Triangulation Position Detection Method and Apparatus

The present invention relates generally to a triangulation position detection method and device for detecting the presence of an object within a predetermined target window using light radiation. More specifically, the invention is applied to a dispenser, such as a beverage and/or ice dispenser.

Generally, a beverage and ice dispenser consists of a mechanical push rod closing an electric switch or a manually operated push-button electric switch which actuates a dispenser to dispense product. It is thought that such dispensers transmit communicable diseases. For example, a person with such a disease who drinks out of a cup and returns to the dispenser to refill the cup must contact the cup to the dispensing push rod such that germs may be transferred from the cup to the push rod wherein the next individual to use the mechanical dispenser may come in contact with the germs by drinking from a cup subsequently placed against the same push rod.

Heat sensing devices which are typically used for activating water faucets in response to sensing heat generated by the operator's hand within a certain proximity of the faucet are not very accurate in determining position because of their temperature dependency. Heat sensing devices are activated when an object of a given temperature is at a certain proximity to the heat sensing device. However, if the temperature is lower than the temperature expected at the given proximity, the device will not be activated until the object with lower temperature is brought closer to the heat sensing device which shortens the expected proximity. In other words, an object's distance from the heat sensing device, to activate the device, will vary with temperature and therefore will not give precise and predictable results.

Another type of position sensing device is a light beam interrupter system in which a beam of infrared light is transmitted to a photodetector mounted opposite the infrared transmitter which transmits a steady light beam and wherein the interruption of the light beam indicates the presence of an object therebetween. For example, see U.S. Pat. No. 4,822,996 issued to Lind. This type of system is only capable of determining whether an object is present between the transmitter and the receiver and not the proximity or position of an object. In other words, this type of a detector would only function on a single axis.

An alternative transmitter and receiver arrangement was provided by Hosel, U.S. Pat. No. 5,002,102 which emits a steady beam of light from a transmitter which is reflected back to a receiver mounted adjacent the transmitter. The Hosel system requires a microcomputer with a microprocessor for calculating a distance between the transmitter/receiver and the fill level in a bin-the distance being an inverse function of the intensity of the light beam. The Hosel apparatus is based on direct reflection, that is, it simply emits light and determines how much is returned to determine the fill level distance and is therefore limited to detection on a single axis, and unless confined within a closed system such as the fiber storing bin disclosed by Hosel, the Hosel device would be susceptible to stray light sources and be inoperative in the presence of such stray light sources.

The main disadvantage of these prior systems is that they are limited to detection on a single axis and therefore are not true position detection devices. In other words, a light beam interrupter system, for example Lind U.S. Pat. No. 4,822,996, detects an interruption in the light beam anywhere in the linear axis defined to extend from the light emitting source to the light receiving detector, and cannot differentiate the position of the interruption along that linear axis. A heat sensing device may be able to detect on multiple axes, but unless the temperature of the intruding object is constant, the point of detection varies with the temperature of the object, and therefore true position detection cannot be achieved.

The present invention overcomes the disadvantages of the prior art devices by using the concept of triangulation and simplifies the circuitry by using inexpensive, discrete components to digitize the light beam of the triangulation position detection device. The present invention uses a light beam produced by a transmitter mounted at a given angle in the same plane as a receiver. The receiver is mounted in the plane at the same given angle such that the transmitter and receiver have lines of projection and reflection, respectively, which form a target intercept point at a given distance from the mounting plane. The transmitter, receiver, and target intercept point form the three corners of the triangle which forms the basis for the triangulation concept. A light transmitter typically has a radiation pattern with an amount of light beam diffusion forming a cone-shaped light beam. The radiation pattern can be controlled by recessing the transmitter in an orifice to control the size of the cone-shaped light beam. Similarly, the receiver can be recessed to receive a given amount of light. Recessing the transmitter and receiver creates a position target window having a volumetric shape of two intersecting cones having a given size formed by the cone-shaped light beam emitted by the transmitter intersecting the conical outline of the reflected light beam to the receiver. The target window contains the target intercept point.

In operation, when an object enters the spherical target window a portion of the emitted light beam is reflected in the direction of the receiver and the more the object occupies the volumetric target window, the greater the portion of light beam is reflected into the receiver. When the object passes the target intercept point and is sufficiently within the volumetric target window, enough of the emitted light beam is received by the receiver for the control circuitry to recognize that an object is in position. In this manner, the present invention is said to detect the presence of an object on three axes. That is, if an object is too far to the right or too far to the left (X-axis), too high or too low (Z-axis), too close or too far (Y-axis), the object will not be sufficiently within the volumetric target window and will not be detected.

The present invention is implemented using a digitized, or pulsed, light beam which eliminates the need of a microprocessor and allows the system to ignore errant and stray light beams. The system includes a clock which activates the transmitter to emit a pulse of light equal in time to the pulse width created by the clock. This allows the control circuitry to ignore any errant and stray light received by the receiver when the transmitter is not emitting the pulse of light. The control circuitry includes an amplifier and a signal strength detector to ensure that the object occupies a majority of the spherical target window. A synchronous checker functions to ignore all light received while the transmitter is not emitting a pulse of light.

The system can be used for a beverage and/or ice dispensing unit wherein a delay can be provided to not only ensure that a cup is adequately in place under the dispenser, but also to eliminate nuisance dispensing. The system then activates the dispenser until the cup is no longer sufficiently within the volumetric target window wherein the control is instantly disabled.

The triangulation position detection device disclosed is implemented with discrete circuitry, however, the system may easily be adapted into a microprocessor based circuit and implemented via software. A flow chart is provided for this purpose. Additional benefits and advantages of the present invention will become apparent from the subsequent detailed description of the preferred embodiment, the drawings, and the claims.

