Dispenser Control Systems and Methods
A method of operating a dispensing system having a material delivery cycle. In some embodiments, the material delivery cycle includes supplying water to a receptacle, performing an operation intended to release a material into the water, and delivering the material to a downstream component. The first step of the method is to initiate the material delivery cycle. Next, a conductivity proximate to the receptacle is monitored. Additionally, one or more error conditions are identified during the material delivery cycle based at least partially on the monitored conductivity.
This application is a continuation of and claims priority to U.S. patent application Ser. No. 12/524,052, filed Jul. 22, 2009, which is a national stage entry of and claims priority to PCT Application No. PCT/US2008/052672, filed Jan. 31, 2008, which claims priority to U.S. Provisional Application Ser. No. 60/939,142, filed May 21, 2007, and U.S. Provisional Application Ser. No. 60/887,681, filed Feb. 1, 2007, the entire contents of each of which are hereby incorporated by reference.
BACKGROUNDThe invention generally relates to material dispensing systems. More specifically, the invention relates to methods and systems of operating and controlling material dispensing systems.
As washing machines (e.g. dish washing machines, clothes washing machines, etc.) have become more sophisticated, systems have been implemented to automatically feed such machines with detergents, sanitizers, rinse aids, and the like, which may be produced in liquid, condensed, compressed, granulated, and/or powdered form. Such materials may be automatically delivered to a variety of types of washing machines.
SUMMARYIn one embodiment, the invention includes a method of operating a dispensing system having a material delivery cycle. The material delivery cycle includes supplying water to a receptacle, performing an operation intended to release a material into the water, and delivering the material to a downstream component. The method includes initiating the material delivery cycle; monitoring a conductivity proximate to the receptacle; and identifying one or more error conditions during the material delivery cycle based at least partially on the monitored conductivity.
In another embodiment a dispensing system for delivering a material to a receiving component positioned downstream of the dispensing system includes a receptacle, a valve, a material metering device, a sensor, and a controller. The valve controls a supply of water to the receptacle and has an off position that prevents water from entering the receptacle and an on position that allows water to enter the receptacle. The material metering device dispenses a material into the receptacle. The sensor is positioned proximate to the receptacle and generates a first signal that is indicative of conductivity. The controller receives the first signal from the sensor and generates a valve control signal and a material metering device control signal. The valve control signal can toggle the valve between the on position and the off position. The material metering device control signal can to initiate a dispensing of the material. The valve control signal and the material metering device signal are generated at least partially in response to a comparison by the controller of the first signal to one or more stored conductivity threshold values.
In another embodiment, a method of operating a dispensing system includes initiating a material delivery cycle having a pre-flush period, a material dosing period, and a post-flush period. Next, a first conductivity during the pre-flush period is monitored and compared to one or more thresholds, where the comparison is used to determine whether to initiate a material delivery during the material dosing period. Next, a second conductivity is monitored during the dosing period and compared to the one or more thresholds, where the comparison is used to determine whether material has been dispensed during the material dosing period. Next, a third conductivity is monitored during a post-flush period and compared to the one or more thresholds, where the comparison is used to verify that the material delivered during the dosing period has been delivered to a receiving component positioned downstream of the dispensing system.
Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
As should also be apparent to one of ordinary skill in the art, the systems shown in the figures are models of what actual systems might be like. Many of the modules and logical structures described are capable of being implemented in software executed by a microprocessor or a similar device or of being implemented in hardware using a variety of components including, for example, application specific integrated circuits (“ASICs”). Terms like “controller” may include or refer to both hardware and/or software. Furthermore, throughout the specification capitalized terms are used. Such terms are used to conform to common practices and to help correlate the description with the coding examples, equations, and/or drawings. However, no specific meaning is implied or should be inferred simply due to the use of capitalization. Thus, the claims should not be limited to the specific examples or terminology or to any specific hardware or software implementation or combination of software or hardware.
In some embodiments, the dispensing system 100 is configured to dispense or deliver a granulated material or powder (e.g., a chemical such as a detergent, a sanitizer, a rinse aid, bleach, pesticides, pool chemicals, etc.). For example, in some embodiments, a granular or powder material is delivered to a clothes washing machine. In other embodiments, a granular or powder material is delivered to a dish washing machine. In yet other embodiments, the granular or powder material is delivered to devices or areas, such as a swimming pool, bucket, other wash system, and the like.
