TECHNICAL FIELD
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The present invention relates generally to a unique and novel method and
apparatus for the high speed dispensing of all beverages, and particularly
carbonated beverages. More particularly, the major elements of the apparatus
include tubing connected at one end to a beverage supply in the form of a
pressurized container such as a beer keg (or pumped flow source of liquid beverage)
and at the other end to a positive bottom shut-off filling nozzle, a main flow control
valve coupled to the tubing, a pressure control valve downstream of the main flow
control valve and associated with the filling nozzle via a nozzle pressure control
port fluid line, and requisite electronic controller and actuators to establish a
dispenser operating sequence. In addition, a heat exchanger may be disposed
upstream of the positive bottom shut-off filling nozzle.
BACKGROUND OF THE INVENTION
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The dispensing of beer for public and consumption is a ubiquitous activity.
The dispensing of other carbonated and still beverages is equally widespread. In the
particular case of draft beers and carbonated beverages in general, numerous
problems and limitations associated with known dispensing systems are well
documented.
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A first limitation of known types is the control of foaming within the fluid
flow pathway as a result of the rate of flow and associated pressure changes within a
carbonated beverage or beer dispensing apparatus. It is well understood that the
flow rate and pressure directly correlate and that drops in pressure beyond a defined
magnitude or rate cause dissolved gases (typically carbon dioxide) in a sparkling
beverage to leave solution and enter gas phase. This physical phenomenon is
variously referred to in the beverage domain as foaming, blooming, breakout, out
gassing, or foam out.
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A second limitation of known systems is the control of foaming as a result of
the physical interaction of the beer or carbonated beverage with the vessel into
which it is dispensed. For example, it is well understood that the degree of foaming
that occurs during the pouring of a draft beer increases with increasing flow rates
into the cup, glass, or pitcher, or any other vessel. The excessive foaming that may
occur as a draft beer is flowed into a drinking vessel is increased as a function of
the turbulence and trauma directly associated with flow rate and foam formation is
further increased by the entrainment of air into the beer as a function of such flow
induced agitation. This foam event associated with high flow rates into the serving
vessel is variously referred to as foaming, frothing or fobbing. In all cases of foam
associated dispensing problems, the general concept that foam makes more foam is
valid for understanding such fluids behavior.
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The consequences of excessive foaming of carbonated beverages and draft
beer from all causes in known systems are so severe as to limit and slow dispense
flow rates. This, in turn, results in protracted and lengthened dispense times. This
problem is particularly pervasive and notable in the case of draft beer, where lagers,
ales, stouts and all other styles exhibit excessive foaming problems on a frequent
basis, and are filled slowly into vessels as a matter of preferred practice. The
inability of beverage dispense designs of known type to dispense carbonated drinks
and draft beers at high speeds carries substantial penalties. It results in an
inefficient serving environment where prompt service is demanded or desired. It
slows the rate at which beverages can be served, impairing cash flow and return on
installed equipment and facility investment. It compromises drink quality by
forcing the pre-service dispensing of draft beers to meet peak demand in venues of
high periodic demand such as sports arenas and stadiums.
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It is also important to note that dispensing systems of know design and in
common usage cannot dispense on a dose or portion controlled basis because of the
excessive and variable foam problem. Thus, the economic and quality benefits of
portion controlled dosing are not available to the consumer or the vendor. This
forces costs up for the consumer and profits down for the vendor.
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In one recent study of draft beer dispensing at a National Football League
stadium (US) it was observed that the absolute dispense time or absolute dose time,
the time from start of beer flow to end of beer flow, into a 20 ounce plastic serving
cup varied from 15 to 20 seconds. This provides some perspective on the
limitations faced in providing the thousands of draft beer servings which may be
demanded in the space of a 15 to 30 minute sports intermission period. Clearly,
dispenser devices of known type present severe limitations in design and practice to
the high speed dispensing of beverages.
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Numerous designs have been set forth in the prior art for the specific
purpose of improving the speed and dispensing characteristics of draft beer and
other carbonated beverages. Vetrano (US 2,450,315) teaches a beer faucet with a
tubular portion with a bottom plug having a conical valve seat, an operating rod
with guide spiders within the tubular portion and a ball valve shut-off fitted to the
rod thus providing a bottom shut-off filling nozzle. Filling with the nozzle at the
bottom of the glass is shown and a first gentle and second fast flow rate are
provided for, but operation is manual and speed of fill, amount of foam and amount
of pour are dependent upon the technique and skill of the bartender. Vetrano is
silent regarding any other aspects, methods or apparatus associated with the
dispensing apparatus.
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In UK Patent Application GB 2,283,299 A, Rawling discloses three
embodiments of a beverage dispenser valve system. Each embodiment provides for
manual dispensing without portion control. Each device does provide for variable
flow rate control based on a variable flow area arrangement. Also provided is a gas
trap designed to collect gas bubbles at the point of dispense and manually introduce
them as desired into the beverage being served in order to cause the formation or
addition of a foam head or fob. In one version a sealed dome is fitted at the filling
tap for the purpose of trapping or accumulating gas bubbles emerging from the
beverage, thus to reduce frothing or foaming of the beverage. The dome is
transparent and thus the bartender can determine when it is full and manually purge
it through the filling tap as desired. Rawling does not disclose any bottom or
subsurface filling structure or method.
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In European Patent Application EP 0,861,801 A1, James discloses a bottom
shut-off filling nozzle-valve for the manual dispensing of beverages. The device is
particularly intended to reduce the time taken to dispense a carbonated beverage
such as a lager. The device consists of a long spout with a bottom sealing valve
element, designed to be placed at the bottom of the vessel into which the beverage is
dispensed and to remain below the level of the beverage as it is dispensed. The
spout has an external centering structure at its tip to keep the valve generally coaxial
with the spout. James teaches a higher flow rate of dispense without excessive
foam formation by reducing the velocity of flow into the vessel with vertical flow in
the nozzle being gradually altered to horizontal flow into the cup, the reduced
velocity causing less agitation and thus less liberation of gas. James does not
disclose variable flow rate capability and the filling valve sees the pressure applied
to or by the beverage at all times.
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Nelson (5,603,363) teaches a carbonated beverage dispenser designed for
rapid dispensing on a defined dose basis consisting of an elevated and liquid level
controlled tank holding beverage at atmospheric pressure such that timed flow from
the tank into a vessel defines a dose. Flow from the tank is through a long nozzle
with a rod operated conical bottom shut-off designed for bottom-up subsurface
filling of a vessel. The tank is chilled to maintain the beverage at a desired
temperature. The nozzle actuator is controlled electronically to define a desired
dose size. The system is equipped with a clean-in-place sanitizing apparatus.
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Nelson does not teach method or apparatus to alter dispensing flow rate, the
nature of reservoir replenishment valve, nature of the control computer, ability to
prevent loss of carbonation or sparkle in the beverage held at atmospheric pressure
for extended periods, means to alter or define or calibrate the desired amount of
foam associated with a particular beverage, actuation speeds or motion
characteristics of the filling nozzle, or means and method to assure that the
reservoir beverage supply flow rate equals or exceeds the takeaway rate as a means
of assuring continuous dispenser operating capability without depletion of available
beverage in the reservoir.
OBJECTS AND SUMMARY OF THE INVENTION
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It is a primary object of the present invention to overcome the numerous
disadvantages and limitations, as set forth above, of presently known beverage
dispense methods and devices.
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More particularly, the primary objects of the present invention include:
- 1. To disclose a unique and novel beverage dispenser apparatus where the fluid
flow pathway is hydraulic and at an essentially uniform rack pressure when
dispensing is not occurring, the rack pressure being the pressure applied to
the beverage supply.
- 2. To disclose a unique and novel beverage dispensing method where the
pressure in the dispensing nozzle is actively lowered, under electronic
control, from an essentially uniform rack pressure to a pressure at or near
atmospheric pressure just prior to the start of a dispensing cycle.
- 3. To disclose a unique and novel method and apparatus for priming or packing
the disclosed beverage dispensing system, such that a hydraulic condition is
established quickly and efficiently with a minimal loss of beverage and
minimal generation of foam.
- 4. To disclose a unique and novel method and apparatus, termed a watchdog
timer, for eliminating foam or gas in the fluid flow pathway of the dispenser
as it accumulates or generates over an electronically definable period of
dispenser inactivity.
- 5. To disclose unique and novel methods and apparatus for establishing a
defined amount of foam in the dispenser fluid flow pathway just prior to a
dispense cycle such that a specified and desired amount of foam can be
repeatably and automatically created in a successive series of dispensed
drinks.
- 6. To disclose a unique and novel valve arrangement and valve control
sequence which eliminates the problems of excessive foaming associated
with high speed dispensing of carbonated and sparkling beverages of all
types in a hydraulic beverage dispense system.
- 7. To disclose unique and novel filling nozzles which eliminate large areas or
pockets for gas or foam to become trapped.
- 8. To disclose unique and novel filling nozzles which provide means to remove
small quantities of trapped foam or gas on an active control basis.
- 9. To disclose a beverage dispenser method and apparatus wherein the speed
and motion control and motion characteristics of the filling nozzles are
controllable and manipulated and can be empirically demonstrated to alter
and influence and control the dosing characteristics of the system
particularly with regard to amount of foaming and dosing set point stability
and repeatability.
- 10. To disclose beverage filling nozzles which are unique and novel with respect
to means and methods to reduce internal nozzle volume while preserving low
velocity, high speed dispensing capabilities.
- 11. To disclose a unique and novel dispensing method and apparatus capable of
filling a 20 ounce plastic drink cup with a wide variety of draft beers in an
absolute dose time, as defined above, in 2.5 seconds or less, with an
electronically definable and controllable amount of foam.
- 12. To disclose the unique and novel use of precise fast-acting pinch valves for
control of flows and pressures within the preferred embodiments of the
beverage dispensing system.
- 13. To disclose a unique and novel beverage dispenser apparatus where the flow
rate or pressure of a beverage moving hydraulically through the fluid flow
pathway can be widely and dynamically varied by electronic control of a
true digital pressure control apparatus defining motive force pressure at the
beverage keg or any other beverage supply source container.
- 14. To disclose a unique and novel beverage dispenser apparatus where the flow
rate or pressure of a beverage moving hydraulically through the fluid flow
pathway can be widely and dynamically varied through the use and
electronic control of a novel long axis non-invasive progressively restrictive
flow control apparatus, the several embodiments of the flow control
apparatus being the subject of a separate patent specification.
