U.S. patent application number 16/401768 was filed with the patent office on 2020-04-02 for thermal mass in a solid-production system.
The applicant listed for this patent is Electrolux Home Products, Inc.. Invention is credited to George Marshall Horne, Christopher Regan Hoy, Thomas Josefsson, Stephen Smith.
Application Number | 20200103153 16/401768 |
Document ID | / |
Family ID | 69947266 |
Filed Date | 2020-04-02 |
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United States Patent
Application |
20200103153 |
Kind Code |
A1 |
Smith; Stephen ; et
al. |
April 2, 2020 |
THERMAL MASS IN A SOLID-PRODUCTION SYSTEM
Abstract
A solid-production system for producing a solid on demand is
disclosed herein. In some aspects, the solid-production system
includes a cooling block arranged to interact with one or more
fluid molds to reduce a first temperature of a fluid dispensed in
each of the one or more fluid molds to a second temperature, the
second temperature being lower than the first temperature, to
solidify the fluid in each of the one or more fluid molds; wherein
the cooling block has a thermal mass operable to absorb and store
thermal energy transferred by the fluid in each of the one or more
fluid molds so as to reduce the first temperature of the fluid to
the second temperature.
Inventors: |
Smith; Stephen; (Concord,
NC) ; Josefsson; Thomas; (Concord, NC) ; Hoy;
Christopher Regan; (Charlotte, NC) ; Horne; George
Marshall; (Kannapolis, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Electrolux Home Products, Inc. |
Charlotte |
NC |
US |
|
|
Family ID: |
69947266 |
Appl. No.: |
16/401768 |
Filed: |
May 2, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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62738143 |
Sep 28, 2018 |
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62738277 |
Sep 28, 2018 |
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62738207 |
Sep 28, 2018 |
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62738283 |
Sep 28, 2018 |
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62738231 |
Sep 28, 2018 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F25C 1/246 20130101;
F25C 1/12 20130101; F25C 2400/06 20130101; F25C 1/22 20130101; F25C
1/24 20130101; F25C 1/10 20130101; F25C 2700/00 20130101; F25C
2305/022 20130101; F25C 1/04 20130101; F25C 5/182 20130101; F25C
1/25 20180101; F25C 5/22 20180101; F25C 2400/04 20130101; F25C
2400/10 20130101; F25C 2600/04 20130101 |
International
Class: |
F25C 1/10 20060101
F25C001/10; F25C 1/25 20060101 F25C001/25 |
Claims
1. A solid-production system comprising: a cooling block arranged
to interact with one or more fluid molds to reduce a first
temperature of a fluid dispensed in each of the one or more fluid
molds to a second temperature, the second temperature being lower
than the first temperature, to solidify the fluid in each of the
one or more fluid molds; wherein the cooling block has a thermal
mass operable to absorb and store thermal energy transferred by the
fluid in each of the one or more fluid molds so as to reduce the
first temperature of the fluid to the second temperature.
2. The solid-production system of claim 1, further comprising a
pressure plate arranged to urge the one or more fluid molds into
interaction with the cooling block, the pressure plate being
arrangeable in an initial position adjacent to a top surface of the
fluid in each of the one or more fluid molds so as to urge the one
or more fluid molds into interaction with the cooling block in
order to reduce the first temperature of the fluid in each of the
one or more fluid molds to the second temperature, and being
arrangeable in a second position in spaced apart relation from the
top surface of the fluid in each of the one or more fluid molds so
as not to urge the one or more fluid molds into interaction with
the cooling block.
3. The solid-production system of claim 2, further comprising one
or more actuation mechanisms arrangeable to bias the pressure plate
into the initial position adjacent to the top surface of the fluid
in each of the one or more fluid molds, and arrangeable to bias the
pressure plate into the second position in spaced apart relation
from the top surface of the fluid in each of the one or more fluid
molds.
4. The solid-production system of claim 3, wherein the one or more
actuation mechanisms comprise a biasing member arranged adjacent to
a top surface of the pressure plate to exert a normal force on the
top surface of the pressure plate so as to bias the pressure plate
into the initial position adjacent to the top surface of the fluid
in each of the one or more fluid molds.
5. The solid-production system of claim 4, wherein the one or more
actuation mechanisms further comprise a sliding member, wherein the
sliding member is slidingly engaged with the pressure plate and is
movable in a reverse machine direction to exert an opposing normal
force against the normal force exerted on the top surface of the
pressure plate by the biasing member, the opposing normal force
being greater than the normal force exerted by the biasing member,
so as to bias the pressure plate into the second position in spaced
apart relation from the top surface of the fluid in each of the one
or more fluid molds
6. The solid-production system of claim 5, wherein the one or more
actuation mechanisms further comprise a motor and a reciprocating
shaft engaged with the sliding member, wherein actuation of the
motor drives the reciprocating shaft to reciprocatingly move the
sliding member in a machine direction and the reverse machine
direction.
7. The solid-production system of claim 6, further comprising a
control mechanism comprising a hardware processor and at least one
memory, the control mechanism interfacing with and being operable
to actuate the motor.
8. The solid-production system of claim 1, further comprising a
conveying mechanism arranged to convey the one or more fluid molds
in a machine direction through the solid-production system.
9. The solid-production system of claim 8, wherein the conveying
mechanism is arranged to convey the one or more fluid molds in the
machine direction through a cooling region of the cooling block, so
that in the cooling region, each of the one or more fluid molds is
urged into interaction with the cooling block.
10. The solid-production system of claim 9, wherein the fluid in
each of the one or more fluid molds entering the cooling region is
at the first temperature and the fluid in each of the one or more
fluid molds exiting the cooling region is reduced to the second
temperature and solidified.
11. The solid-production system of claim 1, wherein the cooling
block comprises at least one tube, extending laterally between a
top surface and a bottom surface of the cooling block in a pattern,
and arranged to have a cooling material flowed therethrough.
12. The solid-production system of claim 11, wherein the at least
one tube extends in a serpentine pattern along and within the
cooling block, the serpentine pattern extending laterally within a
plane of the cooling block.
13. The solid-production system of claim 11, wherein the cooling
block defines longitudinally-extending channels extending parallel
to a longitudinal axis of the cooling block, each of the
longitudinally-extending channels being arranged to receive one of
the at least one tube, each tube being arranged in a coiled pattern
extending along a length of the corresponding
longitudinally-extending channels.
14. The solid-production system of claim 1, wherein a material of
the thermal mass is aluminum.
15. The solid-production system of claim 1, further comprising a
fluid-dispensing mechanism arranged adjacent to the one or more
fluid molds to dispense the fluid at the first temperature into
each of the one or more fluid molds when the fluid molds are in a
dispensing position relative to the fluid-dispensing mechanism.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional
Application No. 62/738,143, filed Sep. 28, 2018 and entitled,
"Utilizing Thermal Mass in a Solid-Production System", U.S.
Provisional Application No. 62/738,277, filed Sep. 28, 2018 and
entitled "Design of Fluid Molds in a Solid-Production System", U.S.
Provisional Application No. 62/738,207, filed Sep. 28, 2018 and
entitled "Fluid Dispense System for a Solid-Production System",
U.S. Provisional Application No. 62/738,283, filed Sep. 28, 2018
and entitled "Software Logic in a Solid-Production System", and
U.S. Provisional Application No. 62/738,231, filed Sep. 28, 2018
and entitled, "Solid Detection System for a Solid-Production
System", each of these applications being incorporated by reference
herein.
TECHNOLOGICAL FIELD
[0002] The present disclosure relates generally to solid production
such as ice production and, in particular, to a thermal mass in a
solid-production system for producing a solid on demand.
BACKGROUND
[0003] Conventional refrigeration appliances, such as domestic
refrigerators, typically have both a fresh food compartment and a
freezer compartment or section. Such conventional refrigerators are
often provided with a unit for making ice pieces, commonly referred
to as "ice cubes" despite the non-cubical shape of many such ice
pieces. These ice making units normally are located in the freezer
compartments of the refrigerators and manufacture ice by
convection, e.g., by circulating cold air over water in an ice tray
to freeze the water into ice pieces or by conduction e.g., transfer
thermal energy through a thin conductive material when the
temperature of the water is hotter than the thin conductive
material. Storage bins for storing the frozen ice pieces are also
often provided adjacent to the ice making units. The ice pieces can
be dispensed from the storage bins through a dispensing port in the
door that closes the freezer to the ambient air. The dispensing of
the ice usually occurs by means of an ice delivery mechanism that
extends between the storage bin and the dispensing port in the
freezer compartment door.
[0004] However, conventional ice making units that employ
conduction using a thin conductive material, convection, or another
similar ice making modality tend to be inefficient at reducing a
temperature of water to form ice pieces. This is because, in part,
compressors utilized in conventional ice making units are generally
inefficient due to the economic limitations of compressor sizing.
For example, a very large compressor may increase the rate of ice
production by reducing a temperature of water for form ice pieces
quicker than a smaller compressor, but may be extremely cost and
energy inefficient as a whole. As such, the ice production rate in
conventional ice making units may be inefficient due to at least
compressor sizing limitations as well as the heat transfer delivery
method (e.g., conduction or convection).
[0005] Therefore, a need exists for a system for producing ice
pieces that utilizes a heat transfer coefficient that is higher
than heat transfer coefficients used in typical ice making
modalities, so as to be more efficient and adaptable to demands of
users.
SUMMARY
[0006] Example implementations of the present disclosure are
directed to a thermal mass in a solid-production system for
producing a formed solid, for example, ice. The present disclosure
includes, without limitation, the following example
implementations.
[0007] Some example implementations provide a solid-production
system, comprising a cooling block arranged to interact with one or
more fluid molds to reduce a first temperature of a fluid dispensed
in each of the one or more fluid molds to a second temperature, the
second temperature being lower than the first temperature, to
solidify the fluid in each of the one or more fluid molds; wherein
the cooling block has a thermal mass operable to absorb and store
thermal energy transferred by the fluid in each of the one or more
fluid molds so as to reduce the first temperature of the fluid to
the second temperature.
[0008] In some example implementations of the solid-production
system of any preceding example implementation, or any combination
of any preceding example implementations, the solid-production
system further comprises a pressure plate arranged to urge the one
or more fluid molds into interaction with the cooling block, the
pressure plate being arrangeable in an initial position adjacent to
a top surface of the fluid in each of the one or more fluid molds
so as to urge the one or more fluid molds into interaction with the
cooling block in order to reduce the first temperature of the fluid
in each of the one or more fluid molds to the second temperature,
and being arrangeable in a second position in spaced apart relation
from the top surface of the fluid in each of the one or more fluid
molds so as not to urge the one or more fluid molds into
interaction with the cooling block.
[0009] In some example implementations of the solid-production
system of any preceding example implementation, or any combination
of any preceding example implementations, the solid-production
system further comprises one or more actuation mechanisms
arrangeable to bias the pressure plate into the initial position
adjacent to the top surface of the fluid in each of the one or more
fluid molds, and arrangeable to bias the pressure plate into the
second position in spaced apart relation from the top surface of
the fluid in each of the one or more fluid molds.
[0010] In some example implementations of the solid-production
system of any preceding example implementation, or any combination
of any preceding example implementations, the one or more actuation
mechanisms comprise a biasing member arranged adjacent to a top
surface of the pressure plate to exert a normal force on the top
surface of the pressure plate so as to bias the pressure plate into
the initial position adjacent to the top surface of the fluid in
each of the one or more fluid molds.
[0011] In some example implementations of the solid-production
system of any preceding example implementation, or any combination
of any preceding example implementations, the one or more actuation
mechanisms further comprise a sliding member, wherein the sliding
member is slidingly engaged with the pressure plate and is movable
in a reverse machine direction to exert an opposing normal force
against the normal force exerted on the top surface of the pressure
plate by the biasing member, the opposing normal force being
greater than the normal force exerted by the biasing member, so as
to bias the pressure plate into the second position in spaced apart
relation from the top surface of the fluid in each of the one or
more fluid molds
[0012] In some example implementations of the solid-production
system of any preceding example implementation, or any combination
of any preceding example implementations, the one or more actuation
mechanisms further comprise a motor and a reciprocating shaft
engaged with the sliding member, wherein actuation of the motor
drives the reciprocating shaft to reciprocatingly move the sliding
member in a machine direction and the reverse machine
direction.
[0013] In some example implementations of the solid-production
system of any preceding example implementation, or any combination
of any preceding example implementations, the solid-production
system further comprises a control mechanism comprising a hardware
processor and at least one memory, the control mechanism
interfacing with and being operable to actuate the motor.
[0014] In some example implementations of the solid-production
system of any preceding example implementation, or any combination
of any preceding example implementations, the solid-production
system further comprises a conveying mechanism arranged to convey
the one or more fluid molds in a machine direction through the
solid-production system.
[0015] In some example implementations of the solid-production
system of any preceding example implementation, or any combination
of any preceding example implementations, the conveying mechanism
is arranged to convey the one or more fluid molds in the machine
direction through a cooling region of the cooling block, so that in
the cooling region, each of the one or more fluid molds is urged
into interaction with the cooling block.
[0016] In some example implementations of the solid-production
system of any preceding example implementation, or any combination
of any preceding example implementations, the fluid in each of the
one or more fluid molds entering the cooling region is at the first
temperature and the fluid in each of the one or more fluid molds
exiting the cooling region is reduced to the second temperature and
solidified.
[0017] In some example implementations of the solid-production
system of any preceding example implementation, or any combination
of any preceding example implementations, the cooling block
comprises at least one tube, extending laterally between a top
surface and a bottom surface of the cooling block in a pattern, and
arranged to have a cooling material flowed therethrough.
[0018] In some example implementations of the solid-production
system of any preceding example implementation, or any combination
of any preceding example implementations, the at least one tube
extends in a serpentine pattern along and within the cooling block,
the serpentine pattern extending laterally within a plane of the
cooling block.
[0019] In some example implementations of the solid-production
system of any preceding example implementation, or any combination
of any preceding example implementations, the cooling block defines
longitudinally-extending channels extending parallel to a
longitudinal axis of the cooling block, each of the
longitudinally-extending channels being arranged to receive one of
the at least one tube, each tube being arranged in a coiled pattern
extending along a length of the corresponding
longitudinally-extending channels.
[0020] In some example implementations of the solid-production
system of any preceding example implementation, or any combination
of any preceding example implementations, a material of the thermal
mass is aluminum.
[0021] In some example implementations of the solid-production
system of any preceding example implementation, or any combination
of any preceding example implementations, the solid-production
system further comprises a fluid-dispensing mechanism arranged
adjacent to the one or more fluid molds to dispense the fluid at
the first temperature into each of the one or more fluid molds when
the fluid molds are in a dispensing position relative to the
fluid-dispensing mechanism.
[0022] It will therefore be appreciated that the above Summary is
provided merely for purposes of summarizing some example
implementations so as to provide a basic understanding of some
aspects of the disclosure. As such, it will be appreciated that the
above described example implementations are merely examples of some
implementations and should not be construed to narrow the scope or
spirit of the disclosure in any way. It will be appreciated that
the scope of the disclosure encompasses many potential
implementations, some of which will be further described below, in
addition to those here summarized. Further, other aspects and
advantages of implementations disclosed herein will become apparent
from the following detailed description taken in conjunction with
the accompanying drawings which illustrate, by way of example, the
principles of the described implementations.
BRIEF DESCRIPTION OF THE DRAWING(S)
[0023] Having thus described the disclosure in general terms,
reference will now be made to the accompanying drawings, which are
not necessarily drawn to scale, and wherein:
[0024] FIG. 1 illustrates a schematic of a solid-production system
according to example implementations of the present disclosure;
[0025] FIG. 2 illustrates a schematic of processing circuitry
configured to implement a master state machine and slave state
machines for controlling a solid-production system according to
example implementations of the present disclosure;
[0026] FIG. 3 illustrates a schematic of a conveying mechanism
slave state machine according to example implementations of the
present disclosure;
[0027] FIGS. 4A-4K illustrate different states and sub-states of a
conveying mechanism slave state machine according to example
implementations of the present disclosure;
[0028] FIG. 5 illustrates a schematic of states of fluid molds
according to example implementations of the present disclosure;
[0029] FIGS. 6A and 6B illustrate states and sub-states of a
conveying mechanism slave state machine according to example
implementations of the present disclosure;
[0030] FIG. 7 illustrates a fluid-dispensing mechanism slave state
machine according to example implementations of the present
disclosure;
[0031] FIG. 8 illustrates a pressure plate slave state machine
according to example implementations of the present disclosure;
[0032] FIG. 9 illustrates a solid-dispensing mechanism slave state
machine according to example implementations of the present
disclosure;
[0033] FIG. 10 illustrates an apparatus according to some example
implementations;
[0034] FIG. 11 illustrates a fluid-dispensing mechanism according
to example implementations of the present disclosure;
[0035] FIG. 12 illustrates a solid-production system according to
example implementations of the present disclosure;
[0036] FIG. 13 illustrates a top plan view of a cooling block with
flow tubes arranged in a serpentine pattern according to one
example implementation of the present disclosure;
[0037] FIG. 14 illustrates a front perspective view of a cooling
block with flow tubes arranged in a coiled pattern according to
another example implementation of the present disclosure;
[0038] FIG. 15 illustrates a computer-generated model of an
optimized cooling block according to example implementations of the
present disclosure;
[0039] FIGS. 16A and 16B illustrate two different views of a
computer-generated model of an optimized cooling block according to
example implementations of the present disclosure;
[0040] FIGS. 17A and 17B illustrate two different views of a
computer-generated model of a solid according to example
implementations of the present disclosure;
[0041] FIG. 18 illustrates a solid-detection mechanism according to
example implementations of the present disclosure;
[0042] FIGS. 19A and 19B illustrate two different views of a
solid-production system with an indication of a location of a
solid-detection mechanism according to example implementations of
the present disclosure;
[0043] FIGS. 20A and 20B illustrate schematics of temperature
measurement areas as detected by a solid-detection mechanism
according to example implementations of the present disclosure;
[0044] FIG. 21 illustrates a graphical representation of a
temperature profile of a fluid/solid over time according to example
implementations of the present disclosure;
[0045] FIG. 22 illustrates different designs of fluid molds
according to example implementations of the present disclosure;
[0046] FIG. 23 illustrates different views of a fluid mold
according to example implementations of the present disclosure;
[0047] FIG. 24 illustrates a solid-production system with an
indication of a location of a sensing mechanism of an example
solid-detection mechanism according to example implementations of
the present disclosure;
[0048] FIGS. 25A and 25B illustrate different arrangements of
sensors on chute adapters for a solid-dispensing mechanism
according to example implementations of the present disclosure;
[0049] FIG. 26 illustrates a schematic of a solid-production system
with an example solid ejector according to example implementations
of the present disclosure; and
[0050] FIG. 27 illustrates different operational modes of a solid
ejector according to example implementations of the present
disclosure.