In the embodiment shown in
The dispensing system 100 also includes a water intake conduit 140 that is controlled by a solenoid valve 145. The water intake conduit 140 and solenoid valve 145 are utilized to introduce water into the receptacle 110. For example, in some embodiments, when the solenoid valve 145 is energized, water from the water intake conduit 140 is allowed to enter the receptacle 110. Alternatively, when the solenoid valve 145 is de-energized, water is prevented from entering the receptacle 110. In other embodiments, a valve mechanism other than the solenoid valve 145 may be used.
A water solution outlet conduit 150 is also in communication with the receptacle 110. For example, the outlet conduit 150 allows water to exit the receptacle 110. In some embodiments, as described in greater detail below, water is mixed with dispensed material prior to exiting the receptacle 110 through the outlet conduit 150. In the embodiment shown in
In some embodiments, as described in greater detail below, the dispensing system 100 can also include electronic components such as a controller and one or more conductivity sensors. For example, in one embodiment, one or more conductivity sensors are positioned in the receptacle 110 to monitor the conductivity of the receptacle 110 (and the liquid disposed or flowing therein).
As shown in
Rotatable disks 215 and 230 are rotated by the shaft 120 (see
Referring to
Referring to
The dispensing systems described with respect to
Although
Generally, the controller 505 is a suitable electronic device, such as, for example, a programmable logic controller (“PLC”), a personal computer (“PC”), and/or other industrial/personal computing device. As such, the controller 505 may include both hardware and software components, and is meant to broadly encompass the combination of such components. In some embodiments, the solenoid valve 510 is a normally closed valve that opens when energized. For example, the controller 505 transmits a signal to the solenoid valve 510 to open the solenoid valve 510. The material metering device 515 can be used to control the amount of material that is dispensed from a container. For example, in some embodiments, the metering device 515 is similar to the closure 115 shown in
In operation, generally, the controller 505 utilizes the information from the sensors 525 to determine how to control the solenoid valve 510, the metering device 515, and the dispensing system condition indicator 520. For example, in some embodiments, during a material delivery cycle (e.g., a cycle in which one or more doses of material are dispensed), the controller 505 initially transmits a signal to the solenoid valve 510 to energize the solenoid valve 510. Once energized, the solenoid valve 510 allows water to flow. This initial influx of water can be referred to as a pre-flush. Additionally, the controller 505 receives conductivity information via signals from the sensors 525. For example, in some embodiments, when the material is mixed with water, the solution is substantially more conductive than water alone. Thus, the sensors 525 can measure the conductivity of the water and/or water/material solution, and generate a corresponding signal that is transmitted to the controller 505. The controller 505 utilizes the conductivity information to determine whether to dispense one or more doses of material into the flowing water. If the controller 505 determines not to dispense the material, the controller 505 may generate a dispensing error condition signal that is transmitted to the condition indicator 520, which then indicates the error. After dosing, the controller 505 keeps the solenoid valve 510 energized to allow the flowing water to clear away the delivered material. This water flow after dosing can be referred to as a post-flush. Following and/or during the post-flush, the controller 505 also utilizes the conductivity information from the sensors 525 to verify that the material was properly administered and/or received by downstream components. If the controller 505 determines that the material was not properly administered and/or received by downstream components, the controller 505 may generate a dispensing error condition signal that is transmitted to the condition indicator 520, which then indicates the error.
In some embodiments, the control system 500 may include an input device that allows a user to input and control one or more user changeable settings. For example, a user may use the input device to enter a material amount (e.g., a number of doses to deliver), a length and/or amount of pre-flush, and a length and/or amount of post-flush. In some embodiments, for example, the pre-flush is adjustable between approximately 1.5 and 5 seconds in duration and the post-flush is adjustable between approximately 2 and 10 seconds in duration. Additionally, as described in greater detail below, a user may enter one or more conductivity thresholds, which the controller 505 can use to decide whether to deliver the material.
In some embodiments, the control system 500 may contain more components than those shown in
In some embodiments, the controller 505 may generate a dispensing error condition signal for reasons other than those described above. For example, in embodiments that include more than one sensor 525 (e.g., one sensor 525 positioned proximate to a water intake conduit and one sensor 525 positioned near an outlet conduit), the controller 505 may generate a dispensing error condition signal if the signals from the sensors 525 are not consistent. For example, if the sensor that is proximate to the water intake conduit 525 indicates that water is present, but the sensor 525 that is proximate to the outlet conduit does not indicate that water is present, a dispensing error condition may be identified. In another embodiment, an error condition signal may be generated if a problem with the communication system is identified (e.g., the communication system is unable to transmit information to other systems).
