FIELD OF THE INVENTION The present invention relates to systems and methods for remotely controlling and monitoring ice making machines.
BACKGROUND OF THE INVENTION Ice making machines are typically leased by a vendor to owners of hotels, taverns, and restaurants. The vendee pays a periodic fee to the vendor, typically monthly, and the vendor is responsible for maintaining the ice making machines in good working order. If a leased ice making machine stops functioning, the vendor will replace or repair the ice making machine. However, the vendor can encounter difficulties with vendees who do not pay in a timely manner. These vendees may react in a hostile manner when the vendor attempts to enter the premises and reclaim the ice making machines.
SUMMARY OF THE INVENTION The present invention provides a system and method for controlling an ice making machine inside a building, room, or business, from outside the building, room, or business, respectively. By remotely controlling the ice machine, an owner, lessor, or maintainer of the machine, may maintain some control over the machine even though it is located where entry is difficult or would cause resistance from the entity leasing or otherwise using the machine. The invented apparatus and methods may include remotely controlling one or more functions of the ice machine, including those which disable ice production, and also may include remotely receiving status information from the machine to confirm the effectiveness of the control.
In preferred embodiments, disabling ice production may be done by controlling the ice bin level indicator to report a full bin even when it is not full, as this should not result in melting ice or in the entity suspecting that someone has interfered with the ice machine. Therefore, the preferred apparatus and methods may result in an apparent ice machine malfunction requiring repair, which may be used as leverage to encourage the user of the machine to become current on an overdue account.
The control and status-monitoring transmissions are preferably wireless transmissions carried by radio waves between a portable master transmitting and receiving device and an ice machine receiver and transmitter, wherein the master device may communicate with a selected ice machine or plurality of ice machines. Selecting and controlling fewer than all of the entity's ice machines, or selecting and controlling different of the entity's ice machines at different times, may help prevent the malfunction from appearing to be from outside interference with the machine.
BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings illustrate several aspects of embodiments of the present invention. The drawings are for the purpose only of illustrating preferred modes of the invention, and are not to be construed as limiting the invention.
FIG. 1 is a block diagram of one general embodiment of a monitoring system for ice making machines in accordance with the present invention.
FIG. 2 is a partial schematic diagram of a prior art ice making machine before a remote device is installed.
FIG. 3 is a partial schematic diagram of an ice making machine after a remote device is installed.
FIG. 4 is a partial schematic of the encoding circuitry wiring in a remote device after it has been installed in an ice making machine.
FIG. 5 is a partial schematic of the decoding circuitry wiring in a remote device installed after it has been installed in an ice making machine.
FIG. 6 shows the input and output circuitry for the preferred user interface for the master selector device.
FIG. 7 shows the preferred security selector for the master selector device.
FIG. 8 shows a preferred truth table for the security selector shown inFIG. 7.
FIG. 9 is a table showing statuses and functions for an ice making machine.
FIG. 10 shows the controls portion of an ice making machine.
FIG. 11 shows the mechanisms of an ice making machine.
FIG. 12 shows the interface between an ice making machine and the relays and contactors of the preferred remote device.
FIG. 13 shows an ice making machine with a remote device of the preferred embodiment of the invention installed.
DESCRIPTION OF THE PREFERRED EMBODIMENT General Embodiment
The preferred embodiment remotely controls at least one status of an ice making machine by providing a wireless mobile hand-held secure monitoring system, which is comprised of a single hand-held master selector device and a remote device (or receiver device) installed in the ice making machine. The master selector device could be installed in a dashboard or console instead of hand-held. The master selector device allows the operator to transmit control data to a selected ice making machine and receive data from a remote device connected to an ice making machine using secure data encoded on an RF (radio frequency) signal. The remote device, once installed in the ice making machine, decodes the secure data received from the hand-held master selector device, electrically controls functions of the ice making machine based on the received data, electrically detects a status of the ice making machine, and transmits the status to the hand-held master selector device, using secure data encoded on an RF signal.
The master selector device and the receiver device are each coded with two hexadecimal switches, for 256possible codes 00 to FF. The code is read by both the master selector device and the receiver device. The master selector device and the receiver device must have the same code in order for them to interface with each other, enabling the operator to control and monitor up to 256 ice making machines.
