US20140290284A1

US20140290284A1 - Proximity detection in networked freezer stocking management

Info

Publication number: US20140290284A1
Application number: US13/900,368
Authority: US
Inventors: Thomas H. Johnson; Carrol E. Johnson
Original assignee: Spinnaker Process Instruments
Current assignee: Spinnaker Process Instruments
Priority date: 2013-04-01
Filing date: 2013-05-22
Publication date: 2014-10-02
Also published as: CA2825435A1

Abstract

A system for an ice merchandiser having a compressor in a compressor enclosure to cool the ice merchandiser includes a proximity sensor positioned to detect an amount of ice within the ice merchandiser, and a communications component coupled to the proximity sensor to receive signals from the proximity sensor representative of the amount of ice in the ice merchandiser, wherein the communications component is configured to convert the received signals to a digital format and publish the signals via a network connection.

Description

RELATED APPLICATION

This application claims priority to U.S. Provisional Application Ser. No. 61/807,131 (entitled PROXIMITY DETECTION IN NETWORKED FREEZER STOCKING MANAGEMENT, filed Apr. 1, 2013) which is incorporated herein by reference.

BACKGROUND

Managing ice merchandisers to keep them stocked with bags of ice has been performed by drivers of ice trucks, who visit sites and check the ice merchandisers visually to determine whether more bags of ice should be added. This process leads to wasted effort when the ice merchandisers do not need more ice. It also may lead to delay in refilling ice merchandisers and result in lost sales if not refilled quickly enough.
One proposal to begin to address such problems has been to add weight sensors under the ice merchandiser to weigh the entire ice merchandiser. This retrofit solution is not able to offer level information on more than one product inside the merchandiser. Additionally, the retrofit solution components are all located on the exterior of the ice merchandiser, and may be negatively affected by adverse weather conditions or subject to tampering or vandalism.

SUMMARY

A system for an ice merchandiser compartment having a compressor in a compressor enclosure to cool the ice merchandiser compartment includes a proximity sensor positioned to detect an amount of ice within the ice merchandiser compartment, and a communications component coupled to the proximity sensor to receive signals from the proximity sensor representative of the amount of ice in the ice merchandiser compartment, wherein the communications component is configured to convert the received signals to a digital format and publish the signals via a network connection. The proximity sensor can include one or more of a capacitive sensor, Doppler sensor, inductive sensor, infrared sensor, laser rangefinder, magnetic sensor, optical sensor, reflective photocell sensor, radar, sonar, and combinations thereof.
In one embodiment, the proximity sensor includes a heating element proximate the proximity sensor. The proximity sensor provides an output to a system outside a cooled volume of the ice merchandiser compartment. The system takes the output and provides a signal on a network representative of the level of ice inside the ice merchandiser compartment.
In some embodiments, multiple proximity sensors may be used in the chest to measure the level of different sized bags of ice.
In further embodiments, temperature sensors and contact switches may be coupled to the system to provide signals representative of temperature inside and outside of the chest, and to indicate whether a chest door is open.
The system may provide signal processing to provide signals representative of the sensed parameters to the network. In one embodiment, the system includes a device having an IP address to facilitate exposing the sensed information via a website like interface. A wireless modem may be included.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1B are block diagrams of systems to detect stocking of ice in an ice merchandiser, according to example embodiments.

FIG. 2 is a top view block diagram of components in a compressor enclosure for the ice merchandiser of FIGS. 1A-1B, according to an example embodiment.

FIGS. 3A-3B are side block diagrams illustrating further details of sensor enclosures within the ice merchandiser compartment of FIGS. 1A-1B, according to example embodiments.

FIG. 4 is a block schematic diagram of an example heater, according to an example embodiment.

FIG. 5 is a block flow diagram illustrating sensed parameters and components involved in data flow, according to an example embodiment.

FIG. 6 is an example interface to interact with the system of FIGS. 1A-1B, according to an example embodiment.

FIG. 7 is a block diagram a system for performing functions and communications, according to an example embodiment.

