GB2465632A

GB2465632A - Icebank cooler

Info

Publication number: GB2465632A
Application number: GB0821780A
Authority: GB
Inventors: Christopher Michael Cook
Original assignee: IMI Cornelius Inc
Current assignee: Cornelius Inc
Priority date: 2008-11-28
Filing date: 2008-11-28
Publication date: 2010-06-02
Also published as: GB0821780D0

Abstract

An icebank cooler 1 is presented in which operation of the cooler to form an icebank 7 is regulated by a control system based on information concerning trends in the demand placed on the cooler and information concerning the extent of the icebank in the cooler at any given time. Preferably, the cooler is provided with an array of sensors 15 for monitoring the thickness of the icebank formed on a refrigeration system evaporator coil 3 within the cooler. The cooler may also be provided with a temperature sensor 17 for monitoring the coolant temperature in the cooler. In use, the coolant temperature provides an indication of the cooling demand, where the control system, comprising a controller 13, is responsive to the extent of the icebank and trends in the cooling demand to regulate operation the refrigeration system to control the extent of the icebank.

Description

COOLERS

The present invention relates to coolers and in particular ice bank coolers.

More especially the invention relates to the formation, maintenance and extent of ice banks. T he invention may have particular application in relation to beverage dispense and it is therefore convenient to describe the invention in terms of this application. It is to be understood however that that the invention is not limited to use with beverages.

One commonly used method of delivering chilled beverages is to provide a cooler, often in close proximity to beverage containers stored remotely from a serving area. Beverage from the containers may then be passed through the cooler, where heat exchange occurs with a coolant to cool the beverage. The beverage then passes in a product line to a dispense point in the serving area. Additionally coolant supply and return lines may extend between the cooler and the serving area in association with the product line containing the beverage. This arrangement is commonly referred to as a python, and serves to maintain the temperature of the beverage in the product line between the cooler and the serving area.

In order to meet times of high demand for cooled beverage, some coolers are designed to form an icebank. In this way the increased cooling demand may be met by slowly using up the icebank. This may provide the cooler with much greater endurance, such that high demand may not result in the cooler being unable to adequately cool consecutively dispensed beverages.

* ****. * * *

While icebanks increase endurance, it is recognised that maintaining a **** substantial icebank can be relatively inefficient. This may be due to factors including reduction in volumetric efficiency and the low suction pressure effect experienced by the compressor. Typically coefficients of performance of 1.0 or less may be expected as well as extended ice bank recovery times as refrigeration duty falls away due to evaporator performance loss. This problem is exacerbated by non-flexible icebank designs, which have as an object the maintenance of the maximum possible icebank extent, regardless of whether a particular installation requires this to meet demand.

The present invention has been made from a consideration of the aforementioned problem.

A preferred aim of the invention is a cooler where the size of the icebank may be tailored according to the needs of a particular installation.

According to a first aspect of the invention there is provided a controller for regulating operation of an icebank cooler based on information concerning trends in the demand placed on the cooler and information concerning the extent of the icebank in the cooler at any given time.

Regulating operation of the cooler in this way may allow the extent of the icebank to be better tailored to the needs of an individual installation.

Thus, if the extent of the icebank at any given time is analysed alongside a realistic assessment of the demand that the cooler might be placed under, over or under capacity of the icebank may be more easily avoided. *.S. * *

S

**S*SS. . . * * 25 By processing information concerning trends in the demand placed on the icebank cooler, the controller may identify a target extent for the icebank and regulate operation of the cooler with a view to achieving and maintaining that extent. As explained previously, an icebank may be advantageous in providing reserve cooling capacity, but unregulated operation to maintain the maximum icebank extent (where possible) may be inefficient. The present invention may therefore be advantageous, as the controller may make use of trends in the demand on the cooler as a predictive tool to determine the optimal icebank size. The controller may then regulate the operation of the cooler to maintain where possible an icebank that is sufficient to meet expected cooling demand, but that is not unnecessarily large. The controller may therefore be capable of tailoring the operation of the cooler so as to be best suited to the requirements of a particular installation.

The controller may be capable of responding dynamically to changes in demand trends on the cooler recorded as a result of on-going monitoring.

This may be advantageous where demand on the cooler might reasonably be expected to change over time (for example with varying seasonal ambient conditions or a change in circumstances). Because a dynamic controller is not limited by an assessment of cooling demand on a single occasion, the controller of the present embodiment might be far less likely to become obsolete and even counterproductive.

The controller may periodically review trends for a given preceding period and adjust its regulation of the cooler accordingly. The controller might for example review trends every day for the preceding twenty four hours. It is to be understood however that any suitable time period might be selected. The time period might for example be selected so that it is not so long that a meaningful change in demand might be missed and not S...