DETAILED DESCRIPTION
[0051] Some implementations of the present disclosure will now be
described more fully hereinafter with reference to the accompanying
figures, in which some, but not all implementations of the
disclosure are shown. Indeed, various implementations of the
disclosure may be embodied in many different forms and should not
be construed as limited to the implementations set forth herein;
rather, these example implementations are provided so that this
disclosure will be thorough and complete, and will fully convey the
scope of the disclosure to those skilled in the art. For example,
unless otherwise indicated, reference to something as being a
first, second or the like should not be construed to imply a
particular order. Also, something may be described as being above
something else (unless otherwise indicated) may instead be below,
and vice versa; and similarly, something described as being to the
left of something else may instead be to the right, and vice versa.
Further, for example, reference may be made herein to quantitative
measures, values, relationships or the like. Unless otherwise
stated, any one or more if not all of these may be absolute or
approximate to account for acceptable variations that may occur,
such as those due to engineering tolerances or the like. Like
reference numerals refer to like elements throughout.
[0052] Example implementations of the present disclosure are
generally directed to solid production, such as ice production, and
may be utilized in any of a number of different types of
applications. Some example applications include commercial food
storage and processing, chemical manufacturing, concrete mixing and
curing, packaged ice production, and the like. Other example
applications include household appliances such as refrigerators,
freezers, or the like. As such, some example implementations of the
present disclosure may be suitable for use in a household
refrigeration system, where ice is produced on demand by the system
upon a request for ice by a user.
[0053] More particularly, an appliance, such as for example, a
household refrigeration system, may include the appropriate
hardware and/or software to allow a user to interact with the
appliance either directly on the appliance or remotely by way of
network-connectivity between the appliance and a user device.
Examples of appliances provisioned with network-connectivity are
provided in U.S. Patent Application Pub. No. 2016/0315810 to
Francescangeli, which is incorporated by reference herein in its
entirety. For example, the user may be able to control the
appliance, monitor operation of the appliance, initiate a service
request for the appliance, and/or perform other management tasks
via a service platform integrated with the appliance or on the user
device.
[0054] In some example implementations, the user may be able to
interact with the service platform in order to control, monitor,
initiate a service request, and/or perform other management tasks
with regard to a solid-production system of the appliance. For
example, the user may be able to request dispense of one or more
solids (e.g., ice pieces), which may be produced and dispensed
based on this request. The service platform may also provide the
user with the capability to tailor the solid production to his/her
needs. For example, the user may be able to monitor a rate of solid
production to determine how many solids are available for dispense
(e.g., number of ice pieces formed) and/or when more solids will be
available for dispense. If the user wishes to increase the speed of
solid production, the service platform may further allow the user
to modify or choose a volume of the solid (i.e., size of the solid)
produced, and thus, modify the speed of solid production; where a
solidification time of the solid is dependent on the desired volume
of the solid. Therefore, the solid-production system disclosed
herein advantageously allows a user to control a solid-production
rate to increase the rate of solid production as desired.
[0055] According to some example implementations, FIG. 1
illustrates a solid-production system 100, which may be used to
produce a solid, such as ice, from a fluid, such as water. Other
solids produced from other fluids may also be produced using the
solid-production system as described herein. As shown in FIG. 1,
the solid-production system may include a fluid-dispensing
mechanism 101, a cooling block associated with a pressure plate
102, a solid ejector 103, and a solid-dispensing mechanism 104. The
solid-production system illustrated in FIG. 1 also may include a
plurality of fluid molds M0-M29 that can move in a machine
direction through a conveying mechanism 105. The fluid molds may
comprise a geometry (e.g., size, shape, dimensions, material, etc.)
that advantageously promotes a rate of solid formation in a manner
that may be over an order of magnitude larger than conventional
solid-production systems. The generated solid is dispensable or
provided to a user at the solid-dispensing mechanism 104. An
example operation of the solid-production system 100 is described
in further detail below.
[0056] The conveying mechanism 105 may be configured to
individually index a fluid mold of the plurality of fluid molds
M0-M29 into an initial physical position P0 aligned with the
fluid-dispensing mechanism 101. The fluid-dispensing apparatus may
be configured to dispense a quantity of fluid, such as water, into
the fluid mold M0 upon detection of the fluid mold in the
fluid-dispensing position. The fluid-dispensing mechanism may be
configured with a sensor to determine a fill level of the fluid
dispensed from the fluid-dispensing apparatus into the fluid mold
so as to determine whether the fluid mold is filled with a
pre-determined threshold quantity of fluid.
[0057] After the fluid-dispensing mechanism 101 determines that a
fluid mold, such as the fluid mold M0, is filled with the
pre-determined threshold quantity of fluid, the conveying mechanism
105 may be configured to index the fluid mold out of the
fluid-dispensing position P0 and index a subsequent fluid mold,
such as fluid mold M29, into the fluid-dispensing position for
receipt of the fluid by the fluid-dispensing mechanism. The fluid
mold that is filled with the pre-determined threshold quantity of
fluid may then be moved by the conveying mechanism in the machine
direction from the fluid-dispensing mechanism to the cooling block
102. For example, the fluid mold M0 can be indexed from the
fluid-dispensing position P0 to a subsequent physical position P1
in the cooling block by the conveying mechanism.
[0058] In one example implementation, the solid-production system
100 includes a pressure plate. The pressure plate may be arranged
relative to a top surface of the fluid in the fluid molds in a
cooling region (i.e., P1-P10). The pressure plate may be
arrangeable into an initial position adjacent to a top surface of
the fluid in the fluid molds so as to urge the fluid molds into
interaction with the cooling block. The pressure plate may also be
arrangeable in a second position in spaced apart relation relative
to a top surface of the fluid in the fluid molds so as not to urge
the fluid molds into interaction with the cooling block. When the
pressure plate is in the initial position and the fluid molds are
urged into interaction with the cooling block, the cooling block
may reduce a first temperature of the fluid in the fluid molds to a
second temperature so as to solidify the fluid in the fluid molds
and form a solid.
[0059] The cooling block 102 may be configured to cool the quantity
of fluid dispensed in the fluid molds as they are indexed or are
moved therethrough by the conveying mechanism 105 in order to form
a solid in the fluid molds. In some example implementations, the
solid-production system includes one or more tracks that may be
received through the fluid mold, such that the cooling block may
simultaneously or substantially simultaneously solidify fluid in
fluid molds on multiple tracks. For example, there may be a single
track with 30 fluid molds, with a cooling region in the cooling
block being sized to accommodate ten fluid molds therein (e.g.,
fluid molds M1-M10 as shown in FIG. 1. The solidification time,
which is a time it takes a fluid mold to reduce in temperature from
the first temperature to the second temperature and thereby
solidify may be determined by several characteristics including,
but not limited to, a geometry of the fluid molds, a threshold fill
level of the fluid in the fluid molds, a length of the cooling
block, a temperature of a material of the cooling block, a thermal
conductivity of a material of the fluid molds, a first or initial
temperature of the fluid in the fluid mold, etc.
[0060] A fluid mold, such as the fluid mold M11, may be indexed or
transmitted through the cooling region of the cooling block and
arrive at a position P11 at the solid ejector 103. At position P11,
the solid ejector may include a sensor that may be configured to
detect whether a solid, such as ice, has formed in the fluid mold.
For example, the sensor at the solid ejector may be configured to
detect whether or not an entirety or a substantial entirety of a
volume of fluid in the fluid mold has been cooled to a temperature
at which it has formed a solid. After the sensor at the solid
ejector determines that fluid in the fluid mold has formed a solid,
the fluid mold can be loosened by the solid ejector. The solid
ejector may be configured to loosen the solid in the fluid mold
such that the bond between the solid and the fluid mold may be
broken. Optionally, the solid ejector or a secondary solid ejector
may be located at the solid-dispensing mechanism 104, proximate to
position P27 to loosen a solid in the fluid mold.
[0061] After the solid ejector 103 loosens the solid in the fluid
mold, the fluid mold with the loosened solid may be indexed using
the conveying mechanism 105 from the position P11 to subsequent
positions, such as, for example, positions P12-P28. When being
indexed by the conveying mechanism through positions P12-P28, each
fluid mold may include a housing or a cap so that the solid will
not be disturbed and potentially removed from an interior of the
fluid mold. In this way, when a fluid mold moves from the position
P11 to the position P28, although the fluid mold may be upside down
as shown in FIG. 1, the loosened solid may not fall out from the
interior of the fluid mold.
[0062] The solid-dispensing mechanism 104 may be configured to
dispense the solid from an interior of the fluid mold once the
fluid mold arrives at the position P28. The solid-dispensing
mechanism 104 may have an exit port positioned proximate to the
position P28. When a fluid mold, such as the fluid mold M28,
arrives at the position P28, the exit port may allow dispense of
the loosened and dispensed solid from the fluid mold. In some
example implementations, a sensor may be located proximate to the
position P28 to detect whether the solid is dispensed or provided
to the user through the exit port. After the solid in the fluid
mold is dispensed at the solid-dispensing mechanism, the empty
fluid mold may then be indexed from the position P28 to the
position P29 by the conveying mechanism 105.
[0063] In some example implementations, operation of the
solid-production system 100 is initiated when a user requests one
or more solids from a user interface. Upon receiving the user's
request, the exit port positioned proximate to the position P28 may
open to allow dispense of the requested number of solids from the
fluid mold to the user. As the requested number of solids is
dispensed by the solid-dispensing mechanism, the empty fluid molds
may be indexed from the position P28 to the position P29 by the
conveying mechanism 105, as described above.
[0064] FIG. 2 illustrates a schematic of processing circuitry 200
for a solid-production system configured to implement a master
state machine 201 and slave state machines 202, 203, 204, 205 for
respective ones of a conveying mechanism, a fluid-dispensing
mechanism, a pressure plate, and a solid-dispensing mechanism such
as the ones described above in FIG. 1. As shown, the master state
machine may control the operation of the solid-production system by
being configured to send commands to the slave state machines based
on states of the slave state machines. Likewise, the slave state
machines may control operation of the conveying mechanism, the
fluid-dispensing mechanism, the pressure plate, and the
solid-dispensing mechanism by being configured to execute the
commands to control respective ones of the conveying mechanism, the
fluid-dispensing mechanism, the pressure plate, and the
solid-dispensing mechanism.
[0065] In one example implementation, the master state machine 201
is configured to send first and second commands to the conveying
mechanism slave state machine 202 based on respectively first and
second states of the conveying mechanism slave state machine. The
conveying mechanism slave state machine may be arranged to control
the conveying mechanism (e.g., 105 in FIG. 1) including at least
one track arranged to engage and move a fluid mold through the
solid-production system, which includes at least a fluid-dispensing
mechanism, a pressure plate, a solid ejector, and a
solid-dispensing mechanism.
[0066] In this example implementation, the first state of the
conveying mechanism slave state machine 202 may be defined by the
conveying mechanism not moving the fluid mold through the
solid-production system, and the second state may be defined by the
conveying mechanism moving the fluid mold through the
solid-production system. As described herein, the first and second
states defined by the conveying mechanism are example states
thereof, and other states may be defined by the conveying
mechanism.
[0067] In some example implementations, the conveying mechanism
slave state machine 202 may receive the commands from the master
state machine 201 and may be configured to execute the first
command and cause the conveying mechanism to move the fluid mold
through the solid-production system; and execute the second command
and cause the conveying mechanism to stop movement of the fluid
mold through the solid-production system. As described herein, the
first and second commands defined by the conveying mechanism are
example commands, and other commands may be defined by the
conveying mechanism.
[0068] In some other example implementations, the master state
machine 201 may be configured to send first and second commands to
a fluid-dispensing mechanism slave state machine 203 based on
respectively first and second states of the fluid-dispensing
mechanism slave state machine. The fluid-dispensing mechanism slave
state machine may be arranged to control a fluid-dispensing
mechanism (e.g., 101 in FIG. 1) arranged to dispense the fluid to
the fluid mold. In this example implementation, the first state of
the fluid-dispensing mechanism slave state machine may be defined
by the fluid-dispensing mechanism dispensing the fluid to the fluid
mold. The second state of the fluid-dispensing mechanism slave
state machine may be defined by the fluid-dispensing mechanism not
dispensing the fluid to the fluid mold. As described herein, the
first and second states defined by the fluid-dispensing mechanism
are example states thereof, and other states may be defined by the
fluid-dispensing mechanism.
[0069] In some example implementations, the fluid-dispensing
mechanism slave state machine 203 may receive the commands from the
master state machine 201 and may be configured to execute the first
command to cause the fluid-dispensing mechanism to stop dispensing
the fluid to the fluid mold; and execute the second command to
cause the fluid-dispensing mechanism to initiate dispensing the
fluid to the fluid mold. As described herein, the first and second
commands defined by the fluid-dispensing mechanism are example
commands, and other commands may be defined by the fluid-dispensing
mechanism.
[0070] In some other example implementations, the master state
machine 201 may be configured to send first and second commands to
a pressure plate slave state machine 204 based on respectively
first and second states of the pressure plate slave state machine.
The pressure plate slave state machine may be arranged to control
interaction of the fluid molds with a cooling block (e.g., 102 in
FIG. 1). In this example implementation, the first state may be
defined by the pressure plate being arranged adjacent to a top
surface of the fluid in the fluid mold so as to urge the fluid mold
into interaction with the cooling block, and the second state may
be defined by the pressure plate being arranged in a spaced apart
relation from the top surface of the fluid mold so as not to urge
the fluid mold into interaction with the cooling block. As
described herein, the first and second states defined by the
pressure plate mechanism are example states thereof, and other
states may be defined by the pressure plate mechanism. For example,
a third state of the pressure plate slave state machine may define
the pressure plate being arranged in spaced apart relation from the
top surface of the fluid in the fluid molds, where the pressure
plate in the third state is spaced apart from the top surface of
the fluid molds a greater distance than the in the second state. As
described in further detail, the first state may correspond to an
initial or default position of the pressure plate, the second state
may correspond to a second position of the pressure plate, and the
third state may correspond to an ejection position of the pressure
plate.
[0071] In some example implementations, the pressure plate slave
state machine 204 may receive the commands from the master state
machine 201 and may be configured to execute the first command to
cause arrangement of the pressure plate into the spaced apart
relation from the top surface of the fluid in the fluid mold so as
not to urge the fluid mold into interaction with the cooling block;
and execute the second command to cause arrangement of the pressure
plate to be adjacent to the top surface of the fluid in the fluid
mold so as to urge the fluid mold into interaction with the cooling
block. As described herein, the first and second commands defined
by the pressure plate mechanism are example commands, and other
commands may be defined by the pressure plate mechanism. For
example, a third command, upon execution by the pressure plate
state slave machine, may cause arrangement of the pressure plate to
be in spaced apart relation from the top surface of the fluid in
the fluid mold, where the pressure plate upon execution of the
third command, is spaced apart from the top surface of the fluid
molds a greater distance than upon execution of the first
command.
[0072] In some other example implementations, the master state
machine 201 is configured to send first and second commands to a
solid-dispensing mechanism slave state machine 205 based on
respectively first and second states of the solid-dispensing
mechanism slave state machine. The solid-dispensing mechanism slave
state machine may be arranged to control a solid-dispensing
mechanism (e.g., 104 in FIG. 1) arranged to dispense the solid
previously loosened by a solid ejector (e.g., 103 in FIG. 1) to a
user through an exit port. In this example implementation, the
first state of the solid-dispensing mechanism slave state machine
may be defined by the solid-dispensing mechanism being arranged to
dispense the solid loosened by the solid ejector to the user
through the exit port. The second state of the fluid-dispensing
mechanism slave state machine may be defined by the
solid-dispensing mechanism being arranged so as to not dispense the
loosened solid. As described herein, the first and second states
defined by the solid-dispensing mechanism are example states
thereof, and other states may be defined by the solid-dispensing
mechanism.
[0073] In some example implementations, the solid-dispensing
mechanism slave state machine 205 may receive the commands from the
master state machine 201 and may be configured to execute the first
command to cause arrangement of the solid-dispensing mechanism so
as not to cause the solid-dispensing mechanism to dispense the
loosened solid, and execute the second command to cause arrangement
of the solid-dispensing mechanism so as to cause the
solid-dispensing mechanism to dispense the solid loosened by the
solid-dispensing mechanism to the user through the exit port. As
described herein, the first and second commands defined by the
solid-dispensing mechanism are example commands, and other commands
may be defined by the solid-dispensing mechanism.
[0074] In some example implementations, the master state machine
201 may be configured to detect variables associated with
respective ones of the states of the slave state machines (e.g.,
the conveying mechanism slave state machine 202, the
fluid-dispensing mechanism slave state machine 203, the pressure
plate slave state machine 204, and the solid-dispensing mechanism
slave state machine 205), and send the commands to the slave state
machines based thereon.
[0075] For example, the variables associated with the states of the
conveying mechanism slave state machine may include a number of
cycles that the conveying mechanism moves through the
solid-production system, an expiration of a time period associated
with a cycle of the number of cycles, detection and update of a
position of the fluid mold in the cycle, a temperature of the fluid
or the solid in the fluid mold, an emptiness of the fluid mold, and
an expiration of a time period associated with cooling the fluid in
the fluid mold to form the solid. Other variables associated with
the states of the conveying mechanism slave state machine are also
contemplated herein.
