Note: Descriptions are shown in the official language in which they were submitted.
CA 02759132 2011-11-21
TITLE: APPARATUS FOR DISPENSING AND/OR VENDING A BULK
PRODUCT AND IMPROVEMENTS THEREIN
FIELD OF THE INVENTION
[0001] The present invention relates to vending and dispensing equipment, and
more
particularly, to vending/dispensing apparatus for bulk products where the
quantity of the product
to be dispensed is specified by a customer at the time of purchase or
selection.
BACKGROUND OF THE INVENTION
[0002] Purchasing products in bulk form has become an acceptable type of
purchase by
consumers. This is evidenced by the range of bulk products offered for sale in
a variety of
settings, such as for example, grocery stores, coffee stores, pet food stores
and candy stores.
[0003] Bulk purchases of a product are made either by weighing the product,
which is
taken from a storage bin, or by buying a package containing a predetermined
amount of bulk
product, in food stores or the bulk food section of grocery stores. The
purchase is completed with
a cashier using a cash register. It will be appreciated that this limits the
locations and times when
a product can be purchased in bulk, which in turn can present a convenience
obstacle for the
consumer.
[0004] In the case of candy manufacturers, when a product is sold in pre-
packaged form
labeled with the manufacturer's brand, it is distributed by the manufacturer
mainly through point-
of-sale outlets. Many candy manufacturers can also supply product in bulk, but
are typically
limited to selling predetermined quantities of bulk product because of
distribution and packaging
considerations. For example, candies can be purchased three different ways: in
pre-packaged
form under the manufacturer label, in bulk form from a vending machine, or in
bulk form from
an open bin in a grocery store or bulk food store.
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[0005] In many cases the bulk bins used to store the products offered are
susceptible to
contamination, shrinkage and spilling, which can be further exacerbated by
consumers reaching
into the bin with their hands to gather or sample the product before purchase.
It is conceivable
that the vendor may be put at risk or incur liability. Furthermore, even where
recently available
bulk gravity bins have been implemented to ensure sanitation, the dispensing
mechanisms are not
able to dispense products in measured quantities.
[0006] Where dry bulk products are acquired in larger quantities there is
typically a need
to employ staff to measure, weigh, and determine a final or sale price and
collect money from the
customer. The overhead cost associated with supplying the equipment and
employing staff is
significantly more than if the acquisition process was an unmanned automated
process.
[0007] In most cases where bulk products are sold, the customer must
"guess" the weight
and the corresponding cost of the purchase which may or may not be close to
the weight the
customer actually desires or the amount of money the customers actually wants
to spend on the
purchase. Even in cases where weigh scales are available in the store, the
customer must perform
the iterative task of dispensing, weighing, adding or removing product, re-
weighing, etc. until the
desired amount of product or cost is determined.
[0008] In the case where products are sold through automated bulk vending
equipment,
the vendor is limited to selling product using a fixed price and a smaller,
fixed vend quantity.
The customer typically inserts a coin (token or paper currency) and a fixed
quantity is dispensed.
Currently available automated equipment therefore does not allow the customer
to specify the
amount of product desired, e.g. based on weight, product count or value. In
addition, automated
vending equipment is limited to dispensing only uniform products that are hard-
coated and not
subject to "sticking" together because of warm or humid conditions.
[0009] In summary, the sale of bulk foods tends to be costly, restrictive
and not customer
friendly in large part due to limitations of known bulk storage and dispensing
technology.
Accordingly, there remains a need for improvements in the art.
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BRIEF SUMMARY OF THE INVENTION
[00010] The present invention comprises a vending system, and
components thereof, and a
method for dispensing and/or vending a product stored in bulk, wherein the
quantity of the
product is specified or determined by a consumer according to weight and/or
dollar value.
[00011] According to an embodiment, there is provided system for
dispensing a bulk
product, the system comprises one or more bins, each for holding a bulk
product, a control panel
for receiving a user request for one of the bulk products; a computer
operatively coupled to the
control panel and a control board operatively coupled to the computer; the
control board being
operatively coupled to the computer and being configured to be responsive to
control commands;
the control board being operatively coupled to the one or more bins, and
responsive to the
control commands for controlling a dispensing component coupled to each of the
one or bins to
dispense the requested bulk product from the associated bin in an amount based
on the user
request.
[00012] According to another embodiment, there is provided an
apparatus for dispensing
one or more bulk products, the bulk products being contained in one or more
bins, each of the
bins including a dispensing mechanism and the dispensing mechanism being
operatively coupled
to a controller, the apparatus comprises: an interface configured for
receiving a user request for
one of the bulk products and generating one or more signals representative of
the user request; a
control unit operatively coupled to the interface for receiving the one or
more representative
signals, and the control unit being configured for generating one or more
controls signals based
on the one or more representative signals; the control unit including an
interface for operatively
coupling to the one or more actuators and being configured for sending one or
more control
signals to the one or more of the actuators; and the one or more actuators
being responsive to the
one or more control signals to dispense the bulk product from the bin based on
the user request.
[00013] According to another embodiment, there is provided a bin for
holding a bulk
product and suitable for use with a dispensing apparatus, the bin comprises: a
housing; an
internal bin scoop; an actuator for moving the bin scoop between a product
loading position and
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a product dispensing position and an agitation mechanism for agitating product
contained in the
bin.
[00014] According to another embodiment, there is provided a cup dropper
module for a
vending kiosk comprising a plurality of bins and each of the bins holding a
product, the cup
dropper module comprises: a plurality of auger units, each of the auger units
being configured to
hold a plurality of cups; an auger motor operatively coupled to each of the
auger units and
configured to actuate the auger unit to individually release the plurality of
cups; a funnel
operatively connected to the plurality of bins and configured to receive a
product from each the
plurality of bins, and the funnel including a downspout configured for
directing the received
product into one of the cups; a conveyor operatively coupled to a conveyer
drive motor for
moving the released cup to the downspout of the funnel; and the conveyer drive
motor and the
auger motors being operatively coupled to a controller and responsive to
control signals for
actuation.
[00015] According to another embodiment, there is provided a computer readable
memory for
storing data and information for access by an application program being
executed on a computer,
said data and information being associated with a vending kiosk configured for
dispensing bulk
products stored in a plurality of bins in response to a customer request, the
computer readable
memory comprising: a data structure configured in the computer readable memory
for storing
data associated with a system configuration for the vending kiosk; and a data
structure
configured in the computer readable memory for storing data associated with a
vending session
for the vending kiosk.
[00016] According to another embodiment, there is provided a mechanism for
monitoring the
operation of a vending kiosk based on the operation of one or more subsystems
associated with
the vending kiosk, the mechanism comprising: an interface for receiving a
request from an
external source; means for processing the request and selecting one of the
subsystems based on
the request; means for querying the selected subsystem; means for receiving
data from the
queried subsystem and transmitting the data to said external source.
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1000171 According to an embodiment, there is provided a bin for dispensing a
bulk product in
a vending machine, the bin comprising: a storage volume for storing the bulk
product; a lid for
enclosing the storage volume; an opening for releasing the bulk product from
the storage
volume; a bin scoop configured adjacent the opening, and operatively coupled
to an actuator to
dispense a portion of the bulk product through the opening.
[00018] This Summary is provided to introduce a selection of concepts in a
simplified form
that are further described below in the Detailed Description. This Summary is
not intended to
identify key features or essential characteristics of the claimed subject
matter, nor is it intended
to be used as an aid in determining the scope of the claimed subject matter.