*****6 so short that the controller responds to insignificant fluctuations. It may also be that the controller has the capacity to statistically weight information it receives. This may be advantageous in that it may prevent the controller making a disproportionate change to its regulation of the cooling system in response to a substantial but short lived change in demand. S S * S.

The controller may be provided with a means of recognising the passage of time and a means of recognising time dependent patterns in demand variation on the cooler, to which it responds by appropriately regulating operation of the cooler. This may be advantageous where it is likely that repeating time dependent factors consistently impact on demand (such factors may include daytime and night-time, opening and closing hours, weekends etc).

The controller may be part of a system that is capable of responding dynamically without outside input or interference. This level of automation may be convenient where it would otherwise be cumbersome to manually feed information to the controller or issue it with instructions.

The controller may be programmable so that regulation of the cooler may be altered. This may for example be advantageous where it is foreseen that future demand (at least in the short term) is likely to substantially differ from previous demand, preventing the controller from responding appropriately in the necessary time period. A sales campaign or holiday closure are examples of occasions where pre-programming might be advantageous. In order to facilitate programming the controller may have a connection port for PC or alternatively may be communicated with by any other suitable device or over a network. Any such method may *S.* provide convenient icebank extent planning.

* . 25 It may be possible to manually override the controller. This may be less efficient and/or effective than pre-programming the controller, but may be beneficial where for example there is a sudden unexpected increase in **** S...., demand. The manual override may for example be configured to cause the . 30 cooler to maintain (where possible) an icebank at the maximum possible extent. The manual override may only be activated with sufficient security clearance. This may be advantageous where a limited number of personnel are authorised to alter regulation of the cooler. The manual override may be automatically reset following a given period whereupon the controller resumes normal regulation of the cooler.

The controller may be locally and/or remotely connected to a diagnostics system. This may be advantageous where it is desirable to analyse the performance of the cooler and/or the controller. The diagnostic system may provide an indication on the duration for which the cooler has been running in a given period and/or an indication of the energy usage for a given period.

It may be that the controller is given a basic set up when manufactured.

This may be advantageous if the controllers are manufactured in large numbers and consumers are prepared to wait for the controller to accumulate demand trend data before operating at peak efficiency.

Alternatively the controller may be tailored to a particular icebank cooler (or range of icebank coolers) during manufacture or when installed.

The controller may comprise a processor programmed to evaluate the extent of the icebank at any given time, analyse data in relation to demand trends for the cooler and adjust regulation of the cooler accordingly. The controller may include a user interface and/or display module providing information on the performance of the cooler and/or S..... . * * 25 allowing adjustments to be made to the cooler regulation. The user interface and/or display module may possess multiplexing functionality allowing control of multiple cooling systems (preferably with extra low voltage (ELy) links). I... * S *. * . S S 05

The extent of the icebank at any given time may be measured by any suitable method and then communicated as an input to the controller by

any suitable means.

Icebank extent may, for example, be measured by methods employing: 1. Evaporating temperature 2. Evaporating pressure 3. Icebank thickness by temperature gradient (using multiple sensors or thermostats).

4. Icebank thickness (using progressive resistance change) 5. Icebank thickness (using multiple pin resistance pairs) 6. Sonic/ultrasonic detection of icebank wall or free water volume 7. Natural frequency of exposed sensor 8. Light sensing of ice wall Information concerning trends in the demand placed on the cooler may be collected by any suitable means and then communicated as an input to the controller by any suitable means.

Trends may, for example, be collected by: 1. Direct data capture recording the quantity of use of the icebank cooler.

2. Recording the effectiveness of the icebank cooler by measuring the temperature of products or articles intended to be cooled by it.

* .***S 3. Recording temperature profiles of the coolant in the evaporation cycle of the cooling system during icebank *.*.

recovery periods.

, . 30 4. Recording the quantity of product or articles that are passed through the icebank cooler.

5. Till receipt records (where appropriate) recording quantity of product sold that has been cooled by the icebank cooler.

6. Operator observation and/or experience (where appropriate).

7. Temperature rise profiles for a given time of liquid water which might otherwise form part of the icebank.

The means of measuring the extent of the icebank at any given time and of gathering information concerning trends in the demand placed on the cooling system may be combined in a multi sensor probe.

The controller may be suitable for use with any cooler designed to utilise an icebank. This may include coolers using water or a mixture of water a freeze point depressant as the coolant. Suitable freeze point depressants include glycol, alcohol, salt. Freeze point depressants allow formation of a sub-zero ice bank which may be beneficial for certain beverages, for example alcoholic beverages such as beer, lager, cider and the like. The coolant may include additives such as anti-corrosion agents and anti-fungal agents or biocides.