[0076] In another example, the variables associated with the states
of the fluid-dispensing mechanism slave state machine 203 may
include a fill level and a fill time of the fluid dispensed to the
fluid mold, an emptiness of the fluid mold, a detection of the
fluid mold in a fill or fluid-dispensing position aligned with the
fluid-dispensing mechanism, a volume of the solid in the fluid
mold, and a temperature of the fluid or the solid in the fluid mold
and an expiration of a time period associated with dispensing the
fluid to the fluid mold. Other variables associated with the states
of the fluid-dispensing slave state machine are further
contemplated.
[0077] In still another example, the variables associated with the
states of the pressure plate slave state machine 204 may include an
arrangement of the pressure plate from a top surface of the fluid
in the fluid mold, detection of the fluid mold in an ejection
position aligned with the solid ejector, an emptiness of the fluid
mold, a temperature of the fluid or the solid in the fluid mold,
and an arrangement of the solid ejector relative to the fluid mold
in the ejection position. Other variables associated with the
states of the pressure plate slave state machine are further
contemplated.
[0078] In a still further example, the variables associated with
the states of the solid-dispensing mechanism slave state machine
205 may include detection of the fluid mold in a solid-dispensing
position aligned with the solid-dispensing mechanism, an emptiness
of the fluid mold, a temperature of the fluid or the solid in the
fluid mold, a status of the exit port, expiration of a time period
associated with dispensing the solid from the fluid mold, and a
volume of the solid in the fluid mold. Other variables associated
with the states of the solid-dispensing slave state machine are
further contemplated.
[0079] With regard to the conveying mechanism slave state machine
202, the conveying mechanism slave state machine may receive
commands from the master state machine 201 for controlling one or
more tracks. Each of the tracks may be controlled in parallel so
that fluid molds on each of the tracks are incrementally moved or
indexed one position at a time. For example, in some
implementations, the conveying mechanism may comprise three tracks
having a single motor or three designated motors (i.e., one motor
per track). In some example implementations, the conveying
mechanism slave state machine may execute commands received from
the master state machine by actuating a main processor that may be
configured to control the track(s) via control of the associated
motors. For example, the main processor may be configured to
actuate the associated motors for controlling track speed by
implementing closed loop speed control.
[0080] In other example implementations, the conveying mechanism
slave state machine 202 may execute commands and/or subcommands
received from the master state machine 201 by actuating one or more
co-processors that may supplement the capabilities of the main
processor. For example, each co-processor may be associated with a
motor, so that each co-processor may be configured to actuate the
motor associated with each track in order to control track
directional movement upon receiving a pulse that may be generated
by pulse-width modulation (PWM) output from a general purpose input
output (GPIO) or another similar mechanism. In this example, each
motor may move the respective track only in one direction (e.g.,
the machine direction) and the associated co-processor may send a
feedback of one pulse when the track is moved successfully. The
co-processor may send two pulses as a negative acknowledgement
(NACK) if the tracks are not moved successfully by its respective
motor. Otherwise, each track may be jointly controlled by a single
motor actuated by the co-processor.
[0081] FIG. 3 illustrates a schematic of a conveying mechanism
slave state machine 300, which may be the same as or similar to the
conveying mechanism slave state machine 202 in FIG. 2, according to
example implementations of the present disclosure. The conveying
mechanism slave state machine in FIG. 3 may illustrate one example
implementation of the conveying mechanism slave state machine
described in FIG. 2, which receives commands and/or subcommands
from the master state machine based on respective states of the
conveying mechanism slave state machine. Execution of the commands
by the conveying mechanism slave state machine may be initiated by
the conveying mechanism slave state machine after receipt of the
commands from the master slave state machine.
[0082] For example, as shown in FIG. 3, when the pressure plate is
arranged in an initial position, i.e., arranged adjacent to a top
surface of a fluid mold as a result of a normal biasing force
exerted on a top surface of the pressure plate by a biasing
mechanism, such as a spring, a track door associated with a
solid-dispensing mechanism(e.g., 104 in FIG. 1) is closed, and a
temperature of a cooling block (e.g., 102 in FIG. 1) is less than a
temperature set point, then the conveying mechanism slave state
machine may be in a first state, where the track associated with
the conveying mechanism may not be moving through the
solid-production system. In the first state, the conveying
mechanism slave state machine may receive a first command that
initiates a series of subcommands from a master state machine, such
as master state machine 201 in FIG. 2, to cause the conveying
mechanism slave state machine to transition to a second state or
another state or sub-state. Likewise, where the conveying mechanism
slave state machine is in the second state, the conveying mechanism
slave state machine may receive a second command that initiates a
series of subcommands from a master state machine to cause the
conveying mechanism slave state machine to transition back to the
first state or another state or sub-state.
[0083] In some example implementations, subcommands may define
parameters of the first or second command sent by the master state
machine to the conveying mechanism slave state machine 300, such
that execution of the subcommands may be initiated by the conveying
mechanism slave state machine after receipt of the first or second
command from the master state machine. Completion of the first or
second command and/or subcommands may then result in the transition
of the conveying mechanism slave state machine between the various
states through a series of sub-states.
[0084] In particular, for example, the conveying mechanism slave
state machine 300 in the first state may receive the first command,
which may then initiate execution of a subcommand to measure and
read a temperature of the cooling block relative to a temperature
set point. For example, there may be one or more sensors located
proximate to the cooling block to measure the temperature of the
cooling block and transmit the measured temperature to the
conveying mechanism slave state machine. The temperature set point
may be a temperature that the cooling block has reached in order to
solidify the fluid in the fluid molds, i.e., reduce the first
temperature of the fluid to a second temperature.
[0085] If the temperature of the cooling block is less than the
temperature set point, then the conveying mechanism slave state
machine 300 may move into a track recover state, "TRACK RECOVER"
301, as described in detail in FIG. 4A. If the temperature of the
cooling block is not less than the temperature set point (i.e., is
greater than the temperature set point), then the conveying
mechanism slave state machine may transition to a start sub-state,
"START", and then transition to a track initialize state, "TRACK
INIT" 302, and may wait to receive and then execute further
commands to transition out of this sub-state, as described in
detail in FIG. 4B.
[0086] In FIG. 4A, for example, the track recover state, "TRACK
RECOVER" 301, is illustrated. When the conveying mechanism slave
state machine 300 is in the track recover state, the pressure plate
is in an the initial position adjacent to a top surface of the
fluid in the fluid molds and a track door for dispensing solids
from the fluid molds is down or closed, and the temperature of the
cooling block is less than the temperature set point. The conveying
mechanism slave state machine may then execute a subcommand to
retrieve and read stored previous states of the conveying mechanism
slave state machine from a memory associated with a respective
co-processor or a main processor, such as a non-volatile
random-access memory (NVRAM). If the read of the stored previous
states of the conveying mechanism slave state machine fails (e.g.,
retrieval of the previous states fails) or the previous state of
the conveying mechanism slave state machine is in the track rotate
state, "TRACK ROTATE" 303, such that the conveying mechanism is
moving, then the conveying mechanism slave state machine may
transition to the start state, "START" and then transition to the
track initialize state, "TRACK INIT" 302, and may wait to receive
and then execute further commands to transition out of this
sub-state.
[0087] If the previous state of the conveying mechanism slave state
machine is a track ready state, "TRACK READY" 306 or a track
maintenance state, "TRACK MAINTENANCE ROTATION" 307, then a
pressure plate slave state machine, such as the pressure plate
slave state machine 204 in FIG. 2, may receive and execute a
command to cause arrangement of the pressure plate into the second
position in spaced apart relation from the top surface of the fluid
in the fluid mold so as not to urge a bottom surface of the fluid
mold into interaction with the cooling block.
[0088] Referring back to FIG. 3, when the conveying mechanism is in
the start state, "START", the pressure plate is in an second
position in spaced apart relation from the top surface of the fluid
in the fluid molds, a track door for dispensing solids from the
fluid molds is up or open, and the temperature of the cooling block
is greater than the temperature set point. The pressure plate slave
state machine 204 may then execute a command to cause arrangement
of the pressure plate to be in the initial position or adjacent to
the top surface of the fluid in the fluid molds and a
solid-dispensing mechanism slave state machine (e.g., 205 in FIG.
2) may execute a command to cause the track door to move down or
closed. In this manner, the conveying mechanism slave state machine
300 may then transition to the track initialize state, "TRACK INIT"
302.
[0089] In FIG. 4B, for example, the track initialize state, "TRACK
INITIALIZE" 302, is illustrated. When the conveying mechanism slave
state machine 300 is in the track initialize state, the pressure
plate is in the initial position adjacent to a top surface of the
fluid in the fluid molds, the track door for dispensing solids from
the fluid molds is down or closed, and the temperature of the
cooling block is greater than the temperature set point. The master
state machine may then be configured to detect variables associated
with the track initialize state of the conveying mechanism and send
commands and/or subcommands to the conveying mechanism slave state
machine based thereon. The conveying mechanism slave state machine
may then execute the commands and/or subcommands.
[0090] For example, as illustrated in FIG. 4B, the conveying
mechanism slave state machine 300 may be configured to execute a
subcommand to initialize track variables, such as, for example, a
volume of the fluid or the solid in the fluid mold, a time period
associated with a fluid or a solid in the fluid mold, sub-states of
the conveying mechanism, a track error state, a number of cycles
that the conveying mechanism moves through the solid-production
system, an expiration of a time period associated with a cycle of
the number of cycles, detection and update of a position of the
fluid mold in the cycle, a temperature of the fluid or the solid in
the fluid mold, an emptiness of the fluid mold, and an expiration
of a time period associated with cooling the fluid in the fluid
mold to form the solid. In this example, the pressure plate slave
state machine may receive and execute another command to cause
arrangement of the pressure plate into spaced apart relation from
the top surface of the fluid in the fluid mold (i.e., second
position), such that the fluid molds are not urged into interaction
with the cooling block via the pressure plate. The conveying
mechanism slave state machine may then transition to a track rotate
state, "TRACK ROTATE" 303, described in greater detail in FIG.
4C.
[0091] In FIG. 4C, for example, the track rotate state, "TRACK
ROTATE" 303, is illustrated. In the track rotate state, the
conveying mechanism slave state machine 300 may execute a
subcommand to cause initialization of a track rotation count. The
subcommand may comprise monitoring a position of the fluid molds
within the solid-production system to determine when a fluid mold
has moved through every position within the system, i.e., completed
one cycle or rotation. For example, each position within the
solid-production system may be numbered (e.g., positions P0-P29 in
FIG. 1). In this example, the track rotation count may decrement
the number of positions left before a specific fluid mold returns
to an initial position, beginning with a total number of positions
in the solid-production system and then decreasing that number by
one each time that the fluid molds are moved one position in the
machine direction. Thus, when a specific fluid mold returns to the
initial position and there are 28 positions in the solid-production
system, then the value is 0 and when it leaves the initial
position, and when the specific fluid mold moves to the next
position, the value is 27.
[0092] Further in this example, the number decremented each time
the fluid molds are moved one position in the machine direction is
used to count the number of full rotations made by the fluid molds
(e.g., molds M0-M29) in the machine direction. As used herein, a
"full rotation" or a "full cycle" refers to the track moving or
indexing a fluid mold (e.g., M0) in the machine direction around
the entire solid-production system. More particularly, the number
of full rotations is based on how many times a fluid mold returns
to an initial position. If, for example, the initial position of a
fluid mold is P0, then each time the specific fluid mold returns to
that initial position will be equivalent to a full rotation of that
fluid mold throughout the system. As such, each subsequent full
rotation will have its value increased by a value of one, so that a
first rotation has a value of one (i.e., the specific fluid mold
has returned to the initial position a first time), a second
rotation has a value of 2 (i.e., the specific fluid mold has
returned to the initial position a second time), etc.
[0093] Once the subcommand is initialized, then another command
(e.g., the first command) may be executed to cause track movement
via actuation of one or more motors associated with the track of
the conveying mechanism. The track movement may be movement of each
fluid mold one position in a machine direction.
[0094] Once the track of the conveying mechanism begins movement,
then the conveying mechanism slave state machine 300 may transmit a
signal back to the master state machine indicating that the
conveying mechanism slave state machine has transitioned to the
second state. In some example implementations, subcommands may
define parameters of the second command, such that execution of the
subcommands may be initiated by the conveying mechanism slave state
machine after receipt of the second command from the master state
machine. Completion of the second commands and/or subcommands may
then result in the transition of the conveying mechanism slave
state machine from the second state to the first state or another
state through a series of sub-states, where the track moves the
fluid mold through the solid-production system.
[0095] Movement of the fluid mold may be determined by analyzing
whether a specific fluid mold (indicative of relative positions of
all the fluid molds) has advanced one position from its previous
position to a current position in the machine direction (e.g., from
P0 to P1). If the fluid mold has not moved from its previous
position, then another subcommand may be executed to determine if
the move has failed (e.g., there is a system error) such that the
track has not moved the fluid molds one position. If the move has
not failed, then the command will run until the fluid molds have
moved one position in the machine direction. If the move has
failed, then the conveying mechanism slave state machine may
transmit a signal to the master state machine to indicate the track
error status of the track.
[0096] If the fluid molds have moved one position in the machine
direction, then the command may continue execution to move the
track so that the fluid molds each advance one position. More
particularly, for example, the command may be configured to cause a
motor associated with the track of the conveying mechanism to move
the fluid molds one position in the machine direction in the track
one position (e.g., move from P1 to P2). The conveying mechanism
slave state machine 300 may then execute a subcommand to access an
associated memory device to retrieve the track rotation count
and/or previous and current positions of each of the fluid molds,
and thereby determine whether the fluid molds of the track of the
conveying mechanism have moved a number of positions equal to a
full rotation (i.e., count value is 1). If the count value is not
1, then a subcommand may be executed and the number of positions
left before the fluid molds return to their initial position may be
decremented (e.g., by one). The subcommand may be executed then to
move each fluid mold one position in the machine direction.
[0097] If the fluid molds of the track of the conveying mechanism
have moved a number of positions equal to a full rotation, then the
conveying mechanism slave state machine may transition to a track
waiting state, "TRACK WAIT ON COOLING BLOCK" 304, described in more
detail in FIG. 4D.
[0098] In FIG. 4D, for example, the track waiting state, "TRACK
WAIT ON COOLING BLOCK" 304, is illustrated. The conveying mechanism
slave state machine 300 may execute a subcommand to measure and
read the temperature of the cooling block relative to a temperature
set point. In particular, execution of the subcommand may cause a
determination of whether the difference in temperature between the
temperature of the cooling block and the temperature set point is
greater than a predetermined tolerance (e.g., one (1) degree
Fahrenheit (.degree. F.), two (2) .degree. F., etc.) If the
difference in temperature is not greater than the predetermined
tolerance, then a subcommand may cause re-reading of the
temperature of the cooling block and comparison of the temperature
of the cooling block to the temperature set point. If the
temperature of the cooling block is less than the temperature set
point, then conveying mechanism slave state machine may receive a
command to transition back to the track rotate state, "TRACK
ROTATE" 303, and cause the conveying mechanism to move the fluid
mold through the solid-production system for a full rotation.
[0099] If the temperature of the cooling block is greater than the
temperature set point, the conveying mechanism slave state machine
300 may transition to a track fill and solidify state, "TRACK FILL
AND SOLIDIFY" 305, as described in greater detail in FIG. 4E.
[0100] In FIG. 4E, for example, the track fill and solidify state,
"TRACK FILL AND SOLIDFY" 305, is illustrated. For example, the
fluid-dispensing mechanism slave state machine, such as the
fluid-dispensing slave state machine 203 in FIG. 2, may define a
first state of the fluid-dispensing mechanism, "FILL" 401, so as to
execute a command to begin dispensing fluid to the fluid molds
(e.g., M0 in FIG. 1) at the fluid-dispensing position (e.g., P0 in
FIG. 1). Any fluid may be dispensed using the fluid-dispensing
mechanism, including, for example, water.
[0101] The conveying mechanism slave state machine 300 may then be
configured to determine whether the fluid-dispensing mechanism is
currently dispensing the fluid to the fluid mold using, for
example, a sensor. A signal may be transmitted by the sensor to the
conveying mechanism slave state machine indicating whether or not
fluid dispensed by the fluid-dispensing mechanism is occurring.
Fluid-dispensing may be complete after a predetermined threshold
fill level has been achieved. The conveying mechanism slave state
machine may be configured to receive measurements from the sensor
of a measured fluid fill level for comparison against the
predetermined threshold fill level. If the predetermined threshold
fill level is met, fluid dispense is complete. The conveying
mechanism slave state machine can then transition to the state
"MOVE" (e.g., second state) to move the filled fluid mold through
the cooling block.
[0102] If the fluid-dispensing mechanism is not currently filling a
fluid mold, the conveying mechanism slave state machine can
determine whether the fluid mold is empty. For example, the sensor
may be configured to measure a temperature of the fluid mold to
determine whether there is a solid, a fluid, or nothing in the
fluid mold. In this example, if the sensor detects a temperature
other than an ambient temperature of air, then the sensor may
output a signal to the conveying mechanism slave state machine
indicating that the fluid mold is not empty. If the fluid mold is
not empty, the conveying mechanism slave state machine can
determine whether a solid in the fluid mold has been ejected at,
for example, ejection position P11 in FIG. 1. If so, then the
pressure plate slave state machine can enter the solidify state
"SOLIDIFY" 402, so as to urge the fluid mold into interaction with
the cooling block. If the solid in the fluid mold has not been
ejected, the conveying mechanism slave state machine can transition
to the state defined by the conveying mechanism moving the fluid
mold through the solid-production system. Further, the
fluid-dispensing mechanism can record whether the fluid in the
previous fluid mold was solidified, so that the conveying mechanism
can index or move the fluid mold with the formed solid to the
ejection position, e.g., P11 in FIG. 1, to eject the formed solid
from the fluid mold.