[00019] Additional and other features of the invention will be set forth in
the description
which follows, and in part will be obvious from the description, or may be
learned by the
practice of the invention. The features and advantages of the invention may be
realized and
obtained by means of the instruments and combinations particularly pointed out
in the appended
claims. These and other features of the present invention will become more
fully apparent from
the following description and appended claims, or may be learned by the
practice of the
invention as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[00017 I Reference will now be made to the accompanying drawings which show,
by way
of example, embodiments of the present invention, and in which:
[00018 1 Fig. 1 shows in diagrammatic form a dispensing apparatus according to
an
embodiment of the present invention;
[00019 1 Fig. 2(a) shows in diagrammatic form a bin according to an embodiment
of the
present invention and suitable for use with the dispensing apparatus of Fig.
1;
[00020 ] Fig. 2(b) shows in diagrammatic form a right hand side view of the
lower portion
of the bin of Fig. 2(a);
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[00021 ] Fig. 2(c) shows in diagrammatic form the bin of Fig. 2(a)
with certain internal
components removed;
[00022 ] Fig. 3(a) shows in diagrammatic form a bin scoop configured
for the bin of Fig. 2
according to an embodiment of the present invention;
[00023 1 Fig. 3(b) shows in diagrammatic form a bin throat configured
for the bin of Fig. 2
according to an embodiment of the present invention;
100024 1 Fig. 3(c) shows in diagrammatic form a portion control
component configured for
the bin scoop of Fig. 3(a) according to an embodiment of the present
invention;
[00025 1 Fig. 3(d) shows a right side view of the portion control
component of Fig. 3(c)
positioned inside the bin scoop depicted in a transparent view in broken
outline;
100026 1 Fig. 4(a) shows the bin of Fig. 2 configured with an in-situ
agitator according to
an embodiment of the present invention;
[00027 1 Fig. 4(b) shows the in-situ agitator of Fig. 4(a) in
isolation;
100028 1 Fig. 5(a) shows a bin lid for the bin of Fig. 2 according to
an embodiment of the
present invention;
100029 1 Fig. 5(b) shows a mounting bracket according to an
embodiment of the present
invention and configured for the bin lid of Fig. 5(b);
[00030 1 Fig. 5(c) shows the mounting bracket configured in the top
opening of the bin of
Fig. 2;
[00031] Fig. 5(d) shows a rod and cork screw configured for the
mounting bracket of Fig.
5(c);
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[00032 1 Fig. 6 shows in diagrammatic form a database structure according
to an
embodiment of the invention and configured for storing and retrieving
information and data
associated with the operation of the dispensing apparatus;
[00033 ] Fig. 7 shows in diagrammatic form a kiosk probe implemented as an
API
according to an embodiment of the present invention;
[00034 ] Fig. 8 shows in schematic form a system and networkable
configuration for
controlling the dispensing apparatus according to an embodiment of the present
invention;
[00035] Fig. 9(a) shows in flowchart form a computer-implemented process
for deploying
software updates and other process control programs to dispensing apparatus
according to an
embodiment of the present invention;
[00036] Fig. 9(b) shows in flowchart form a computer-implemented process
for
controlling registered clients;
100037 ] Fig. 9(c) shows in diagrammatic form a system configuration for
controlling and
managing the dispensing apparatus over a network;
[00038 1 Fig. 9(d) is a signal flow diagram showing a control sequence for
a computer-
implemented loader process;
[00039 ] Fig. 9(e) shows in flowchart form a computer-implemented process
for a loader
update process according to an embodiment of the present invention;
[00040] Fig. 10 is a diagrammatic view of a cup dispenser module
configured for storing
and releasing multiple cups;
[00041 1 Fig. 11 shows a schematic of a sensor circuit according to an
embodiment of the
present invention.
[00042 1 Fig. 12(a) shows a cup holder configured without the cup alignment
ring of Fig.
13(a);
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[00043 ] Fig. 12(b) shows a cup holder configured with the cup alignment
ring of Fig.
13(a);
[00044] Fig. 13(a) shows in diagrammatic form a cup alignment ring
according to an
embodiment of the present invention;
[00045] Fig. 13(b) is a top view of the cup alignment ring of Fig.
13(a);
[00046] Fig. 13(c) is a side view of the cup alignment ring of Fig.
13(a); and
[00047 1 Fig. 14 shows in block diagram form an exemplary implementation
for a control
unit and controller system and sub-system for the vending kiosk of Fig. 1
according to an
embodiment of the present invention.
[00048] In the drawings, like elements are indicated by like
components.
DETAILED DESCRIPTION OF THE EMBODIMENTS
100049 1 Reference is first made to Fig. 1, which shows a vending and
dispensing
apparatus according to an embodiment of the present invention, and indicated
generally by
reference 100. As shown, the dispensing and vending apparatus 100 (i.e. a
vending machine or
vending kiosk) comprises an enclosure (e.g. cabinet or housing) indicated
generally by reference
110, a control panel for a user interface 120, a payment unit 130, and bin
compartment 140. The
bin compartment 140 is configured to hold one or more bins 142. The bins 142
are indicated
individually by 140a, 140b,.. .140n. The bins 142 store product and the number
of bins 142 used
in an implementation of the apparatus 100 will depend on factors such as the
types and number
of the products being offered, the size of the apparatus 100, etc. According
to one
implementation, the control panel 120 is coupled to a control unit 122 (Fig.
14) comprising a
computer or computing device, e.g. one or more microprocessors or programmable
devices,
operating under stored program control, e.g. software or firmware stored in
non-volatile memory
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or other computer readable media, and utilizing data and other operational
information stored in
memory or on other computer readable media.
[00050 1 According to an embodiment and as shown in Fig. 14, the control
unit 122
comprises a computer 1400, e.g. a personal computer or PC based platform, and
one or more
control boards 1410 comprising one or more microprocessor based control
circuits, operatively
coupled to the PC and other system components. According to an embodiment, the
control board
1410 comprises an input/output interface 1420 which is configured for
outputting control signals
and other control data/information, e.g. to the bins 142 and bin
motors/actuators and other
system components and sub-systems as described below, and inputting status
signals and other
output data/information, for example, from the bins 142, sensors and other
system components
and sub-systems as described below. The control board 1410 is operatively
coupled to the
computer 1400 and is responsive to commands, status requests and other control
information
from the computer 1400. The computer 1400, e.g. PC, is configured to run or
execute one or
more computer programs, software modules and the like, to provide the
functionality as
described in more detail below. The computer programs can be stored in non-
volatile memory,
disk drives or other computer readable storage media, and according to an
embodiment can be
updated remotely, as described in more detail below. The microprocessors for
the control
board(s) operate under stored program control, e.g. firmware stored in non-
volatile memory,
storage devices or computer readable media, and according to an embodiment,
the firmware can
be updated remotely as described in more detail below.
[00051 1 According to one aspect, the control panel 120 comprises a
control/command
interface for the bins 142. The control unit functions with the associated bin
142 to dispense an
exact or an approximate amount or quantity of product specified in weight,
product count and/or
dollar value by the consumer. According to an embodiment, the apparatus 100
includes a
container access opening 150. The container access opening 150 is integrated
with a container
dispensing module, which is described in more detail below with reference to
Fig. 10. The
container dispensing module is operatively coupled to the control unit and
responsive to control
commands for dispensing a carton, cup or box with product filled from one of
the bins 142, and
the filled cup is removed from the container access opening 150 by the
customer.
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[00052 The control panel 120 is utilized by a user, e.g. a consumer,
shopper, customer,
etc., to select the product and specify an exact or an approximate quantity of
the product, and
then purchase, dispense or otherwise acquire the product, as will be described
in more detail
below. The control panel 120 comprises a main or central controller, a keypad
and a display
module, or a touch-screen. In another embodiment, the control panel 120 is
implemented in the
form of a voice-activated device and a display device. The control panel 120
is responsive to
inputs from a customer and generates output data or signals for a control
application or program.