- 15. To disclose a unique and novel beverage dispenser apparatus where the flow
rate or pressure of a beverage moving hydraulically through the fluid flow
pathway can be widely and dynamically varied through the use and
electronic control of a positive rotary displacement pump.
- 16. To disclose a unique and novel beverage dispensing apparatus where the
reduced pressure in the fluid flow pathway during dispensing is rapidly
restored to rack pressure at the end of a dispensing cycle through the use of
an electronically controlled valve sequence.
- 17. To disclose a unique and novel beverage dispensing apparatus where a
carbonated beverage can be held for long periods of time within the fluid
flow pathway without change in character or deterioration in quality, by
virtue of being held at rack pressure.
- 18. To disclose a unique and novel beverage dispensing system where the worst
case delay between successive dispensing cycles is one second or less, and
where the apparatus can execute dispense cycles indefinitely with this
minimal delay period, dependent only upon the availability of a bulk supply
of beverage to the systems.
- 19. To disclose a unique and novel beverage dispensing system in which the
optimal operating parameters for a particular specific beverage, including
flow rate, operating pressure, pressure control intervals and sequences, dose
time, dispensing temperature, filling nozzle motions and speeds, priming
flow time, and flow profiling data during dispensing can be grouped as a
machine setup or recipe and entered into the machine electronic controller
on a non-volatile basis such that it may be recalled in a display at any time
among many other recipes and utilized to electronically configure the
machine for operation as desired.
- 20. To disclose a unique and novel dispensing system wherein the filling nozzle
can be automatically lowered into a vessel prior to a dispense cycle and held
near the bottom of the cup for a defined period during the dispense cycle,
and raised out of the vessel at a desired rate, all nozzle articulations being
under electronic control via the dispenser controller.
- 21. To disclose a unique and novel dispensing method and apparatus wherein the
flow rate of the beverage during the dispensing cycle can be electronically
profiled to compress or reduce the dose time to a minimum interval while
allowing dispensing of foamy or carbonated beverages with a minimal but
programmable amount of foam to meet a desired presentation criteria.
- 22. To disclose a unique and novel beverage dispensing apparatus wherein a
defined portion or dose is established by electronic control of flow time at a
defined pressure or pressures, and in which it can be empirically
demonstrated that dose set point stability and repeatability is dependent upon
the unique ability of the invention to manipulate and control pressures and
flows in a repeatable manner and sequence with each successive dose cycle.
- 23. To disclose a unique and novel beverage dispensing apparatus in which the
beverage pressure in the filling nozzle may be reduced below rack pressure
just prior to the filling cycle by increasing the fluid flow pathway or lumen
volume through the opening or decompression of a partially compressed but
not occluded flexible tube installed in the nozzle pressure control port fluid
line.
- 24. To disclose a unique and novel beverage dispensing apparatus in which the
flow and pressure control pinch valves can be shown to be particularly
suitable for the flow and pressure control of carbonated beverage, and
especially beer, because the pressure drop across the valve devices is very
low due to the characteristic full opening flow pathway through the valves,
and because of the fast opening and closing action of the valve devices, both
properties serving to allow on-off valving action without inducing foaming
of the beer.
- 25. To disclose a unique and novel beverage dispensing apparatus in which the
flow and pressure control pinch valves preferably utilized provide inherently
non-invasive and sanitary operation within the dispenser fluid flow pathway,
the valves providing straight through and seamless construction, free of
crevices or pockets.
- 26. To disclose a unique and novel beverage dispenser in which the priming or
packing sequence upon system start-up or beverage source changeover can
be electronically controlled and automatic in nature such that a minimal
quantity of beverage is lost to the start-up process, and in which the priming
process is carried out in an efficient and minimal amount of time, and in
which a distinct and unique set of priming parameters can be defined for
each unique beverage type and electronically stored in association with the
electronically defined dispensing parameters for the particular beverage.
- 27. To disclose a unique and novel beverage dispenser in which the full open
position of the filling nozzle is sensed or encoded such that a closed loop
control condition is established, thus insuring that beverage flow into a
vessel cannot occur until a correct open nozzle condition is assured; nozzle
open encoding providing a guarantee of minimal delay for beverage flow to
be initiated thus minimizing dispensing time and eliminating gravity
mediated beverage fallout from the nozzle and consequent air entry into the
nozzle thus further minimizing beverage foaming; nozzle open encoding
providing a safety assurance that high speed flow of beverage cannot ensue
from a partially open nozzle, thus protecting the dispenser operator; nozzle
open encoding providing an empirically demonstrable improvement in filling
dose set point accuracy and stability.
- 28. To disclose a unique and novel beverage dispenser in which the fluid flow
pathway has been particularly designed to minimize foaming, by means
including the elimination of threaded fittings and connectors, the use of large
diameter flow tubes and conduits, the use of smooth and gradual transitions
in fluid flow pathway sizes, the use of smooth bore sanitary fittings and
connectors, and the elimination of sharp bend elbows in favor of large radius
sweep ells.
- 29. To disclose a unique and novel beverage dispenser in which the exterior
surfaces of the nozzle fill tube are maintained in a clean and sanitary
condition for extended operating periods by the provision for and use of one
or more ozone generators positioned adjacent to but apart from the nozzle
such that the nozzle fill tube is periodically or continuously exposed to a low
concentration of ozone gas, thus greatly reducing the rate of bacterial growth
on the nozzle shank or tube.
- 30. To disclose a unique and novel beverage dispenser in which the electronic
control design allows extensive alarm diagnostic and supervisory functions
including alarms such as nozzle fail to open, low or no beverage condition,
low gas pressure, high gas pressure, pressure control valve fail to cycle,
main flow control valve fail to operate, improper product temperature, low
mains voltage, and low battery voltage in portable systems; including
annunciation of maintenance intervals, sanitation intervals, inspection
intervals, inventory control data and functional status.
- 31. To disclose a unique and novel beverage dispenser in which the electronic
controller contains one or more clean-in-place (CIP) routines or sequences
for automatic sanitizing of the system fluid flow pathway.
- 32. To disclose a unique and novel beverage dispenser in which the electronic
controller can optionally be linked in a network array such that the device
can be addressed from a remote mode for data retrieval; so that the machine
can be remotely setup on a selected beverage; so that the machine can
provide status polling; and so that the machine can be accessed for remote
diagnosis of fault conditions.
- 33. To disclose a unique and novel beverage dispenser in which the small
quantity of foam or liquid beverage removed from the fluid flow pathway by
the brief opening of the pressure control valve prior to each dispense cycle is
connected into the hollow operator rod connecting to the nozzle plug and
through the plug and thus into the vessel receiving the beverage dose.
- 34. To disclose a unique and novel beverage dispenser in which the nozzle plug
associated with the positive bottom shut-off filling nozzle can open inward to
allow liquid flow as well as outward.
- 35. To disclose a unique and novel beverage dispenser in which filling nozzles
of different lengths and diameters can readily and interchangeably be fitted
to the system, thus enhancing the flexibility and versatility of the invention
with a broad range of beverage vessel shapes and sizes.
- 36. To disclose a unique and novel beverage dispenser in which a start fill delay
time may be entered into the dispensing sequence after the filling nozzle has
been read as open by the nozzle open sensor; the start fill delay allowing
further control over the amount of foam created in the vessel being filled.
- 37. To disclose a unique and novel beverage dispensing apparatus in which the
amount of beverage flow required to prime or pack the fluid flow pathway
can be electronically defined.
- 38. To disclose a unique and novel beverage dispensing apparatus in which the
dispensing or flow time required to define and to maintain a desired
beverage dose or dispensed volume can be automatically and electronically
varied as a function of varying beverage supply pressure.
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The foregoing objects and advantages of this invention will become apparent
after a consideration of the following detailed description taken on conjunction with
the accompanying drawings in which differing forms of this invention are
illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
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FIG. 1 is an illustration of a first embodiment of the invention, showing the
system without a heat exchanger.
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FIG. 2 is an exploded view of a nozzle assembly shown in FIG. 1.
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FIG. 3 is a view similar to FIG. 2, but showing the parts in their normal
operative position when a beverage is not being dispensed.
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FIG. 4 is an enlarged view of the lower portion of the nozzle assembly
showing a conventional actuator tip in a closed position.
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FIG. 5 is an enlarged view of a portion of the structure shown in FIG. 2, the
centering spider not being shown in this view.
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FIG. 6 is a view of the electronic and pneumatic controls which may be used
for the operation of the system shown in the various figures.
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FIG. 7 is a flow chart illustrating the operation of the system of this
invention.
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FIG. 8 is a view similar to FIG. 1 but shows another preferred embodiment
of this invention wherein a heat exchanger is disposed between the bulk supply
source container of the beverage to be dispensed, for example a beer keg, and the
filling nozzle assembly.
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FIG. 8A is a view similar to FIG. 8 but additionally showing a pressure
sensor.
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FIG. 9 is a view similar to FIG. 8 but showing a flow control valve (or
volume controller) disposed between the beverage container and the main flow
pinch valve.
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FIG. 10 is an enlarged view of one version of the flow control valve shown
in FIG. 9.
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FIG. 11 is a section taken generally along the line 11-11 in FIG. 10.
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FIG. 12 is an alternate design of a flow control valve.
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FIG. 12A is a section taken generally along the line 12A-12A in FIG. 12.
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FIG. 13 is a further alternative design of a flow control valve.
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FIG. 14 is a view similar to FIG. 9 but showing the volume controller or
flow control valve located between the heat exchanger and the filling nozzle
assembly.
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FIG. 15 is a view similar to FIG. 9 but showing the filling nozzle assembly
and pressure control valve mounted upon a support which is moveable vertically so
that the nozzle can be moved down into a beverage cup and upwardly out of the
beverage cup as it is filled.
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FIG. 16 is a partial illustration of the dispensing system of this invention
wherein a digital pressure control unit is associated with the source of gas to control
the pressure within the keg.
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FIG. 17 is a partial illustration of a system wherein the flow rate is
controlled by a positive displacement pump which is located between the beer keg
and the main flow control valve.
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FIGS. 18,19, and 20 show variations of the nozzle tube, FIG. 18 showing
the inlet tube at right angles to the nozzle tube with the bottom face of the
displacement plug at a differing angle than that shown in FIG. 2, FIG. 19 showing
the inlet port at an angle to the nozzle tube, and FIG. 20 showing a curve inlet port.