The controller may be suitable for retro-fitting to existing coolers. This may be facilitated by the provision of a plug-in' probe associated with the controller. This may provide an economically acceptable solution where a new cooler fitted with the controller is inappropriate. * * I...

The controller is particularly suited for use with coolers designed to cool beverages. The controller may then be used so that an icebank is ** S..

* provided, the extent of which can be tailored to the demand trends placed on the cooler, in accordance with the quantity of beverage dispensed in a given time. In this way an icebank may be provided, suitable for giving sufficient reserve cooling capacity given normal loading, and yet not larger (more inefficient) than is necessary.

According to a second aspect of the invention there is provided an icebank cooler including a controller according to the first aspect of the invention.

According to a third aspect of the invention there is provided a machine readable medium for instructing a controller for regulating the use of an icebank cooler, where the regulation is based on information concerning trends in the demand placed on the cooler and information concerning the extent of the icebank in the cooler at any given time.

A machine readable medium should be understood to include, a floppy disc, CD-ROM, hard drive, memory stick or any other suitable device for use in instructing a suitable controller. Such a machine readable medium may provide a quick and easy method of programming one or more controllers to regulate the activities of a cooler so as to control the extent of an icebank.

According to a fourth aspect of the invention there is provided a method of regulating the use of an icebank cooler including the steps of providing a controller programmed with and/or adapted to accumulate data on trends in the demand placed on an icebank cooler for selecting an appropriate extent for an icebank in the cooler, and regulating the cooler accordingly depending on information concerning the extent of the icebank in the icebank cooler at any given time.

An embodiment of the invention will now be described in more detail by S..

way of example only, with reference to the accompanying drawing, in which Figure 1 is a schematic view showing an embodiment of the invention for use with a beverage dispense system.

Referring to Figure 1 an icebank cooler is generally shown at 1. The icebank cooler 1 is provided with an evaporator coil 3 of a refrigeration system including a compressor (not shown) and condenser (not shown).

The cooler 1 contains coolant 5 to a level sufficient to cover the evaporator coil 3. In this embodiment the coolant 5 is water but other coolants may be employed such an aqueous water/glycol mixture. An icebank 7 is shown formed on the evaporator coil 3 by operation of the refrigeration system to cool the coolant 5 to a temperature sufficient to cause the coolant 5 to freeze.

In Figure 1 the icebank cooler 1 is shown in use with a beverage dispense system. When a beverage dispense is required an operator activates a dispense tap (not shown). Beverage flows from a beverage supply (not shown) through a product line 9 to the dispense tap. The product line 9 passes through the icebank cooler 1 where the beverage is cooled by heat exchange with the liquid coolant 5.

The product line 9 passes from the icebank cooler 1 to the dispense tap within an insulated sleeve 11 where it may be bundled with other product lines and/or with supply and return lines for circulating liquid coolant 5 between the cooler and a serving area (not shownO where the dispense tap is located. Such an arrangement is commonly referred to as a python where the circulating coolant 5 reduces heat transfer from the *.** surroundings to beverage in the product line(s) so as to prevent the beverage warming up between the cooler 1 and the dispense tap. The circulating coolant may be used for other purposes in the serving area such as forming ice or condensation on the outer surface of a dispense unit or for providing additional cooling prior to dispense as will be familiar to those skilled in the art. The type of beverage dispense system described above (or variations on it) is commonly used and understood in the beverage dispense industry and no further explanation is required here.

The icebank cooler 1 is provided with a regulation system comprising controller 13, a sensor array generally provided at 15 for monitoring the extent of the icebank 7 and a temperature sensor 17 for monitoring the coolant temperature. The controller 13 is used to regulate operation of the cooler 1, more specifically the refrigeration system for controlling the icebank extent based on information received as an input from sensor array 15 (concerning the extent of the icebank 7 at any given time), and information received as an input from temperature sensor 17 (concerning the demand placed on the icebank cooler 1). Although in this embodiment the sensor array 15 and temperature sensor 17 are separate systems, it will be appreciated that in other embodiments the two may be combined in a multi sensor probe.