The control application responds to the inputs from the customer and operates
the apparatus 100
to dispense or vend the product as will be described in more detail below. The
control
application is implemented in software and comprises, for example, a stand-
alone computer
program or software module or firmware application or function, which is
executed by the
control unit to control the interaction between the customer and the
apparatus. The control
application 112 may reside on a device or hardware component that is
integrated with the control
panel 110, for example, as shown in Fig. 1.
[00053 1 It will be appreciated that the vending machine or apparatus 100
according to an
embodiment of the present invention can be implemented or function in two ways
or modes:
vending mode and dispensing mode. In vending mode, the apparatus 100 is
implemented as a
vending apparatus 100 wherein a user selects a product and specifies a
quantity (i.e. exactly or
approximately by weight and/or dollar value) of the product desired for
purchase, and the
apparatus 100 dispenses the specified quantity of the product upon receiving
payment. The
vending implementation of the apparatus 100 is suitable for commercial
applications, such as,
grocery stores, bulk food stores, vending kiosks, etc. In dispensing mode, the
apparatus 100 is
implemented as a dispensing apparatus wherein the apparatus 100 dispenses the
specified
quantity of the product selected by the user without requiring payment. The
dispensing
implementation of the apparatus 100 is suitable for non-commercial
applications, for example, a
private club, a daycare, etc. According to an embodiment, the apparatus 100 is
convertible to a
dispensing apparatus by disabling the payment unit 120 and/or the payment
function or module
in the control application.
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100054 1 In the context of a vending application or implementation, once a
user has
selected the product and quantity desired, the apparatus prompts the user to
pay for the purchase
using the payment unit 130. The control unit includes a function or module to
calculate the cost
of the product purchase and the purchase price is displayed for the user on
control panel 120. The
user pays the purchase price using the payment unit 130, and the payment unit
130 is
implemented to accept as payment in multiple forms, such as, coins or bills,
tokens, smart cards,
credit or debit cards, or any combination of these. The tokens may be
purchased from a third-
party or from a token dispenser (not shown) associated with the vending
apparatus 100.
[00055 ] Once the correct payment is received by the payment unit 130, the
dispensing of
the selected product and the specified quantity begins. According to an
embodiment, the control
unit is implemented as an intelligent device that runs or executes a
dispensing application or
program (e.g. implemented in software and/or firmware), which functions to
dispense the
specified quantity of the selected product into a container (e.g. a cup)
through the operation and
actuation of the integrated bin and bin scoop as described in more detail
below.
[00056 ] Reference is next made to Fig. 2(a), which shows a bin according to
an
embodiment of the present invention and indicated generally by reference 200.
The bin 200 as
shown in Fig. 2 comprises a bin storage volume 202, a top end 204 and a bottom
end 206. The
bin storage volume 202 comprises a lower portion 203 with a sloping bottom
that is configured
to direct or funnel product towards the bottom end 206. According to an
embodiment, the bin
200 is configured with a bin scoop indicated generally by reference 210 and a
bin throat
component indicated generally by reference 212. The bin scoop 210 is shown in
more detail in
Figs. 2(b) and 3(b), and the bin throat component 212 is shown in more detail
in Fig. 3(b).
[00057 ] According to an embodiment, the bin 200 is configured with an
agitation
mechanism. The agitation mechanism comprises one or more agitation arms
indicated generally
by reference 214. According to an embodiment, and as shown in Fig. 2(a), the
bin scoop 210 is
shown with an agitation arm attached or coupled to the left side and indicated
by reference 214a.
Similarly, the bin scoop 210 includes a second agitation arm attached to the
right side and
indicated by reference 214b in Fig. 2(b). The agitation arm 214 according to
an embodiment is
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further depicted in Figs. 4(a) and 4(b). The agitation arms 214 are configured
to agitate, stir or
otherwise move product that is in the vicinity of the bin scoop 210, and
actuated by movement of
the bin scoop 210. In an exemplary implementation, the bin scoop 210 is
configured with an
actuator indicated by reference 216 in Figs. 2(a) and 2(b). The actuator 216
comprises a servo
motor or other type of drive mechanism or gear mechanism that is responsive to
the control
signals from the control board 1410 (Fig. 14) to move the bin scoop 210
between a product fill
position and a product dispense position, i.e. generally in the direction of
arrow 217. As the bin
scoop 210 is moved between the product fill and the product dispense
positions, the agitation
arms 214 move in a generally arcuate and/or linear and reciprocal direction
indicated generally
by arrow 219. This has the effect of mixing or agitating the product in the
proximity of the bin
scoop 210 (and the bin throat 212 if installed) and thereby preventing product
(e.g. candy) from
sticking together if left undisturbed.
[00058] As shown in Fig. 3(a), the bin scoop 210 is configured with
apertures or other
suitable openings indicated by references 312a and 312b for coupling or
attaching one end of the
respective agitation arm 214. As shown in Figs. 4(a) and 4(b), one end of the
agitation arm 214 is
configured with a snap fitting or other coupling mechanism 416 that is pressed
or fitted into the
respective aperture 312 (Fig. 3(a)) to secure the arm 214 to the bin scoop
210. The other end of
the agitation arm 214 can be configured or shaped with one or more bends
indicated generally by
reference 418 to match the geometry or shape of the bin 200, and/or put the
arm end 418
substantially into the middle region or area of the interior of the bin 200.
According to another
embodiment, the ends 418 of the two arms 214a and 214b are joined or coupled
together.
According to another aspect, the agitation arms 214 are configured with a
circular or oval cross
section to facilitate movement of the arms 214 through the product. As shown
in Fig. 3(a), the
bin scoop 210 is configured with a coupling mechanism 314a and 314b, for
instance, a snap fit
connector, for coupling a drive or gear mechanism.
[00059 1 The bin 200 can be configured with the bin throat 212 as
described above. The bin
throat 212 functions as a type of funnel and is configured to facilitate the
movement of product
into the bin scoop 210. As shown in Fig. 3(b), the bin throat 214 includes
guide members 324 to
help funnel product into the opening of throat and the bin scoop 210.
According to an
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embodiment, the guide members 324 include respective notches or cut-outs
indicated generally
by reference 326. The notches or cut-outs 326 allow the agitation arms 214 to
move back and
forth into the product as described above. According to another aspect, the
notches 326 can be
configured to act as guide and/or fulcrum or support surface for the
respective agitation arms
214a and 214b. According to an embodiment, the bin 200 is formed or fabricated
from a plastic
or composite material, and configured with suitable guide or stop members for
engaging
corresponding rails 328 and thereby positioning and securing the bin throat
212 inside the bin
200.
100060 1 In the product fill position (as shown in Figs. 2(a) and 2(b)), the
opening of the
bin scoop 210 is communication with the bin throat 212 and product inside the
bin 200 enters
and fills the bin scoop 210 through one end. When the bin scoop 210 is moved
to the product
dispense position, the product moves out and falls through an opening 205 in
the bottom end 206
of the bin 200 into a cup or other suitable container. To control or limit the
quantity of product
that enters or fills the bin scoop 210, the bin scoop 210 can be configured
with a portion control
component as shown in Figs. 2(a) and 2(b) and indicated generally by reference
220. The portion
control component 220 comprises a top section 222 and a lower section 224 as
shown in Fig.
