to be stored; and

a basket in which each of the ice-filled bags is adapted to be disposed before being stored in the region;

wherein the basket is movably coupled to the storage unit so that at least a portion of the basket is permitted to move within the region along a first axis;

wherein the basket is rotatable, about a second axis, between a first rotational position and a second rotational position, the second axis being generally perpendicular to the first axis; and

wherein the basket is rotatable about a third axis, the third axis being;

generally perpendicular to the first axis when the basket is in the first rotational position; and

coaxial with, or generally parallel to, the first axis when the basket is in the second rotational position.

20. The apparatus of claim 19, further comprising:

a first motor coupled to the basket and configured to rotate the basket about the second axis; and

a second motor coupled to the basket and configured to rotate the basket about the third axis.

21. The apparatus of claim 20, further comprising:

a ring bearing, the ring bearing comprising a first ring and a second ring coupled thereto and circumferentially extending thereabout, wherein the ring bearing is configured to permit relative rotation between the first and second rings and about the second axis;

wherein the first and second motors are coupled to one of the first and second rings; and

wherein the basket, the first and second motors, and the one of the first and second rings are rotatable, about the second axis and relative to the other of the first and second rings.

22. The apparatus of claim 21, further comprising:

a first sensor coupled to the one of the first and second rings so that the first sensor is positioned at a first location; and

a second sensor coupled to the one of the first and second rings so that the second sensor is positioned at a second location that is generally diametrically opposite the first location;

wherein the basket, the first and second motors, the first and second sensors, and the one of the first and second rings are rotatable, about the second axis and relative to the other of the first and second rings.

23. The apparatus of claim 22, further comprising:

a carriage to which the other of the first and second rings is coupled;

wherein the basket, the first and second motors, the first and second sensors, and the one of the first and second rings are rotatable, about the second axis and relative to the carriage and the other of the first and second rings; and

wherein the carriage is movably coupled to the storage unit to thereby movably couple the basket to the storage unit.

24. The apparatus of claim 19, further comprising the plurality of ice-filled bags, each of the ice-filled bags having a length and a width;

wherein the region comprises a plurality of disposal zones in which the ice-filled bags are stacked, each disposal zone defining a stacking level;

wherein the temperature-controlled storage unit comprises at least one door movable between an open position in which access to the region is permitted, and a closed position;

wherein each of the ice-filled bags is stacked in one of the disposal zones in response to the rotation of the basket about the third axis when the basket is in the second rotational position, the ice-filled bag being stacked so that the length of the ice-filled bag is generally perpendicular to the door when the door is in the closed position.

25. The apparatus of claim 19, wherein the region comprises a plurality of disposal zones in which the ice-filled bags are adapted to be stacked, each disposal zone defining a stacking level;

and

wherein the apparatus further comprises;

a processor; and

a computer readable medium operably coupled to the processor, the computer readable medium comprising a plurality of instructions stored therein and executable by at least the processor, the plurality of instructions comprising;

instructions for determining the stacking level of each of the disposal zones in the plurality of disposal zones; and

instructions for determining the lowest stacking level of the respective stacking levels of the disposal zones in the plurality of disposal zones.

26. A method comprising:

providing a basket and an ice-filled bag initially disposed therein, the ice-filled bag having a length and a width;

providing a temperature-controlled storage unit, the storage unit comprising front and back inside walls spaced in a parallel relation, the storage unit defining a region, the region comprising a plurality of disposal zones; and

actuating the basket to dispose the ice-filled bag in one of the disposal zones so that;

the length is generally perpendicular to each of the front and back inside walls; and

the width is generally parallel to each of the front and back inside walls.

27. The method of claim 26, wherein actuating the basket to dispose the ice-filled bag in the one of the disposal zones comprises:

rotating the basket, and thus the ice-filled bag disposed therein, about a first axis;

moving the basket, and thus the ice-filled bag disposed therein, along a second axis to a position that is generally aligned with the one disposal zone along the second axis, the second axis being generally perpendicular to the first axis; and

rotating the basket about a third axis, the third axis being generally perpendicular to the first axis and coaxial with, or generally parallel to, the second axis;

wherein, in response to the rotation of the basket about the third axis, the ice-filled bag is discharged from the basket and disposed in the one of the disposal zones.