DETAILED DESCRIPTION

In the following description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific embodiments that may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural, logical, and electrical changes may be made without departing from the scope of the present invention. The following description of example embodiments is, therefore, not to be taken in a limited sense, and the scope of the present invention is defined by the appended claims.
The functions or algorithms described herein may be implemented in software or a combination of software and human implemented procedures in one embodiment. The software may consist of computer executable instructions stored on computer readable media such as memory or other type of storage devices. Further, such functions correspond to modules, which are software stored on a storage device, hardware, firmware, or any combination thereof. Multiple functions may be performed in one or more modules as desired, and the embodiments described are merely examples. The software may be executed on a digital signal processor, ASIC, microprocessor, or other type of processor operating on a computer system, such as a personal computer, server or other computer system.
FIGS. 1A-1B are block diagrams of systems 100A and 100B to detect stocking of ice in an ice merchandiser 110, according to example embodiments. The ice merchandiser may include one or more ice merchandiser compartments 112. One or more different types of sensor enclosures may be placed inside an ice merchandiser compartment 112 in various embodiments. FIG. 1A depicts a system 100A that includes a single sensor enclosure 115A. FIG. 1B depicts a system 100B that includes two sensor enclosures 115B. The ice merchandiser may include one or more sensor electronics modules 142, which may control or provide power to the sensor enclosures 115A or 115B. In one embodiment, two proximity sensors may be housed in one or two sensor enclosures 115A or 115B. The proximity sensors may be arranged to obtain proximity measurements of items, such as bags of ice placed on the floor of the ice merchandiser. For example, FIG. 1A may include a single sensor enclosure 115A that includes two proximity sensors, and FIG. 1B may include two sensor enclosures 115B that each include a proximity sensor. In one embodiment, one side of the ice merchandiser compartment is used to hold bags 124 of one size or weight, and the other side is used to hold bags 126 of a different size or weight. While each proximity sensor is shown located within sensor enclosure 115A or 115B, each proximity sensor may be positioned within a wall of the compartment 112 or outside the compartment 112, with a hole in the compartment permitting sensing of the amount of ice in the compartment 112 in further embodiments.
In one embodiment, a proximity sensor has a field of proximity detection 128 that is wide enough to enable a proximity sensor to detect items located anywhere on one side of the ice merchandiser compartment. For example, the field of proximity detection can be thirty-five degrees, though other angles may be used. One or more further sensors may be included in a sensor compartment disposed within the ice merchandiser compartment 112. For example, a temperature sensor may be coupled to the system to provide signals representative of the temperature within the ice merchandiser. In another example, a contact switch sensor may be coupled to the system to provide signals to indicate whether a chest door is open. Sensor compartment 130 may also include multiple sensors to sense further parameters, such as humidity.
In some embodiments, multiple proximity sensors may be used in the chest to measure the proximity of different sized bags of ice placed within the ice merchandiser compartment 112. For example, in an ice merchandiser with two doors, one door may be used for bags of one weight having a first proximity sensor, and the other door may be used for bags of a different weight having a second proximity sensor. Thus, two proximity measurements are provided to the system for publishing via the network connection. In some embodiments, the system may provide alerts regarding a need for restocking one side or the other of the ice merchandiser when the ice level falls below a predetermined threshold. In various embodiments, the alerts may be provided via text messages, email, voicemail, or other mechanisms including various social media. Information regarding the ice merchandiser may be accessible from at least mobile devices, computer systems, and other devices capable of providing information.