3(c). The portion control component 220 is affixed or fitted to the interior
of the bin 200, for
example, with mating snap fittings indicated generally by reference 221 and
the lower section
224 of the portion control component 220 extends into the bin scoop 210 as
depicted in Fig. 3(d)
and functions to define the interior volume of the bin scoop 210 which can be
filled by product.
According to another aspect, the portion control component 220 can be
configured in different
sizes to allow the volume of the bin scoop 210 and the portion volume to be
changed by
replacing the portion control component 220 in the respective bin 200. As
shown in Figs. 3(c)
and Fig. 3(d), the portion control component 220 includes cut-outs or openings
225 and 227. The
cut-outs 225, 227 are configured to extend the upward travel (i.e. in the
direction of arrow 217 in
Fig. 2(b)) of the bin scoop 210 by providing clearance or a void for the
respective top edges 325
and 327 of the bin scoop 210.
[00061 J According to another embodiment, the bin 200 is configured with a
whole-bin
agitation mechanism as depicted in Fig. 2(a) and indicated generally by
reference 230. The
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agitation mechanism 230 comprises a mechanical mixing rod 232 that extends
into the bin 200
and contacts the product, and an actuator 234 for moving, e.g. rotating, the
mixing rod 232 to
agitate the product. According to an embodiment, the mechanical mixing rod 232
comprises a
rod 534 with a corkscrew shaped mixing end 536 as shown in Fig. 5(d) and
indicated generally
by reference 534. The rod 534 is operatively coupled to the actuator 234, for
example, a drive
motor indicated by reference 235 in Fig. 2(c), and rotated in a counter-
clockwise direction to
provide a slight lifting action as the corkscrew end 538 passes through the
product, e.g. candies.
It will be appreciated that the product should not be pushed down as a result
of the corkscrew
action as this could pack and jam the product into the bottom of the bin 200.
[00062 1 As shown in Fig. 2(c), the motor or actuator 234 is mounted to a
bin lid 238
which is secured to the top of the bin 200. The bin lid 238 includes an
aperture 540 as shown in
Fig. 5(a) for operatively coupling the motor to one end (i.e. the top) of the
mixing rod 232. As
shown in Fig. 5(b), the bin 200 can include a bracket 542 which is configured,
for example, with
a pair of flanges, to be mounted across the top of the bin 200 as shown in
Fig. 5(c). The bracket
542 includes an aperture or hole 544 for supporting the mixing rod 232 and
allowing the rod 232
to be coupled to the motor 234. According to one aspect, the bracket 542 holds
the mixing rod
232 in place when the bid lid 238 (and the motor 234) are removed, for
example, to refill the
contents of the bin 200. According to an embodiment, the drive motor 235 is
operatively coupled
to the control board 1410 (Fig. 14) and responsive to control commands issued
by the control
board 1410.
100063] According to another embodiment, the mechanical mixing rod 232
comprises a
rod with flanges that protrude out from the rod to provide additional contact
with and agitation of
the product. According to another aspect, the flanges are configured to be
asymmetrical in order
to provide less resistance when the rod is inserted/forced into the product
and also provide some
lift, or aeration, of the product when the rod is retracted. According to an
embodiment, the rod is
oriented vertically into the bin 200 and operatively coupled to the motor to
move up and down
vertically in the product.
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[00064 1 According to another embodiment, the bin 200 can be configured with
more than
one mixing rod with each having a respective motor, or with one motor coupled
to the multiple
mixing rods through a gear or belt drive mechanism.
[00065 ] According to another embodiment, the control unit 122 (Fig. 14) for
the apparatus
100 includes a component for monitoring the current load during operation of
the bin scoop 210
(Fig. 2(a)), and preventing an overload condition on the bin motor or actuator
for the bin scoop.
According to an exemplary implementation, the control board 1410 (Fig. 14) is
configured with a
resistor and an analog to a digital convertor circuit or subsystem. The
current through the resistor
is indicative of the current load on the motor and the resulting voltage is
converted to a digital
value which is inputted and processed by the control board. According to an
exemplary
implementation, the control unit is configured or programmed with a current
load function which
includes a maximum current setting and one or more trip current settings. Due
to typical surge
current on start-up, the current readings are ignored by the control unit, for
example, for the first
100 milliseconds. After the start-up, if the current trip current setting is
exceeded, the control unit
responds by stopping the bin motor or actuator, and reversing the direction of
the motor and
backing up the bin scoop and increasing the trip current level setting. The
control unit then
resumes normal operation of the bin scoop. If the new trip current level is
exceeded, the control
unit backs the bin scoop up a further distance, the trip current level is
increased to a maximum
current level, and normal operation of the bin scoop is resumed. If the
current level is again
exceeded, then an error condition exists, e.g. there is a jam with the bin
scoop and/or product,
and the associated bin is shut down. The control unit issues an error message
and/or diagnostic
message for an administrator, e.g. a remote computer.
[00066] According to another aspect, the control unit 122 is configured to
perform a
process for un-jamming product, e.g. candy, in one of the bins by measuring
the current and if at
any point the current exceeds a set value, performing the following processing
steps:
(1) stopping the motor for approximately 100 millisecond to let voltages and
currents
settle
CA 02759132 2011-11-21
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(2) reversing or backing up the motor for a predetermined amount of time to
reverse the
bin scoop
(3) stopping the motor for 100 milliseconds to allow the current and voltage
levels to
settle
(4) increase trip current and run motor forward to actuate bin scoop, e.g.
move bin scoop
to the dispensing position
(5) if trip current level is exceeded, steps (1) to (4) are repeated two more
times with each
time the motor backing up slightly more and the trip current increased until
at the
maximum current level setting is reached
(6) if at this point the blockage is still there, an error exception condition
is "thrown", i.e.
issued
[00067 ] Reference is next made to Fig. 6, which shows a data structure
configuration or
data schema indicated generally by reference 600 for storing operational data
and other
information associated with the vending apparatus 100. The database structure
600 and
associated data are configured and stored in non-volatile memory or mass
storage media
accessible by the computer. According to an embodiment, the data schema 600
comprises a
"Config" data structure or object indicated by reference 610 and a "Sessions"
data structure or
object indicated by reference 650. The Config data structure 610 is associated
with a "Language"
data structure or object 612 (which is further linked to a "LanguageSelection"
data structure or
object 613), a "Version" data structure 614, a "Bin" data structure 616 (which
is further linked or
associated with a "BinImages" data structure or object), a "Cup" data
structure 618, a
"CupImages" data structure 620. As shown, the Session data structure or object
650 is associated
with a "CupSelection" data structure or object 652, a "Scoop" data structure
654, a "SignUp"
data structure 656 (which is further linked or associated with a "SignUPType"
data structure 657)
and a "CameraDemographics" data structure 658. As shown, the Session data
object 650 is also
linked to the LanguageSelection data object 613. The Session data object 650
is also linked or
associated with an "AttemptedTransaction" data structure or object 670, which,
as shown, is
linked or associated with a "CashPreferred" data structure or object 672, a
"Cash" data structure
or object 674, a "GiftCard" data structure or object 676, a "PromoCode" data
structure or object
678 and a "CreditCard" data structure or object 680 (which is further linked
or associated with a
CA 02759132 2011-11-21
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"CreditCardType" data structure or object 681). As also shown in Fig. 6, the
data structure or
schema can further comprise a "AcceptedDenomination" data structure or object
690, and a
"LogEntry" data structure or object 692.
100068 1 According to an embodiment, the database structure 600 is
implemented utilizing
a transactional SQL database engine, such as, SQLite. For example, each time a
customer starts
to use the vending machine, a "Session" is created. The user chooses a cup
size (a Session
instance is related to 1 CupSelection instance), multiple scoops (a Session
instance is related to
multiple Scoop instances). The user payment information is stored in
AttemptedTransactions.