This system enables the vendor to control the ice making machines remotely from off the premises, without the vendee's knowledge. The system also enables the vendor to monitor the ice making machines remotely, ensuring that the desired changes have taken effect. The vendor can turn one or more of the ice making machines off on a vendee who has not paid pursuant to the lease agreement, while outside the building in which the ice making machines are being used. The system can be installed with the remote device inside multiple or all of the leased ice making machines away from view so that, upon repeated non-payments and repeated remote control of ice-making machines to “malfunction”, the vendee does not suspect that it is a single ice making machine that is defective, nor that a master selector device is remotely controlling the ice making machine. In order to prevent the risk of melted ice causing damage to the premises, the system is preferably installed to cause the ice making machine to report that the ice bin is full, even if the ice bin is not full. This will cause the ice making machine to stop making ice. The vendee will then call the vendor, asking for the ice making machine to be repaired. The vendor will agree to repair the ice making machine only upon payment of the amount due. The vendor then purports to repair the ice making machine, but actually changes the status of the ice making machine by use of the system described herein so that the ice making machine no longer reports the ice bin as being full and will once again make ice. This enables the vendor to quickly collect overdue accounts without resistance from the vendees.
The hand-held master selector device is comprised of an operator interface and circuitry for transmitting, receiving, encoding, and decoding data on an RF signal. Using the operator interface, the operator is able to select a particular ice making machine of interest by matching the preset code in the remote device attached to the ice making machine of interest. Using the operator interface, the operator is then able to transmit data to the selected remote device using the RF signal and effectively control any of the output points of the remote device, which in turn affects the controllable conditions, or statuses, of the ice making machine. After the transmission sequence is complete, the operator interface indicates the status of the selected remote device, giving the operator feedback as to the status of the ice making machine. The operator does not have to guess as to whether the transmission was successful and changed the status of the ice making machine to the desired condition.
The remote device installed in the ice making machine is comprised of momentary and/or latching relays, electrical contactors, code selection dials, and circuitry for transmitting, receiving, encoding, and decoding data on an RF signal. During installation into the ice making machine, the electrical momentary and latching relays will be connected so as to electrically control the desired functions of the ice making machine; the electrical contactors will be connected so as to monitor the status of the desired functions of the ice making machine because the status is indicated on the operator interface.
The master selector device initiates an interface cycle with the receiver device. When the code selection dials are set to the desired code and the ice making machine is powered, the remote device will wait for a signal from a hand-held master selector device. The receiver device is constantly in the receive mode. Upon input by an operator on the operator interface, the master selector device is energized in the transmit mode and transmits a first signal to the receiver device, and the receiver device receives the first signal. This first signal can contain up to eight discrete bits of data corresponding to up to eight commands, on or off, corresponding to up to eight functions of the ice making machine. The RF switch of the master selector device then switches the antenna from the radio frequency transmission circuitry to the radio frequency reception circuitry and enables the receive mode.
When the first signal is detected by the receiver device, the decoding circuitry decodes the data and determines the recipient's secure code. If the recipient's secure code matches the selector dials of the remote device, then the remote device responds by activating the appropriate electrical contactors in accordance with the received data. The receiver unit then checks the status of the function that was changed, and the RF switch of the receiver unit switches the antenna of the receiver device from the radio frequency reception circuitry to the radio frequency transmission circuitry and enables the transmit mode. The receiver unit then encodes a second signal which contains up to eight discrete bits of data corresponding to up to eight statuses of the same number of functions, and sends this second signal to the master selector device. After a predetermined time elapses after the receiver unit sends the second signal, the RF switch of the receiver device switches the antenna of the receiver device from the radio frequency transmission circuitry back to the radio frequency reception circuitry and enables the receive mode. The master selector device then decodes the second signal and outputs the status on light-emitting diodes of the operator interface. After a predetermined time elapses after the master selector device sent the first signal, the master selector device turns itself off.
A greater appreciation for the invention will be developed by referring to the drawings.FIG. 1 shows a monitoring and control system for ice making machines according to the general embodiment of the invention. The monitoring system includes a hand-heldmaster selector device1 which remains in the possession of the operator of the ice making machines, and up to 256remote devices3 installed in ice making machines identified as 1-00 to 1-FF; the ice making machines may be installed in, for example, halls of hotels, kitchens of restaurants, or taverns.