Sensor array 15 comprises a plurality of temperature sensors that extend linearly from near to the evaporator coil 3 towards the centre of the cooler 1. The sensor array i s used to provide the controller 13 with information on the thickness of the icebank 7. The array of temperature sensors may be replaced by any other means for monitoring icebank thickness. The temperature sensor 17 is used by the controller 13 to record temperature rise profiles (including magnitude, frequency and * ..* duration) of the liquid coolant 5. We have found that the temperature of the liquid coolant 5 falls into temperature bands dependent upon whether the cooler 1 is under no load, is under a steady load from coolant re-****.

circulating in the python 11, is under low load from the product in the product line 9, is under moderate load from the product in the product *.** line 9, is under high load from the product in the product line 9, or is under sufficiently high load that the icebank 7 is exhausted (has no extent). The temperature rise profiles recorded by the controller 13 can therefore be used to assess the load placed on the cooler 1. Controller 13 is provided with a timing device 19 to enable it to recognise time dependent patterns in demand and also to help it statistically weight information it receives. The timing device 19 greatly adds to the functionality of the controller 13, as it allows it to make regulation adjustments to the refrigeration circuit (not shown) depending on time dependent variations in load on the cooler 1. It also allows the controller 13 to statistically assess the significance of any loading event.

The controller 13 uses the information collected from the sensor array 15 and temperature sensor 17 to regulate the output of the refrigeration system. In this embodiment operation of the refrigeration system is started and stopped under the control of controller 13.

In communication with the controller 13 is a user interface module 21.

This displays to the user information concerning the performance of the controller 13 and/or the refrigeration system. In this embodiment the user interface module 21 displays the energy used by the refrigeration system in a given time period as well as an indication of whether it is currently operating. It will be appreciated that in other embodiments alternative or additional information may be provided.

The controller 13 of the present embodiment is capable of responding dynamically to trends in demand on the cooler 1, without outside input or interference. Nonetheless the present embodiment does allow manual adjustments to be made to regulation of the refrigeration circuit (not shown). An override button 23 is associated with the user interface 21.

When pressed the override button 23 instructs the controller 13 to I..,.. regulate the refrigeration circuit (not shown) such that the icebank 7 is maintained (where possible) at its maximum possible extent. Once one hour has elapsed after the override button 23 was pressed it is automatically reset, whereupon the controller 13 resumes normal regulation of the refrigeration circuit (not shown). In addition to the manual override function the controller's regulation may also be altered by programming the controller 13 via computer 25, which may be temporarily or permanently in communication with the controller 13. It will be appreciated that functions such as programming and manual override may be controlled by the user interface module 21, the computer or any other suitable interface means.

In use the controller 13 is provided with basic programming that is approximately suitable for regulating the refrigeration circuit (not shown) based on expected demand on the particular system. The controller 13 initially regulates operation of the refrigeration circuit (not shown) based on this programming, which identifies a target extent for the icebank 7 and regulates the use of the refrigeration circuit (not shown) with a view to achieving and maintaining this extent. The extent of the icebank 7 at any given time is determined by the controller 13 from information received from the sensor array 15.

Over time and as the beverage dispense system is used, the controller 13 accumulates information on trends in the demand placed on the cooler 1 using temperature sensor 17. The trend analysis includes time dependent trends which are assessed using timing device 19. Over time the controller 13 adjusts its regulation of the refrigeration circuit (not shown) (identifying one or more targets, possibly time dependent, for the extent of the icebank 7) so as the refrigeration circuit (not shown) is not loaded for longer than is required to meet the expected demand. S...

It will be understood that the invention is not limited to the embodiment above-described and various modifications and improvements can be made without departing from the various concepts described herein. Any of the features may be employed separately or in combination with any other features and the invention extends to and includes all combinations and sub-combinations of one or more features described herein in any form of system for product cooling. It will also be appreciated that although the invention has been described for convenience in terms of use with a beverage cooling system, the invention is not intended to be so limited, and the skilled man will understand that the invention may have considerably wider application. **** * * *

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Claims

CLAIMS1. An icebank cooler in which operation of the cooler to form an icebank is regulated by control means based on information concerning trends in the demand placed on the cooler and information concerning the extent of the icebank in the cooler at any given time.
2. An icebank cooler according to claim 1 wherein operation of the cooler is regulated to avoid over or under capacity of the icebank.
3. An icebank cooler according to claim 1 or claim 2 wherein operation of the cooler is regulated to maintain a target extent for the icebank.
4. An icebank cooler according to any preceding claim wherein the control means is capable of responding dynamically to changes in demand trends on the cooler recorded as a result of on-going monitoring.
5. An icebank cooler according to any of claims 1 to 3 wherein the control means periodically reviews trends for a given preceding period and adjusts regulation of the cooler accordingly. * * ***.
6. An icebank cooler according to any of claims 1 to 3 wherein the * : control means is provided with a means of recognising the passage of time *****.* and a means of recognising time dependent patterns in demand variation :. 25 on the cooler and regulating operation of the cooler in response thereto. * *** * * * * S.
7. An icebank cooler according to any preceding claim wherein the control means is part of a system that is capable of responding dynamically without outside input or interference.
8. An icebank cooler according to any of claims 1 to 6 wherein the control means is programmable so that regulation of the cooler may be altered.
9. An icebank cooler according to claim 8 wherein the control means has a connection port for a control device or alternatively may be communicated with over a network.
10. An icebank cooler according to any preceding claim wherein means is provided to override the control means.
11. An icebank cooler according to claim 10 wherein the override means is configured to cause the cooler to maintain the icebank at a maximum possible extent.
12. An icebank cooler according to claim 10 or claim 11 wherein operation of the override means is restricted.
13. An icebank cooler according to any of claims 10 to 12 wherein the override means automatically reset following a given period whereupon the control means resumes normal regulation of the cooler. * .5*S