Each bill entered creates an instance of the Cash Entity which derives from
AttemptedTransaction (Cash is a type of AttemptedTransaction). CreditCard,
GiftCard and
PromoCode transactions can also exist. Most AttemptedTransactions will have a
Status of
success however failed credit card, gift card or promo-code transactions will
have a failed Status.
Once a Session is complete, it is stamped with an EndStamp. If candy was
dispensed then the
CandyDispensed flag is set. An InvoiceNumber is generated for each session
with a payment and
it is sent to the credit card company during credit card processing. Cup
choices, scoop choices
and the related graphics can all be configured in the database (for example,
using an
administrative function, e.g. an AdminPanel). Alternative drivers can be
configured (for
example, copy the DLL in and configure the driver name and location in the
AdminPanel).
[00069 ] According to an embodiment, the data and operational data collected
and/or
stored (along with machine ID and date/time stamps) comprises:
(1) transaction data such as product type, price, amount, payment type,
payment amount,
transaction ID, electronic transaction ID or authentication number
(2) interface data such as media played, audio played, graphics displayed,
buttons
touched, session duration, screen touches
(3) service data such as person logged in, software reboots, computer reboots,
connection
issues, errors, warnings, notices, events, product fill dates
(4) performance data such as current, amperage used
CA 02759132 2011-11-21
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(5) external customer data such as age, gender, ethnicity, whether or not they
looked at
the machine, length of look, customer height, color of clothes, an image or
video of
the customer (optional)
(6) configuration data such as product types, vend amounts, prices, names,
pictures,
recipes, language translations, server addresses, account information,
scheduling
The control unit 122 at the vending apparatus 100 can be configured to store
and/or use this data
in a number of unique combinations that allow for value to be generated for
the operators and
the brands that sponsor kiosks.
[00070] According to an embodiment, external customer data is obtained
through a device
or through a camera operatively coupled to the control unit or another
computing device in the
vending apparatus or kiosk. Images from the camera are analyzed to generate
the data using
image analysis techniques. The external customer data can also come from other
sources, such as
Facebook profile information or provided by the customer through registration
with a website.
[00071] According to an embodiment, external customer data correlated
with transaction
data is stored. This allows for the study of purchasing and payment patterns
based on
demographics, for example, in the situation where the uniqueness of an
individual customer can
be verified.
[00072 ] According to an embodiment, interface data correlated with
transaction data is
stored. This allows for the study of interface patterns such as products
chosen, products deleted,
order of products displayed, with the purchase data from transactions. This
can show, for
example, if there is a preference for certain products early in the purchase
process (impulse) and
then a later preference for different products (reasoning), for example,
allowing comparison of
healthy versus unhealthy products.
[00073] According to an embodiment, external customer data correlated
with interface
data is stored. This allows for the study of interface patterns with
information about the
customer. This could show, for example, patterns of interface behavior in
certain groups. For
CA 02759132 2011-11-21
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instance, it could show that the elderly have difficulty with a certain part
of the purchase process.
It could show a preference for using with the screen in a certain way for a
certain gender (tap vs.
touch). It could also show that certain demographics are likely to walk away
when they get to the
pricing page.
100074 1 According to an embodiment, configuration data from a vending
machine is
replicated and stored on a central or remote server. This also allows for
central configuration data
to be deployed out to all the machines. This aids in installation because a
machine can be pre-
configured to have all the applicable data automatically set up based on the
machine ID and
install location.
[00075 1 According to an embodiment, the database structure 600 and
control unit are
configured to track and store inventory data. According to an embodiment, the
control unit is
configured (e.g. through software) to store inventory data locally at the
apparatus and also
transfer data to a remote site, e.g. a central data server. This configuration
allows for reports to
be compiled for customer use. It also allows for inventory data to be used to
scale manufacturing
as needed. It can also be used to control logistics and shipping, for example,
by sending certain
operators the appropriate amount of product and a list of locations where the
product is to be
delivered. In an exemplary implementation, a machine ID destination is
associated with each
individual container of product. The inventory data is updated when the
vending machine is
serviced. The control unit can also be configured (e.g. programmed) to attach
a service person's
ID to the event. According another aspect, the amount of time that product has
been in a bin is
tracked. Because bins operate on an approximate "first in, first out" system,
the control unit is
configured (e.g. operating under stored program control) to calculate how much
product must be
removed from the bin in order to keep only the freshest amount of product in
the bin. According
to a further aspect, the control unit is configured to automatically dispense
stale product into a
cup for free or for disposal. According to another aspect, the control unit is
configured with an
inventory tracking system where the appropriate bin is selected (e.g. lighted)
based on scanning
entering data from the product container label.
CA 02759132 2011-11-21
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1000761 According to an embodiment, the control unit for the vending
machine 100 is
configured for transferring data between the machine 100 and another device,
e.g. another
vending machine, a computer, a central server, administrator, etc. As
described above, the
control unit is configured to capture and store data and operational
information in the database
structure 600. According to a further aspect, the data is synchronized, and in
one implementation,
the vending machine or kiosk 100 is configured with a regular synchronization
interval. The
control unit (e.g. the computer) communicates with a central server, and
uploads database data
(e.g. new data captured at the machine 100) and downloads any new data or
updates to the
machine from the central server. In a typical installation, the data uploaded
from the vending
kiosk 100 typically comprises transaction data, and the data downloaded from
the central server
comprises configuration or media data, and software and code updates. This
provides the
capability to install updates and fixes to one or more of the vending machines
or kiosks via a
network (e.g. Internet) connection. According to another aspect, the
synchronization operation
comprises uploading data related to the current status of one sub-systems in
the vending machine
or kiosk 100. According to another aspect, the synchronization interval
comprises either a fixed
time-based value, or a dynamic interval, for example, based on sales traffic,
customer traffic,
data/records generated since last synchronization operation. Accord to another
aspect, kiosk
specific commands can be packaged in a designated type of database record or
object.
Commands that the kiosk is to execute can be sent through a special type of DB
record. To
bandwidth requirements and operating costs the transfer data can be compressed
using known
techniques.
100077 1 According to an exemplary implementation, the control unit (i.e.
the computer) in
each vending machine or kiosk is configured to query the central server (i.e.
a loader server)
periodically (at a configurable time interval) and send an identifier which
identifies the kiosk to
the loader the server. In response, the loader server is configured (e.g.
through computer software
or stored program control) to send back a checksum of the current version
information file
deployed to the kiosk. If the checksum does not match the version information
at the kiosk, then
the required updates are downloaded to the kiosk to bring the software and any
other
programmable components up to date. In accordance with this implementation,
the control unit
at the kiosk is configured to decompress each update and then execute an
installation script
CA 02759132 2011-11-21
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included in the update. In addition to updates from the loader server, the
database record system
can be configured to supports synchronization between client and server
databases. For instance,
data from each of the vending machines or kiosks can be tabulated and sent to
the central server.
This data enables detailed marketing reports to be generated on, for example,
usage trends,
market payment type preferences, the speed at which the user proceeds through
various screens,
market demographic information captured from images taken by a TruMedia
camera, and email
sign-ups. The synchronization operation also comprises data on the current
status of one or more
of the subsystems in the vending machine or kiosk. The synchronization of data
can also
comprise encrypted communications, such as, a SSH tunnel or a HTTP based SSL
connection.
According to another implementation, data can be encrypted using encryption
key pair unique to
a specific customer or group of customers.
[00078 ] Reference is next made to Fig. 7, which shows in
diagrammatic form a software
configuration 700 for transferring data from the vending machine or kiosk via
a network
connection 710 to a central server 720 and other devices or entities.