The hand-heldmaster selector device1 is comprised of anoperator interface15 and themobile RF circuitry23. Themobile RF circuitry23 is comprised the following components. Thesecurity selector circuitry20 sets the security code entered on theoperator interface15 for theremote device3 to be used by both theencoding circuitry16 and thedecoding circuitry17. The encodingcircuitry16 combines the data from theoperator interface15 and the data from thesecurity selector circuitry20 for the radiofrequency transmission circuitry18. The radiofrequency transmission circuitry18 interprets and transmits the encoded data from the encodingcircuitry16 to a radio frequency data stream.RF switch21 switches theantenna22 between radiofrequency reception circuitry19 and radiofrequency transmission circuitry18, enabling use of asingle antenna22 for efficiently transmitting and receiving radio signals through air.
When theRF switch21 has switched theantenna22 to receive mode, the radiofrequency reception circuitry19 receives and interprets the incoming radio frequency data stream and sends the data to thedecoding circuitry17. Thedecoding circuitry17 combines the data from the radiofrequency reception circuitry19 and the data from thesecurity selector circuitry20 for theoperator interface15.
The ice making machines 1-00 to 1-FF are comprised of an ice making machine mechanism and controls2. The codedremote device3 is installed onto the ice making machine mechanism and controls2. The ice making machine mechanism and controls2 is comprised of equipment and control circuitry capable of controlling the equipment to automatically turn water into ice. Each remote device is comprised ofrelays4,encoding circuitry5,contactors6,decoding circuitry7,security selector circuitry8, radiofrequency transmission circuitry9, radiofrequency reception circuitry10, anRF switch11, and anantenna12. Therelays4 are connected to the monitored statuses of the ice making machine mechanism and controls2; therelays4 condition the signals for input into theencoding circuitry5. Theencoding circuitry5 encodes data from therelays4 andsecurity selector circuitry8 and sends it to the radiofrequency transmission circuitry9. The radiofrequency transmission circuitry9 transmits encoded data from theencoding circuitry5 to a radio frequency data stream. TheRF switch11 switches theantenna12 between radiofrequency reception circuitry10 and radiofrequency transmission circuitry9. The antenna efficiently transmits and receives radio signals through air.
The radiofrequency reception circuitry10 receives the incoming radio frequency data stream and produces data for thedecoding circuitry7. Thedecoding circuitry7 combines data from the radiofrequency reception circuitry10 and thesecurity selector circuitry8 and sends signals to thecontactors6. Thesecurity selector circuitry8 sets the security code for theremote device3 that is used by both theencoding circuitry5 and thedecoding circuitry7. Thecontactors6 are connected to the functions of the ice making machine mechanism and controls2, and transfer the functions from thedecoding circuitry7 to the ice making machine mechanism and controls2.
The ice making machines 1-00 to 1-FF each can be any of the types of known ice making machines such as batch type ice making machines, cell type ice making machines, or continuous ice making machines, or any other type of ice making machine. Regardless of the type of ice making machine 1-00 to 1-FF, the statuses the operator wishes to monitor and the functions the operator wishes to control can be connected electrically to the contactors and relays, thus allowing these statuses and functions of the ice making machine to be transferred electrically to and from the remote device.
FIG. 2 shows an example electrical schematic for the ice making machine before the addition of aremote device3.STATUS1 toSTATUS4 are switches, relay or other existing electrical components on the ice making machine which have functions associated with them.RUNG1 toRUNG4 shows eachSTATUS1 toSTATUS4 and an associatedFUNCTION1 toFUNCTION4. Each status contact closes to allow power to flow from V to COMMON, energizing the corresponding function.
FIG. 3 shows the example electrical schematic shown inFIG. 2 for the ice making machine after the installation of aremote device3.RUNG11 shows that theRELAY1 is installed in parallel withFUNCTION1; thus when theSTATUS1 contact closes, power will flow from V throughFUNCTION1 and throughRELAY1 to COMMON, energizing bothFUNCTION1 andRELAY1. The same phenomenon occurs withRUNG12. This allows theremote device3 to monitor the statuses by use of therelays4. Similarly,RUNG13 shows thatCONTACTOR1 is installed in parallel withSTATUS3; thus whenCONTACTOR1 closes, power will flow from V throughFUNCTION3 toCOMMON energizing FUNCTION3 regardless of whether theSTATUS3 contact is closed. The same phenomenon occurs withRUNG14. This allows theremote device3 to control the functions.
FIG. 4 shows the interaction of the added relays4 from theremote device3 shown inFIG. 3 with theencoding circuitry5 from theremote device3. WhenRELAY1 is energized, the contact ofRELAY1 is closed, completing the circuit between I-0 COM and I-0 +. WhenRELAY2 is energized, the contact ofRELAY2 is closed, completing the circuit between I-1 COM and I-1 +. Similarly, for the other points, statuses can complete the circuit between the COM and the + terminal of the encoding circuitry, thus causing theencoding circuitry5 to send a signal to the radiofrequency transmission circuitry9 that the status is “on.”