[0103] Where the fluid mold is empty at the fluid-dispensing
position, e.g., P0 in FIG. 1, the sensor may detect that the
temperature in the fluid mold is the ambient temperature of air and
transmit a signal indicating the same to the fluid-dispensing slave
state machine. The fluid-dispensing slave state machine may be
configured to determine if the previous mold was filled with fluid
and then execute a command to initiate dispense of fluid into the
current, empty fluid mold.
[0104] In some example implementations, where the pressure plate
slave state machine is in the solidify state "SOLIDFY" 402, the
pressure plate slave state machine can determine whether the
pressure plate is in a steady state. If so, the conveying mechanism
slave state machine can transition to the state defined by the
conveying mechanism moving the fluid mold through the
solid-production system.
[0105] If the pressure plate is not in a steady state, the pressure
plate slave state machine can determine whether all the fluid molds
in the cooling region relative to the cooling block include fluid
for solidification. If so, the pressure plate slave state machine
can execute a command to cause arrangement of the pressure plate to
be adjacent to a top surface of the fluid in the fluid mold so as
to urge the fluid mold into interaction with the cooling block and
solidify the fluid in the fluid molds. In particular, motor(s)
associated with the pressure plate can receive a signal from a
sensing mechanism indicating that the fluid molds in the cooling
region relative to the cooling block are filled to the
predetermined fill level with fluid. The motors can then actuate an
actuation mechanism so as to cause arrangement of the pressure
plate to be adjacent to a top surface of the fluid in the fluid
mold, i.e., move into the initial position, so as to urge a bottom
surface of the fluid mold into interaction with the cooling block
so as to reduce a first temperature of the fluid in the fluid molds
to a second temperature to form a solid.
[0106] If all the fluid molds in the cooling region relative to the
cooling block do not include fluid, fluid-dispensing mechanism can
determine whether a fluid mold at the position P0 is empty via
receiving a signal from an associated sensor. If so, the
fluid-dispensing mechanism slave state machine can transition to
the fill state "FILL" 401 to dispense fluid to the empty fluid mold
in position P0. If the fluid mold at the position P0 is not empty,
the fluid-dispensing slave state machine can receive a signal from
a sensor whether a previous or last mold at the position P0 is
filled with fluid. If so, then the pressure plate slave state
machine may be configured to transition to the first state upon
executing a second command so as to cause arrangement of the
pressure plate to be adjacent to the top surface of the fluid in
the fluid mold and solidify the fluid therein.
[0107] When the pressure plate is arranged adjacent to a top
surface of the fluid in the fluid mold, a sensing mechanism may be
configured to determine whether all the fluid molds in the cooling
region relative to the cooling block have formed a solid from the
fluid. The sensing mechanism may be a thermopile, a timer, a
combination thereof, and the like. The sensing mechanism may be
configured to detect whether or not a solid has formed and transmit
the signal to the pressure plate slave state machine. If a solid
has not formed, the sensing mechanism may continuously monitor the
fluid molds to determine when the solid has formed. If a solid has
formed, the pressure plate slave state machine can transition to
the second state upon executing a first command so as to cause
arrangement of the pressure plate into spaced apart arrangement
from the top surface of the fluid in the fluid mold and not
solidify the fluid therein. Then the conveying mechanism slave
state machine can transition to the move state "MOVE" or the
dispensing mechanism slave state machine can transition to the fill
state "FILL" 401 based on whether the fluid mold is empty or not.
If a timer for maintenance of the pressure plate is expired, the
track fill and solidify state, "TRACK FILL AND SOLIDIFY" 305 can
transition to the pressure plate maintenance rotation state,
"PRESSURE PLATE MAINTENANCE ROTATION" 310.
[0108] Returning back to FIG. 3, in some example implementations,
the pressure plate slave state machine (e.g., 204 in FIG. 2) may
receive and execute a command to determine a state of the fluid
mold (e.g., whether a solid is formed in the fluid mold, whether
the fluid mold is empty, etc.) in an ejection position (e.g.,
position P11 in FIG. 1). If the fluid mold in the ejection position
comprises a solid, then the pressure plate mechanism slave state
machine may receive an eject command from the master state machine
to cause a solid ejector (e.g., 103 in FIG. 1) to loosen the solid
from the fluid mold. A sensing mechanism arranged adjacent to the
solid ejector mechanism may determine whether the solid was ejected
from the fluid mold. If so, then the conveying mechanism slave
state machine 300 may transition to the track ready state, "TRACK
READY" 306, as described in greater detail in FIG. 4F.
[0109] In FIG. 4F, for example, the track ready state, "TRACK
READY" 306, is illustrated. The solid-dispensing slave state
machine, such as the solid-dispensing slave state machine 205 in
FIG. 2, may receive a command to determine if a solid is available
to dispense at a solid-dispensing position (e.g., position P28 in
FIG. 1) and open the track door to dispense a loosened solid to the
user through the track door. A sensing mechanism associated with
the solid-dispensing mechanism may be utilized to measure a
temperature of the fluid mold and/or a fill level of a fluid in the
fluid mold to determine whether a solid is formed and available.
The master state machine may then transmit a second command to the
solid-dispensing mechanism to cause arrangement of the
solid-dispensing mechanism so as to cause the solid-dispensing
mechanism to dispense the loosened solid in the fluid mold (e.g.,
M28 in FIG. 1) loosened by the solid ejector. The second command
may cause the track door to open or be up so that the dispensed
solid can exit from the track door through the exit port to the
user. The conveying mechanism slave state machine may then
transition to a solid dispense waiting state, "TRACK WAIT ON SOLID
DISPENSE" 308.
[0110] If the master state machine does not transmit the second
command to the solid-dispensing mechanism slave state machine, then
the solid dispensing mechanism slave state machine may execute a
subcommand to cause a determination of whether the track door to
the exit port is closed. If the track door is not closed (i.e., is
open), then the solid-dispensing mechanism slave state machine may
execute a subcommand to close the door and may receive and
re-execute a subcommand to determine if the fluid mold is in a
solid state.
[0111] If the track door is closed, the conveying mechanism slave
state machine 300 may execute a subcommand to cause a determination
of whether a track maintenance timer has expired. The track
maintenance timer, which may differ from or be the same timer as a
pressure plate maintenance timer, may be activated during the track
fill and solidify state, "TRACK FILL AND SOLIDIFY" 305 in order to
monitor movement of the pressure plate. Specifically, the pressure
plate maintenance timer may provide capabilities to determine that
the pressure plate is not stuck in either of the first or the
second position due to, for example, excessive frost due to water
vapor. By comparison, the track maintenance timer may be activated
during the track ready state, "TRACK READY" 306 so as to ensure
that movement of the fluid molds is not hindered due to, for
example, excessive frost due to water vapor.
[0112] If the track maintenance timer has expired (e.g., there is a
period of inactivity in the system, such as for example, five
minutes, ten minutes, etc.), then the conveying mechanism slave
state machine may receive and execute the first command and cause
the track of the conveying mechanism to move the fluid mold and
transition to a track maintenance rotation state, "TRACK
MAINTENANCE ROTATION" 307. Inactivity may include not receiving a
user-request for a specified number of solids, such that none of
the track(s) is/are rotating. The track maintenance rotation state
is described in more detail in FIG. 4G. If the track maintenance
timer has not expired, then the solid-dispensing mechanism slave
state machine may receive and re-execute a command to determine if
the fluid mold is in a solid state.
[0113] If a solid is not available (e.g., is still a fluid, the
fluid mold is empty, etc.), then the solid-dispensing mechanism
slave state machine may receive and execute a first command from
the master state machine to cause arrangement of the
solid-dispensing mechanism so as not to cause the solid-dispensing
mechanism to dispense the loosened solid (i.e., the track door is
closed to the exit port). The conveying mechanism slave state
machine 300 may then transition back to the track waiting state,
"TRACK WAIT ON COOLING BLOCK" 304.
[0114] In FIG. 4G, for example, the track maintenance rotation
state, "TRACK MAINTENANCE ROTATION" 307, is illustrated. When the
conveying mechanism slave state machine 300 is in the track
maintenance rotation state, the pressure plate is in a second
position in spaced apart relation relative to a top surface of the
fluid in the fluid molds and a track door for dispensing solids
from the fluid molds is down or closed. The conveying mechanism
slave state machine 300 may then execute a subcommand to initialize
a track rotation count, as previously described, and then execute a
first command and cause the conveying mechanism to move the fluid
mold through the solid-production system. If the track is
successfully moved one position and a fluid-dispensing mechanism
slave state machine, e.g., 203 in FIG. 2, receives a second command
from a master state machine (e.g., 201 in FIG. 2) to cause the
fluid-dispensing mechanism to initiate dispensing the fluid to the
fluid mold, then the conveying mechanism slave state machine can
transition back to the track ready state, "TRACK READY" 306.
[0115] If the fluid-dispensing mechanism slave state machine does
not receive the second command from the master state machine, and a
full rotation of the track of the conveying mechanism is complete,
the pressure plate slave state machine (e.g., 204 in FIG. 2) can
execute a second command to cause arrangement of the pressure plate
to be adjacent to the top surface of the fluid in the fluid mold so
as to urge the fluid mold into interaction with the cooling block,
and the conveying mechanism slave state machine can transition to a
pressure plate maintenance rotation state, "PP MAINTENANCE
ROTATION" 310.
[0116] If the track move has failed, then a solid-dispensing
mechanism slave state machine (e.g., 205 in FIG. 1) can execute a
first command to cause arrangement of the solid-dispensing
mechanism so as not to cause the solid-dispensing mechanism to
dispense the loosened solid (i.e., the track door can be closed),
if the track door is not already closed. Then, the conveying
mechanism slave state machine can execute a first command and cause
the conveying mechanism to move the fluid mold through the
solid-production system so that the track is removed from
dispensing. The pressure plate slave state machine can make one
attempt to execute a second command to cause arrangement of the
pressure plate to be adjacent to the top surface of the fluid in
the fluid mold so as to urge the fluid mold into interaction with
the cooling block. If the pressure plate slave state machine tries
once to execute the second command, then the conveying mechanism
slave state machine can send a signal to the master slave state
machine to record the state of the conveying mechanism slave state
machine as "TRACK STATUS ERROR".
[0117] Referring back to FIG. 3, when the conveying mechanism slave
state machine is in the track ready state, "TRACK READY" 306, the
master slave state machine may send a second command to the
solid-dispensing mechanism slave state machine to cause arrangement
of the solid-dispensing mechanism so as to cause the
solid-dispensing mechanism to dispense the solid loosened by the
solid ejector to the user through the exit port. The solid dispense
may be a result of a user request transmitted to the master state
machine from a user's interaction with a user interface. The user
request for additional solids may be in the form of a request for a
specified number of solids (i.e., one solid, two solids, three
solids, etc.), which may be input into the user interface upon user
interaction therewith. Receipt of the user request at the master
state machine can initialize the sending of a subcommand to the
solid-dispensing mechanism slave state machine to initialize a
solid counter equal to the user-requested number of solids. For
example, if the user inputs into the user interface a request for
five solids, then the solid counter is set to "5" and each time a
solid is dispensed to the user through the exit port, the solid
counter is decremented by one. As such, the solid-dispensing
mechanism slave state machine may then execute the second command,
so as to open the track door so that solids can be dispensed to the
exit port through the track door. Then the conveying mechanism
slave state machine 300 can transition from the track ready state,
"TRACK READY" 306 to the solid dispense waiting state, "TRACK WAIT
ON SOLID DISPENSE" 308, described in more detail in FIG. 4H.
[0118] In FIG. 4H, for example, the solid dispense waiting state,
"TRACK WAIT ON SOLID DISPENSE" 308 is illustrated. The
solid-dispensing mechanism slave state machine, such as the
solid-dispensing slave state machine 205 in FIG. 2, may receive
subcommands to initialize a solid wait timer to count down from a
predetermined solid wait time during which the user-requested
number of solids can be dispensed from a fluid mold (e.g., M28 in
FIG. 1) in a solid-dispensing position (e.g., P28 in FIG. 1) and a
solid counter. The predetermined solid wait time may be 0.5
seconds, 1 second, 2 seconds, etc., which may be determinant on the
number of solids requested by the user at the user-interface.
However, the predetermined solid wait time may also be less than
0.5 seconds or may be increments smaller than 0.5 or 1 second
intervals (e.g., 0.05 seconds, 0.05 seconds, 1.5 seconds, etc.). If
the user-requested number of solids is dispensed from the fluid
mold in the solid-dispensing position, then the solid-dispensing
mechanism can send a signal to the master slave state machine to
record the state of the fluid mold in the solid-position as "EMPTY"
and can decrement the user-requested solid counter by one. Then,
the conveying mechanism slave state machine can transition to a
track dispense state, "TRACK DISPENSE" 309.
[0119] If the user-requested number of solids is not dispensed from
the fluid mold in the solid-dispensing position, then the
solid-dispensing mechanism can determine whether or not there is
more time left in the predetermined solid wait time. If yes, then
the solid-dispensing mechanism slave state machine can remain in a
first state defined by the solid-dispensing mechanism being
arranged to dispense the solid loosened by the solid ejector to the
user through the exit port, and the second state defined by the
solid-dispensing mechanism being arranged so as to not dispense the
loosened solid. If no, then the solid-dispensing mechanism slave
state machine can send a signal to the master slave state machine
to record the state of the fluid mold in the solid-dispensing
position as "SOLID" and can stop the solid counter. Then, the
conveying mechanism slave state machine can transition to a track
dispense state, "TRACK DISPENSE" 309, described in more detail in
FIG. 4I.
[0120] In FIG. 4I, for example, the track dispense state, "TRACK
DISPENSE" 309 is illustrated. When the conveying mechanism slave
state machine 300 is in the track dispense state, the track door is
up or open and the track of the conveying mechanism is moving the
fluid molds through the solid-production system. The conveying
mechanism slave state machine can receive and execute a first
command and cause the conveying mechanism to move the fluid mold
through the solid-production system a certain number of positions
based on a user-request for a specified number of solids. Track
movement may comprise incrementally moving the track by one
position in a machine direction so as to transport the fluid molds
(e.g., M0-M29 in FIG. 1) through the solid-production system (e.g.,
100 in FIG. 1). If track movement is complete (i.e., the
user-requested number of solids has been dispensed), then a
subcommand may be executed by the conveying mechanism slave state
machine and the position of the fluid molds in the solid-production
system may be updated (e.g., updated by decremented the number of
positions left before the fluid molds return to their initial
position), and the conveying mechanism slave state machine can
transition back to the track ready state, "TRACK READY" 306.
[0121] If track movement is not complete and track movement has
failed, the solid-dispensing mechanism slave state machine can
receive and execute a first command from the master state machine
to cause arrangement of the solid-dispensing mechanism so as not to
cause the solid-dispensing mechanism to dispense the loosened
solid, such that the track door is closed or down. Then the
conveying mechanism slave state machine can receive and execute a
second command and cause the conveying mechanism to stop movement
of the fluid mold through the solid-production system. Then, the
conveying mechanism slave state machine can send a signal to the
master slave state machine to record the state of the conveying
mechanism slave state machine as "TRACK STATUS ERROR".
[0122] Referring back to FIG. 3, when the conveying mechanism slave
state machine is in the track fill and solidify state, "TRACK FILL
AND SOLIDIFY" 305 or the track maintenance rotation state, "TRACK
MAINTENANCE ROTATION STATE" 307, the conveying mechanism slave
state machine my transition to a pressure plate maintenance
rotation state, "PP MAINTENANCE ROTATION" 310, as described in more
detail in FIG. 4J, if there has been at least two (2) minutes of
inactivity as measured by the track maintenance timer and
solidification of the fluid in the fluid molds in the cooling
region, or if one full rotation of the track of the conveying
mechanism is complete.
[0123] In FIG. 4J, for example, the pressure plate maintenance
rotation state, "PP MAINTENANCE ROTATION" 310 is illustrated. In
the pressure plate maintenance rotation state, the pressure plate
is in the second position or arranged in a spaced apart relation
from the top surface of the fluid in the fluid mold so as not to
urge the fluid mold into interaction with the cooling block. If the
pressure plate is in the initial position, or arranged adjacent to
the top surface of the fluid mold, then the pressure plate slave
state machine may then execute a first command to cause arrangement
of the pressure plate into second position or spaced apart relation
from the top surface of the fluid in the fluid mold so as not to
urge the fluid mold into interaction with the cooling block. If
execution of the first command fails or the pressure plate remains
in the initial position, then the conveying mechanism slave state
machine may send a signal to the master slave state machine to
record the state of the conveying mechanism slave state machine as
"TRACK STATUS ERROR".
[0124] If execution of the first command is successful, then the
pressure plate slave state machine can execute a subcommand to
determine if the number of solids has been ejected by the solid
ejector, i.e., has the number of solids requested by the user been
loosened in the respective fluid molds for dispensing by the
solid-dispensing mechanism to the user. If yes, then the conveying
mechanism slave state machine can transition back to the track
ready state, "TRACK READY" 306. If not, then the pressure plate
slave state machine can receive and execute a second command from
the master state machine to cause arrangement of the pressure plate
to be adjacent to the top surface of the fluid in the fluid mold so
as to urge the fluid mold into interaction with the cooling block,
and the conveying mechanism can transition back to a track fill and
solidify state, "TRACK FILL AND SOLIDIFY" 305.
[0125] Referring now to FIG. 4K, a dispense manager 400, which can
be software implemented by the master state machine, is
illustrated. The dispense manager can be associated with the user
interface, such that any request from the user (e.g., specified
number of solids, different volume of solids, and the like) can be
transmitted to the dispense manager of the master state machine.