According to an
embodiment, the vending machine 100 is configured with a kiosk probe indicated
by reference
730. As described in more detail below, the kiosk probe 730 comprises one or
more API's and is
implemented and configured to provide an interface for monitoring the other
software
subsystems, including as shown in Fig. 7, a local database module 740, a user
interface software
module 742, operating and file system 744, and other software components or
modules indicated
generally by reference 746. The kiosk probe 730 is configured using known
computer software
and programming techniques to monitor the system health of the kiosk and
respond to requests
(for example, from the central server 720) for status and other system
information. For example,
the kiosk probe 730 can be configured to report on both current, or
historical, status of a kiosk.
According to one implementation, the kiosk probe 730 is configured to track
the following data:
computer usage (for example, hard drive = usage, RAM usage); current status of
the kiosk
components, such as, bin status and amount of product in each bin; status of
the payment
methods (eg: credit card reader, VNR, coin acceptor); statues of software
systems, subsystems or
modules; sales per hour/day. According to another aspect, the kiosk probe 730
comprises a
service that runs on the kiosk operating system and is responsible for
managing external data
CA 02759132 2011-11-21
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transfer and kiosk control commands with a central server or administrator
control network
indicated generally by reference 720.
100079 1 According to an exemplary implementation, the kiosk probe 730 is
configured to
provide the following functionality:
(1) a client 726 initiates a request using an external API 724 to the central
server
or administrator control network 720. The request can be secured with
encryption and/or authentication
(2) The administrator control network 720 is configured to route and initiate
a
request to the appropriate kiosk connected to the network 710
(3) the kiosk probe 730 on the vending machine accepts the API request and
processes the request at the vending machine
(4) the kiosk probe 730 transmits the results of the request back to the
control
network 720, either synchronously or asynchronously
(5) the control network 720 compiles or otherwise processes the received data
and
generates data, for example, a summary or report on kiosk back to the client
726
(6) the client 726 accepts the kiosk results and the request is completed
100080 Reference is next made to Fig. 8, which a software system
configuration or
architecture 800 for controlling a plurality of vending machines or kiosks
810, indicated
individually by references 810a, 810b, 810c, 810d,....810n. As shown, the
system configuration
800 comprises multiple Application Programming Interfaces or API comprising
functions for
data storage, data transfer, kiosk control, dashboard and reporting systems.
This allows for each
component to be abstracted and separate from each other. According to an
embodiment, the
system 800 comprises an external API indicated by reference 820. The external
API 820 further
comprises three functional modules: (1) kiosk control; (2) reporting; and (3)
content control. For
kiosk control, the external API 820 comprises a kiosk control API that is
configured to provide
fine granularity control (i.e. "setup") of kiosk functions, such as,
- enabling and disabling bins, cup droppers
- enabling and disabling LED lights
CA 02759132 2011-11-21
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- enabling and disabling payment options
For reporting, the external API 820 comprises a reporting API that is
configured to provide a
mechanism for querying various reports from the kiosks 810 such as:
- sales per time frame
- product status
- historical kiosk activity
- error reports and summaries
For content control, the external API 820 comprises a content API that is
configured to provide a
mechanism for transmitting data or advertising content to the kiosk. The
content API can also be
configured with rules for how/when content should be presented on the kiosk.
For clients
(indicated generally by reference 840), the kiosk probe provides the
capability to report on sales
activities, push content such as media to the kiosk, and change configurable
parameters (such as,
kiosk on/off schedule, kiosk lighting schedule).
[00081 1 According to an exemplary implementation, the control unit
(i.e. computer) on
each vending machine or kiosk is configured with a loader program. The loader
program checks
in with the central server. The check in interval is determined in a
configuration file on the
machine but can be changed via the remote update system. Each software package
is associated
with a "channel". The version for the software package and for the channel on
a kiosk are
compared, as well as the time stamp for each compared, and the latest package
is deployed. The
version information for each vending machine is stored in a manifest file,
coded in XML. A copy
of the deployed manifest for each machine is stored on the central server.
When a machine
"checks-in", the manifest on the machine is compared to the manifest on the
central server to
determine what packages, if any, are installed. The kiosk then downloads any
necessary
packages and installs them, and is configured to report to the central server,
and the central
server in turn records a successful installation. If the install fails, then
the original software is
restored and the machine continues to under that operate with the original
software.
100082] According to another aspect, the loader mechanism is
configured to be updatable
utilizing a deployed and delayed installation package. The package is
configured to not run fully
when downloaded, but instruct the operating system to perform certain commands
at reboot.
CA 02759132 2011-11-21
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When the machine is rebooted these commands update the Loader component of the
machine
before it is run. In a further aspect, numerous packages can be bundled
together using a meta-
package structure. Packages can also be deployed incrementally where a package
depends on
certain other packages to having been present first. The meta-package can also
specify the order
of installation and whether an internal package is critical to overall success
or is optional.
According to another aspect, the system is configured with a deployment
scheduler that allows
for packages to be deployed during certain hours (for example, at night).
According to another
aspect, vending machines or kiosks can be grouped together in numerous ways,
such as by
geography, equipment type, or operator and packages deployed accordingly.
[00083 ] Reference is made to Figs. 9(a) to 9(e) which illustrate the
operation of the
software update and loader functions in more detail.
[00084 1 Fig. 9(a) shows in flowchart form, a process 900 comprising
steps or operations
depicted in individual blocks/steps for remotely deploying software and other
updates to one or
more kiosks arranged in a network configuration for example as described
above.
[00085] Fig. 9(b) shows in flowchart form, a process 920 comprising
steps or operation
depicted in individual blocks/steps for registering a loader client and
recording software
versions.
[00086] Fig. 9(c) shows in block diagram form a system configuration
930 for the loader
function or mechanism.
[00087] Fig. 9(d) shows signal/data flow between the loader program and
the application
program according to an embodiment of the invention.
[00088 1 Fig. 9(e) shows in flowchart form, a process 950 comprising
steps or operation
depicted in individual blocks/steps for updating the loader application.
CA 02759132 2011-11-21
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[00089] According to embodiment and as shown in Fig. 14, the control
unit 122 comprises
the computer 1400 (e.g. a PC based computer platform) and the control board
1410 operatively
coupled to the computer. According to an exemplary implementation, the control
board 1410
utilizes a MSP430 processor from Texas Instruments as a main processor 1412 on
the board. It
uses a serial COM port or a virtual USB COM port to communicate to the
computer 1400. It will
be appreciated that this means that reprogramming the firmware on the chip can
be difficult and
requires a boot loader that can switch between running programs. If any errors
occur during
programming in this method the only way to recover a machine is to send the
board back to the
factory for reprogramming. According to another embodiment, the control board
1410 is
configured with a secondary processor 1413, such as the MSP430 processor from
Texas
Instruments, and the secondary processor 1413 is configured to monitor the COM
signal line.
The secondary processor 1413 is configured as a "programming chip" or
processor and is
connected to the low-level flash reset pins of the main MSP430 processor 1412.
The
programming processor 1413 is configured to listen to the COM lines for a
selected signal packet
that indicates it should put the main processor 1412 into programming mode.
The programming
processor 1413 then receives the data from the COM line and programs the main
processor 1412
accordingly. Checksums are used for every packet to ensure integrity. If any
errors occur then
the process can safely be restarted without the need for attaching extra wires
or ports to the main
chip as would be done in a factory reset. It will be appreciated that the two
processor
configuration comprises both devices working on the same serial communications
lines, i.e. one
processor 1412 (i.e. the main MSP430 processor) operates the board and the
other processor
1413 (i.e. the second MSP430 processor) sits and listens waiting for a
specific byte sequence.