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FIGS. 21 to 23A are illustrations of a nozzle tube provided with means to
reduce the volume of the tube, FIGS. 21 and 22 having the volume reducer attached
to the actuator rod, and FIGS. 23 and 23A showing the volume reducer being
supported by the nozzle tube.
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FIGS. 24 and 25 are further illustrations of a nozzle assembly having a
reduced diameter, wherein the tip is flared to reduce agitation of the fluid being
discharged, and wherein the tube is provided with insulation; FIG. 24 showing the
disposition of the parts when the nozzle assembly is closed, and FIG. 25 showing
the disposition of the parts when the nozzle assembly is open.
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FIG. 26 shows a variation of the purge tube design with the purge beverage
and gas being discharged into the operator rod for direct discharge into a beverage
vessel.
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FIG. 27 shows apparatus for retarding the rate of growth of bacteria on the
external surface of the nozzle tube in the form of an ozone generator.
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FIGS. 28-30 show an inward opening beverage filling nozzle, FIG. 28
showing the nozzle in a closed position, FIG. 29 showing it in an open position, and
FIG. 30 being an exploded view.
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FIG. 31 disclosed an apparatus wherein gas pressure above the rack pressure
is employed to inhibit gas and bubble formation in the filling nozzle and thus
prevent or inhibit foaming when beverage flow under rack pressure into the serving
cup or glass.
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FIG. 32 shows a the application of a volume controller to the pressure
control line.
DETAILED DESCRIPTION
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The high speed dispensing of beverages, especially carbonated and sparkling
beverages and especially of beer, is fraught with problems and difficulties. Of
particular note are the problems of controlling foaming at high flow rates and of
maintaining beverage quality and character in a high speed dispensing system.
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The present invention is uniquely capable of high speed dispensing of
carbonated beverages, especially beer. The notion of high dispensing speed has two
components, the absolute dispense time and the machine cycle time. Absolute
dispense time is defined as the elapsed time from the start of a dispense cycle to the
end of a dispense cycle. The machine cycle time is defined as the minimum
possible time the machine functions can accommodate between dispense cycles.
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In the case of the present invention, as one benchmark of high speed, the
dispenser is uniquely capable of producing a 20 ounce (600 mL) dose of beer in an
absolute dose time of 2.5 seconds or less, and typically well less than 2.0 seconds.
The actual duration of beer flow into the cup is typically about 1.5 seconds. These
absolute dispense times are characterized by a defined and controlled amount of
foam associated with the pour.
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The dispenser of the present invention also manifests a very fast cycle time.
Typically, the system is capable of resuming a dispense cycle in no more than 0.25
seconds and, in the worst case, in 1 second. This is an important and novel feature
in that in practical terms the cycle time is constrained in the design herein disclosed
only by the human element of operation, which requires the placement and removal
of drink cups under the filling nozzle. It is also important to understand that the
minimal cycle time of the dispenser design herein presented is a direct consequence
of its hydraulic design where there is no intermediate reservoir requiring beverage
supply or re-supply maintenance and thus beverage is always available in real time
for dispense into the serving cup.
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Overall, the beverage dispenser machine detailed here is capable of
producing one complete 20 ounce serving cycle as fast as every 2.25 seconds. At
this speed, the machine is unconstrained in speed of function by any beverage flow
limitations through the fluid flow pathway of the machine save for the availability of
beverage to the machine from a bulk supply source.
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By comparison, the beverage dispenser of the present invention can dispense
over twenty-six beer pours per minute of 20 ounces each, while conventional beer
dispensers can typically dispense three to four pours per minute of the same serving
size. Thus, the high speed beverage dispenser herein detailed and disclosed offers a
speed increase of over six times compared to known conventional designs.
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The present invention consists of a solution to the high speed dispensing
problem in which beverage quality and character are maintained through the use of
a pressurized hydraulic system. By hydraulic, it is meant that the fluid flow
pathway of the dispenser is completely filled with the beverage to be dispensed.
The foaming problem associated with high speed dispensing is solved by active
electronic control, manipulation and sequencing of beverage flows and pressures
within the system and careful control of beverage flow out of the filling nozzle and
into a receiving vessel such as a cup C.
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The present invention consists of numerous preferred embodiments
including:
- 1. A basic dispenser version consisting of a fluid line connecting a source of
beverage to a main flow control valve, a fluid line connecting the main flow
control valve to a positive bottom shut-off filling nozzle, a pressure control
valve controlling flow through a flow pathway generally connected to the
upper portion of the filling nozzle, actuators for manipulating the three valve
elements, a trigger or start sensor associated with the nozzle tip for initiating
dispensing, and an electronic controller providing control of the apparatus.
- 2. A second version of the dispenser apparatus in which a heat exchanger is
coupled to the filling nozzle for the purpose of controlling and maintaining
the temperature of the beverage being dispensed. The heat exchanger may
be close coupled to the filling nozzle in which case the main flow control
valve is interposed between the beverage supply and the heat exchanger, or
alternatively the heat exchanger may be more remotely located from the
filling nozzle such that the main flow control valve is interposed between the
heat exchanger and the filling nozzle.
- 3. A third version of the dispenser apparatus in which a suitable flow rate
control device, typically a long axis non-invasive progressively restrictive
flow control or a progressively less restrictive flow control is inserted into
the fluid flow pathway between the beverage source and the filling nozzle,
the flow control device being locatable variously relative to the heat
exchanger and the main flow control valve.
- 4. A fourth version of the dispenser apparatus wherein flow rate control of the
beverage through the fluid flow pathway of the apparatus is substantially
defined by a digital pressure control device, the device being electronically
controlled and the desired flow rate determining pressure being applied to
the beverage source and defined and established by the dispenser electronic
controller.
- 5. A fifth version of the dispenser apparatus wherein flow rate control of the
beverage through the fluid flow pathway of the apparatus is substantially
defined by the use of a rotary positive displacement pump or linear
peristaltic pump interposed between the beverage supply source and the main
flow control valve; the pump type being widely variable and the pump being
especially useful in establishing adequate flow rates for high speed
dispensing of beverages where the beverage dispenser apparatus is
substantially separated from the beverage source.
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In operation, the various components of the first or second preferred
embodiments operate together to provide high speed beverage dispensing.
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Various embodiments of the high speed beverage dispensing apparatus are
shown in the various figures. In these figures, common reference numerals are
used for common parts. With reference first to FIGS. 1-5, the bulk supply
container is a beer keg 1, there being a beer line 2 extending from the keg tap 19
through a main flow pinch valve 3 to a side feed entry or inlet port 10.1 of a filling
nozzle or nozzle fill tube 10. The valve 3 is supported on a bracket 4 which may be
secured to the port 10.1 or to heat exchanger 5 (FIG. 8). At the upper end of the
nozzle fill tube 10 is a small flow tube 10.2 (FIG. 2) to which is connected a
pressure control line 6. A pressure control pinch valve 7 carried by amounting
bracket 8 engages the tube in a manner which will be more fully discussed below.
The valves 3 and 7 are pneumatically operated valves and to this end they are
connected to air lines 9 and 8, respectively. The other end of the air line 8 is
connected to pressure control solenoid valve V1, which is in turn coupled to
electronic controller EC (FIG. 6) and more specifically to a pressure control
regulator R1. Similarly, the other end of air line 9 is connected to main flow
solenoid control valve V2, which is in turn coupled to a main flow control regulator
R2.
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Mounted within the nozzle fill tube 10 is a hollow operating rod 39 having a
piston (not shown) on an upper end portion, the piston being mounted in a nozzle
actuation air cylinder 16. Air lines 12 and 13 extend between the air cylinder 16
and a filling nozzle solenoid valve V3 which is in turn coupled to regulator R3. The
rod can be moved up or down or be held stationary. Its position can be determined
by a nozzle position encoder reed switch 17 which sends an electrical position
signal to the electronic controller EC. In its up position shown in FIG. 4 the
bottom of the tube 10 is sealed by a nozzle plug. The nozzle plug consists of an
actuator tip 22 and an actuator tip O-ring 21 (FIG. 5), the actuator tip being carried
by the operating rod 39. A centering spider 23 (FIG. 2) insures that the nozzle plug
21, 22 will properly seat when the plug is raised to its closed position, and will
remain centered when it is lowered to insure even distribution of the beverage being
dispensed.
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As pictured in FIG. 5, the sealing tip of the filling nozzle (inward or
outward) can be fitted with a unitized elastomeric membrane with an external
elastomeric operator block or button, the deflectable rubber assembly being fitted
and glued to the nozzle plug. This device is for the purpose of starting the
dispenser when the inside bottom of a serving vessel is pressed up against the
button. This structure is known in the commercial art and is not novel.
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The specific mechanism of actuation acted upon by the deflectable rubber
button 20 shown in FIG. 5 is novel. It consists of a plastic or glass fiber of the type
used in fiber optic devices, and may be a fiber optic fiber bundle 14 of several
fibers within a sheath. At its lower end it is secured in place by epoxy filler 29.
The rubber button or fiber actuator boot is secured in place by RTV silicone sealant
28.
-
As pictured in FIG. 2, the fiber runs up through the hollow operator rod 39
of the nozzle and emerges at the top of the nozzle to be connected to an optical
amplifier 15 which converts the optical signal transmitted through the fiber into an
electronic grade output.
-
In operation, modulated infrared light is transmitted from the amplifier down
the fiber. When the rubber button is displaced toward the fiber tip by contact with
a drink cup, the amount of light reflected off of the inner surface of the rubber
button and back up the fiber to the amplifier is increased. This increase in light is
detected by the amplifier and the electrical output to the dispenser controller
constitutes a start signal.
-
Mounted within the tube 10 adjacent the side port 10.1 is a displacement
plug 24. O-rings 25 are mounted in plug 24 and prevent liquid from flowing above
the plug 24. A clamp block 26 is mounted on the upper end of the rod 39. A
nozzle bridge 11 (FIG. 2) is secured at its upper end to an upper flange 10.3 on fill
tube 10 by a tri-clamp fitting 27.
-
Fitted to the pressure control port on the upper portion of the filling nozzle
and communicating to it is a small flow tube 10.1 (FIG. 2). This tube is connected
to a small diameter flexible tube 6 which passes through a valve 7, preferably a
pinch valve, which may be smaller but otherwise similar in detail to the main flow
valve 3. This second pinch valve is termed the pressure control valve. This valve
may also be encoded so that its open or closed position or flow status can be
electronically detected by the dispenser control electronics, shown at EC in FIG. 6.