FIG. 2 is a top view block diagram 200 of components in the compressor enclosure 140 for the ice merchandiser of FIGS. 1A-1B, according to an example embodiment. The compressor enclosure 140 may include a compressor electrical enclosure 210, where the compressor electrical enclosure 210 may contain circuitry for controlling the compressor and fan, as in standard compressor designs. The compressor electrical enclosure 210 may include a signal conditioner that takes voltage signals entering the system on the lower part of the picture and converts them to a zero to five-volt range. In some embodiments, sensors may be provided within the compressor electrical enclosure 140 to sense internal temperature, external temperature, and compressor power draw. Still further sensors may be included in further embodiments. The compressor electrical enclosure 210 may include condenser tubing, and wires from the sensors may follow the path of the condenser tubing.
A communications enclosure 215 may be included, which may contain circuitry for controlling sensors that have been added to the ice merchandiser 110 in various embodiments. The communications enclosure 215 may receive compatible voltage signals from the signal conditioner in the electrical controller 210. The circuitry may include an IP address and modem, which may provide data to a network such as the internet. The data may be representative of the sensed parameters, which may indicate the amount of ice within the ice merchandiser compartment 112. For example, sensed parameters may include proximity measurements, temperature, humidity, or other parameters. While the communications enclosure 215 is shown located within the compressor electrical enclosure 140, the communications enclosure 215 may be positioned in any other location that allows it to receive sensed parameters.
A communications enclosure 215 may include a web-enabled sensor appliance 144. The web-enabled sensor appliance 144 may include an internet communication device, analog/digital inputs, or relay outputs. The web-enabled sensor appliance 144 may include a microcontroller, such as an Arduino microcontroller. The web-enabled sensor appliance 144 may operate with a power source, such as a nine-volt DC transformer. The internet communication device may send data to a webserver on the internet, and a web browser may be used to view the data collected by the webserver. The web-enabled sensor appliance 144 may include an antenna extending out of the container to facilitate communication.
FIGS. 3A-3B are side block diagrams 300A and 300B illustrating further details of sensor enclosures 115A or 115B within the ice merchandiser compartment 112 of FIGS. 1A-1B, according to example embodiments. A circuit board 310 can have one or more proximity sensors 315 mounted on it, along with one or more light emitting diodes (LEDs) 320 near the proximity sensors. In an embodiment, two proximity sensors may be housed in one or two enclosures. For example, FIG. 3A depicts a sensor enclosure 115A that includes two proximity sensors 315, and FIG. 3B depicts a sensor enclosure 115B that includes a single proximity sensor 315. In one embodiment, the proximity sensors 315 and LED 320 may be enclosed in a transparent proximity sensor enclosure 325. The proximity sensor enclosure 325 may be made of polycarbonate materials in one embodiment, and the volume enclosed may be heated sufficiently by the LED 320 to remove or prevent moisture from condensing or freezing on the proximity sensors 315, enabling increased accuracy of the proximity measurements of the items stocked in the ice merchandiser 110. In further embodiments, the LED 320 may be positioned very close to the proximity sensors 315, and the LED 320 may heat the proximity sensors 315 sufficiently to obviate the need for the enclosure 325. The proximity of the LED 320 to the proximity sensors 315 may thus vary in different embodiments, but should be within a distance to allow it to perform the function of enabling increased accuracy of the proximity measurements. In still further embodiments, a heater substrate 400 can be attached to the inside or outside of the enclosure 325, which can heat the enclosure to remove or prevent moisture from condensing or freezing on the proximity sensors 315.