The first step in the process 600 is to begin measuring conductivity in the receptacle 110 (step 605). This can be accomplished, for example, by initializing the conductivity sensor 525. In some embodiments, the conductivity sensor 525 is in constant operation, generating and transmitting signals indicative of conductivity to the controller 505, and does not need to be initialized. Next, water is supplied to the receptacle 110 for a pre-flush operation (step 610), and a change in conductivity is verified (step 615). For example, the controller 505 verifies that the conductivity monitored by the sensor 525 changes when water is added. The controller 505 can verify or determine if conductivity changes are appropriate by comparing the conductivity signal from the sensor 525 to a stored set of conductivity thresholds. With reference to
The comparison of conductivity values to conductivity thresholds can also aid in determining whether a dispensing error condition is present. For example, if the conductivity that is monitored by the sensor 525 does not change in accordance with bounds or thresholds set in the controller 505 pertaining to a material delivery cycle, a dispensing error condition may be indicated (e.g., displayed by the condition indicator 520) (step 620). For example, in some embodiments, the condition indicator 520 can indicate a dispensing error condition using an array of lights (e.g., as described with respect to
Referring still to
In other embodiments, an alternative process may be used to deliver the material to the receptacle 110. For example, in some embodiments, conductivity may be verified at additional points during the process. Additionally or alternatively, other parameters may be monitored (e.g., material weight, inductance, turbidity, etc.) and used to determine if one or more doses of material should be delivered and/or if the doses were properly received.
In some embodiments, the pause and resume functions may be used differently. For example, in some embodiments, solution concentration (i.e., the amount of dispensed material per unit of water) is measured downstream from the dispensing system 100 (e.g., in an associated washing machine). If the solution concentration approaches or reaches a material concentration set point (e.g., a concentration set point stored in the controller 505), the dispensing system 100 can be paused while the number of material doses actually delivered is verified. The dispensing system 100 can then be recalibrated accordingly. For example, the system 100 can recalculate the number of doses of material needed to increase the washing machine tank's conductivity by a predetermined amount. Other recalibration schemes are also possible.
In another embodiment, the pause and resume functions may be used while delivering two materials to the receptacle 110 (see
In yet another embodiment, the pause and resume functions may be used in dispensing systems that do not include a conductivity sensor (or when the conductivity sensor is turned off). In such embodiments, an associated downstream washing machine may send a trigger signal to the dispensing system as a request to deliver the material. If the trigger signal is lost or interrupted during delivery, the material dosing may be paused until the trigger signal is restored.
The water conductivity threshold 1030 is set relative to dry conductivity (e.g., the conductivity of the idle period 1005). Generally, the water conductivity threshold 1030 is set just above the dry conductivity (e.g., an offset from the dry conductivity) to provide a differentiation between a dry receptacle 110 and a receptacle 110 that includes water. For example, the controller 505 can determine that the receptacle 110 contains water if the signal from the sensor 525 breaches the water conductivity threshold 1030. In some embodiments, the water conductivity threshold 1030 is variable, and allows for a user to specify a tolerance range for the sensor 525 to provide accurate detection of the presence or absence of water despite variations in the dry conductivity. For example, for a relatively wide tolerance, the user may choose to set the water conductivity threshold 1030 a relatively greater amount above the dry conductivity. Setting a relatively wide tolerance can allow the controller 505 to determine that the receptacle 110 is substantially empty and dry, even if a small amount of water and/or material is present.
The maximum dry conductivity limit 1035 is set to ensure that the dry conductivity monitored by the sensor 525 is valid. For example, the dry conductivity of the receptacle 110 should be below the maximum dry conductivity limit 1035 for the controller 505 to determine that the dry conductivity value is valid. Generally, the maximum dry conductivity limit 1035 is a fixed limit.