-
The main flow control valve and the pressure control valve can be of many
suitable and known forms but are preferably dual anvil fast-acting pinch valves,
typically actuated by pneumatic cylinders. The particular form of pinch valve is
unique and novel and is fully disclosed in WO 98/31935. This form of pinch valve
is particularly suited on several counts for on-off valving service of carbonated
beverages in the present invention. First, it provides for a dual floating anvil
geometry which provides for essentially symmetrical compression of the liquid flow
tube and thus a symmetrically shaped flow aperture through the valve. Second, it
provides for more than ninety percent of the flow area through the open pinch
valve, as defined by the area of the uncompressed round flow tube, even though the
tube remains partially compressed and captured by the dual round compression
anvils. Third, it provides for a high speed of opening to a full open position.
These features allow this form of pinch valve to serve as a liquid flow control valve
in carbonated beverage service without causing or generating outgassing or foam
formation. Thus for example, it can be empirically shown that the comparatively
high speed of valve operation and flow orifice opening and closing of the pressure
and flow control pinch valves minimizes or eliminates foaming in the fluid flow
pathway of the dispenser, such foaming with other valve types being caused by
excessive flow velocity increases and hence excessive pressure drops in valve
orifice and flow channels with slow changing and narrow flow pathways or
apertures upon opening or closing.
-
The means of valve actuation is preferentially by pneumatic cylinder.
However, as has been detailed in regard to the filling nozzle actuator, all known
alternative conventional forms of actuation are possible and practical for use in the
present beverage dispenser invention.
-
In operation, the system is primed or packed with a beverage, for example
draft beer, by applying CO2 or other gas pressure to the beverage source through
tube 1A and simultaneously opening the main flow control valve 3 and the pressure
control valve 7. When this occurs, beverage flows from the source 1 through the
connecting line 2 and heat exchanger 5 to the nozzle 10. Gas in the nozzle tube or
barrel is displaced and exits via the pressure control valve line 6, as does the foam
and mixed gas-liquid phase flow from the priming process. It will be understood
that because the filling nozzle is in a vertical orientation and is vented to atmosphere
by the pressure control valve 7 during priming, the nozzle quickly and
preferentially fills with the liquid beverage with any trapped gas in the nozzle
volume being readily and preferentially displaced upward and out of the pressure
control valve line. Thus, this arrangement is particularly efficient, quick and
effective in priming the system with liquid beverage and purging the system of gas.
Further, the amount of beverage lost to priming is particularly small in volume, for
example typically representing less than one part in two hundred of the volume of a
common beer keg.
-
After a suitable amount of flow has occurred to prime or pack the system,
which can be electronically defined, the pressure control valve 7 is closed, but the
main flow control valve 3 remains open. This completes the priming of the system
and places the beverage throughout the dispenser fluid flow pathway at the pressure
applied to the beverage supply, generally termed the rack pressure. By way of
example, in the US a typical pressure of CO2 gas ranging from 8 to 30 psi is
generally applied to beer kegs.
-
A beverage dispense cycle is initiated by a start input signal to the electronic
controller (FIG. 6) which can be by a wide variety of devices but most typically
from a nozzle tip actuator 20 detecting the presence of a vessel such as a glass,
cup, or pitcher to be filled.
-
The electronic controls provided with the dispenser of the present invention
are integral to its operation and function, and are to a large extent incorporate on a
printed circuit board indicated at EC in FIG. 6. The controls generally consist of a
logic and input/output engine which can be a microcontroller and associated
hardware or a programmable logic controller PLC, or a PC or the like. The
controls also include an operator interface OI, also termed a man-machine-interface
(MMI) which generally consists of an input/output capability such as a membrane
keypad KP and a display, such as a multi-line LCD display. Other components of
the electronic controller include input/output drivers I/O D, a transformer T, a
power supply PS, wire connectors WC, and wire ways WW.
-
The design of the controls for the present dispenser invention are unique in
providing extensive grouped parameters of machine setup, termed recipe setup, as
well as an extensive suite of diagnostic parameters and capabilities. The design also
accommodates remote access and control and status polling. A recipe can be
created for each beverage and stored in controller memory for use as required.
-
The numerous and particular functions of the electronic controller associated
with the dispenser herein disclosed are fully detailed throughout the specification in
association with discussion of the specific methods and apparatus of the invention.
The operating parameters controlled include flow rate, flow controller function and
settings, operating pressures, flow rate profiling, pressure control timing settings,
valve actuations, pressure control sequences, dose time and volume, operating
sequence and timing, filling nozzle motions, filling nozzle speeds, flow and control
valves positioning and status, priming flows and times, automatic bottom-up nozzle
filling motions and speeds, control of foam defining methods and sequences, clean-in-place
(CIP) machine sequencing and operation, integration and control of CIP
operating hardware such as cleaning pumps, and watchdog timer and supervisory
functions and actuations.
-
The numerous diagnostic functions carried out and monitored by the
electronic controller include monitor of beverage supply status, pneumatics, gas
pressure, failure of filling nozzle or flow control valves to open or close properly,
high or low beverage pressure, high or low AC mains voltage, and battery power
status in portable versions of the dispenser. Audible, visual and data alarms (not
shown) are provided for annunciation of out of specification conditions.
-
The electronic controller also annunciates required CIP intervals based either
upon number of dispense cycles or elapsed operating time, and proper maintenance
intervals and maintenance items based upon number of dispense cycles or elapsed
operating time.
-
The electronic controller can also be linked into a network array with other
beverage dispensers, or to a remote control node. This linkage is carried out using
conventional data integration hardware and software protocols. When linked, the
device can be remotely set up and configured by selecting and entering any desired
beverage operating recipe in the current machine operating parameters, and the
machine can be status polled for operating status and condition, including fault
conditions. The controller also has a self-teach capability with regard to some
operating parameters as detailed elsewhere in the specification.
-
The electronic controller, upon receipt of a start input signal, first causes the
main flow control valve 3 to close, thus isolating the beverage source from the
system beyond the valve. After the main flow control valve is closed the pressure
control valve 7 is opened briefly and then closed. This has the effect of removing
all or part of the foam or gas which may have accumulated at the top of the nozzle
10 since the previous dispensing cycle. The open interval is electronically defined
and can be varied as desired, the varying time having the direct effect of allowing
determination of the amount of foam desired in or on top of the drink to be
dispensed. The principles and mechanisms for this control will be extensively
discussed in a later section of this specification.
-
The opening and closing of the pressure control valve also has the effect of
reducing the pressure inside of the nozzle and communicating structure to a level
below the rack value. The pressure level can be defined by the opening period or
duration of the pressure control valve. Most typically, the pressure is lowered to a
level at or near atmosphere. However, this is electronically controllable and
variable as desired, the varying open time of the pressure control valve having the
direct effect of allowing determination of the amount of foam desired in or on top of
the drink to be dispensed. A more complete discussion of this foam defining
methodology will be found further on in this specification.
-
After the pressure control valve has cycled as described, the filling nozzle is
opened. This opening is preferably pneumatically defined and controlled in such a
way as to assure that the downward motion of the nozzle plug 21, 22 is relatively
gentle. A sensor 17 on the nozzle actuator critically detects the completion of
nozzle opening, at which time the main flow control valve is opened. The sensor
may be a nozzle encoding reed switch. It is important to understand that by first
lowering the pressure of the beverage in the nozzle to a level at or near atmospheric
pressure, or to a desired level below the rack pressure, the filling nozzle can be
opened with little or no pressure mediated flow occurring simultaneously with
opening. This is because of the action of the pressure control valve to cause a low
or lowered pressure in the nozzle and because at the time of nozzle opening the
main flow valve remains closed.
-
Opening of the main flow control valve allows beverage to flow through the
system at a rate defined by the rack pressure. Note that because the nozzle was
opened with the beverage in the nozzle at low pressure, no violent or turbulent flow
into the cup or glass occurs as a result of nozzle opening.
-
After the main flow control valve is opened, flow ensues for a period of time
which serves to establish a dispensing dose quantity on a time-pressure basis, for
example 2 seconds to fill a beer cup with 20 oz. of beer and 1/2 inch of foam.
-
At the completion of the dose flow time, the filling nozzle is closed. The
closing motion is unique and novel and critically consists of closing the nozzle at a
fast rate of motion. This is important in that as the nozzle closes its flow orifice
diminishes and the flow of beverage therefore accelerates in velocity. This increase
in velocity can result in turbulence within the volume of dispensed beverage and the
turbulence can induce the formation of substantial amounts of foam. This
phenomenon is largely avoided or reduced to an absolute minimum by virtue of the
fast nozzle closure.
-
The closure of the nozzle completes a dispensing event and the main flow
valve remains open to insure that the beverage in the system remains at rack
pressure and is thus preserved in character and quality relative to preventing
substantial out gassing or foaming of the beverage within the dispenser fluid flow
pathway.
-
In a variant of the basic operating sequence described initially, it is possible,
at the end of the dose defining flow time to stop beverage now by first closing the
main flow control valve, followed immediately thereafter by closure of the filling
nozzle. However, when this operating valve sequence is utilized, it is essential that
the main flow control valve be reopened after the filling nozzle has completely
closed so that the entire dispenser fluid flow pathway is re-established at the rack or
system operating pressure.
-
It is important to note still another variant to the basic dispense sequence
described above. At the end of each dispense cycle, a watchdog timer is started in
the dispenser's electronic controller. This timer may also be alternately termed a
quality timer, an outgas timer, a re-prime timer, or a purge timer. The purpose of
this timer is to measure the duration of time between successive dispenser events. It
will be understood by one knowledgeable in the art that in a closed and beverage
filled dispenser fluid flow pathway at rack pressure, some of the carbon dioxide gas
dissolved in the liquid will come out of solution over time. This process is
dependent upon numerous physical variables but is well known in the art. Thus,
over time, gas pockets or bubble trains or groupings can form on the inner surfaces
of the fluid flow pathway. As these bubbles merge and combine, they eventually
migrate upward to the top of the containment structure which, in the present
embodiment, is the top of the filling nozzle. Thus, over time, an undefined gas or
mixed phase pocket can form. The purpose of the novel watchdog timer in this
instance is to initiate a short re-prime sequence in the dispenser if sufficient time has
passed to allow an unwanted or undefined gas pocket to form at the top of the
nozzle. This restores the system to a known, fully primed condition thus assuring
tight repeatability of all dispensing functions.