FIG. 5 shows the interaction of the addedcontactors6 from theremote device3 shown inFIG. 3 with thedecoding circuitry7 from theremote device3. When thedecoding circuitry7 decodes the signal received from the radiofrequency reception circuitry10 calling forFUNCTION3 to be active, thedecoding circuitry7 energizes O-0 + which energizesCONTACTOR1. WhenCONTACTOR1 is energized, the contactor is closed, thus energizingFUNCTION3. Similarly, when thedecoding circuitry7 decodes the signal received from the radiofrequency reception circuitry10 calling forFUNCTION4 to be active, thedecoding circuitry7 energizes O-1 + which energizesCONTACTOR2. WhenCONTACTOR2 is energized, the contactor is closed, energizingFUNCTION4.
In operating the hand-heldmaster selector device1, the operator uses theoperator interface15 to enter the security code for the ice making machine of interest within range. Commands entered into theoperator interface15 are then combined with the data from thesecurity selector circuitry20 and encoded for transmission by the encodingcircuitry16. These encoded data are converted to an RF data stream by the radiofrequency transmission circuitry18 and sent out theantenna22 by way of theRF switch21. This RF data stream is picked up by all of theantennae12 of theremote devices3 within range and transferred through theRF switch11 to the radiofrequency reception circuitry10 that converts the data for thedecoding circuitry7. Thedecoding circuitry7 decodes the data and determines if they match the data received from thesecurity selector8. If the data match the security selector, then the data are transferred to thecontactors6 which affect the functions of the ice making machine mechanism and controls2. If the data do not match the security selector, then the RF data stream is ignored because it was not intended for thatremote device3. This secures the communication to theremote devices3 so that they can be controlled only bymaster selector devices1 with the security code. The effect of one or more of these functions on the matchingremote device3 will be to initiate the data transmission cycle back to the hand-heldmaster selector device1.
The transmission cycle for theremote unit3 is initiated by the ice making machine mechanism and controls2 in response to a function that was received from the hand-heldmaster selector device1. Therelays4 transfer data regarding the statuses of the ice making machine mechanism and controls2 to theencoding circuitry5; theencoding circuitry5 combines the data from the ice making machine and controls2 with data from thesecurity selector circuitry8 and encodes these data for transmission. These encoded data are converted to an RF data stream by the radiofrequency transmission circuitry9 and sent out theantenna12 by way of theRF switch11. This RF data stream is picked up by theantenna22 of a hand-held master selector device within range and transferred through theRF switch21 to the radiofrequency reception circuitry19 that converts the data for thedecoding circuitry17. Thedecoding circuitry17 decodes the data and determines if they match the data received from thesecurity selector20. If the data are deemed to match then data are transferred to theoperator interface15 for display, thus allowing the operator to monitor the statuses of the ice making machine of interest. If the data do not match, then they are ignored, causing themaster selector device1 to ignore signals from sources other than the selectedremote device3, even if the signals are at the same frequency.
Especially Preferred Embodiment
Hereinafter, the especially preferred embodiment of the present invention will be described in view of the general embodiment. With regard toFIG. 1, the specifications for the preferred embodiment provide more detailed descriptions of theoperator interface15, thesecurity selector circuitry20,8, theradio frequency components9,10,11,12,18,19,21,22 the functions and statuses of the ice making machine, and the interface between thereceiver device3 and the ice making machine mechanism and controls2 via therelays4 andcontactors6.
FIG. 6 depicts a preferred embodiment of theoperator interface15. Theoperator interface15 preferably has data entry means, eight single pole single throw momentary switches21-28 corresponding to the eight controlled functions, and data display means, eight indicator lights (preferably LEDs)31-38 corresponding to the eight monitored statuses. The data transferred to theencoding circuitry16 include the statuses of the eight switches21-28, corresponding to the desired function(s); the data received from thedecoding circuitry17 are displayed on the indicator lights31-38, which represent the monitored statuses of the ice making machine.