Once the correct command comes in, the programming processor 1412 puts the
controller
processor, i.e. the main processor 1412, into reset mode and prepares it for
programming. At this
point the programming processor 1413 will take control of the transmit line on
the serial port as
well.
[00090 1 A process for updating firmware according to an exemplary
implementation
comprises the following steps/operations:
. . CA 02759132 2011-11-21
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(1) the programming processor is waiting and monitoring main serial line for
special byte sequence and passes along any other commands to the main
processor
(2) the programming processor receives special byte sequence and intercepts
the
byte before it goes to the main processor
(3) the programming processor activates two signal lines to the main chip that
put
the main chip in programming mode
(4) the programming processor receives a stream of bytes from the computer can
contain the new firmware to be placed on the main chip
(5) the programming processor puts each byte of the new firmware in program
memory for the main processor
(6) the programming processor checks the written firmware for errors and
notifies
the computer if there are any errors or code faults
When all the firmware bytes have been transferred to the main processor
correctly, the
programming programming lines are released and the main processor returns to
normal operating
mode with the new firmware update, and the programming processor goes back to
waiting for
the special byte sequence.
[00091 1 Reference is next made to Fig. 10, which shows a cup dropper
module for the
vending machine 100 according to an embodiment of the present invention. The
cup dropper
module is indicated generally by reference 1000 and comprises a plurality of
auger units 1010,
indicated individually by references 1010a, 1010b, 1010c and 1010d in Fig. 10.
Each of the
auger units 1010 comprises an auger 1012, an auger motor 1014 and an auger
motor position
sensor 1016. Cups are stacked into each of the auger units 1010 and the auger
motor 1014 is
actuated by the control unit 122 (e.g. via ports on the control board 1410) to
drop or release a cup
from the respective auger unit 1010. For the configuration depicted in Fig.
10, each of the auger
units 1010 can be set up to hold a different size cup or container. The cup
dropper module 1000
is configured with a funnel 1020 which is operatively coupled to the bins 142
(Fig. 1), for
example, a tube or other type of conduit, that directs product (e.g. candy)
released from one of
the bins to the funnel 1020. As shown, the funnel 1020 has a lower end 1022
which directs the
CA 02759132 2011-11-21
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product into a cup or other container positioned below the funnel 1020. As
also shown in Fig. 10,
the cup dropper module 1000 is configured with a front face or panel 1030
having an opening
1032 where the cup is positioned below the funnel 1020, and the opening 1032
is configured to
align with the opening or access doors 150 on the vending kiosk 100 as shown
in Fig. 1.
100092 ] Referring again to Fig. 10, the cup dropper module 1000 is
configured with a
conveyer belt 1040 and a conveyer belt drive motor 1042. The conveyer belt
1040 is configured
to move a cup dropped from one of the augers 1010 to a position below the
candy funnel 1020,
i.e. lined up with the lower end 1022 of the funnel 1020 so that the cup can
be filled with candy
or other product. The conveyer belt drive motor 1042 is operatively coupled
and controlled by
the control unit 122 (e.g. via ports on the control board 1410). According to
an embodiment, a
front cup sensor 1044 is positioned in the opening 1032 and configured to
detect when a cup has
been moved into position by the conveyer belt 1040. In response to the output
from the front cup
sensor 1044, the control unit stops the conveyer belt 1040 to position the cup
under the funnel
1022. If necessary, the control unit can incrementally advance or reverse the
conveyer belt 1040
using the conveyer belt drive motor 1042 to re-position the cup.
[00093 1 As shown in Fig. 10, the cup dropper module 1000 is
configured with a candy fall
sensor indicated generally by reference 1046. The candy fall sensor 1046 is
located proximate
the lower end 1022 of the funnel 1020 and operatively coupled to the control
unit to monitor the
release of candy through the funnel 1020 and into the cup positioned below the
funnel 1020. The
cup dropper module 1000 is also configured with a cup drop sensor 1048 for
each of the augers
1010. The cup drop sensors 1048 are operatively coupled to the control unit
and configured to
detect/monitor the release of cup from the respective auger 1010 onto the
conveyer belt 1040
running inside the cup dropper module 1000.
[00094] According to another embodiment, the conveyor belt 1040 is
replaced by a bar
that is configured to move back and forth along the bottom of the cup dropper
module 1000. The
bar (not shown) can also function to clean the bottom surface of the module
1000. According to
another embodiment, the bottom surface of the cup dropper module 1000 is
sloped so that a cup
released from one of the augers 1010 slides into position under the funnel
1020.
CA 02759132 2011-11-21
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[00095 ] According to an embodiment, the control unit is configured
to operate under
stored program control (e.g. software and/or firmware) to perform the
following process:
(1) the control unit establishes a baseline sensor reading, e.g. infrared
level, using one or
more of the cup drop sensors
(2) the control unit checks that the sliding access door for the cup drop
opening 150 (Fig.
1) is closed
(3) the control unit actuates the auger motor for one of the auger units to
drop or release a
cup
(4) the control unit reads the output from the associated cup drop sensor to
check for the
presence of a cup
(5) if a cup is not present, the control unit runs the auger unit again; if a
cup is still not
detected, the control unit is configured to use of the other auger units to
drop or
release a cup
(6) when the control unit detects a cup, the conveyer belt drive motor is
activated to start
the belt moving forward and move the cup towards the front face of the cup
dropper
module
(7) the control unit monitors the front cup sensor along the surface of the
belt near the
funnel area
(8) when the Front Cup Sensors are tripped (there are two sensors for this
detection
process), the control unit stops the conveyer belt
(9) the control unit actuates the bin with the selected product (e.g. candy)
causing product
to fall down the flow tube, into the candy funnel which directs the candy into
the cup
(10) the control unit checks the candy fall sensor to verify that product fell
through the
candy funnel
(11) when the candy has finished falling into the cup, the control unit
activates a
solenoid that unlocks the sliding access door
(12) the customer is then able to open the door and remove the cup with the
dispensed
product
(13) the control waits for the door to close and activates the lock when
closed
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(14) the control runs the belt backwards to clear the chamber. If the control
unit detects
a large object (i.e. using the front cup sensors or the cup drop sensors),
such as cup
full of candy, on the belt when going backwards, the control unit moves the
conveyer
belt in the forward direction to bring the cup back to front access door and
to give the
customer another opportunity to remove the cup by unlocking the door
(15) if after a timeout period, the object is not removed, the control unit
locks the door
and runs the belt backwards to transfer the transfer the object to a waste
chute or
container
[00096 1 As described above, the cup dropper module 1000 is
configured with a conveyor
belt 1020 and conveyer belt drive motor 1022. The conveyor belt 1020 allows
the cups to be
effectively brought forward to the funnel area; allows multiple augers (i.e.
cup columns) to be
used to maximize cup capacity or cup sizes; allows for any cups that have
errors when dropped
to be cleared out the back into the garbage area by running the conveyer belt
drive motor in
reverse; allows for any spilled candy to be cleared using the same method;
allows for any
external objects placed in the cup dropper to be cleared as well.
[00097 1 According to another embodiment, the conveyor belt drive
motor 1022 is coupled
to a belt mechanism roller. The belt mechanism roller comprises a sprocket
socket on one side
and a half moon key socket on the other. The belt mechanism roller is
configured to tighten the
conveyor belt 1020 is as follows:
(1) plastic piece sandwiches an L-bracket to the side of the cup dropper frame
via two
bolts. This bracket is able to slide back and forth.