-
If a start event is noted by the controller before the expiration of the
watchdog time, which can be varied as desired and is generally dependent upon the
particular beverage being dispensed, the watchdog timer is reset and begins a new
watchdog period at the end of the dispensing cycle.
-
In the instance where the watchdog time has expired and a start signal is
entered, the main flow control valve remains open and the pressure control valve is
briefly opened. This sequence is akin to the priming sequence previously
described, and is independently definable in the control sequence. The purpose of
this sub-routine is to re-initialize or re-establish known pressure and gas conditions
in the dispenser fluid flow pathway. The specifics of this methodology will be
extensively discussed further on.
-
After the watch dog timer mediated re-prime sequence has been completed,
the dosing event proceeds, and the main flow control valve is closed, the pressure
relief valve is closed, the pressure relief valve is cycled, the filling nozzle is opened
and a defined dose of beverage is dispensed, all in a manner identical to that
previously described. Additional components will be discussed below.
-
Considering FIG. 8 of the second embodiment, a source of beverage in
container or keg 1 is connected to the flexible tube 2 connecting to the main flow
control valve 3. The main flow control valve is most preferably and typically a
dual anvil fast-acting pinch valve, actuated pneumatically. This valve type will be
extensively discussed further on in this specification. The main flow control valve
may be encoded so that its open or closed position or flow status can be
electronically detected by the dispenser control electronics.
-
In the case where the main flow control valve is a pinch valve, the flexible
line continues through the valve and is coupled to a heat exchanger 5 using a
smooth walled sanitary connector generally known as a tri-clamp fitting. The valve
3 is supported on the heat exchanger 5 by a mounting bracket 4.
-
The beverage emerges from the heat exchanger, typically through a tri-clamp
fitting with a diameter as large as practical to limit absolute flow velocity in
the conduit which connects the heat exchanger to the positive bottom shut-off
beverage filling nozzle 10. The filling nozzle is coupled to the heat exchanger using
a tri-clamp connection.
-
The filling nozzles utilized In the embodiments of the beverage dispenser
invention herein disclosed have several unique and novel features.
-
Although many varied types and geometries of active valved filling nozzles
can be utilized, inward and outward opening bottom shut-off filling nozzles are
particularly effective in the dispenser invention. It will be understood that filling
nozzles of these general types are well known and long utilized in the commercial
art in association with liquid filling machines utilized in manufacturing and
production settings to package liquids into containers of every kind.
-
One novel feature of the nozzles disclosed herein concerns the small flow
tube 10.1 fitted to the upper portion of the nozzle and communicating with the
lumen of the nozzle. This tube is termed the pressure control port and may be
alternately termed the blow-off port, the purge port, the foam control port or the
prime port. The important function of this novel filling nozzle structure is
extensively detailed further on in this specification in conjunction with methods of
beverage foam control possible with this invention.
-
A second novel feature of the nozzles disclosed herein is the use of a beveled
or angled displacement plug 24, as shown in of FIG. 2 and FIG. 21, generally at the
top of the filling nozzle tube. The displacement plug eliminates the void or space
above the side feed entry port of the nozzle thus largely eliminating a gas trap area.
This trap exists because the top of the nozzle is gas and liquid sealed by the seal O-rings
25 best shown in FIG. 2. Thus a domed area is created which would fill with
gas accumulated from a carbonated beverage if the space were not displaced by the
solid displacement plug.
-
The angle of the bottom face 24.1 of the displacement plug 24 is novel and
important in that it provides for a more gradual deflection and turning of the
flowing beverage as it enters the nozzle tube from the side port. This reduces flow
pressure changes and kinetic flow trauma which helps to prevent unwanted foaming
of the carbonated beverage. In FIG. 2 the bottom face 24.1 is shown at a slight
angle, whereas in FIG. 18 it is at a greater angle. FIGS. 19-20 show other novel
geometries of an inlet tube 10.1 for assuring gentle flow through the nozzle tube 10.
Thus, in FIG. 19 the side feed entry pot 10.1 is at a 45° angle to the inlet tube 10,
whereas in FIG. 20 the inlet port 10.1 is curved.
-
As can best be seen from FIG. 21, the annular groove 24.2 novelty cut
circumferentially in the displacement block coincides with the pressure control port
10.2 when the plug is installed in the nozzle tube, thus aiding flow of gas and foam
around the plug and out through the port. The passage hole 24.3 from the annular
groove to the operator rod hole (no number) piercing the plug centrally from top to
bottom further promotes ease of movement of gas and foam toward the pressure
control port.
-
As will be detailed extensively further on, the nozzle is novelly encoded
such that its full open or flow position or status can be electronically detected. The
encoding can also define initial opening of the nozzle.
-
The filling nozzles preferably utilized in the present invention are most
typically actuated pneumatically. This is because of the inherent availability of
pressurized gas in most carbonated beverage installations and by virtue of the
ruggedness and simplicity and low cost of pneumatics. It is also possible to achieve
reliable and reproducible motion rate control using precision orifices or servopneumatic
controls and techniques. It is also provided herein for other actuation
methods including use of all types of rotary motors, use of solenoid operators, use
of voice coil operators and use of linear motors.
-
It will be understood that when the beverage dispenser is in a non-flow
condition shown in FIG. 3, the beverage, often beer, is held in the fluid flow
pathway. Thus, the smaller the lumen volume of the nozzle, the less beer must be
held in the nozzle, the nozzle being subject to an increase in temperature as chilled
beer warms up over time. This quantity of beer subject to warming in the nozzle
can be novelly reduced by several means as shown in FIGS. 21-25.
-
In FIGS. 21 and 22, a self-centering displacement tube 62 is provided which
is uniquely designed to drop over the operator rod of the nozzle, displacing a
significant volume of the nozzle lumen. The tube may include an integral set of
centering fins 62.1 , or operate with a separate centering spider (not shown).
-
In FIGS. 23 and 23A a novel unitized displacement sleeve 63 is fitted to the
nozzle tube from the top, integrating the displacement function and the flow
contouring requirement of plug 24. The unitized displacement sleeve includes, in
addition to the displacement portion, a curved face 63.1, an annular groove 63.2,
and a passage hole 63.3 which function in the same manner as the corresponding
parts of the displacement plug 24. In the designs of FIGS. 21-23A the large square
area of flow at the nozzle tip is not compromised or reduced. In these figures the
fiber optic fiber bundle is not shown.
-
Still another unique and novel feature of the filling nozzles of the present
invention is shown in FIGS. 24 and 25. The nozzle pictured in these figures has a
main flow tube 10a which is sheathed or wrapped in thermal insulation 64. This
design substantially reduces the rate of warming of the beer held in the nozzle for
extended periods. The insulation can be of many forms and can be bonded and
sealed to the nozzle for sanitary service such that it can be immersed in the
beverage container being filled. An external stainless steel sheath (not shown)
covering the insulation can also be welded to the bottom of the fill tube thus
providing an immersible design. In this instance, lumen volume is reduced by the
use of a reduced internal diameter main flow tube 10a, with a bell 10a.4 or flair
geometry at the nozzle tip to again establish the large annular flow area which
advantageously allows low velocity beverage flow into the serving vessel or cup. It
will be understood that reducing the volume of beer in the nozzle that can warm
over time and/or reducing the rate of warming allows a drink dispensed after a
standby period to be lower in temperature than would otherwise be the case.
-
Another embodiment of the beverage dispenser of the present invention is
shown In FIG. 26. This filling nozzle design allows the small quantity of foam
originating from the upper portion of the nozzle prior to a fill as a consequence of
operating the pressure control valve to be connected via a flexible tube 6 to the top
of the nozzle operator rod 39. The operator rod in this embodiment is hollow and
communicates all the way down to and through the nozzle tip. This design allows
the small discharge of beverage to enter the serving container rather than be
discharged from the pressure control valve flow tube 6, thus further reducing
beverage waste and loss.
-
It is an object of the present invention to disclose unique and novel methods
and apparatus for controlling and establishing a defined and specified amount of
foam in reproducible and automatic ways so that a desired amount of foam can be
repeatably and automatically created in a successive series of dispensed drinks.
These numerous methods will now be discussed.
-
As previously disclosed, the pressure control valve 7 as pictured in Figure 8
may be used to control and define the desired amount of foam in a dispensed drink.
The pressure control valve may also be termed the blow-off valve, the purge valve,
the foam control valve, or the prime valve, and it fulfills all of these functions. In
the drink dispense sequence previously described the filling nozzle is first isolated
from the beverage source by closure of the main flow control valve 3. The pressure
control valve is then opened for a precise and defined period. This opening period
is electronically defined by the controller associated with the dispenser, typically as
a controller timer function. The opening time for a particular beverage type or
brand is defined as one of numerous dispenser parameter variables that define drink
dispense volume and drink character or presentation.
-
The pressure control valve 7 is connected through a fluid tight conduit 6 into
a flow tube 10.1 located generally at the top of the filling nozzle 10. The flow tube
connected to the nozzle is termed the pressure control port and alternately termed
the blow-off port, the purge port, the foam control port, or the prime port.
-
With the main flow control valve 3 closed and the pressure control valve 7
open, flow of a carbonated beverage, and particularly beer, occurs from the nozzle
through the pressure control port and conduit to atmosphere. It will be understood
that if the portion of the dispenser fluid flow pathway on the dispensing nozzle side
of the closed main flow control valve were filled with a still liquid such as water,
and given that the fluid flow pathway is essentially rigid and undistended, little if
any flow would occur through the pressure control valve pathway because the water
is, in practical terms, incompressible and thus no motive force to cause flow would
be present even though the water would be at the rack pressure previously defined.
But, in the case of a carbonated beverage, the dissolved gases provide a means to
effect flow by virtue of their accumulation and ability to compress and expand as a
function of applied pressure as explained in the discussion of system priming, and
also by virtue of the outgassing that occurs with any sudden reduction of pressure of
a highly gas solvated liquid. Thus, it will be clear to one skilled in the art that the
pressure control valve, when opened with flow from the beverage supply blocked,
allows the pressure in the filling nozzle and adjacent structure up to the main flow
control valve to decrease as a function of flow induced by the expansion of the
trapped gas with the decreasing pressure. The pressure can be empirically shown to
be at rack value prior to opening, and to decay or decrease toward atmosphere at a
finite rate as a function of the duration for which the pressure control valve is open.