FIG. 7 depicts a preferred embodiment of thesecurity selector circuitry8,20, used by both the hand-heldmaster selector device1 and theremote device3, designed for eight bits of security. The circuit is comprised of two four-bit switches SW1,SW2, each capable of adjustment to any of eight positions from 0 to F, giving a secure address of 00-FF for 256 secure addresses. This number of addresses enables an operator to control and monitor a plurality of ice making machines within a single premises, and is sufficient for the number of ice making machines that would likely be within range of the hand-heldmaster selector device1. These 256 addresses would be sufficient to control all of the subject ice making machines: the same address could be used for two different machines as long as they could not both be within range of the hand-heldmaster selector device1. Thus, more than 256 ice making machines could be controlled and monitored with the same master selector device utilizing 256 addresses. The correlation between position 0-F and the binary output bits from the switches is shown in the truth table ofFIG. 8. The two switches shown inFIG. 7 provide the security code for use by theencoding circuitry5,16 anddecoding circuitry7,17 for both the hand-heldmaster selector device1 and theremote device3.
Theradio frequency components9,10,11,12,18,19,21,22 may be tuned to radio frequencies up to 1 GHz; frequencies above 300 MHz allow for line-of-sight relaying of the signals. Therefore, frequencies between 300 MHz and 1 GHz are preferred. These frequencies are preferred in order to provide an RF signal that is capable of penetration through standard construction materials such as wood and concrete while staying in an unlicensed, under populated bandwidth. In the preferred embodiment, the frequency of 433 MHz allows the operator to connect to ice making machines in the proximity of 75-150 feet, while using a low power RF transmitter in accordance with FCC regulations.
FIG. 9 depicts the ice making machine mechanism and controls2 which comprises controls and mechanisms. In the preferred embodiment, the controls are comprised of seven control inputs: a bin full input which causes the machine to cease ice production to keep the ice from overflowing, a transmit status input which causes the machine to transmit its statuses to the hand heldmaster selector device1 via theremote device3, a high speed input which causes the machine to produce ice at the fastest rate, a low speed input which causes the machine to produce ice at the slowest rate, twenty-four hour mode input which causes the machine to produce ice twenty-four hours each day, an eight hour mode input which causes the machine to produce ice eight hours each day, and activate machine or compressor on input which activates the machine refrigerant compressor. The control inputs are effectuated by three mechanism functions: an ice making mechanism run function which causes the ice making machine to run and produce ice, a high speed mechanism function which causes the ice making machine to produce ice at the fastest rate, and the freeze mechanism function which activates the refrigerant mechanism of the ice making machine.
FIG. 10 shows the controls portion of the ice making machine mechanism and controls2, which has five status switches which govern the seven status inputs, seven relays, and seven contacts. The five status switches are an ice bin full switch which closes when the ice bin is full, a transmit status switch which closes when there is a request to transmit data to the hand-held master selector device, a speed select switch with two contact points which select the speed of ice production (high or low), a mode switch with two contact points which select the twenty-four hour mode or eight hour mode, and the activate machine or run switch which activates the ice making machine. In parallel with the controls are the sevenrelays4, which are used to transfer the data from the ice making machine to theremote unit3.
FIG. 11 shows the mechanism portion of the ice making machine mechanism and controls2. The ice making machine mechanism and controls are connected to the actual mechanisms of the ice making machine in order to control actual operations of the ice making machine. In series with the mechanism portion are threecontactors6, which allow theremote device3 to control the operation of the ice making machine.
FIG. 12 depicts the ultimate interface between the ice making machine mechanism and controls2 and theremote device3. To facilitate this interface, theremote device3 uses therelays4 andcontactors6 shown previously inFIGS. 10 and 11. The statuses (ice bin full, transmit, speed, mode, and run) will activate the sevenrelays4 and allow the data to be transmitted back to the hand-heldmaster selector device1. The functions (ice making mechanism run, high speed mechanism, and freeze mechanism) can be activated by the threecontactors6 in accordance with the operator's desires using the hand-heldmaster selector device1. Other functions and statuses can be connected in a similar manner to allow a more robust control and monitoring system to be implemented.
The preferred embodiment allows an operator to control and monitor ice making machines inside a building within seventy-five feet of the operator, who is generally outside the building, with no physical connection between themaster selector device1 and the ice making machine. The system becomes less effective at distance greater than seventy-five feet, and generally does not work at distances greater than 150 feet. The system will not work when either themaster selector device1 or thereceiver device3 is enclosed in ferrous casing. It is envisioned that the system described herein could be used on other types of equipment that has electrical components, such as vending machines.
Although this invention has been described above with reference to particular means, materials and embodiments, it is to be understood that the invention is not limited to these disclosed particulars, but extends instead to all equivalents within the scope of the following claims.