The master state machine can then send a subcommand to the
conveying mechanism slave state machine (e.g., 202 in FIG. 2) to
assign a track of the conveying mechanism, where there is more than
one track, to begin rotation in order to dispense the
user-requested number of solids. The track can be assigned based on
whichever track is in the track ready state, "TRACK READY" 306 in
order of incremental track number if there is more than one track
(i.e., first track, second track, third track, etc.). FIG. 5 is a
schematic 500 illustrating various example states of fluid molds in
a solid-production system according to example implementations of
the present disclosure. As shown, a fluid mold may have five
states: empty, filling, fluid, solid; and ejected. Other states for
the fluid molds and/or additional or less states are also
contemplated, such as partially solid. The states can be detected
by one or more sensing mechanisms associated with the conveying
mechanism, the fluid-dispensing mechanism, the pressure plate, or
the solid-dispensing mechanism. The states of the fluid molds may
be set by one or more sensing mechanisms associated with the
conveying mechanism, the fluid-dispensing mechanism, the pressure
plate, or the solid-dispensing mechanism, which may be transmitted
to the master state machine.
[0126] FIGS. 6A and 6B illustrate example states and sub-states of
the conveying mechanism slave state machine, according to example
implementations of the present disclosure. For example, in FIG. 6A,
a schematic 600A is illustrated. In particular, when the conveying
mechanism slave state machine is in an initialize track move state,
"TRACK MOVE INIT" (e.g., 302 in FIG. 3), the conveying mechanism
slave state machine can receive and execute a first command from a
master state machine (e.g., 201 in FIG. 2) to transition to the
track moving state, "TRACK_MOVING" (e.g., 303 in FIG. 3) so as to
cause the conveying mechanism to move the fluid mold through the
solid-production system. After track movement is complete, the
track moving state, "TRACK_MOVING", can transition to a track move
complete sub-state, "TRACK MOVE COMPLETE", indicating that track
movement is complete.
[0127] As noted herein, in some example implementations, the
conveying mechanism slave state machine can use a timer to monitor
the track movement. In some instances, timeout may occur when the
track is still moving. When timeout occurs and the maximum number
of allowed retries is exceeded to move the track (i.e., a specified
number of retries that the conveying mechanism slave state machine
can try to execute the first command sent by the master state
machine), the state "TRACK_MOVING" may transition to a sub-state
"TRACK UNKNOWN", indicating an unknown state of the track. The
sub-state "TRACK UNKNOWN" may transition to the state "TRACK MOVE
INIT" to initialize track movement. In another example, when
timeout occurs, the conveying mechanism slave state machine can
attempt to re-execute the first command to enter the state
"TRACK_MOVING" to enable track movement.
[0128] In FIG. 6B, a schematic 600B is illustrated. Upon receiving
a command, a GPIO associated with the conveying mechanism slave
state machine may be configured as an output such that a particular
pin may be turned or "pulled" HIGH so that the voltage may be up to
about 3.3 volts (V). The GPIO may comprise one or more uncommitted
digital signal pins on an integrated circuit or an electronic
circuit board on one of the processors used to the control the
conveying mechanism slave state machine. A series of pulses may be
generated by the GPIO via pulse width modulation (PWM) and a timing
mechanism, e.g., a timer, may be started. The series of pulses may
be generated for a period of time, such as, for example between
about 3 (three) and about 10 (ten) seconds, or once a number of
pulses has been generated, such as, for example, one, two, three,
four, etc., pulses and received by one or more co-processors
associated with the conveying mechanism slave state machine for
controlling track movement and/or a pressure plate slave state
machine for controlling pressure plate arrangement.
[0129] The conveying mechanism slave state machine may then receive
and execute a subcommand from the master state machine to
transition to a stop pulse sub-state, "SUB-STATE STOP PULSE", in
order to stop generating the series of pulses once the period of
time has expired or the number of pulses has been generated. The
GPIO may then be configured as an input such that the pin may be
turned or pulled "LOW". The voltage may be about zero (0) V to
about one (1) V. A series of pulses may be generated by the GPIO
via PWM and the timing mechanism may be restarted. The series of
pulses may be generated for a period of time, such as, for example
between about three (3) seconds and about ten (10) seconds, or once
a number of pulses has been generated, such as, for example, one,
two, three, four, etc., pulses. The conveying mechanism slave state
machine may then receive and execute a subcommand from the master
slave state machine to enter the wait for response sub-state,
"SUB-STATE WAIT FOR RESPONSE", in order to stop generating the
series of pulses once the period of time has expired or the number
of pulses has been generated and received by one or more
co-processors responsible for controlling track movement and/or
pressure plate arrangement.
[0130] In the wait for response sub-state "SUB-STATE WAIT FOR
RESPONSE," the conveying mechanism slave state machine can
determine whether track movement is successfully completed based on
a number of pulses received by the co-processors associated with
the conveying mechanism slave state machine for controlling track
movement.
[0131] If the period of time is expired, or the conveying mechanism
slave state machine receives two pulses, the conveying mechanism
slave state machine may receive and execute a subcommand from the
master state machine to transition from the wait for response
sub-state "SUB-STATE WAIT FOR RESPONSE" to a transition timeout
sub-state "SUB-STATE TRANSITION TIMEOUT". The transition timeout
sub-state is defined by the track of the conveying mechanism not
being successfully moved the necessary number of positions in the
required period of time.
[0132] If the co-processor receives one pulse as generated by the
GPIO, the conveying mechanism slave state machine may receive and
execute a subcommand from the master state machine to transition
from the wait for response sub-state, "SUB-STATE WAIT FOR
RESPONSE", to the transition complete sub-state, "SUB-STATE
TRANSITION COMPLETE". The transition complete sub-state may be
defined by the track of the conveying mechanism having successfully
moved the fluid molds the necessary number of positions.
[0133] When the conveying mechanism slave state machine is in
either of the transition timeout sub-state or the transition
complete sub-state, the conveying mechanism slave state machine may
receive and execute a subcommand from the master state machine to
transition from either of these sub-states to the wait for start
sub-state "SUB-STATE WAIT FOR START". The wait for start sub-state
may be defined by the conveying mechanism receiving and executing a
first command and cause the conveying mechanism to move the fluid
mold through the solid-production system. Notably, the execution of
various commands and subcommands by the conveying mechanism slave
state machine so as to transition into one or more sub-states as
described in FIGS. 6A and 6B may define one or more states of a
conveying mechanism slave state machine. For example, the
transitions to various sub-states in FIGS. 6A and 6B may be used in
conjunction with and/or define the track rotate state, "TRACK
ROTATE" 303 in FIG. 3.
[0134] FIG. 7 illustrates a fluid-dispensing mechanism slave state
machine 700, which may be the same as or similar to the
fluid-dispensing mechanism slave state machine 203 according to
example implementations of the present disclosure. The
fluid-dispensing mechanism slave state machine in FIG. 7 may
illustrate one example implementation of the fluid-dispensing
mechanism slave state machine 203 described in FIG. 2, which
receives commands and/or subcommands from the master state machine
based on respective states of the fluid-dispensing mechanism slave
state machine. Execution of the commands by the fluid-dispensing
mechanism slave state machine may be initiated by the
fluid-dispensing mechanism slave state machine after receipt of the
commands from the master slave state machine.
[0135] In some example implementations, as shown in FIG. 7, the
fluid-dispensing mechanism slave state machine 700 may define four
different states or sub-states: "FILL IDLE," "FILL IN PROCESS,"
"BEFORE FILL WAIT" and "AFTER FILL WAIT" indicating different
states of the fluid-dispensing mechanism. A timing mechanism, such
as a timer, can be used in the fluid-dispensing mechanism slave
state machine to control transitions between the states or
sub-states.
[0136] For example, upon receiving a subcommand from the master
slave state machine, the fluid-dispensing mechanism slave state
machine 700 can execute the subcommand and start a wait timer so as
to transition to a before fill wait sub-state, "BEFORE FILL WAIT".
When the wait timer expires, the fluid-dispensing mechanism slave
state machine can send a signal to the master state machine, which
can then send a second command to the fluid-dispensing mechanism
slave state machine to cause the fluid-dispensing slave state
mechanism to transition to a first state, "FILL IN PROCESS",
defined by the fluid-dispensing mechanism dispensing the fluid to a
fluid mold in a fluid-dispensing position relative to the
fluid-dispensing mechanism (e.g., P0 in FIG. 1). In particular, the
fluid-dispensing mechanism slave state machine can execute the
second command to activate a valve mechanism, e.g., a solenoid, of
the fluid-dispensing mechanism and start a fill timer.
[0137] After the fill timer is expired, the fluid-dispensing
mechanism slave state machine can receive and execute a first
command from the master state machine to cause the fluid-dispensing
mechanism to stop dispensing the fluid to the fluid mold. In
particular, the fluid-dispensing mechanism slave state machine can
deactivate the valve mechanism and start the wait timer. The
fluid-dispensing mechanism slave state machine can then transition
from the first state, "FILL IN PROCESS", to the after fill wait
sub-state, "AFTER FILL WAIT". After the wait timer has expired, the
fluid-dispensing mechanism slave state machine can receive and
execute a first command from the master state machine to cause the
fluid-dispensing mechanism to stop dispensing the fluid to the
fluid mold in the dispensing position, so as to transition from the
after fill wait sub-state, "AFTER FILL WAIT" to the second state,
"FILL IDLE", defined by the fluid-dispensing mechanism not
dispensing the fluid to the fluid mold.
[0138] FIG. 8 illustrates a schematic of an example implementation
of a pressure plate state machine 800, which may be the same as or
similar to the pressure plate slave state machine 204 in FIG. 2,
according to example implementations of the present disclosure. The
pressure plate slave state machine in FIG. 8 may illustrate one
example implementation of the pressure slave state machine
described in FIG. 2, which receives commands and/or subcommands
from the master state machine based on respective states of the
pressure plate slave state machine. Execution of the commands by
the pressure plate slave state machine may be initiated by the
pressure plate slave state machine after receipt of the commands
from the master slave state machine.
[0139] For example, as shown in FIG. 8, when the pressure plate is
arranged in an initial position, i.e., arranged adjacent to a top
surface of a fluid mold as a result of a normal biasing force
exerted on a top surface of the pressure plate by a biasing
mechanism, then the pressure plate slave state machine 800 may be
in a first state defined by the pressure plate being arranged
adjacent to a top surface of the fluid in the fluid mold so as to
urge the fluid mold into interaction with the cooling block.
[0140] In the first state, the pressure plate slave state machine
may receive a first command that initiates a series of subcommands
from a master state machine, such as master state machine 201 in
FIG. 2, to cause the pressure plate slave state machine to
transition to a second state or another state or sub-state
Likewise, where the pressure plate slave state machine is in the
second state, the pressure plate slave state machine may receive a
second command that initiates a series of subcommands from a master
state machine to cause the pressure plate slave state machine to
transition back to the first state or another state or
sub-state.
[0141] In some example implementations, subcommands may define
parameters of the first or second command sent by the master state
machine to the pressure plate slave state machine 800, such that
execution of the subcommands may be initiated by the pressure plate
slave state machine after receipt of the first or second command
from the master state machine. Completion of the first or second
command and/or subcommands may then result in the transition of the
pressure plate slave state machine between the first state and the
second state or to another state through a series of
sub-states.
[0142] In particular, the pressure plate slave state machine 800,
may be in an initialization state, "PP INIT". The pressure plate
slave state machine may receive and execute a subcommand from the
master state machine to transition from the initialization state,
"PP INIT" to a wait sub-state, "PP INIT WAIT." If the transition
from the initialization state, "PP INIT" to the wait sub-state, "PP
INIT WAIT" takes longer than a predetermined amount of time (e.g.,
longer than one minute, two minutes, three minutes, etc.), then
pressure slave state machine may receive and execute a subcommand
from the master slave state machine to transfer to an unknown
sub-state, "PP UNKNOWN."
[0143] If the transition is complete, then the pressure plate slave
state machine 800 may receive and execute a second command to cause
arrangement of the pressure plate to be adjacent to the top surface
of the fluid in the fluid mold so as to urge the fluid mold into
interaction with the cooling block, i.e., the initial state. In
particular, the pressure plate slave state machine may actuate an
actuation mechanism so as to move the pressure plate into the
initial state. Then the pressure plate slave state machine may
transition to the second wait sub-state, "PP INIT WAIT 2." If the
transition from the second wait sub-state, "PP INIT WAIT 2", takes
longer than the predetermined amount of time, then pressure slave
state machine may receive and execute a subcommand from the master
slave state machine to transfer to the unknown sub-state, "PP
UNKNOWN." Otherwise, if the transition is complete, the conveying
mechanism slave state machine can transition to a first state, "PP
DN" defined by the pressure plate being arranged adjacent to a top
surface of the fluid in the fluid mold so as to urge the fluid mold
into interaction with the cooling block. The first state assists in
more efficient solidification of the fluid in the fluid molds in
the cooling region relative to the cooling block.
[0144] If the pressure plate is requested to be in the second
state, "UP", then the pressure plate slave state machine may
receive and execute a first command so as to transition to the
second state, defined by the pressure plate being arranged in a
spaced apart relation from the top surface of the fluid in the
fluid mold so as not to urge the fluid mold into interaction with
the cooling block. Upon receiving the first command from the master
state machine, the pressure plate slave state machine may cause
arrangement of the pressure plate into the spaced apart relation
from the top surface of the fluid in the fluid mold so as not to
urge the fluid mold into interaction with the cooling block, and
transition to the down to up sub-state, "PP DN TO UP". A signal may
be sent from the pressure plate slave state machine to the master
state machine to indicate that the transition from the first state
to the second state.
[0145] If the pressure plate is requested to be in a eject or
ejection state, "EJECT", then the pressure plate slave state
machine may receive and execute a command so as to transition to
the eject state, defined by the pressure plate being arranged in a
spaced apart relation from the top surface of the fluid in the
fluid mold so as not to urge the fluid mold into interaction with
the cooling block, where in the eject state the pressure plate is
arranged in a spaced apart relation from the top surface of the
fluid in the fluid mold a greater distance than in the second
state. Upon receiving the command from the master state machine,
the pressure plate slave state machine may cause arrangement of the
pressure plate into the eject state, and transition to the down to
up sub-state, "PP DN TO UP". A signal may be sent from the pressure
plate slave state machine to the master state machine to indicate
the transition between the states.
[0146] In the down to up sub-state, "PP DN TO UP", the pressure
plate slave state machine may receive and execute a subcommand from
the master state machine to transition from the down to up
sub-state to the second state, "PP UP", if the transition from the
first state to the second state is complete. If the transition from
the first state to the second state times out (i.e., the pressure
plate does not transition to the second state within a
predetermined period of time), then the pressure plate slave state
machine may receive and execute a subcommand from the master state
machine to transition to the unknown sub-state, "PP UNKNOWN".
[0147] In the second state, "PP UP", the conveying mechanism slave
state machine may receive and execute a subcommand to transition to
an up to down sub-state, "PP UP TO DN", where the pressure plate
slave state machine is requested to be in the first state, "PP DN".
In the up to down sub-state, the pressure plate slave state machine
may receive and execute a second command so as to transition to the
first state, defined by the pressure plate being arranged adjacent
to a top surface of the fluid in the fluid mold so as to urge the
fluid mold into interaction with the cooling block. Upon receiving
the second command from the master state machine, the pressure
plate slave state machine may cause arrangement of the pressure
plate to be adjacent to the top surface of the fluid in the fluid
mold so as to urge the fluid mold into interaction with the cooling
block, and may transition to the up to down sub-state, "PP UP TO
DN". A signal may be sent from the pressure plate slave state
machine to the master state machine to indicate that the transition
from the second state to the first state.
[0148] In the up to down sub-state, "PP UP TO DN", the pressure
plate slave state machine may receive and execute a subcommand from
the master state machine to transition from the up to down
sub-state to the first state, "PP DN", if the transition from the
second state to the first state is complete. If the transition from
the second state to the first state times out (i.e., the pressure
plate does not transition to the first state within a predetermined
period of time), then the pressure plate slave state machine may
receive and execute a subcommand from the master state machine to
transition to the unknown sub-state, "PP UNKNOWN".
[0149] Further, in the second state, "PP UP", the conveying
mechanism slave state machine may receive and execute a subcommand
to transition to an up to eject sub-state, "PP UP TO EJECT", where
the pressure plate is requested to be in the eject sub-state,
"EJECT". In the up to eject sub-state, the pressure plate slave
state machine may receive and execute subcommand so as to
transition to an eject state, defined by the actuation mechanism
interacting with the solid ejector to move it into an ejection
position. Upon receiving the subcommand from the master state
machine, the pressure plate slave state machine may cause
interaction of the actuation mechanism with the solid ejector to
move it into an ejection position, and a signal may be sent from
the pressure plate slave state machine to the master state machine
to indicate that the transition from the first state to the eject
state.
[0150] If the transition is complete, then the pressure plate slave
state machine 800 may transition to the eject state, "PP EJECT",
where a fluid mold in the ejection position is ejected (or
loosened) by the solid ejector. In particular, the pressure plate
slave state machine may actuate an actuation mechanism to eject the
solid in the ejection position. If the transition takes longer than
the predetermined amount of time, then pressure slave state machine
may receive and execute a subcommand from the master slave state
machine to transfer to the unknown sub-state, "PP UNKNOWN."
[0151] If the pressure plate is requested to be in the second
state, "UP", then the pressure plate slave state machine may
receive and execute a first command so as to transition to the
second state, defined by the pressure plate being arranged in a
spaced apart relation from the top surface of the fluid in the
fluid mold so as not to urge the fluid mold into interaction with
the cooling block. Upon receiving the first command from the master
state machine, the pressure plate slave state machine may cause
arrangement of the pressure plate into the spaced apart relation
from the top surface of the fluid in the fluid mold so as not to
urge the fluid mold into interaction with the cooling block, and
transition to the eject to up sub-state, "PP EJECT TO UP". A signal
may be sent from the pressure plate slave state machine to the
master state machine to indicate that the transition from the eject
state to the second state.