Thus, it is clear that by electronically determining the open time of the pressure
control valve, direct control of the pressure in the filling nozzle can be achieved.
Therefore it is a particular novel feature of the present invention that such direct
pressure control is possible and that it is predictable and reproducible with suitable
controls and valve apparatus, and that at any given system or rack pressure a
relationship between valve open time and resultant pressure can be mathematically
defined and such relationship can be entered and stored in the dispenser electronic
controls to allow direct selection of desired nozzle volume pressure at the start of a
dispense event.
-
Because pressure can be directly controlled in the nozzle volume of the
dispenser herein disclosed, direct control over a desired amount of foam in a pour
of beer or other carbonated beverage is achieved. This is partially true because
when the filling nozzle opens to begin the filling event, the initial flow into the
serving vessel is mediated by a combination of a fixed gravimetric flow or fallout of
beverage from the nozzle, and by the propulsion furnished by the gas associated
with the beverage. Thus, the lower the pressure in the nozzle the lower the initial
rate of flow of beverage into the serving vessel and the lower the turbulence and
therefore the less the foam formed, which forms largely as a function of outgassing
induced by flow turbulence.
-
The complete explanation for the efficacy of this method of foam control
also requires an understanding of the role of gas and foam reduction effected by the
pressure control valve before the start of the fill. Recall that gas and foam
accumulate at the top of the nozzle. This occurs relatively quickly after each pour.
When the pressure control valve opens, this foam and gas are forced out to
atmosphere. Thus, the amount of foam and free gas can be altered from essentially
none to a relatively defined quantity. Recall further that in a carbonated beverage
under flow, foam makes foam and more foam makes more foam. Thus, when the
filling nozzle opens and then the main flow control valve opens, rack pressure
induced flow begins into the beverage serving vessel. During this flow period,
which constitutes a defined volume dose, the amount of foam or free gas in the
nozzle at the start of the fill directly influences how much foam is formed within the
body of the liquid dose and ultimately how much foam is found on top of the
beverage in the serving vessel.
-
Therefore, the first method of foam control is both by the timed opening of
the pressure control valve which influences foam formation as a function of
modulation of initial flow velocity or rate and also as a function of control of gas to
liquid induced foam forming turbulence during rack pressure mediated flow.
-
It is important to note that the quantity of liquid or gas or mixed phase
beverage lost to atmosphere with each beverage pour is quite small. For example,
in dispensing twenty ounce servings of beer from a US keg, the total weight of
beverage displaced through the pressure control valve pathway typically ranges
from less than thirty to no more than ninety grams for the entire keg.
-
An important and novel variant to the timed pressure control valve method
described above is to open the valve until a defined and desired pressure is reached
as determined by a pressure sensor. The sensor can be located anywhere on the
downstream or nozzle side of the main flow control valve but most preferably at or
near the filling nozzle. Any suitable sensor type will serve as appropriate to the
pressure range and sanitary service requirement. This sensor based pressure control
method provides enhanced reproducibility and pressure set point resolution but at a
higher economic cost for the apparatus.
-
Still another important variant of the timed opening of the pressure control
valve to define and control foam is found in FIG. 32 which is a view of one version
of the filling nozzle of the present invention in which the pressure control conduit 6
leading to the pressure control valve 7 has inserted into a device indicated generally
at 30 for alternately increasing and reducing the system or lumen volume contained
in the portion of the beverage dispenser fluid flow pathway on the nozzle side of the
main flow control valve. The device includes a tube 45, similar in diameter to tube
2, which is coupled to upstream and downstream portions of the pressure control
line 6. In operation, the device 30, termed a volume controller, is partially
compressed when dispensing is not occurring. The partial compression does not
prevent flow through the device and thus the prime valve 7 pictured in FIG. 32
beyond the volume controller 30 can function to allow rapid and efficient priming of
the beverage fluid flow pathway. The flow control valve or volume controller 30
shown in FIG. 32, as well as in FIGS. 10 and 11, includes a pair of anvil
compression cylinder assemblies 31 mounted on a cylinder support plate 32. The
operation of the cylinder assemblies is controlled by the electronic controller EC,
and more specifically by a solenoid operated compression cylinder control valve and
regulator (not shown) operating through the cylinder air feed line 33. Bridge
supports 34 carry a tubing backer plate 35, the tubing 2 being disposed between
plate 35 and compression anvil 36 which is carried by the pistons of the
compression cylinder assemblies 31.
-
A single cylinder assembly volume controller 30 is shown in FIGS. 12 and
12A and functions in a manner similar to a pinch valve in that a compressible flow
tube 2 or conduit is laterally collapsed to reduce lumen volume in the tube but not
occlude flow. Alternatively, the actuator may be retracted to allow the tube to
assume its full lumen volume. The motion described can be established
mechanically or be defined electronically. In the example shown, the stroke of the
actuator is a mechanically defined pneumatic design. However, encoding of the
stroke can provide electronic control and actuation can be by any known means
including by rotary motors, solenoids, linear motors or voice coils. It should also
be understood that many alternate forms of the volume controller are possible
including piston types, diaphragm types and bladder types.
-
The purpose and function of the volume controller in beverage dispensing
foam management and control is straightforward. From a compressed or minimum
volume position, the volume controller is shifted to its maximum volume condition
at the start of a filling event after the main flow control valve has been closed. This
increase in volume in the portion of the fluid flow pathway isolated by the main
flow control valve from rack or system pressure causes the pressure in this portion
of the system to drop. This drop in pressure allows foam control and definition in a
manner akin to that previously described in conjunction with the function of the
pressure control valve.
-
It should be noted that the prime valve associated with the volume controller
remains closed during dosing events and thus there is no flow of gas or beverage to
atmosphere in this method except when the prime valve is opened for system
priming or re-priming after a watchdog timed prompt.
-
The volume controller 30 may be shifted to its minimum volume
configuration at any time after beverage flow from the beverage supply has begun,
and it is thus readied for the next subsequent pour. It should also be noted that it is
possible to combine the functions of the volume controller and the prime valve into
one integrated device, the many forms of volume controllers and integrated volume
control and flow control devices being the subject of a separate disclosure.
-
The second principal method of foam control and definition is by control and
manipulation of the actuation timing and motion relationship between the filling
nozzle and the main flow control valve. This method may or may not be utilized
operatively in conjunction with the first method.
-
This method may be termed start fill delay and consists of sensing the
opening of the dose nozzle to its full open condition and then electronically varying
the opening of the main flow control valve from essential no delay to a desired
delay. This manipulation controls foam formation in the serving vessel by
controlling flow turbulence as a function of the amount of air introduced into the
drink. This foam control is possible because, from the time that the nozzle opens
until system pressure mediated flow is allowed, gravimetric flow occurs from the
open nozzle. Because the nozzle volume is not open to atmosphere, air enters the
nozzle as the liquid beverage flows or falls out of the nozzle. The longer main flow
from the beverage supply is delayed, the more air enters the filling nozzle. When
the flow control valve is opened and flow from the supply ensues, the air that has
entered the nozzle is largely displaced out of the nozzle and into the volume of
beverage being filled into the cup. Because more air in the pour results in more
turbulence and more turbulence results in more foam, it can be understood that a
mechanism for defining foam quantity in the drink pour is established where no
delay between nozzle opening and flow control valve opening represents minimum
foam and more delay represents more foam. This method is electronically defined
and controlled in the control electronics of the dispenser of the present invention
and may be altered at will and may be included as a setup variable or machine
operating parameter associated with each distinct beverage type or brand to be
dispensed from the device.
-
It should be understood that while the preferred configuration of this second
principal foam control method provides for the filling nozzle open condition to be
sensed by a sensor encoding or marking such nozzle status, the method can be
implemented on a timer basis only if desired.
-
The third principal method of foam control and definition is also by control
and manipulation of the actuation and timing and motion between the filling nozzle
and the main flow control valve, but utilizing a different motion relationship.
-
This method may be termed nozzle opening aperture control. It consists of
sensing the opening of the filling nozzle such that the very initial motion or opening
of the nozzle is detected or encoded, and then electronically varying the opening of
the main flow control valve from essentially no delay relative to initial nozzle
opening to a desired delay including until the filling nozzle is fully open. This
manipulation controls foam formation in the serving vessel by controlling flow
turbulence as a function of flow velocity at the nozzle opening, which is a function
of the amount of opening of the nozzle tip and thus the square area of the nozzle
flow aperture.
-
This foam control methodology is possible because when the nozzle begins
to open the annular flow pathway around the nozzle plug 21, 22 is relatively small.
Thus, if flow from the beverage supply is allowed at the first opening of the
nozzle, the velocity of the flow is relatively high and decreases as the nozzle
becomes progressively more fully open, dropping to some finite and minimal
velocity when the nozzle becomes fully opened. It will be understood the flow
velocity of the beverage into the serving vessel is directly correlated with the
amount of foam formed as a function of the dose flow.
-
This third method of foam manipulation is electronically defined and
controlled in the control electronics of the dispenser of the present invention and
may be altered at will and can be included as a setup variable or machine operating
parameter associated with each distinct beverage type or brand to be dispensed.
-
As with the second method of foam control, this method may be established
on a purely timer related basis in lieu of nozzle encoding, and may or may not be
used in conjunction with the first method of foam control.
-
The fourth principal method of foam control and definition is by control and
manipulation of the motion of the filling nozzle alone, at the end of the pour or dose
event.
-
This method may be termed filling nozzle closing aperture control. It
consists of controlling and varying the rate of filling nozzle closure at the end of the
filling dose event.
-
The design of the dispenser of the present invention provides for electronic
means to determine the beverage dose as a function of time pressure flow, and it
also can provide means to control the rate at which the filling nozzle closes at the
end of the fill, from very fast to relatively slow. It will be understood from
discussion of the first three foam defining methodologies that flow velocity into the
serving vessel defines flow turbulence in the vessel and thus the amount of foam
created in the vessel. It is also understood from previous discussion that the size of
the annular flow area at the nozzle tip, as a function of the position of the nozzle tip
relative to the nozzle barrel defines flow velocity of the beverage exiting the nozzle.
Thus it is clear that if the nozzle is slowly closed, the flow velocity will slowly
increase, thus increasing turbulence and thus increasing foam. Conversely, if the
nozzle is closed quickly, the duration of the flow velocity increase as a function of
nozzle closing is minimized and thus foam is minimized as a function of nozzle
closure.