The chemical conductivity threshold 1040 is set relative to the water conductivity (e.g., relative to the conductivity monitored during the pre-flush period 1010 or the post-flush period 1020). Generally, the chemical conductivity threshold 1040 is set at a point above the water conductivity (e.g., an offset from the water conductivity), which provides a differentiation between a receptacle 110 that contains only water and a receptacle 110 that contains water and the material (e.g., a chemical). For example, the controller 505 can determine that the water in the receptacle 110 contains the material if the conductivity signal from the sensor 505 breaches the chemical conductivity threshold 1040 (provided that the solution containing water and the material has a higher conductivity than water alone). In some embodiments, the chemical conductivity threshold 1040 is variable, and is set relative to the water conductivity to allow the controller 505 to accurately detect the presence or absence of material despite relatively wide variations in water conductivity. The chemical conductivity threshold 1040 also allows a user to specify a tolerance range for the sensor 525. For example, for a relatively wide tolerance, the user may choose to set the chemical conductivity threshold 1040 a relatively greater amount above the water conductivity. Setting a relatively wide tolerance can allow the controller 505 to determine that the receptacle 110 contains only water, even if a small amount of material is present.
The maximum water conductivity limit 1045 is set to ensure that the water conductivity monitored by the sensor 525 is valid. For example, the water conductivity of the receptacle 110 should be below the maximum water conductivity limit 1045 for the controller 505 to determine that the water conductivity value is valid. Generally, the maximum water conductivity limit 1045 is a fixed limit.
In other embodiments, more or fewer conductivity thresholds may be set. For example, in one embodiment, the absolute conductivity thresholds are not employed, leaving only the water conductivity threshold 1030 and the chemical conductivity threshold 1040. Alternatively, more conductivity thresholds may be implemented, for example, a maximum chemical conductivity threshold.
Generally, the light elements 2005-2015 can be used to indicate a condition of the dispensing system and/or a status of each material. For example, in one embodiment, as described in greater detail below, the light elements 2005-2015 change color according to the condition of the dispensing system. For example, a green light can indicate that the dispensing system is operating properly. However, if an error condition is identified, the light may change color to indicate to a user that an error condition is present.
For example, in one embodiment, after an error condition has been identified (e.g., a “blocked receptacle” condition), a yellow flashing light is used to indicate that the material dispensing system has been disabled (i.e., material will not be dispensed during a dosing period). In order to clear the error condition and continue with dispensing system operation, power to the dispensing system 100 may have to be removed and then restored. In other embodiments, the error condition may be cleared using another method, for example, with an input device located on the face of the condition indicator (e.g., a “clear fault” pushbutton).
In some embodiments, the dispensing system is not disabled until after a certain number of errors or faults have been identified, or after a predetermined time period has elapsed. For example, a controller can register and/or store identified error conditions as they are identified, and disable the dispensing system after three consecutive error conditions. Such embodiments can minimize disabling of the dispensing system due to faulty identified error conditions.
Various features of the invention are set forth in the following claims.
Claims
1. A method of operating a dispensing system adapted to dispense material from a container, the method comprising:
- connecting the container to a receptacle at least partially contained within the dispensing system;
- supplying water to the receptacle;
- performing an operation intended to release material into the water from the container;
- monitoring a conductivity proximate the receptacle via a sensor positioned to sense conductivity in the receptacle;
- delivering the material and water from the receptacle through an outlet conduit of the dispensing system for use in cleaning operations by a downstream component;
- identifying one or more error conditions via a controller during at least one of the steps of supplying water to the receptacle, performing an operation intended to release material into the water, and delivering the material and water; and
- determining a location within the dispensing system where the one or more error conditions has occurred based on the identification of the one or more error conditions.
2. The method of claim 1, further comprising:
- supporting the container in the receptacle; and
- delivering the material to a washing machine that is positioned downstream of the dispensing system.
3. The method of claim 1, wherein performing an operation intended to release material into the water comprises releasing a powder material or a granulated material into the water.
4. The method of claim 1, wherein performing an operation intended to release material into the water comprises operating a material metering device to release one or more doses of material into the water.
5. The method of claim 1, wherein identifying the one or more error conditions includes comparing the monitored conductivity to one or more stored thresholds.
6. The method of claim 5, wherein comparing the monitored conductivity to one or more stored thresholds includes comparing the conductivity to a first threshold and a second threshold, the first threshold corresponding to the sum of a conductivity of the receptacle when the receptacle is relatively dry and a first offset value, the second threshold corresponding to the sum of a conductivity of the receptacle when the receptacle includes water and a second offset value.
7. The method of claim 6, further comprising identifying a blocked receptacle error condition via the controller during at least one of the steps of supplying water to the receptacle, performing an operation intended to release material into the water, and delivering the material and water in response to the monitored conductivity being greater than the second threshold.