[0152] In the eject to up sub-state, "PP EJECT TO UP", the pressure
plate slave state machine may receive and execute a command from
the master state machine to transition from the eject state to the
second state, "PP UP", if the transition from the eject state to
the second state is complete. If the transition from the eject
state to the second state times out (i.e., the pressure plate does
not transition to the second state within a predetermined period of
time), then the pressure plate slave state machine may receive and
execute a subcommand from the master state machine to transition to
the unknown sub-state, "PP UNKNOWN".
[0153] FIG. 9 illustrates a solid-dispensing mechanism slave state
machine 900, which may be the same as or similar to the
solid-dispensing mechanism slave state machine 205 in FIG. 2
according to example implementations of the present disclosure. The
solid-dispensing mechanism slave state machine in FIG. 9 may
illustrate one example implementation of the solid-dispensing
mechanism slave state machine described in FIG. 2, which receives
commands and/or subcommands from the master state machine based on
respective states of the solid-dispensing mechanism slave state
machine. Execution of the commands by the solid-dispensing
mechanism slave state machine may be initiated by the
solid-dispensing mechanism slave state machine after receipt of the
commands from the master slave state machine.
[0154] For example, as shown in FIG. 9, the solid-dispensing
mechanism slave state machine 900 may be in an initialization
state, "DOOR INIT". In some example implementations, after the
track door is initialized in in the initialization state, "DOOR
INIT", the solid-dispensing mechanism slave state machine 900 can
receive and execute a set of subcommands from the master state
machine to set the PWM of a GPIO to transmit a series of pulses to
control the motors for track door control at one hundred percent
(100%) of the full speed of the motors and set a timing mechanism,
such as a timer, to control the speed of closing the track door.
The solid-dispensing mechanism slave state machine may then receive
and execute a subcommand from the master state machine to
transition from the initialization state, "DOOR INIT" to a door
closing at full speed sub-state, "DOOR CLOSING FULL SPEED."
[0155] In the door closing at full speed sub-state, "DOOR CLOSING
FULL SPEED", the solid-dispensing mechanism slave state machine 900
can receive and execute a first command to cause arrangement of the
solid-dispensing mechanism so as not to cause the solid-dispensing
mechanism to dispense the loosened solid, i.e., the motors can
control the closing of the track door at the full speed so that the
solid-dispensing mechanism slave state machine is in a second state
defined by the solid-dispensing mechanism being arranged so as to
not dispense the loosened solid. If the transition of the
solid-dispensing mechanism slave state machine from the door
closing at full speed sub-state to the second state is successful,
then the solid-dispensing mechanism slave state machine can clear
the timer and transition to the second state, "DOOR CLOSE". If the
transition of the solid-dispensing mechanism slave state machine
from the door closing at full speed sub-state to the second state
is not successful during the time period (i.e., the timer expires),
then the solid-dispensing mechanism slave state machine can receive
and execute a subcommand from the master state machine to set the
PWM associated therewith to transmit a series of pulses to control
the motors at a reduced speed, such as at 60% of the full speed and
reset the timer to control the speed of closing the track door at
the reduced speed. The solid-dispensing mechanism slave state
machine can then transition from the door closing at full speed
sub-state, "DOOR CLOSING FULL SPEED", to the door closing at
reduced speed sub-state, "DOOR CLOSING REDUCED SPEED". In the door
closing at reduced speed sub-state, the motors can control the
closing of the door at a reduced speed.
[0156] In some example implementations, the solid-dispensing
mechanism slave state machine 900 can activate a switch mechanism
connected to the GPIO that is configured to control closing of the
track door by deactivating the switch mechanism so as to cause a
low signal or low state to be transmitted to the processor on the
GPIO. The solid-dispensing mechanism slave state machine can clear
timers and can transition from the door closing at reduced speed
sub-state "DOOR CLOSING REDUCED SPEED" to the second state, "DOOR
CLOSE". In another example, the solid-dispensing mechanism slave
state machine can clear timers and can transition from the door
closing at reduced speed sub-state "DOOR CLOSING REDUCED SPEED"
state to the second state, "DOOR CLOSE", when the switch is
activated or the timer is expired. A sensing mechanism located
proximate to the track door may be configured to detect whether the
track door is successfully closed or not. When the track door is
closed, it may indicate that there is no solid to be dispensed at
the solid-dispensing position (e.g., P28 in FIG. 1).
[0157] In some example implementations, when the solid-dispensing
mechanism slave state machine 900 is in the second state, "DOOR
CLOSE," the solid-dispensing mechanism slave state machine may
receive and execute a second command to cause arrangement of the
solid-dispensing mechanism so as to cause the solid-dispensing
mechanism to dispense the solid loosened by the solid ejector to
the user through the track door to the exit port. In particular,
the solid-dispensing mechanism slave state machine may receive and
execute the second command from the master state machine to open
the track door, and subcommands from the master state machine to
set the PWM of the GPIO to control the motors at a full speed and
set the timer to control the speed of opening the track door at the
full speed. The solid-dispensing mechanism slave state machine can
transition from the second state, "DOOR CLOSE", to a door opening
at full speed sub-state, "DOOR OPENING FULL SPEED".
[0158] In the door opening at full speed sub-state, "DOOR OPENING
FULL SPEED", the motors can control the closing of the door at the
full speed. In another example, when the timer is expired, the
solid-dispensing mechanism slave state machine can receive and
execute a subcommand to set PWM to control the motors at a reduced
speed, such as at 80% of the full speed, and reset the timer to
control the speed of opening the track door at the reduced speed.
The solid-dispensing mechanism slave state machine can then
transition from the door opening at full speed sub-state, "DOOR
OPENING FULL SPEED", to the door opening at reduced speed
sub-state, "DOOR OPENING REDUCED SPEED", where the motors can
control the closing of the door at the reduced speed.
[0159] In some example implementations, the solid-dispensing
mechanism slave state machine 900 may receive and execute a
subcommand from the master state machine to activate another switch
connected to the GPIO, which may control opening the track door by
opening the switch so as to cause a low signal or low state to be
transmitted to the processor on the GPIO. The solid-dispensing
mechanism slave state machine can receive and execute another
subcommand to clear timers. Further, the solid-dispensing mechanism
can receive and execute a second command to cause arrangement of
the solid-dispensing mechanism so as to cause the solid-dispensing
mechanism to dispense the solid loosened by the solid ejector to
the user through the exit port, so that the solid-dispensing
mechanism slave state machine can transition from the door opening
at reduced speed sub-state, "DOOR OPENING FULL SPEED", to the first
state, "DOOR OPEN".
[0160] In a further example, the solid-dispensing mechanism slave
state machine 900 can receive and execute a subcommand from the
master state machine to clear timers so as to transition from the
door opening at reduced speed sub-state, "DOOR OPENING REDUCED
SPEED", to the first state, "DOOR OPEN", when the other switch is
activated or the timer is expired. A sensing mechanism located
proximate to the track door may be configured to detect whether the
track door is successfully opened or not. When the solid-dispensing
mechanism is arranged to dispense the solid loosened by the solid
ejector to the user through the exit port, i.e., track door is open
or in the first state, the sensing mechanism may indicate that
there is solid to be dispensed at the solid-dispensing
position.
[0161] In some implementations, when the timer is expired and the
other switch controlling opening the track door is activated, the
solid-dispensing mechanism slave state machine can transition from
the door closing at reduced speed sub-state, "DOOR CLOSING REDUCED
SPEED", to the first state, "DOOR OPEN". In another example, when
the timer is expired and the switch controlling closing of the
track door is activated, the solid-dispensing mechanism slave state
machine can transition from the door opening at reduced speed
sub-state "DOOR OPENING REDUCED SPEED", to the second state "DOOR
CLOSE".
[0162] In some example implementations, when the solid-dispensing
mechanism slave state machine 900 is in the first state, "DOOR
OPEN," the solid-dispensing mechanism slave state machine may
receive and execute a first command to cause arrangement of the
solid-dispensing mechanism so as not to cause the solid-dispensing
mechanism to dispense the loosened solid, i.e., close the track
door. In particular, for example, the solid-dispensing mechanism
slave state machine can set the PWM of the GPIO to control the
motors at full speed and set the timer to control the speed of
closing the track door at full speed. The solid-dispensing
mechanism slave state machine can then transition from the first
state, "DOOR OPEN", to the door closing at full speed sub-state,
"DOOR CLOSING FULL SPEED". For example, after the solid is
dispensed to the user at the solid-dispensing position, the
solid-dispensing mechanism slave state machine can receive the
first command to cause arrangement of the solid-dispensing
mechanism so as not to cause the solid-dispensing mechanism to
dispense the loosened solid, i.e., close the track door.
[0163] In some example implementations, when the solid-dispensing
mechanism slave state machine is in the first state, i.e., the
track door is open, a user-requested number of solids can be
dispensed to the user or consumer through the track door, as
described above. After the user-requested number of solids is
dispensed to the user, then the solid-dispensing mechanism slave
state machine 900 may receive and execute a first command to cause
arrangement of the solid-dispensing mechanism so as not to cause
the solid-dispensing mechanism to dispense the loosened solid,
i.e., close the track door. In some example implementations, when
the track is still moving and not ready for the solid to be
dispensed, the GPIOs of the two switches associated with the
solid-dispensing mechanism slave state machine may be "HIGH". When
the GPIOs are "HIGH", no solid may be dispensed to the user.
[0164] FIG. 10 illustrates an apparatus 1000 according to some
example implementations of the present disclosure. In some
examples, the apparatus may include the one or more processors and
motors to implement the state machines as described above. As
shown, the apparatus may include one or more of each of a number of
components such as, for example, a processor 1002 connected to a
memory 1004.
[0165] The processor 1002 is generally any piece of computer
hardware that is capable of processing information such as, for
example, data, computer-readable program code, instructions or the
like (at times generally referred to as "computer programs," e.g.,
software, firmware, etc.), and/or other suitable electronic
information. The processor is composed of a collection of
electronic circuits some of which may be packaged as an integrated
circuit or multiple interconnected integrated circuits (an
integrated circuit at times more commonly referred to as a "chip").
The processor may be configured to execute computer programs, which
may be stored onboard the processor or otherwise stored in the
memory 1004 (of the same or another apparatus). In other examples,
the processor may be embodied as or otherwise include one or more
application-specific integrated circuits (ASICs),
field-programmable gate arrays (FPGAs) or the like. Thus, although
the processor may be capable of executing a computer program to
perform one or more functions, the processor of various examples
may be capable of performing one or more functions without the aid
of a computer program.
[0166] The memory 1004 is generally any piece of computer hardware
that is capable of storing information such as, for example, data,
computer programs (e.g., computer-readable program code 1006)
and/or other suitable information either on a temporary basis
and/or a permanent basis. The memory may include volatile and/or
non-volatile memory, and may be fixed or removable. Examples of
suitable memory include random access memory (RAM), read-only
memory (ROM), a hard drive, a flash memory, a thumb drive or the
like. In various instances, the memory may be referred to as a
computer-readable storage medium. The computer-readable storage
medium is a non-transitory device capable of storing information,
and is distinguishable from computer-readable transmission media
such as electronic transitory signals capable of carrying
information from one location to another. Computer-readable medium
as described herein may generally refer to a computer-readable
storage medium or computer-readable transmission medium.
[0167] In addition to the memory 1004, the processor 1002 may also
be connected to a real-time clock (RTC) 1008 configured to keep be
set to and keep the current standard time. In addition, the
processor may be connected to one or more interfaces for
displaying, transmitting and/or receiving information. The
interfaces may include a communications interface 1010 and/or one
or more user interfaces. In some examples, particularly in
instances in which the apparatus 1000 is configured to implement a
network interface unit (NIU), the apparatus may not include a
separate user interface, and may instead interact with one provided
by the appliance. The communications interface may be configured to
transmit and/or receive information, such as to and/or from other
apparatus(es), network(s) or the like. The communications interface
may be configured to transmit and/or receive information by
physical (wired) and/or wireless communications links. Examples of
suitable communication interfaces include a network interface
controller (NIC), wireless NIC (WNIC) or the like.
[0168] The user interfaces may include a display 1012 and/or one or
more user input interfaces 1014. The display may be configured to
present or otherwise display information to a user, suitable
examples of which include a liquid crystal display (LCD),
light-emitting diode display (LED), plasma display panel (PDP) or
the like. The user input interfaces may be wired or wireless, and
may be configured to receive information from a user into the
apparatus, such as for processing, storage and/or display. Suitable
examples of user input interfaces include a microphone, image or
video capture device, keyboard or keypad, mouse, joystick,
touch-sensitive surface (e.g., touchpad, touchscreen), biometric
sensor or the like.
[0169] As indicated above, program code instructions may be stored
in memory, and executed by a processor, to implement functions
described herein. As will be appreciated, any suitable program code
instructions may be loaded onto a computer or other programmable
apparatus from a computer-readable storage medium to produce a
particular machine, such that the particular machine becomes a
means for implementing the functions specified herein. These
program code instructions may also be stored in a computer-readable
storage medium that can direct a computer, a processor or other
programmable apparatus to function in a particular manner to
thereby generate a particular machine or particular article of
manufacture. The instructions stored in the computer-readable
storage medium may produce an article of manufacture, where the
article of manufacture becomes a means for implementing functions
described herein. The program code instructions may be retrieved
from a computer-readable storage medium and loaded into a computer,
processor or other programmable apparatus to configure the
computer, processor or other programmable apparatus to execute
operations to be performed on or by the computer, processor or
other programmable apparatus.
[0170] Retrieval, loading and execution of the program code
instructions may be performed sequentially such that one
instruction is retrieved, loaded and executed at a time. In some
example implementations, retrieval, loading and/or execution may be
performed in parallel such that multiple instructions are
retrieved, loaded, and/or executed together. Execution of the
program code instructions may produce a computer-implemented
process such that the instructions executed by the computer,
processor or other programmable apparatus provide operations for
implementing functions described herein.
[0171] Execution of instructions by a processor, or storage of
instructions in a computer-readable storage medium, supports
combinations of operations for performing the specified functions.
In this manner, an apparatus 1000 may include a processor 1002 and
a computer-readable storage medium or memory 1004 coupled to the
processor, where the processor is configured to execute
computer-readable program code 1006 stored in the memory. It will
also be understood that one or more functions, and combinations of
functions, may be implemented by special purpose hardware-based
computer systems and/or processors which perform the specified
functions, or combinations of special purpose hardware and program
code instructions.
[0172] FIG. 11 illustrates a fluid-dispensing mechanism 1100 that
may be used in conjunction with the solid-production system 100 in
FIG. 1, according to example implementations of the present
disclosure. The fluid-dispensing mechanism 1100 can be configured
to dispense fluid, such as water, individually into each fluid mold
(e.g., M0-M29 in FIG. 1) of the solid-production system at a
fluid-dispensing position, e.g., P0 in FIG. 1. Dispensing fluid
individually into each fluid mold is different from some fluid
dispensing solutions that introduce fluid at one location and rely
on a cascading mechanism to distribute fluid throughout all the
fluid molds. In another example implementation, the
fluid-dispensing mechanism can dispense fluid into another
container vessel that is different from the fluid molds.
[0173] In some example implementations, the fluid-dispensing
mechanism 1100 includes a dispensing apparatus 1101 configured to
dispense a quantity of fluid, such as water, individually into the
fluid molds M0-M29 indexed into the fluid-dispensing position. The
dispensing apparatus may comprise a dispensing nozzle configured to
direct the quantity of fluid into the fluid molds, as well as
sealing components, valve mechanisms, and the like. A length of
tubing 1102 may be coupled to the dispensing apparatus to transmit
the quantity of fluid thereto. An inlet 1103 of the length of
tubing may receive the quantity of fluid from a reservoir, fluid
pipes, or the like.
[0174] In some other example implementations, the fluid-dispensing
mechanism 1100 may further comprise a pressure regulator 1104. The
pressure regulator may be disposed in-line with the length of
tubing 1102 or may be provided upstream and externally to the
length of tubing. The pressure regulator may be configured to
measure a fluid pressure of the fluid flowing through the length of
tubing and control the fluid pressure. With lower fluid pressure,
the flow rate of the fluid flow may be lower. As such, it may be
desirable to control the fluid pressure using the pressure
regulator to maintain the fluid pressure at a substantially lower
fluid pressure than what is typically used in residential homes so
as to prevent splash of the dispensed fluid at the dispensing
apparatus 1101.
[0175] For example, water flowing through the length of tubing may
have a water pressure of 12 pounds per square inch (psi), which is
substantially lower than current operating pressures (30-100 psi)
of typical residential water pressure. The dispensing apparatus
1101 may also incorporate a tube fitting that maintains an opening
to the atmosphere, so as to prevent the dispensing fluid from
exiting the tubing prior to dispensing into the desired fluid mold.
In this way, the dispensing apparatus 1101 can facilitate a break
in the fluid vacuum built up in the tubing from a dispense
operation at a location above the freezing point, in order to
prevent ice formation and blockage in the tube.
[0176] In some example implementations, it may be desirable to
provide the fluid regulator 1104 at the inlet 1103. The fluid
regulator can be configured to regulate the fluid pressure at the
inlet to have a value (e.g., 12 psi) that is below current
operating pressures (30-100 psi) of typical residential water
pressure. In this way, the fluid-dispensing mechanism 1100 may not
need to use a flow meter to monitor or measure variable flow rates
and can precisely regulate fluid dispense based on time alone. For
example, the fluid-dispensing mechanism can be configured to
control the time of fluid dispense to achieve accurate dispensing
of fluid to each of the fluid molds. Software logic, such as that
described in FIGS. 2-10, can be used to control or change
quantities of fluid dispensed to each fluid mold by the
fluid-dispensing mechanism. Properly controlled quantities of fluid
dispensed by the fluid-dispensing mechanism 1100 may provide a
tradeoff between volume of the formed solid in the fluid molds and
time for cooling the fluid in the fluid molds to form the solid. A
user may select the desired volume of the solid at a user
interface, which will in turn affect the quantity of fluid
dispensed by the fluid-dispensing mechanism and then the time for
cooling the fluid to form the solid.