The circuit board 310 may further include control circuitry 330 that may control the proximity sensors 315 and LED 320, and may communicate with the circuitry in the electrical enclosure 210 in various embodiments. The processing of data may be split between such circuitry in various embodiments, or only one set of circuitry may perform all the functions. In still further embodiments, one or more sensors, such as temperatures sensor 335 may be included on the circuitry board 310.
FIG. 4 is a block schematic diagram of an example heater 400, according to an example embodiment. The example heater 400 may be used to provide a clear field of proximity detection for the proximity sensor. The example heater 400 may include a substrate 340 having fine resistive heating wires 410 to provide heat when powered via circuitry. The substrate 340 may be adhesive, with the wires on or embedded, similar to add-on rear windshield heaters for automobiles. The example heater 400 can be positioned proximate the proximity sensor, in the field of proximity detection of the proximity sensor, such as on or embedded within the transparent proximity sensor enclosure 325. The heater may be positioned outside the field of proximity detection on the proximity sensor enclosure 325 if it provides sufficient heat to create a clear field of proximity detection when proximity measurements are obtained.
FIG. 5 is a block flow diagram 500 illustrating sensed parameters and components involved in data flow, according to an example embodiment. Internal conditions 510 represent conditions inside of the ice merchandiser 110 in one embodiment. Internal conditions may include measurements from two proximity sensors 512 and 514, and an internal temperature sensor 518. External conditions 520 may include compressor enclosure or hood temperature 522, compressor power draw 524, a maintenance log 526, and power loss indications 528.
The connection module 215 may receive the information corresponding to these conditions at 530. The connection module 215 may be a 3G, 4G, WIFI, or other type of wireless communications module in various embodiments that is coupled to the internet represented at 532. The information may be provided to server 534, and then via network 536, such as the internet, to a provider of the items at 538. The provider 538 may be an ice company in one embodiment responsible for restocking the ice merchandiser. One or more user interfaces may be provided on a personal computer, smart phone, tablet, or other device enabling a person responsible for restocking to determine whether an ice merchandiser needs restocking, and with what types of items. The information may distinguish between different sized bags of ice, such as 10 lbs or 20 lbs.
FIG. 6 is an example interface 600 to interact with the system of FIGS. 1A-1B, according to an example embodiment. In one embodiment, the server 534 processes the information and creates a user interface allowing viewing of the information in various forms. Multiple different parameters may be published and viewable via interface 600. A web-enabled interface, or any number of other media, such as social media, including email and other forms of electronic communication may be used. Still further, the system may provide visible and audible alerts proximate the ice merchandiser.
In example interface 600, proximity measurements are shown at 610, 612, and 614. The newest proximity measurement is indicated at 614, with prior proximity measurements available to the left side of the display. In one embodiment, clicking on the latest proximity measurement may initiate communications back to the system 100A or 100B to provide a real time proximity measurement. In another embodiment, the proximity measurement may be represented by a diagram (e.g., bar graph, pie chart, etc.) or a series of diagrams indicating how much ice is left in the ice merchandiser.
A graph 620 illustrates desired parameters over time. In some embodiments, the period may be selected by the user. Illustrated on graph 620 are internal ice merchandiser temperature 622 and ambient temperature 624, which varies significantly over the few days that are shown. As desired, the internal temperature 622 may be constant. Note that a winter environment is occurring in this representation as the ambient temperature dips below the internal temperature. While temperature is shown on the graph, other parameters may be shown in further embodiments. In addition, a link to multiple settings 630 may be provided to enable the user to change timing of when data is periodically provided, or change any other control points used to control the system 100A or 100B, including the compressor and fan in some embodiments.
Some example control points and corresponding notes are shown in the following TABLE 1:

	TABLE 1

	Product	Product Level Measured
	Level	Within ± 5%
		Product Level Differentiation
		by Merchandiser Side
	Compressor Status	Defrost Monitoring and
		Control
		Electric Current Draw
		Monitoring
		Power Outage Monitoring
		Compressor Hood
		Temperature Change
		Monitoring
		Maintenance Tracking and
		Alerts
	Interior Case Temperature	Temperature Change
		Monitoring
	Merchandiser Door Status	Open Door Alarm Set Points

FIG. 7 is a block diagram a system for performing functions and communications, according to an example embodiment. FIG. 7 is a block diagram of a computer system or circuitry that may be used to process and publish sensed data and information according to an example embodiment. In the embodiment shown in FIG. 7, a hardware and operating environment is provided that is applicable to any of the circuitry, servers and/or remote clients shown in the other Figures. It should be noted that many devices to provide the functions described herein may be formed with far fewer components than described below. Components may be included or excluded as desired and appropriate for the functions to be provided.
As shown in FIG. 7, one embodiment of the hardware and operating environment includes a general purpose computing device in the form of a computer 700 (e.g., a personal computer, workstation, or server), including one or more processing units 721, a system memory 722, and a system bus 723 that operatively couples various system components including the system memory 722 to the processing unit 721. There may be only one or there may be more than one processing unit 721, such that the processor of computer 700 comprises a single central-processing unit (CPU), or a plurality of processing units, commonly referred to as a multiprocessor or parallel-processor environment. In various embodiments, computer 700 is a conventional computer, a distributed computer, or any other type of computer.
The system bus 723 can be any of several types of bus structures including a memory bus or memory controller, a peripheral bus, and a local bus using any of a variety of bus architectures. The system memory can also be referred to as simply the memory, and, in some embodiments, includes read-only memory (ROM) 724 and random-access memory (RAM) 725. A basic input/output system (BIOS) program 726, containing the basic routines that help to transfer information between elements within the computer 700, such as during start-up, may be stored in ROM 724. The computer 700 further includes a hard disk drive 727 for reading from and writing to a hard disk, not shown, a magnetic disk drive 728 for reading from or writing to a removable magnetic disk 729, and an optical disk drive 730 for reading from or writing to a removable optical disk 731 such as a CD ROM or other optical media.
The hard disk drive 727, magnetic disk drive 728, and optical disk drive 730 couple with a hard disk drive interface 732, a magnetic disk drive interface 733, and an optical disk drive interface 734, respectively. The drives and their associated computer-readable media provide non-volatile storage of computer-readable instructions, data structures, program modules, and other data for the computer 700. It should be appreciated by those skilled in the art that any type of computer-readable media which can store data that is accessible by a computer, such as magnetic cassettes, flash memory cards, digital video disks, Bernoulli cartridges, random access memories (RAMs), read only memories (ROMs), redundant arrays of independent disks (e.g., RAID storage devices) and the like, can be used in the exemplary operating environment.
A plurality of program modules can be stored on the hard disk, magnetic disk 729, optical disk 731, ROM 724, or RAM 725, including an operating system 735, one or more application programs 736, other program modules 737, and program data 738. Programming for implementing one or more processes or method described herein may be resident on any one or number of these computer-readable media.
A user may enter commands and information into computer 700 through input devices such as a keyboard 740 and pointing device 742. Other input devices (not shown) can include a microphone, joystick, game pad, touch screen, mobile phone, mobile pad, satellite dish, scanner, or the like. These other input devices are often connected to the processing unit 721 through a serial port interface 746 that is coupled to the system bus 723, but can be connected by other interfaces, such as a parallel port, game port, wireless, or a universal serial bus (USB). A monitor 747 or other type of display device, including a touch screen, can also be connected to the system bus 723 via an interface, such as a video adapter 748. The monitor 747 can display a graphical user interface for the user. In addition to the monitor 747, computers typically include other peripheral output devices (not shown), such as speakers and printers.
The computer 700 may operate in a networked environment using logical connections to one or more remote computers or servers, such as remote computer 749. These logical connections are achieved by a communication device coupled to or a part of the computer 700; the invention is not limited to a particular type of communications device. The remote computer 749 can be another computer, a server, a router, a network PC, a client, a peer device or other common network node, and typically includes many or all of the elements described above I/O relative to the computer 700, although only a memory storage device 750 has been illustrated. The logical connections depicted in FIG. 7 include a local area network (LAN) 751 and/or a wide area network (WAN) 752. Such networking environments are commonplace in office networks, enterprise-wide computer networks, intranets and the internet, which are all types of networks.
When used in a LAN-networking environment, the computer 700 is connected to the LAN 751 through a network interface or adapter 753, which is one type of communications device. In some embodiments, when used in a WAN-networking environment, the computer 700 typically includes a modem 754 (another type of communications device) or any other type of communications device, e.g., a wireless transceiver, for establishing communications over the wide-area network 752, such as the internet. The modem 754, which may be internal or external, is connected to the system bus 723 via the serial port interface 746. In a networked environment, program modules depicted relative to the computer 700 can be stored in the remote memory storage device 750 of remote computer, or server 749. It is appreciated that the network connections shown are exemplary and other means of, and communications devices for, establishing a communications link between the computers may be used including hybrid fiber-coax connections, T1-T3 lines, DSL's, OC-3 and/or OC-12, TCP/IP, microwave, wireless application protocol, and any other electronic media through any suitable switches, routers, outlets and power lines, as the same are known and understood by one of ordinary skill in the art.

Claims

1. A system comprising:

an ice merchandiser compartment;

a compressor in a compressor enclosure to cool the ice merchandiser compartment:

an optical proximity sensor positioned on a ceiling of the ice merchandizer compartment to detect an amount of ice within the ice merchandiser compartment within a field of proximity detection of the optical proximity sensor; and

a communications component coupled to the optical proximity sensor to receive signals from the optical proximity sensor representative of the amount of ice in the ice merchandiser compartment, wherein the communications component is configured to convert the received signals to a digital format and publish the signals via a network connection.