-
Control of nozzle closure rate can range from manual to fully electronically
controlled and is achieved by most known conventional methods including
pneumatic, variable hydraulic shock absorber, linear motor control, and all methods
of rotary motor control.
-
As with discussion concerning previous foam control methods, the electronic
control of nozzle closure, use with the first method, recipe or parameter based setup
of the dispenser and encoded and timer based control are all possible with the fourth
method of foam control.
-
It should also be noted in regard to the fourth method that the best dose
accuracy or repeatability of the dispenser is achieved when the filling nozzle is
closed quickly.
-
The fifth method of beverage foam control and manipulation is by control of
the nozzle opening distance or dimension throughout the pour period. The
dispenser of the present invention is designed to operate with both inward and
outward opening positive shut-off filling nozzles as illustrated in FIG. 3 and FIG.
30 respectively.
-
An examination of the outward opening type of FIG. 3 will show that the
opening dimension of the nozzle plug can be defined by limiting or controlling the
nozzle stroke. This is done by mechanical or electronic means and either can be
manual or automatic. The mechanical limit of stroke is achieved by interposing a
stop (not shown) between the nozzle operator rod anchor block 26 at the very top of
the nozzle and the upper shoulder 16.1 of the actuator, an air cylinder in the case of
the illustration. This stop can be a simple spacer fitted over the actuator operator
rod 39, or it can be an adjustable stop on a screw actuator, or a cam operated stop,
or many other variants. Except for the spacer, the various means can be controlled
by the control electronics using linear or rotary motors or solenoids or voice coils,
or any other suitable actuator. Furthermore, the primary actuator of the nozzle can
be controlled directly to define the nozzle stroke or opening dimension, actuator
means including those already described.
-
One embodiment of an inward opening beverage filling nozzle is shown in
FIGS. 28-30. Initially, it can be seen that this design has a differing diameter and
length from the filling nozzle shown in FIG. 1. The flow orifice can be defined by
the amount of opening of the nozzle plug as it is moved up into the nozzle lumen,
compare FIGS 28 and 29. The nozzle fill tube is made of upper and lower parts 10
b and 10c, respectively, which are coupled together by a threaded knurled coupler
10d. The lower portion 10c has a frusto-conical inwardly extending tapered lower
end 10c.4 which is sealed by a nozzle plug 21, 22 similar in design to the nozzle
plug 21-22 best shown in FIG. 5. In this design the nozzle bridge 11 is connected
to the upper portion of the nozzle 10b by another knurled coupler 11a, rather than
by a tri-clamp fitting. The bottom taper angle 10c.4 formed by the lower portion of
the nozzle, along with the nozzle plug, defines an increasing flow aperture as the
plug travels further up into the nozzle tube until it is fully into the parallel wall
section of the nozzle tube as shown in FIG. 29. The control of the nozzle stroke in
the case of the inward opening filling nozzle is essentially the reverse of the
outward version and by the same methods and apparatus. In both cases, the
opening dimension can represent a setup parameter in the dispenser control
electronics and can be grouped along with other essential system settings for any
particular beverage.
-
As has already been disclosed in the portions of this specification discussing
foam control, smaller nozzle flow orifices cause higher flow velocities into the
serving vessel and higher flow velocities create more foam, other parameters being
comparatively equal. Thus by defining a nozzle opening geometry throughout the
pour, the total amount of foam created can be influenced or defined or controlled.
This fifth foam control methodology can be utilized in combination with the other
methods.
-
The sixth principal method of foam control and definition is by electronic
control and manipulation of the system or rack pressure at which the dispenser
operates.
-
It is readily apparent that varying the pressure applied to the beverage in the
dispenser herein disclosed will alter the flow rate of beverage through the dispenser
fluid flow pathway and into the serving vessel and thus influence the amount of
foam created in the vessel. It is also clear that under a given set of conditions of
dispenser geometry and operating parameters there is an optimum flow rate for
pouring a carbonated or sparkling beverage into a vessel as rapidly as possible
while creating a desired amount of foam associated with the beverage serving.
-
Manual adjustment of the pressure applied to a beverage, such as beer, is
well known through conventional means such as the use of a mechanical gas
pressure regulator. However, these means are cumbersome and often inconvenient
to implement. The novel means of control of beverage pressure and thus flow rate
and thus foam in the present invention is by use of a digital pressure controller.
-
A digital pressure controller, indicated generally at 40 in FIG. 16, provides
for electronic sensing and control of pressure in an enclosed or defined volume or
containment. Such a device is pictured schematically in FIG. 16, and is
manufactured by Oden Corporation of Buffalo, New York, USA.
-
In operation with a beverage dispenser such as herein disclosed, a
microcontroller 41 and a pressure sensor 42 function to control the gas pressure,
typically carbon dioxide, applied to a keg of beer 1 or other bulk beverage source.
The digital term in the device name refers to the means and mode of pressure
control. When pressure is sensed to be too low, a fast-acting inlet solenoid valve 43
opens to admit gas at relatively high pressure. This quickly increases pressure in
the pressure controlled enclosure, and the valve turns off when the desired set point
is reached. Likewise, when pressure is sensed by the pressure sensor to be too
high, an array of fast-acting exhaust solenoid valves 44 open to exhaust gas from
the pressure controlled enclosure to atmosphere. Thus it can be seen that the
control action in either case is on-off or digital. This form of control is responsive
in less than ten milliseconds and is highly precise. Because gas is compressible, the
digital addition or removal of gas is readily integrated and thus the set point varies
in a relatively smooth analog manner.
-
This use of digital pressure control in beverage dispensers is novel and
allows direct electronic control of primary flow rate in the system with direct access
via the electronic control of the dispenser and with beverage rack pressure
selectable as a grouped parameter for machine setup. The pressure control
apparatus can be a discrete device or be incorporated into the controls for the
dispenser pictured in FIG. 6.
-
The use of an active electronic pressure control device also allows another
novel control aspect of dispenser operation. Because dose time varies as a function
of rack pressure, it is possible to construct a control formula which allows a
particular dose time to be achieved by defining a particular rack pressure. This
allows further automation of dispenser setup.
-
A still more sophisticated aspect of the sixth principal method of foam
control involves the use of flow profiling by varying the applied rack pressure
during a dispensing interval or period.
-
It will be understood that it is possible to generate a minimum amount of
foam into a serving of a carbonated beverage by using a slow or low flow rate to
introduce the beverage into the serving vessel. In fact, this is the essence of most
beer pouring methodologies of conventional or known nature. The consequence is a
very slow dispense time. However, with digital pressure control, it is possible to
begin the pour at a low rack pressure and thus a low flow rate until the nozzle
orifice is subsurface or below the level of the beer in the vessel, then rapidly and
smoothly increase the rack pressure and thus the beverage flow rate for the largest
part of the pour, then rapidly and smoothly decrease the rack pressure and hence the
beverage flow rate at the end of the pour. The result of this novel beverage
dispensing technique is excellent foam control and a net reduction of the total pour
time. This methodology can also be integrated into the set of electronically grouped
and defined system operating parameters for a particular beverage.
-
The seventh principal method of foam control and definition is by
mechanical or electromechanical control and manipulation of the beverage dispense
flow rate by restriction or unrestriction of a novel flow control in the beverage fluid
flow pathway.
-
FIGS. 10, 12, and 13 illustrate novel flow control devices particularly
appropriate to the flow rate control of carbonated beverages. These devices are the
subject of a separate disclosure and will thus be only generally described herein.
FIG. 13 differs from FIGS. 10 and 12 in that the compression anvil is pivotally
supported at one end by a mounting bracket 37 and pivot pin 38.
-
It is understood that rapid restrictions in a carbonated beverage flow line can
cause dissolved gases to leave solution and cause bubbles and foaming in the flow
line downstream of the restriction. The devices generally shown in FIGS. 10 and
13 overcome this problem by providing a gradually restricting profile and a long
axis of restriction. This allows substantial flow rate control without in-line
foaming. The devices also have the novel advantage of being non-invasive to the
flow line and thus exceptionally sanitary in character.
-
The ability of these long axis flow rate controls to operate in carbonated
beverage lines provides a means of flow rate control akin to the digital pressure
control device in method six. Flow is altered as a function of restriction rather than
alteration of motive force, but the result is equivalent. Further, the long axis flow
control device can be modulated during a fill to provide flow rate profiling as in
method six.
-
The eighth principal method of foam control and definition uses an applied
gas pressure above the rack pressure to inhibit gas and bubble formation in the
filling nozzle and thus prevent or inhibit foaming when beverage flow under rack
pressure into the serving cup or glass.
-
The apparatus specific to this method is shown in FIG. 31. It consists of a
filling nozzle 10 of described type with the pressure control port 10.1 connected by
a fluid tight conduit 50 to a tee connector 51 which branches to two pinch valves.
The pinch valve 52 on the horizontal branch 53 serves the priming and pressure
control functions previously and extensively discussed in the specification. The
pinch valve 54 on the vertical branch 55 of the tee connects to a source of
pressurized gas at a pressure substantially above the rack pressure applied to the
bulk beverage source. This second valve 54 is called the high pressure valve or
alternatively the pressure boost valve.
-
It will be understood that the higher the pressure applied to a carbonated
beverage, the more difficult it is for dissolved gas in the liquid to come out of
solution and into gas phase. The physics of such systems is well understood and
will not be recapitulated here. Because higher pressure inhibits outgassing, the
eighth method of foam control is designed to prevent foam or gas bubbles from
forming in the filling nozzle and associated structure and thus reduce foaming in the
vessel during beverage dispensing. This method requires that at the end of a pour,
after the filling nozzle closes, the main flow control valve 3 is closed, isolating that
portion of the fluid flow pathway on the nozzle side of the flow control valve from
the rest of the system. With the main flow control valve closed, the high pressure
valve 54 can be opened, applying the above rack pressure to the isolated portion of
the pathway and thus inhibiting outgassing when the dispenser system is not
dispensing a drink. When a dispensing cycle is initiated, the pressure boost valve
54 is closed and the pressure control valve 52 is actuated as previously detailed.
The main flow control valve is already closed in this method, and after nozzle
opening occurs, it opens in the usual manner to allow rack pressure defined
beverage flow into the serving vessel. As with the other methods described, the
high pressure valve can be electronically defined in function by the dispenser
control electronics.