[0177] The fluid-dispensing mechanism 1100 may further include, in
some example implementations, one or more valves to control flow of
the fluid in the system. For example, and as illustrated in FIG.
11, the fluid-dispensing mechanism includes three valves; although
one valve, two valves, three valves, four valves, etc., provided in
series or in parallel, or a combination thereof may be useful for
controlling the flow of the fluid in the system. As illustrated in
FIG. 11, each of the three valves is or includes a direct current
(DC) solenoid 1105. The DC solenoids may be disposed in-line with
the length of tubing 1102 or may be provided upstream and
externally to the length of tubing. Other types of valves may also
be implemented.
[0178] FIG. 12 illustrates a solid-production system 1200 that is
the same as or similar to the solid-production system 100, in FIG.
1. The solid-production system in FIG. 12 includes a conveying
mechanism 1201, a fluid-dispensing mechanism 1202, a pressure plate
and a cooling block arrangement 1203, a solid ejector 1204, and a
solid-dispensing mechanism 1205. FIG. 12 in particular illustrates
a location of a fluid-dispensing mechanism according to example
implementations of the present disclosure.
[0179] FIGS. 13 and 14 illustrate example cooling blocks 1300,
1400, respectively, which may be used in conjunction with the
solid-production system 100 in FIG. 1, according to example
implementations of the present disclosure.
[0180] A cooling block as contemplated by the present disclosure,
is, for example, arranged to interact with one or more fluid molds
to reduce a first temperature of a fluid dispensed in each of the
one or more fluid molds to a second temperature, the second
temperature being lower than the first temperature, to solidify the
fluid in each of the one or more fluid molds. In such example
implementations, the cooling block has a thermal mass operable to
absorb and store thermal energy transferred by the fluid in each of
the one or more fluid molds so as to reduce the first temperature
of the fluid to the second temperature. In some example
implementations, a material of the thermal mass may be aluminum, or
another material having similar thermal characteristics to
aluminum. In some other example implementations, a material of the
thermal mass may be iron, or another material having similar
characteristics to iron. In some still further example
implementations, a material of the thermal mass may be one having
thermal characteristics that enable the cooling block to absorb and
store thermal energy as efficiently as a thermal mass having a
material of aluminum, iron, and the like.
[0181] In order to increase a rate of solidification or decrease a
solidification time of the fluid molds in a cooling region of the
cooling block, in some example implementations, a pressure plate
may be arranged to urge the one or more fluid molds into
interaction with the cooling block. More particularly, the pressure
plate may be arrangeable in an initial position adjacent to the top
surface of the fluid in each of the one or more fluid molds so as
to urge the one or more fluid molds into interaction with the
cooling block in order to reduce the first temperature of the fluid
in each of the one or more fluid molds to the second temperature,
and may be arrangeable in a second position in spaced apart
relation from the top surface of the fluid in each of the one or
more fluid molds so as not to urge the one or more fluid molds into
interaction with the cooling block. This is described in more
detail in FIG. 27.
[0182] In some still further example implementations, one or more
actuation mechanisms may be arrangeable to bias the pressure plate
into the initial position adjacent to the top surface of the fluid
in each of the one or more fluid molds, and arrangeable to bias the
pressure plate into the second position in spaced apart relation
from the top surface of the fluid in each of the one or more fluid
molds. The one or more actuation mechanisms may comprise a biasing
member arranged adjacent to a top surface of the pressure plate to
exert a normal force on the top surface of the pressure plate so as
to bias the pressure plate into the initial position adjacent to
the top surface of the fluid in each of the one or more fluid
molds. The one or more actuation mechanisms may further comprise a
sliding member, wherein the sliding member is slidingly engaged
with the pressure plate and is movable in a reverse machine
direction to exert an opposing normal force against the normal
force exerted on the top surface of the pressure plate by the
biasing member, the opposing normal force being greater than the
normal force exerted by the biasing member, so as to bias the
pressure plate into the second position in spaced apart relation
from the top surface of the fluid in each of the one or more fluid
molds.
[0183] Further, the one or more actuation mechanisms may further
comprise a motor and a reciprocating shaft engaged with the sliding
member, wherein actuation of the motor drives the reciprocating
shaft to reciprocatingly move the sliding member in a machine
direction and the reverse machine direction. The motor may be
actuated by a control mechanism, which may comprise a hardware
processor and at least one memory. The control mechanism may
interface with and be operable to actuate the motor. In some
example implementations, the control mechanism may comprise a
pressure plate slave state machine (e.g., 204 in FIG. 2), which may
receive commands from a master state machine (e.g., 201 in FIG. 2)
to actuate the motor in order to arrange the pressure plate in
either the initial position, the second position, or an ejection
position, and arrange a solid ejector in a first or second position
as described in detail in FIG. 8.
[0184] In some example implementations, a conveying mechanism may
be arranged to convey one or more fluid molds in a machine
direction through a solid-production system (e.g., 100 in FIG. 1).
The conveying mechanism may be arranged to convey the one or more
fluid molds in the machine direction through a cooling region of
the cooling block, so that in the cooling region, each of the one
or more fluid molds is urged into interaction with the cooling
block. Specifically, the fluid in each of the one or more fluid
molds entering the cooling region may be at the first temperature
and the fluid in each of the one or more fluid molds exiting the
cooling region may be reduced to the second temperature and
solidified.
[0185] In some still further example implementations, a
fluid-dispensing mechanism may be arranged adjacent to the one or
more fluid molds to dispense the fluid at the first temperature
into each of the one or more fluid molds when the fluid molds are
in a fluid-dispensing position relative to the fluid-dispensing
mechanism.
[0186] In some example implementations, the cooling block may
comprise a monolithic mass of a material, such as for example, a
monolithic mass of aluminum. However, in other example
implementations, the cooling block may also comprise multiple
parts, such as, for example, two or more blocks of a material
(e.g., aluminum), which may be coupled together to form the cooling
block. The total volume of the cooling block, whether as a
monolithic mass or as a coupling of multiple blocks, may be between
about 100 inches cubed (in.sup.3) and about 120 in.sup.3; and in
some example implementations, the volume of the cooling block may
be about 110.5 in.sup.3, with dimensions of about 4.25 inches by
about 2 inches by about 13 inches. However, these dimensions, and
volume, may vary.
[0187] Regardless, a cooling block having a thermal mass of a
material so sized, shaped, and/or dimensioned may be advantageous
as it forms a larger heat sink for absorbing and storing the
thermal energy transferred by the fluids in each of the one or more
fluid molds when the fluid molds are in the cooling region of the
cooling block. As such, the thermal mass is able to more
efficiently solidify fluid in more fluid molds on more tracks than
conventional solidification methods using conduction or blowing air
on the fluid.
[0188] In some still further example implementations, a cooling
block may comprise defined channels throughout the cooling block,
which are arranged to have a cooling material flowed therethrough.
In some still other example implementations, a cooling block may
comprise at least one tube, extending laterally between a top
surface and a bottom surface of the cooling block in a pattern, and
arranged to have a cooling material flowed therethrough. The at
least one tube may comprise an evaporator tube and the cooling
material may comprise refrigerant. However, other cooling materials
are also contemplated herein, such as, for example, but not limited
to carbon dioxide, ammonia, water or brine. Depending on the
cooling material used, the cooling material may be provided to the
at least one tube in different manners. For example, the cooling
material may be transmitted to the at least one tube from a heat
exchanger where the cooling material is a refrigerant used in a
compressor. However, the cooling material may be another material
depending on the application of the solid-production system. The
evaporator tube may be inserted or embedded into extruded parts of
the cooling block and may receive the cooling material. In some
examples, where the cooling block comprises two or more blocks, the
at least one tube may be inserted or embedded between the two or
more blocks.
[0189] The cooling material flowing through the at least one tube
can be configured to reduce the temperature of the fluid in the
fluid molds from the first temperature to the second temperature.
For example, where refrigerant is flowed through the at least one
tube in the cooling block, the cooling block is able to absorb and
store the thermal energy transferred by the fluid in each of fluid
molds from a first temperature to a second, refrigerant temperature
(about -22 degrees (.degree. F.)).
[0190] Notably, an energy density or amount of energy stored in the
cooling block may be variable based on the material of the thermal
mass. For example, the energy density of aluminum is about 83.8
mega joule per liter (MJ/L), which may allow the cooling block to
exchange more energy with the fluid in the fluid molds than the
compressor only (over a certain period of time) due to the material
density, specific heat, and thermal conductivity properties. For
example, the cooling block may exchange between about 420 kilowatts
(kW) and about 450 kW with the fluid molds in order to reduce a
temperature of the fluid in the fluid molds to the second
temperature. The thermal mass of the cooling block is sized,
shaped, and/or dimensioned so that the thermal mass of the cooling
block is greater than an energy density of cooling material (e.g.,
refrigerant) flowing through the at least one tube.
[0191] Thus, it is advantageous to provide the thermal mass having
the at least one tube embedded or otherwise inserted in the thermal
mass, so that the thermal mass is positioned between the at least
one tube and a top surface of the fluid in the fluid molds so as to
allow for the cooling block to deliver more cooling power (i.e.,
decrease the solidification time) to the fluid, then would be
typical of a compressor/refrigerant alone, such that the first
temperature of the fluid in the fluid molds is reduced to the
second temperature faster than using a compressor/refrigerant
alone. In addition, the cooling block can advantageously reduce the
temperature of the fluid in the fluid mold from the first
temperature to the second temperature only through conduction using
the thermal mass of the cooling block without the need of using
blown air or convection, such that solidification of the fluid in
the fluid molds is more cost efficient and quicker than
conventional solidification modalities.
[0192] For example, FIG. 13 illustrates a top view of the example
cooling block 1300, according to example implementations of the
present disclosure. In FIG. 13, the cooling block defines a thermal
mass that is sized, shaped, and/or dimensioned to allow three
tracks, each track comprising a plurality of fluid molds 1301 to be
received in a cooling region of the cooling block. At least one
tube 1302 is provided in the cooling block of FIG. 13, where the at
least one tube extends in a serpentine pattern along and within the
cooling block, the serpentine pattern extending laterally within a
plane of the cooling block.
[0193] In another example, FIG. 14 illustrates a front perspective
view of the example cooling block 1400, according to example
implementations of the present disclosure. In FIG. 14, the cooling
block defines a thermal mass that is sized, shaped, and/or
dimensioned to allow a plurality of tracks, each comprising a
plurality of fluid molds (not shown), to be received in a cooling
region of the cooling block. As shown in FIG. 14, the cooling block
defines longitudinally-extending channels 1401 extending parallel
to a longitudinal axis of the cooling block. Each of the
longitudinally-extending channels may be arranged to receive one of
at least one tube 1402, each tube being arranged in a coiled
pattern extending along a length of the corresponding
longitudinally-extending channels.
[0194] In some example implementations, the thermal mass of the
cooling block may be optimized or made most effective. More
particularly, the thermal mass of the cooling block may comprise a
material and be sized, shaped, and/or dimensioned to optimize
performance of the cooling block based on desired functionality of
a solid-production system. For example, where the desired
functionality of a solid-production system is to optimize
performance to produce a solid as quickly as possible, while
keeping a size of the solid-production system small, then the
thermal mass of the cooling block may be optimized to achieve this
functionality.
[0195] A computer generated model may be utilized for optimizing a
design of the thermal mass of the cooling block. The computer
generated model may be a computational fluid dynamics (CFD) model,
or the like, created using any software currently available so as
to run a simulation to determine the dynamics of different elements
in a solid-production system and may then be refined in order to
optimize a design of the elements, e.g., the cooling block. For
example, the computer-generated model may simulate the thermal mass
of the cooling block based on one or more parameters of the
solid-production system, where the parameters may be independent,
dependent or semi-independent in the simulation. The one or more
parameters may include at least, for example, but are not limited
to, full three-dimensional (3D) geometries, unsteady states, phase
changes from fluid to solid. The one or more parameters may also
include, but are not limited to material property changes, full
conjugate heat transfer (CHT), compressor performance
considerations, fully parameterized geometries, and the like.
[0196] The full CHT may further include parameters such as, but not
limited to, conformal meshes, radiation, convection, and
conduction, and material properties including density, specific
heat, thermal conductivity, surface emissivity, and surface
transmissivity. The fully parameterized geometry may further
include parameters such as, but not limited to, thermal mass sizes,
shapes, and/or dimensions, material of the thermal mass, thermal
mass cost, solid dimensions, track dimensions, number of tracks,
track spacing, radius of the at least one tube, location of the at
least one tube, number of bends of the at least one tube, bending
radius of the at least one tube, liner thickness, liner material,
and insulation thickness.
[0197] In some example implementations, simulating the design of
the thermal mass of the cooling block may have objectives such as,
for example, to minimize time to solidify the fluid and minimize
fluid mold material cost. The simulation may have multiple
constraints. For example, the constraints may include that the time
to solidify should be less than 600 seconds, the maximum solid
temperature should be less or equal than -0.2.degree. C., the mass
for the fluid molds should be less or equal than 5 kilograms (kg)
and the total mass of solid in the solid-production system should
be more or equal than 600 grams (g).
[0198] In one example implementation, the parameters input into the
software for creating the computer-generated model may include, but
are not limited to: [0199] CoolingBlock_Xaxis [0200]
CoolingBlock_Zaxis [0201] IceCube_EdgeFillet [0202] IceCube_Yaxis
[0203] IceCube_Xaxis [0204] IceCubeSpacingOffset_Yaxis [0205]
Insulation_Thickness [0206] Liner_Thickness_mm [0207]
NumberofCubes_Yaxis [0208] NumberofTracks [0209]
NumberofTubeBends_MinusY [0210] NumberofTubeBends_PlusY [0211]
NumberofTubes_Inner [0212] LengthofTubes_Inner [0213]
TubeBend_BendRadius [0214] LengthofTubes_Outer [0215]
Tube_Outer_TranslationXaxis [0216] TubeStart_Offset_Xaxis [0217]
TubeStart_Offset_Zaxis [0218] Tube_Radius [0219] IceCube_DraftAngle
[0220] TrackBottom_Fillet [0221] TrackSpacing_InnerXaxis [0222]
TrackDepth_Zaxis [0223] TrackSpacing_OuterXaxis [0224]
IceCube_Zaxis [0225] IceCube_Spacing [0226] IceCube_Liner_Extrusion
[0227] IceCube_Edge_Offset_Yaxis [0228] CoolingBlock_Zaxis_Offset
[0229] TubeStart_Offset_Xaxis_Percent [0230]
Tube_Offset_Xaxis_TotalLength [0231] MoldMaterial [0232]
MaxTemp_IcePlane [0233] XPlane_DerivedPart [0234]
IceCubeWidth_Yaxis [0235] TrackSpacing_InnerXaxis_total [0236]
LinerThickness_m [0237] Liner_Material [0238] Liner_ThermalCond
[0239] FIG. 15 illustrates a computer-generated model of an
optimized cooling block 1500 according to example implementations
of the present disclosure. The optimized cooling block in FIG. 15
may be an example simulated design of a thermal mass of a cooling
block using the parameters as described above. As shown, the
thermal mass includes a base 1501 and extruded regions 1502. The
extruded regions may correspond to a design of the fluid molds,
such that when the fluid molds are urged into interaction with the
cooling block, the fluid molds may be recessed into the extruded
regions thereof.
[0240] Further, as illustrated in FIG. 15, at least one tube 1503
may be inserted or embedded into the base of the thermal mass. The
at least one tube may be inserted or embedded into the thermal mass
of the cooling block in an optimized manner, or in a manner that
will most effectively and efficiently cool fluid molds urged into
interaction with the cooling block.
[0241] Also as shown in FIG. 15 are example parameters of the
simulated design of the thermal mass of the cooling block 1500. The
example parameters illustrated in FIG. 15 are in no way the only
parameters that may be used in simulating the design of the cooling
block. The parameters illustrated in FIG. 15 include the inner and
outer spaces between two tracks (e.g., TrackSpacing_InnerXaxis and
TrackSpacing_OuterXaxis), offset for inserting the evaporator tube
(e.g., TubeStart_Offset_Zaxis) and space between consecutive fluid
molds (e.g., IceCubeSpacingOffset_Yaxis).
[0242] FIGS. 16A and 16B further illustrate two different views of
a computer-generated model of an optimized cooling block 1600
according to example implementations of the present disclosure. As
shown in FIG. 16A, a front perspective view of the optimized
cooling block illustrates a base 1601 and extruded regions 1602.
The base may define multiple, longitudinally extending channels
1603 arranged to receive at least one tube. FIG. 16B illustrates
the optimized cooling block 1600 from a top plan view.
[0243] FIGS. 17A and 17B illustrate two different views of a
computer-generated model of a solid 1700 according to example
implementations of the present disclosure. The solid may be
produced in fluid molds moved along a track of a conveying
mechanism, when the fluid molds are in a cooling region of a
cooling block, such as the cooling block 1600 described above in
FIGS. 16A and 16B. The solid may be formed in a fluid mold that is
sized, shaped, and/or dimensioned to most efficiently form a solid
therein. The fluid mold may be shaped as a rectangular prism, a
square prism, a cylinder, or any other polygonal shape, which may
then produce a correspondingly shaped solid. This may be described
in further detail in FIG. 22.
[0244] FIG. 18 illustrates an example schematic of a
solid-detection mechanism 1800 that may be used in with the
solid-production system 100 in FIG. 1, according to example
implementations of the present disclosure. In one example
implementation, the solid-detection mechanism in FIG. 18 can be a
part of a solid ejector 103 in FIG. 1 as a mechanism to detect
whether or not a solid is formed in a fluid mold when the fluid
mold moves out of a cooling region relative to a cooling block
(e.g., P1-P10 in FIG. 1) and into a solid-detection position (e.g.,
P11 in FIG. 1). In another example implementation, the
solid-detection mechanism can be a separate mechanism proximate to
a fluid-dispensing mechanism 101 in FIG. 1 or in another location
in the solid-production system.