* :
14. An icebank cooler according to any preceding claim wherein a S. S. .* * diagnostics system is provided. S. * . * S..
15. An icebank according to claim 14 wherein the diagnostics system provides an indication of the duration for which the cooler has been running in a given period and/or an indication of the energy usage for a given period.
16. An icebank cooler according to any preceding claim wherein the control means is given a basic set up and adapts to a given cooler over a period of time.
17. An icebank cooler according to any preceding claim wherein the control means comprises a processor programmed to evaluate the extent of the icebank at any given time, analyse data in relation to demand trends for the cooler and adjust regulation of the cooler in response thereto.
18. An icebank cooler according to any preceding claim wherein the control means includes a user interface and/or display module providing information on the performance of the cooler and/or allowing adjustments to be made to the cooler regulation.
19. An icebank cooler according to claim 18 wherein the user interface and/or display module possesses multiplexing functionality allowing control of multiple cooling systems.*: 20
20. An icebank cooler according to any preceding claim wherein means is provided for monitoring the extent of the icebank at any given time and communicating this as an input to the control means. S... * .SS S* .* *
21. An icebank cooler according to claim 20 wherein the icebank monitoring means is selected from evaporating temperature, evaporating *:*.; pressure, icebank thickness by temperature gradient, icebank thickness by progressive resistance change, icebank thickness by multiple pin resistance pairs, sonic/ultrasonic detection of icebank wall or free water volume, natural frequency of exposed sensor, light sensing of ice wall
22. An icebank cooler according to any preceding claim wherein means is provided for collecting information concerning trends in the demand placed on the cooler and communicating this as an input to the control means.
23. An icebank cooler according to claim 22 wherein the trend collecting means is selected from data capture recording the quantity of use of the icebank cooler, recording the effectiveness of the icebank cooler by measuring the temperature of products or articles intended to be cooled by it, recording temperature profiles of the coolant in the evaporation cycle of the cooling system during icebank recovery periods, recording the quantity of product or articles that are passed through the icebank cooler, till receipt records recording quantity of product sold that has been cooled by the icebank cooler, operator observation and/or experience, temperature rise profiles for a given time of liquid water which might otherwise form part of the icebank.
24. An icebank cooler according to any preceding claim wherein means of measuring the extent of the icebank at any given time and of gathering *:::: 20 information concerning trends in the demand placed on the cooling system *::::* is combined in a multi sensor probe.*
25. An icebank cooler comprising a refrigeration system including an S.....* evaporator coil on which an icebank can be formed from coolant covering the evaporator coil within the cooler, means for monitoring the extent of *. the icebank, means for monitoring demand on the cooler, and control means responsive to the icebank monitoring means and the cooler demand means to regulate operation of the refrigeration system.
26. An icebank cooler according to claim 25 wherein the icebank monitoring means comprises an array of sensors for detecting icebank thickness.
27. An icebank cooler according to claim 25 or claim 26 wherein the cooler demand means comprises a sensor for monitoring the coolant temperature in the cooler.
28. An icebank cooler substantially as hereinbefore described with reference to the accompanying drawing.
29. A controller for an icebank cooler, the controller being adapted to receive on information concerning trends in the demand placed on the cooler and information concerning the extent of an icebank in the cooler at any given time and to regulate operation of the cooler in response thereto.
30. A controller according to claim 29 wherein the controller is suitable for retro-fitting to a cooler. *I. * * . S. * *.S.
31. A controller according to claim 29 or claim 30 including a plug-in * probe.S..... * SS....'
32. A method of regulating the use of an icebank cooler including the steps of providing a controller programmed with and/or adapted to accumulate data on trends in the demand placed on an icebank cooler for selecting an appropriate extent for an icebank in the cooler, and regulating the cooler accordingly depending on information concerning the extent of the icebank in the cooler at any given time.