-
Another object of the present invention is to utilize a rotary positive
displacement pump 60 of suitable sanitary type to displace carbonated beverage to
and through the dispensing apparatus, which pump is driven by a suitable pump
drive 61. FIG. 17 somewhat schematically depicts such a system. It is a common
problem in carbonated beverage installations that the bulk supply of beverage can be
quite remote from the dispenser apparatus. As this separating distance increases,
the available flow rate of beverage to the dispenser is reduced and limited by the
flow resistance offered by the longer runs of beverage flow lines. One means to
overcome this problem is to increase the gas pressure at the keg or bulk source so
that more force is operating on the beverage. However, higher gas pressures over
the large square area of the bulk beverage container can drive excess gas into
solution in the beverage and thus alter its quality or character. With this limitation
in mind, it is uniquely possible with the present system to utilize a rotary positive
displacement pump 60 to increase beverage flow rate. This is because the pump can
operate in an already pressurized and hydraulic system, allowing pumping action to
take place without foaming or outgassing as a consequence. This is true because the
pump can be placed near the supply, minimizing suction pressure, with increased
pressure occurring on the balance of the fluid flow pathway downstream of the
pump discharge. Thus, this limitation of the differential pressure across the pump
is the key to its ability to increase beverage flow without foaming. In the present
dispenser invention, the pump can be integrated into the beverage electronic
controls such that it operates only when the dispenser is demanding flow. This
avoids deadhead or no discharge pumping and the foaming it would produce.
Further, the pump can uniquely auto tune such that it steadily increases flow until it
achieves a specified dose time at the dispenser filling nozzle. As an alternative, it is
also uniquely possible to encode or otherwise measure the rotation of the pump and
thus use pump displacement to define the beverage dose at the dispenser.
-
It will be understood that there is a limit to the differential pressure across
the pump before foaming or outgassing of the beverage occurs. This pressure can
be limited and controlled in this design by direct sensing of the differential pressure
using pressure sensors, or the pump can be RPM limited to limit pressure
differential.
-
It will be understood by those knowledgeable in carbonated beverage
dispensing that the best way to dispense such beverages, and especially beer, in the
most rapid way and with the best control of foam, is often to place the filling nozzle
beneath the level of the beer In the serving container. This "bottom-up" filling
technique is widely known and practiced in beverage dispensing as well as in the
filling of many other foamy liquids, and this method of manually manipulating the
beverage filling nozzle relative to the beverage and container is fully contemplated
for use with the present invention.
-
FIG. 15 illustrates a novel aspect of the present invention and illustrates
automated nozzle filling motion and manipulation relative to a serving cup C. This
method allows the filling nozzle 10 to automatically be lowered into a serving cup C
until it is near the bottom of the cup, and to be gradually and progressively raised
up out of the cup on an automatic basis such that the bottom of the nozzle is held
and remains below the rising level of the beverage flowing into the cup, but not
such that the displacement of the nozzle in the dispensed beverage causes the
beverage to overflow the cup. This automatic nozzle motion can be effected
pneumatically, servo-pneumatically, or using known rotary and linear motor drive
and control methods, the nozzle raising and lowering mechanism being shown at
65. It is unique in beverage dispensers, and is beneficial in removing the manual
filling skill or technique otherwise required to fully exploit the high speed
dispensing capability of the invention. The dispenser control electronics can
provide this described nozzle motion control, which can be self-teaching in terms of
motion rates and distances and can be a stored machine setup and operating
parameter associated with a particular beverage type and container type or size.
-
The filling nozzles of the beverage dispenser of the present invention are
particularly designed and intended to operate below the surface of the beverage
being dispensed into a container. Thus, the outside surfaces of the nozzle are
wetted repeatedly by the beverage being dispensed. Most beverages support some
bacterial growth and over time a filling nozzle wetted by a beverage can become
contaminated as a result of such growth. Thus, the nozzle of the present invention
should be cleaned and sanitized from time to time.
-
One novel means of maintaining a filling nozzle of the type disclosed in this
specification in a sanitary condition, is through the use of one or more ozone
generators 66 in relatively close proximity to the nozzle, as shown in FIG. 27.
Ozone is a potent bactericide and can reduce and maintain a low bacterial count on
nozzle surfaces. With further reference to FIG. 27, the cup C is supported by a
support 67, and the ozone generators on supports 68. While the supports 67 and 68
are stationary, they may be moved and the nozzle may be stationary.
-
It is a particular object and novel feature of the invention that the fluid flow
pathway of the dispenser is particularly designed to minimize or eliminate beverage
foaming or outgassing as a function of flow through the system. This is achieved in
numerous ways including the use of large flow aperture straight through flow design
valves, and through the use of features internal to the filling nozzles, both as
detailed elsewhere in the specification. In addition, the fluid flow pathway is
generally uniform in flow diameter throughout or, where transitions occur, the
diameter increases with the transition. Also, wherever possible, smooth, low
turbulence connections are made as with, by example, the use of tri-clamp sanitary
fluid connectors and fittings. Further, the internal finish of the fluid flow pathway
is attended to with a number 3 or better dairy finish helping to further reduce flow
turbulence and hence foaming.
-
It is a particular object and novel feature of the invention that the fluid flow
pathway of the dispenser is particularly designed to minimize or eliminate beverage
foaming or outgassing as a function of flow through the system. This is achieved in
numerous ways including the use of large flow aperture straight through flow design
valves, and through the use of features internal to the filling nozzles, both as
detailed elsewhere in this specification. In addition, the fluid flow pathway is
generally uniform in flow diameter throughout or, where transitions occur, the
diameter increases with the transition. Also, wherever possible, smooth, low
turbulence connections are made as with, by example, the use of tri-clamp sanitary
fluid connectors and fittings. Further, the internal finish of the fluid flow pathway
is attended to with a number 3 or better dairy finish helping to further reduce flow
turbulence and hence foaming.
-
It is a particular object and novel feature of the present invention to provide
for unique electronically programmed and controlled clean-in-place (CIP)
procedures and routines for cleaning and sanitizing the high speed beverage
dispenser. It is evident that cleanability of a beverage dispenser is essentially as
important as the dispensing performance of the device. Hence, the dispenser herein
disclosed is provided with many unique and novel features and apparatus for
enhancing the ease and completeness of system cleaning and sanitizing.
-
Overall, the dispenser is cleaned by following accepted practice which is to
wash, then rinse, then sanitize, then optionally re-rinse the fluid flow pathway.
-
Referring to FIGS. 1 and 8, to clean the dispenser the beverage supply is
first uncoupled from the system. In its place, a pressurized source of soapy wash
water may be connected. More commonly, a five gallon plastic pail of soapy wash
water may be used with the beverage coupler connected into a suitable CIP pump
for moving the wash water through the dispenser system. The pump may be of
many types including centrifugal, rotary positive displacement, rotary peristaltic, air
operated diaphragm or linear peristaltic.
-
The linear peristaltic pump of the gas driven type is particularly suited due
to its high pressure capability, low cost and ease of on-off control. An example of
such a pump is that manufactured by Niagara Pump Corporation of Buffalo, New
York, USA.
-
After a flowable source of wash water is available, the CIP pump is
connected to the beverage dispenser control electronics and the CIP routine is
initiated via the display and keypad as shown in FIG. 6. Many cleaning routines or
sequences can be provided via software for the CIP process. The routine herein
described is typical and generally preferred.
-
The cleaning sequence begins with the CIP pump being turned on and
allowed to run until the system is pressurized, typically to 20 to 25 PSI. This
pressure can be readily defined by specifying the operating gas pressure of the
pump. After the system is pressurized, the main flow control valve (MFCV) and
the pressure control valve (PCV) are opened for three seconds, then closed. This
subsequence is repeated twice to assure the system fluid flow pathway is primed
with the cleaning solution. The CIP pump operates on a demand basis to maintain
flow and pressure. All system valves are then closed for one second.
-
After priming with cleaning solution, the MFCV and filling nozzle are both
opened and closed simultaneously for one second. After a one second cycle
interval, the MFCV and the PCV are opened and closed simultaneously for a one
second duration. After a one second cycle interval, this sequence is automatically
repeated until five repetitions have been completed. The number of repetitions and
the flow durations are adjustable via the electronic controls.
-
After the initial cleaning sequence, a three to five minute soak cycle is
initiated. Time-out and CIP sequence status of this and each stage of cleaning are
shown in the control interface display.
-
After the cleaner solution soak cycle, the MFCV is opened. After the
MFCV is open, thus pressurizing the system, the filling nozzle is opened and closed
at approximately 2 to 5 Hz., thus creating a "chatter" effect during which highly
pulsating cleaner is pulse flowed through the fluid flow pathway of the dispenser
and out the filling nozzle at relatively high discharge velocities. The result of this
part of the sequence is a relatively vigorous "washing machine" like action causing
a scrubbing action in the fluid flow pathway.
-
After the described wash sequence is completed, the beverage source
connector line is removed and a pump out sequence lasting for approximately thirty
seconds is initiated via the keypad control surface of the dispenser electronic
controls. During the pump out, all system valves are opened assuring complete
pathway draining. The described wash sequence consumes approximately two to
five gallons of wash solution dependent upon flows and pressures. The effluent
from the filling nozzle and the pressure control line are typically collected in
another five gallon bucket.
-
After the wash cycle is completed, a similar or identical procedure and
sequence is carried out using clean rinse water, typically at elevated temperature.
-
After the rinse cycle is completed, a sanitizer, typically of the caustic or
chlorine type, is cycled through the system in a similar or identical sequence as
previously detailed.
-
After the system is sanitized, which is to reduce bacterial count to a very
low level, the dispenser fluid flow pathway may be reconnected to a beverage
supply, the beverage moved through the system as a function of priming or packing
the pathway serving as a rinse out of the sanitizer. Alternatively, a water rinse akin
to the first can be carried out followed by re-packing of the system with the
beverage to be dispensed.
-
It is important to understand that the responsive nature of the fluid flow
pathway valving and the sanitary design of all fluid bearing components particularly
provides for a highly refined and efficient cleaning capability in the present
invention which is enhanced by the programmable nature of the dispenser electronic
controller which allows easy optimization and enhancement of cleaning sequences.
-
While the best modes of this invention known to applicant at this time have
been shown in the accompanying drawings and described in the accompanying text,
it should be understood that applicant does not intend to be limited to the particular
details illustrated in the accompanying drawings and described above. Thus, it is
the desire of the inventor of the present invention that it be clearly understood that
the embodiments of the invention, while preferred, can be readily changed and
altered by one skilled in the art and that these embodiments are not to be limiting or
constraining on the form or benefits of the invention.