[0245] The solid-detection mechanism 1800 can be configured to use
a sensor 1801 to detect whether a solid, such as ice, has been
formed in the fluid mold. In some example implementations, the
sensor can include a non-contact temperature sensor to measure a
surface temperature of the fluid or solid in the fluid mold, which
can be, for example, any one of the fluid molds M0-M29 in the
solid-detection position P11. In other example implementations, a
contact temperature sensor configured to contact a fluid in the
fluid mold or a capacitive sensor can be utilized. Other types of
sensors are also contemplated herein.
[0246] Where the sensor 1801 is a non-contact temperature sensor,
the solid-detection mechanism can be configured to determine
whether the solid, such as ice, has been formed in the fluid mold
based on the measured surface temperature of the fluid in the fluid
mold. For example, the non-contact temperature sensor can be
configured to detect whether or not an entirety or a substantial
entirety of a volume of water in the fluid mold has been cooled to
a temperature at which ice has been formed. For example, the
temperature sensor can be a non-contact thermopile temperature
sensor such as a thermopile infrared temperature sensor.
[0247] In some example implementations, the solid-detection
mechanism 1800 can include a thermopile board 1802. The thermopile
board may be placed on a pressure plate 1803. The thermopile board
may define a hole on the board to enable the sensor to measure
thermal energy from the fluid or a solid in a fluid mold 1804,
where the sensor and the hole may be on a side of the thermopile
board shown in FIG. 18. Notably, the thermal energy measured by the
temperature sensor may differ between a solid and a fluid.
[0248] Using a non-contact temperature sensor to measure the
surface temperature of the fluid or solid in a fluid mold may be
advantageous as compared to solutions requiring a temperature
sensor being submerged in the fluid or adjacent to the fluid mold.
More particularly, a temperature sensor submerged in the fluid may
have a build-up of a solid (e.g., ice) on the temperature sensor.
Thus, the temperature sensor submerged in the fluid may have to be
heated to remove the build-up. Heating the temperature sensor to
remove the build-up may inhibit solid creation in the fluid mold
and slow the rotation speed of the fluid molds through the
solid-production system. Further, a temperature sensor positioned
adjacent to the fluid mold may only be able to measure the sides of
the fluid mold, where a solid (e.g., ice) forms first based on
geometry and heat transfer of the fluid mold. Thus, a temperature
sensor adjacent to the fluid mold may have no knowledge of whether
or not the entire volume of the solid in the fluid mold has formed
a solid and may require a secondary timer to compensate. Using a
sensor, such as but not limited to, a non-contact temperature
sensor 1801 as described herein to measure the surface temperature
of the fluid or solid in the fluid mold can thus avoid the above
problems.
[0249] FIGS. 19A and 19B illustrate two different views of a
solid-production system 1900, which may be the same as or similar
to the solid-production system 100 in FIG. 1, with an indication of
a location of an example solid-detection mechanism 1901. The
solid-detection mechanism in FIGS. 19A and 19B may be the same as
or similar to the solid-detection mechanism described in reference
to FIG. 18.
[0250] FIGS. 20A and 20B illustrate schematics of temperature
measurement areas as detected by a solid-detection mechanism 2000
according to example implementations of the present disclosure. The
solid-detection mechanism illustrated in FIGS. 20A and 20B may be
the same as or similar to the solid-detection mechanism described
in reference to FIG. 18.
[0251] The temperature measurement area can be calculated based on
a performance specification of a thermopile temperature sensor of
the solid-detection mechanism 2000. The performance specification
may define one or more variables relating to detection of a
temperature of the fluid or solid formed in the fluid mold. Such
variables may include, but are not limited to: a field of view of
the thermopile temperature sensor, a size of an aperture through
which the thermopile temperature sensor can measure the
temperature, a distance between the thermopile temperature sensor
and a surface of the fluid mold or a top surface of the fluid or
solid formed in the fluid mold, and fluid mold geometry. In some
example implementations, modification of the temperature
measurement area may require a change to the aperture and/or
distance between the thermopile temperature sensor and a surface of
the fluid mold or a top surface of the fluid or solid formed in the
fluid mold.
[0252] FIG. 20A illustrates one example implementation of a
temperature measurement area of a solid-detection mechanism 2000 to
detect a temperature a fluid mold when a pressure plate 2001 is in
an initial position, or arranged adjacent to a top surface of the
fluid in the fluid mold so as to urge the fluid mold into
interaction with the cooling block.
[0253] FIG. 20B illustrates one example implementation of a
temperature measurement area of a solid-detection mechanism 2000 to
detect a temperature of a fluid mold when a pressure plate 2001 is
in a second position, or arranged in a spaced apart relation from
the top surface of the fluid in the fluid mold so as not to urge
the fluid mold into interaction with the cooling block.
[0254] FIG. 21 illustrates a graphical representation 2100 of a
temperature profile of a fluid/solid over time according to example
implementations of the present disclosure. In one example
implementation, a temperature sensor of the solid-detection
mechanism may be configured to detect a characteristic plateau of
the fluid, which then decreases in temperature as the fluid changes
from a sensible cooling phase to a latent cooling phase back to a
sensible cooling phase, with each phase starting after the previous
phases has ended. The "characteristic plateau" of the fluid occurs
during the latent cooling phase, where solid crystals (e.g., ice
crystals) are formed.
[0255] Where the fluid is water, for example, the changes may be a
manifestation of a phase change phenomenon where ice crystals start
forming during the characteristic plateau and grow (as dictated by
latent energy transfer) until the water becomes ice completely and
transitions to sensible cooling. The temperature sensor may be
configured to transmit a signal to the software logic of the
solid-production system, indicating that ice has formed in a fluid
mold when the fluid mold is in a solid-detection position.
[0256] FIG. 22 illustrates different designs of fluid molds
2200-2204 according to example implementations of the present
disclosure. The fluid molds illustrated in FIG. 22 may be the same
or similar to the fluid molds M0-M29 illustrated in FIG. 1. Each of
the fluid molds illustrated in FIG. 22 may be designed with a size,
shape, dimension, and/or material to achieve a desired function
(e.g., quicker solidification time, smaller volume of the fluid
mold). A computer-generated model, such as that described in
reference to FIGS. 15, 16A, and 16B, may run a simulation to
determine the dynamics of the fluid molds and then be refined so
that the fluid molds are optimized to achieve the desired
function.
[0257] For example, the fluid mold 2200 in FIG. 22 may have an
interior width of 16 mm to 20 mm, an interior height of 18 mm to 26
mm, and an interior angle of 85.degree. to 98.degree.. In some
example implementations, the fluid mold comprises an interior width
of 18.20 mm, an interior height of 20.90 mm, and an interior angle
of 94.2.degree.. In some examples, as designed, the fluid mold may
be made of polypropylene, stainless steel, and the like. As such,
the fluid mold of this implementation may be advantageous when
compared to conventional fluid mold designs because the design may
result in a decreased time to solidify fluid such as water in the
fluid mold and decreased mold material cost. The decreased time to
solidify fluid using the fluid mold of this example implementation
may occur because the shape of the fluid mold maximizes heat
transfer into the fluid mold so as to reduce solidification time,
the material of the fluid mold has a high thermal conductivity
material (e.g., polypropylene) which does not restrict the heat
transfer as much as a regular high thermal conductivity material
(e.g., regular polypropylene), and conduction heat transfer is
inherently higher than convection.
[0258] In another example, a fluid mold 2201 in FIG. 22 may
comprise an interior width of 16 mm to 21 mm, an interior height of
18 mm to 26 mm, and an interior angle of 90.degree. to 95.degree..
In some example implementations, the fluid mold comprises an
interior width of 21 mm, an interior height of 20.9 mm, and an
interior angle of 95.degree.. The fluid mold may also comprise a
fillet at an intersection between side surfaces and a bottom
surface thereof. As such, the fluid mold of this example
implementation may be advantageous because it may optimize solid
ejection due to the elimination of sharp interior angles in the
fluid mold.
[0259] In some examples, the designs of the fluid mold 2200 and the
fluid mold 2201 may be combined to provide blended designs that
balance thermal capacity and efficiency, contact between the fluid
mold and the cooling block, and ease of ejection of a formed solid
in the fluid mold. Fluid molds 2202, 2203 and 2204 illustrate a
blend of the designs of the fluid molds 2200 and 2201, which
consider multiple factors as described above.
[0260] For example, the fluid mold 2202 may comprise a draft angle
of 7.degree., a bottom of 3 mm and a side of 1 mm. The fluid mold
2203 may comprise draft angle of 5.degree., a bottom of 4 mm and
sides of 1 mm. The fluid mold 2204 may comprise draft angle of
9.degree., a bottom of 3 mm and sides of 1 mm. The bottom of 3 mm
(or 4 mm) and the sides of 1 mm may refer to the radius of the
fillet on either the bottom of the mold or the vertical
sides/corners. In one example, the fluid molds 2202, 2203, and 2204
may provide an improved ability of ejection of a formed solid from
the fluid mold as compared to conventional fluid mold designs. In
one example, the fluid molds M0-M29 in the solid-production system
100 in FIG. 1 can be produced according to one of the designs of
fluid molds 2202, 2203 and 2204.
[0261] FIG. 23 illustrates five different views of a fluid mold
2300 according to example implementations of the present
disclosure. In one example, the fluid mold 2300 may correspond to
one of the designs of fluid molds 2202, 2203 and 2204 in FIG. 22.
The fluid mold illustrated in FIG. 23 may have one or more
additional components to aid in solid ejection, solid dispense,
and/or solid formation.
[0262] In one example implementation, the fluid mold 2300 may
comprise one or more gripping surfaces 2301 arranged on diagonal
corners of the fluid mold, with the gripping surfaces being
deformable in response to the pressure exerted by a solid ejector
in the first position so as to loosen the solid within the fluid
mold. The solid ejector may be located proximate to the ejection
position (e.g., P11 in FIG. 1) to slightly deform the fluid mold to
break the bond between the formed solid and the fluid mold. That
is, the solid ejector may slightly deform the fluid mold by
squeezing the gripping surfaces on the fluid mold. In another
example implementation, one or more wings or lips 2302 extending
outwardly from the fluid mold can be added to the fluid mold to
enable or enhance transport of the fluid mold along the track of a
conveying mechanism arranged to index the one or more fluid molds
in a machine direction into the ejection position.
[0263] As described above, when a fluid mold arrives at a
solid-dispensing position (e.g., P28 in FIG. 1), a track door may
be open to allow a loosened solid to be dispensed from the fluid
mold though the open track door and out of the exit port of
consumer solid-dispensing mechanism. A sensing mechanism may be
located proximate to the solid-dispensing position to detect
whether the solid is dispensed or provided to the user through the
exit port. In one example implementation, the sensor may be an
optical interrupt, as described below.
[0264] FIG. 24 illustrates a solid-production system 2400, which
may be the same as or similar to the solid-production system 100 in
FIG. 1 with an indication of a location of a sensing mechanism 2401
of an example solid-detection mechanism according to example
implementations of the present disclosure. As shown, the sensing
mechanism or sensor can be a part of a solid-dispensing mechanism
2402. In another example, the sensing mechanism can be separate but
proximate to the solid-dispensing mechanism.
[0265] In one example implementation, the sensing mechanism 2401
may comprise an optical interrupt that can operate by utilizing an
emitter/receiver pair that sends a constant optical beam of
infrared radiation (IR). When a fluid mold arrives at the
solid-dispensing position, one or more track doors may open or
already be opened to allow the solid in the fluid mold to be
dispensed to the user upon request from the user. The sensor may be
installed proximate to the track doors or may be installed at other
locations along a solid dispense path. When the solid such as an
ice piece passes the path of the optical beam and breaks the
optical beam, software logic of the solid-production system 100 may
detect a presence of the ice piece that has been dispensed from the
fluid mold to the user or consumer. If the optical beam is not
broken, then the software logic (e.g., a solid-dispense mechanism
slave state machine 205 in FIG. 2) may detect an absence of the ice
piece and transmit a signal of the same to a master state machine
(e.g., 201 in FIG. 2) indicating the state of the fluid mold as
"SOLID". The master state machine may then send a command to a
fluid-dispensing mechanism slave state machine (e.g., 202 in FIG.
2) to not cause arrangement of a fluid-dispensing mechanism to
dispense fluid to that fluid mold. This fluid mold may pass through
the solid-dispensing position again in a later attempt to dispense
the solid. The sensor may also send an indication to the master
state machine of the number of solids dispensed in response to a
request from a user.
[0266] FIGS. 25A and 25B illustrate different arrangements of
sensors on chute adapters for a solid-dispensing mechanism 2500
according to example implementations of the present disclosure. A
chute adapter may be a hollow chute arranged to receive the
loosened solid dispensed from each of the one or more fluid molds.
As illustrated in FIGS. 25A and 25B, the sensor may be engaged with
an exterior surface of the hollow chute and arranged to interact
with an interior of the hollow chute so as to detect a presence or
an absence of the dispensed solid in the interior of the hollow
chute.
[0267] As illustrated in FIG. 25A, the chute adapter 2501 may
comprise a mouth 2502 and a stem 2503, where the mouth may be wider
than the stem. FIG. 25A illustrates one example implementation of a
sensor 2504 installed on an external surface of the stem of the
chute adapter to allow for more accurate detection of a solid
dispensed through the chute adapter. However, the sensor may be
installed on another location on the chute adapter, such as, for
example, an interior surface of the stem of the chute adapter, an
interior surface of the mouth of the chute adapter, an exterior
surface of the mouth of the chute adapter, or a combination
thereof.
[0268] By comparison, FIG. 25B illustrates multiple sensors 2504
installed on the stem 2503 of a chute adapter 2501 in another
example implementation. As such, one, two, three, four, five, etc.,
sensors may be utilized in series or in parallel or in any
combination for detecting a presence or an absence of a dispensed
solid.
[0269] In other examples, instead of installing one or more sensors
2501 on the chute adapter, the one or more optical interrupts can
be installed on the exit port or the track door of the
solid-dispensing mechanism, or can be installed at other locations
along a solid dispense path that may not be a part of the
solid-production system 100.
[0270] FIG. 26 illustrates a schematic of a solid-production system
2600, being the same or similar to the solid-production system 100
in FIG. 1, with an example solid ejector 2601 according to example
implementations of the present disclosure. In some example
implementations, a solid ejector, such as that illustrated in FIG.
26, is arranged to loosen a solid in each of one or more fluid
molds 2602 indexed into an ejection position relative to the solid
ejector, the one or more fluid molds comprising a bottom surface
and side surfaces extending therefrom. The solid ejector is
actuatable so as to be urged into contact with and to apply
pressure to at least one of the side surfaces of the fluid mold
indexed into the ejection position so as to loosen the solid within
the fluid mold in preparation for dispensing the solid from the
fluid mold.
[0271] In some example implementations of the solid-production
system 2600 illustrated in FIG. 26, a cooling block 2603 may be
arranged to receive each of the one or more fluid molds 2602 having
a fluid dispensed therein. The cooling block may be arranged to
reduce a first temperature of the fluid dispensed into each of the
one or more fluid molds to a second temperature to solidify the
fluid in each of the one or more fluid molds such that the fluid in
each of the one or more fluid molds forms the solid.
[0272] In some further example implementations, one or more
actuation mechanisms may be arranged to urge the solid ejector 2601
into contact with and to apply pressure to the at least one of the
side surfaces of the fluid mold 2602. For example, the one or more
actuation mechanisms may comprise a sliding member 2604 arranged to
engage the solid ejector. The sliding member may engage a pressure
plate 2605 via a cam 2606 arranged about an outside edge of the
sliding member, which can slidingly engage with a slot 2607 defined
on the pressure plate. The cam may have a profile comprising two
parts. The first part of the cam profile may be an incline and the
second part of the cam profile may be a horizontal portion. When
the cam profile is received within the slot and the sliding member
moves the cam within the slot, the different parts of the cam
profile may urge the pressure plate into different positions
relative to the top surface of fluid in the fluid molds. The
sliding member may be reciprocatingly movable so that movement of
the sliding member in a machine direction impacts both arrangement
of the pressure plate relative to a top surface of the fluid molds
and arrangement of the solid ejector relative to the fluid
molds.
[0273] As a result, in some example implementations, the sliding
member 2604 may be movable in a reverse machine direction to urge
the solid ejector 2601 into a first position in contact with and to
apply pressure to the at least one of the side surfaces of the
fluid mold 2602 indexed into the ejection position. The sliding
member may also be movable in a machine direction to urge the solid
ejector into a second position out of contact with the at least one
of the side surfaces of the fluid mold indexed into the ejection
position. By moving in a reverse machine direction, the sliding
member can urge the pressure plate 2605 into a spaced apart
arrangement relative to a top surface of the fluid in the fluid
molds (i.e., into the up position or the ejection position) by
exerting a normal force against a bottom surface of the pressure
plate, against an opposing normal force exerted on a top surface of
the pressure plate by a biasing mechanism 2608. Conversely, by
moving in a machine direction, the pressure plate can be arranged
into an initial position adjacent to a top surface of the fluid in
the fluid molds, which can allow the biasing mechanism to exert the
normal force on the top surface of the pressure plate without any
opposing normal force exerted by the sliding mechanism.
[0274] In this manner, when the solid ejector 2601 is in the first
position, a pressure plate 2605 may be arranged in an ejection
position, where the pressure plate is arranged in a spaced apart
relation relative to a top surface of fluid in the fluid molds.
When the solid ejector is in the second position, the pressure
plate may be arranged in an initial position, where the pressure
plate is arranged adjacent to the top surface of the fluid in the
fluid molds.
[0275] In some example implementations, the solid ejector 2601 may
be movable between the first and second positions via a pivoting
movement. For example, and as illustrated in FIG. 26, the solid
ejector is pivotable about a pivot 2609 and the sliding member 2604
defines a slotted opening 2610 arranged to receive a protrusion
2611 extending from the sliding member. The sliding member may be
movable in the reverse