2. The system of claim 1 wherein the optical proximity sensor further comprises a heating element proximate the optical proximity sensor.

3. The system of claim 2 wherein the optical proximity sensor further comprises a housing surrounding at least the optical proximity sensor, and wherein the heating element comprises a light emitting diode within the housing.

4. The system of claim 3 wherein the light emitting diode is positioned to heat air within the housing to remove condensation from the housing and to provide light to illuminate an inside of the ice merchandiser compartment.

5. The system of claim 4 and further comprising a controller to turn on the light emitting diode to remove condensation, and to control the optical proximity sensor to provide signals from the optical proximity sensor while the diode is on.

6. The system of claim 4 wherein the optical proximity sensor and light emitting diode are supported by a circuit board.

7. The system of claim 2 wherein the optical proximity sensor further comprises a housing surrounding at least the optical proximity sensor, and wherein the heating element comprises a heating wire configured to heat air within the housing to remove condensation from the housing to facilitate capture of proximity measurements of the ice merchandiser compartment.

8. The system of claim 2 wherein the optical proximity sensor provides at least a thirty-five degree field of proximity detection inside the ice merchandiser compartment.

9. The system of claim 8 wherein the optical proximity sensor is angled to enable proximity detection of objects on an entire floor of the ice merchandiser compartment.

10. The system of claim 1 wherein the communications component comprises a web server and a wireless network connection.

11. A system comprising:

an ice merchandiser compartment;

a first optical proximity sensor disposed on a ceiling of the ice merchandizer compartment and adapted to generate a plurality of analog proximity measurement signals representative of an amount of a first portion of ice in the ice merchandiser compartment within a field of proximity detection of the first optical proximity sensor;

a second optical proximity sensor disposed on the ceiling of the ice merchandizer compartment and adapted generate a plurality of analog proximity measurement signals representative of an amount of a second portion of ice in the ice merchandiser compartment within a field of proximity detection of the second optical proximity sensor; and

a communication module adapted to:

receive the plurality of analog proximity measurement signals from the optical proximity sensor;

convert the analog proximity measurement signals to digital signals; and

publish the digital signals via a network connection.

12. The system of claim 11 wherein the system comprises a web server coupled to the optical proximity sensor.

13. The system of claim 11 wherein the system is located in a container that includes a compressor for the ice merchandiser compartment.

14. (canceled)

15. The system of claim 14 wherein:

different size bags of ice are placed on each side of the ice merchandiser compartment;

a first size bag of ice is disposed so as to be detectable by the first optical proximity sensor; and

a second size bag of ice is disposed so as to be detectable by the second optical proximity sensor.

16. A method comprising:

receiving proximity measurement signals from an optical proximity sensor positioned on a ceiling of an ice merchandizer compartment to detect an amount of ice within the ice merchandiser compartment within a field of proximity detection of the optical proximity sensor;

controlling the optical proximity sensor to obtain proximity measurements from the inside of the ice merchandiser compartment sufficient to determine if ice should be restocked;

controlling a heater proximate the optical proximity sensor to remove condensation from the optical proximity sensor; and

publishing the proximity measurements via a wireless network connection to facilitate remote monitoring of the ice merchandiser compartment.

17. The method of claim 16 and further comprising controlling the optical proximity sensor to provide proximity measurements on a selected schedule.

18. The method of claim 17 and further comprising controlling the heater to remove condensation a selected time prior to providing proximity measurements.

19. The method of claim 18 and further comprising sensing temperature within the ice merchandiser compartment and publishing the sensed temperature along with the proximity measurements.

20. (canceled)

21. The system of claim 1 wherein the optical proximity sensor includes an infrared sensor, a laser rangefinder, or a reflective photocell sensor.

22. The system of claim 11 wherein the optical proximity sensor includes an infrared sensor, a laser rangefinder, or a reflective photocell sensor.