8. The method of claim 6, further comprising identifying a blocked receptacle error condition via the controller prior to the operation intended to release the material in response to the monitored conductivity being greater than the second threshold.
9. The method of claim 6, further comprising identifying a no water error condition via the controller during at least one of the steps of supplying water to the receptacle, performing an operation intended to release material into the water, and delivering the material and water in response to the monitored conductivity being not greater than the first conductivity.
10. The method of claim 6, further comprising identifying an out of material condition via the controller while the operation intended to release the material is being performed during at least one of the steps of supplying water to the receptacle, performing an operation intended to release material into the water, and delivering the material and water in response to the monitored conductivity being not greater than the second threshold.
11. The method of claim 1, further comprising identifying a low water flow error condition associated with supply of water in response to the monitored conductivity being lower than a predetermined conductivity threshold.
12. A method of operating a dispensing system adapted to dispense material from a container, the method comprising:
- connecting the container to a receptacle at least partially contained within the dispensing system;
- supplying water to the receptacle;
- performing an operation intended to release material into the water from the container;
- delivering the material and water from the receptacle through an outlet conduit of the dispensing system for use in cleaning operations by a downstream component;
- monitoring a first condition within the dispensing system via a first sensor positioned within the dispensing system, the first sensor configured to generate a first signal indicative of the first condition;
- monitoring a second condition within the dispensing system via a second sensor positioned within the dispensing system upstream of the first sensor, the second sensor configured to generate a second signal indicative of the second condition;
- identifying one or more error conditions via a controller based on the first signal and the second signal during at least one of the steps of supplying water to the receptacle, performing an operation intended to release material into the water, and delivering the material and water.
13. The method of claim 12, further comprising identifying the one or more error conditions when the first and second signals are inconsistent with each other.
14. The method of claim 12, further comprising identifying a blocked container error condition in response to the first signal indicative of a conductivity within the receptacle below a predetermined threshold and the second signal indicative of water being supplied to the receptacle.
15. The method of claim 12, further comprising identifying a blocked water supply error condition in response to the first signal indicative of a conductivity within the receptacle above a first predetermined threshold and the second signal indicative of a conductivity at or below a second predetermined threshold.
16. The method of claim 12, further comprising identifying a blocked receptacle error condition prior to the operation intended to release the material in response to the first signal indicative of a conductivity within the receptacle being greater than a predetermined conductivity threshold and the second signal indicative of water being supplied to the receptacle.
17. A dispensing system adapted to dispense material from a container, the dispensing system comprising:
- a receptacle positioned in communication with the container to receive material from the container via a dispenser;
- a water supply positioned to supply water to the receptacle;
- an outlet conduit fluidly coupled to the receptacle to deliver material and water from the receptacle to a downstream component;
- a first sensor positioned within the dispensing system and configured to monitor a first condition within the dispensing system, the first sensor configured to generate a first signal indicative of the first condition;
- a second sensor positioned within the dispensing system upstream of the first sensor and configured to monitor a second condition within the dispensing system, the second sensor configured to generate a second signal indicative of the second condition;
- a controller programmed to identify one or more error conditions based on the first signal and the second signal during at least one of the steps of supplying water to the receptacle, performing an operation intended to release material into the water, and delivering the material and water.
18. The dispensing system of claim 17, wherein the controller is programmed to identify the one or more error conditions in response to the first and second signals being inconsistent with each other.
19. The dispensing system of claim 17, wherein the one or more identified error conditions includes a blocked container error condition in response to the first signal indicative of a conductivity within the receptacle below a predetermined threshold and the second signal indicative of water being supplied to the receptacle.
20. The dispensing system of claim 17, wherein the one or more identified error conditions includes a blocked receptacle error condition prior to the operation intended to release the material in response to the first signal indicative of a conductivity within the receptacle being greater than a predetermined conductivity threshold and the second signal indicative of water being supplied to the receptacle.
Type: Application
Filed: Sep 22, 2014
Publication Date: Jan 15, 2015
Inventors: Andrew J. Cocking (Ben Lomond, CA), Michael A. Steed (Santa Cruz, CA), Erik Miller (Scotts Valley, CA)
Application Number: 14/493,221
International Classification: D06F 39/02 (20060101); D06F 33/02 (20060101);