(2) a tightening screw puts pressure against the L-bracket which tightens the
belt
(3) the screw is adjusted to the appropriate pressure and then the two bolts
are tightened,
holding the roller securely in place
100098 1 As described above, the control unit utilizes sensors to
determine the position of
the auger motors running the cup augers and the motors for actuating the bin
scoops in the bins.
According to an embodiment, the motors including an attached wheel with one or
more magnets
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inserted. According to an exemplary implementation, a Hall Effect type sensor
is used to
determine the "home" position of the motor and return the motor to this
position after every
operation.
[00099 1 According to another aspect, the control unit 122 (e.g. via
ports on the control
board 1410) utilizes the cup drop sensors 1048 (Fig. 10) to determine and/or
verify that a cup has
been released or dropped from the associated auger unit 1010 (Fig. 10). The
control unit also
utilizes the front cup sensors 1044 (Fig. 10), i.e. two sensors to determine
that the cup has been
moved to the appropriate place under the funnel 1020. The control unit
utilizes the candy fall
sensor(s) 1046 (Fig. 10) to verify that product has been dispensed down the
funnel 1020.
[000100] According to another embodiment, a plurality of sensors (e.g.
infrared sensors)
are placed proximate to the surface of the conveyor belt 1040. The control
unit 122 is configured
(i.e. through firmware and/or software) to determine potential obstructions
(and the height of the
potential obstructions) on the conveyor belt 1040. If a low sensor is tripped
but not a high sensor
while the belt is moving, then control unit determines that the object on the
belt is small and
most likely a piece of candy. A higher obstruction will block both sensors.
The control unit is
configured to use this information to determine whether an object should be
returned to the
funnel area or simply discarded. According to another aspect, the control unit
is configured to
utilize two sensors to approximate the speed of the cup on the belt. This
value is used to calculate
how much longer the belt should be run until the cup is in the ideal position.
[000101 1 Reference is next made to Fig. 11, which shows a sensor board
according to an
embodiment of the present invention and indicated generally by reference 1100.
It will be
appreciated that the cups can comprise clear cups and this can make the
detection more difficult
using infrared sensors. According to an embodiment, the sensor board 1100 is
configured to
utilize the relative thickness of the plastic on the cup as it appears to the
sensor when the cup first
breaks the sensor beam to accurately detect the presence of a cup. This is
also used to detect the
removal of a cup. The sensor board 1100 comprises a multifunction
configuration and can be
populated with infrared emitter(s) 1110 and infrared detector(s) 1120 or Hall
Effect type sensors.
According to an embodiment, the infrared emitter(s) and infrared detector(s)
are configured on
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one side of the sensor board. The sensor board 1100 can be configured as an
infrared emitter
board or as infrared sensor board. For Hall Effect, i.e. magnetic sensing, the
sensor board 1100 is
populated with Hall Effect sensors according to PCB tracks laid out on the
other side of the
sensor board 1100. According to another aspect, the sensor board 1100 is
configured with a
connector having a common pin layout. The sensor board 1100 generates an
analog output that is
converter by an analog-to-digital (A/D) converter to a digital signal for
further processing by the
control unit. According to an exemplary implementation, the control unit is
configured to take a
first base line reading and determine if the reading is a defined range. If
not, then it is assumed
that there is something blocking the infrared source such as a cup or even a
heavy coating of
dust. If the baseline reading is within a defined range, the object will cause
a trip at a value set in
the software or firmware executed by the control unit. According to an
exemplary
implementation, the Hall Effect type sensor comprises an on/off digital device
where the sensor
has a built in hysteresis. Different types of sensors with the same footprint
can be installed on the
sensor board 1100 depending on the functionality as will be within the
understanding of one
skilled in the art. For instance, Hall Effect devices are available that will
switch in the presence
of any magnetic field. There are also Hall Effect devices that switch in the
presence or a north of
south field and other devices that switch when there is a polarity change.
1000102] According to another embodiment, one or more of the sensors are
implemented
utilizing an image capture system, which takes a picture of an operational
area, for example, the
conveyer belt area, and then the image is analyzed to determine the position
and/or orientation of
the cup. According to another embodiment, sensors are utilized that determine
the cup position
by static electricity. The vending kiosk includes other types of sensors for
detecting temperature,
humidity, and intrusion.
[000103] Reference is next made to Figs. 12(a) and 12(b). Fig. 12(a) shows a
stack of cups
1210 that are misaligned in the auger unit 1010 for the cup dropper module
1000. Actuation of
the auger unit 1010 by the control unit would not properly release the cup or
further jam the
auger unit 1010. According to an embodiment, the auger unit 1010 is configured
with a guide
ring as shown in Fig. 12(b) and indicated generally by reference 1220, which
functions to orient
the cup stack 1210 substantially in line with the feed direction of the auger
unit 1010. This
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facilitates the feeding of the cup stack 1210 into the auger unit 1010 and the
release of individual
cups onto the conveyer belt as described above.
[000104 1 Reference is next made to Figs. 13(a) to 13(c) which show the
guide ring
configuration 1220 in further detail. The guide ring 1220 comprises a ring
component 1310 and a
plurality of mounting tabs 1320, as shown. According to an exemplary
implementation, the guide
ring 1220 is fabricated as a single piece, for example, as an injection molded
component. The
ring component 1310 is approximately 2" high and there are three mounting
tabs, indicated by
references 1320a, 1320b and 1320c, each with a hole or aperture 1322 for
receiving a suitable
fastener to secure the guide ring 1220 to an upper face or mounting surface of
the auger unit
1010. According to another embodiment, the mounting tabs 1320 comprise a clip
mechanism to
secure the guide ring 1220 to the auger unit 1010 without the need for bolts.
[000105 1 As shown in Fig. 12(b), the outside diameter of the guide ring
1220 allows the
device to align tightly with the opening of the auger mechanism. The inside
diameter of the ring
component 1310 (Fig. 13(b)) is fitted to the diameter of the cup being
dispensed, for example, a
PKS16C model cup from FabriKal, and can be adapted for any other type or size
cup. As shown
in Fig. 13(a), the ring 1310 includes a beveled top edge 1330. The bevel edge
1330 slopes
towards the inside of the ring and functions to prevent any rims of the cup
stack from getting
caught up on the edge of the ring 1310.
[000106 1 According to an embodiment, the control unit 122 is configured
with a process
(i.e. operating under stored program control, software and/or firmware) to
perform a process for
unjamming a cup by changing the direction of the motor and varying the applied
voltage. The
process comprises the following steps:
Step 1: the auger (i.e. cup) motors 1014 (Fig. 10) are typically operated with
a low
voltage (according to an exemplary implementation at 5V) to manage the speed
of
the dispenser
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Step 2: if a jam is encountered (high current), the voltage is raised (for
example,
12V) to overcome the jam for a predetermined amount of time (for example,
250mS)
Step 3: when the voltage is lowered to normal levels, if the current is within
the
normal range the jam has been overcome and cup should dispense
Step 4: if the current is still high, the control unit repeats Step 2 for a
total of 3
attempts. If high current is encountered at high voltage, the control unit
changes
the direction and the operation is attempted running the motor in reverse for
a
total of 2 attempts. If after all this there is still a jam at high voltage,
the control
unit generates an error condition.
[000107 1 Reference is next made to Fig. 15, which shows in block
diagram a system
configuration for the vending kiosk of Fig. 1 and according to an exemplary
implementation
indicated generally by reference 1500.
[000108 1 The present invention may be embodied in other specific
forms without departing
from the spirit or essential characteristics thereof. Certain adaptations and
modifications will be
obvious to those skilled in the art. Therefore, the presently discussed
embodiments are
considered to be illustrative and not restrictive.