FIG. 1 is a schematic illustration in top plane view of a system in accordance with the invention.

FIG. 2 is a schematic in top plane view of various mounting arrangements for a portion of the system of FIG. 1.

FIG. 3 is a horizontal plane view of the system of FIG. 1.

FIG. 4 is a side elevation view of the system of FIG. 1.

FIG. 5 is a circuit block diagram of a system in accordance with the invention.

FIG. 6 is a system flow chart in accordance with the invention.

FIG. 7 is a timing diagram of a system in accordance with the invention.

Referring to FIG. 1, transmitter 10 and receiver 12 are mounted in plane 14 of mounting block 16. Transmitter 10 and receiver 12 are orientated in mounting block 16 such that an axis of projection 18 of transmitter 10 and an axis of reflection 20 of receiver 12 are 45.degree. to plane 14 of mounting block 16 as shown by angles 22 and 24. Axes of projection and reflection 18 and 20 converge at target intercept point 26 which defines a point above which a dispensing spigot (not shown) is located to dispense beverages, ice, or any other type of dispensable product. Light beam 28 emitted from transmitter 10 has a cone-shaped radiation pattern which defines volumetric target window 30 such that when a container 48, for example a cup, glass, or other beverage holder, is placed within volumetric target window 30, at least a portion of light beam 28 is reflected toward receiver 12 as reflected light 32 having a cone-shaped sensing pattern.

FIG. 1 shows the general concept behind triangulation position detection wherein an object placed within volumetric target window 30 reflects at least a portion of the emitted light beam 28 from transmitter 10 toward receiver 12. The more an object occupies target window 30, the larger the portion of light beam 28 is reflected into receiver 12. This forms the basis for the triangulation theory of position detection. In other words, as an object begins to enter target window 30, only a small portion of light beam 28 is reflected off the object and toward receiver 12. The intensity of reflected light beam 32 increases as more of the object occupies target window 30. Preferably, when the leading edge of the object passes intercept point 26, the dispenser is activated by the intensity of reflected light beam 32.

Transmitter 10 and receiver 12 are recessed in mounting block 16 a recessed distance 34 for controlling the radiation pattern. As shown in FIG. 2, the preferred embodiment uses a straight orifice 36 which acts as a wave guide for narrowing light beam 28 emitted from transmitter 10 and reflected light 32 received by receiver 12. Recessed distance 34 controls the radiation pattern by varying included angle 38. Increasing recessed distance 34 by recessing transmitter 10 further inside mounting block 16 decreases included angle 38 which results in a smaller target window 30, FIG. 1. Reducing recessed distance 34, FIG. 2, by mounting transmitter 10 closer to plane 14 provides a larger included angle 38 which results in a larger target window 30, FIG. 1. Alternatively, a tapered orifice 40 in mounting block 16 provides similar results by machining a taper in plane 14 of mounting block 16. A wider taper provides a larger included angle 38 and a larger target window 30, FIG. 1. A narrower taper 40, FIG. 2, provides a smaller included angle 38 and a smaller target window 30, FIG. 1. Straight orifice 36 is preferred because it is simply implemented by drilling a hole in mounting block 16, whereas tapered orifice 40 requires drilling a straight orifice for transmitter 10 and receiver 12, then machining the required taper corresponding to a desired target window 30, FIG. 1. Straight orifice 36 is also preferred because included angle 38 and the resulting target window size may be easily altered by simply adjusting recessed distance 34 of transmitter 10 and receiver 12. By testing the system with various containers, it was found that a preferred included angle 38 of 10.degree. provided a target window 30, FIG. 1, which accommodates a majority of beverage cup sizes.

As previously described, the size of target window 30, FIG. 1, is generally dependent upon included angle 38, FIG. 2, and recessed distance 34; however, target intercept point 26 is defined by mounting angles 22 and 24 in combination with mounting distance 42 and since light beam 28, FIG. 1, is cone-shaped, varying target intercept point 26 has a corresponding effect on the size of target window 30. Mounting distance 42 is the distance transmitter 10 and receiver 12 are mounted apart from one another in mounting block 16. As can be seen in FIG. 1, holding mounting distance 42 constant and decreasing mounting angles 22 and 24 brings target intercept point 26 closer to mounting block 16 and decreases target intercept distance 44 which also decreases the size of target window 30. Conversely, increasing mounting angles 22 and 24 increases target intercept distance 44 and extends target intercept point 26 further away from mounting block 16 also increases the size of a target window 30. Similarly, holding mounting angles 22 and 24 constant and increasing mounting distance 42 increases target intercept distance 44 and extends target intercept point 26 further away from mounting block 16 which also increases the size of target window 30. Conversely, decreasing mounting distance 42, decreases target intercept distance 44 bringing target intercept point 26 closer to mounting block 16 and decreases the size of target window 30. Target window 30 is centered about target intercept point 26 and moves correspondingly. In the preferred embodiment, a preferred mounting distance 42 of approximately 2.5" with a preferred mounting angle of 45.degree. provide a desired target intercept distance of approximately 1.75". However, these parameters are easily adjustable to acquire various target intercept distances, as previously described.

FIG. 3 shows a horizontal view of mounting block 16 in which transmitter 10 and receiver 12 are mounted in plane 14. While FIG. 1 shows target window 30 on a two-dimensional X-Y axis, FIGS. 3 and 4 show a third dimension of target window 30 on the Z axis. FIG. 4 shows a profile view of mounting block 16 in which light beam 28 is emitted from transmitter 10, reflected off container 48 in target window 30, and returned as reflected light beam 32 to receiver 12 in mounting block 16. When a sufficient portion of container 48 is within target window 30, the dispenser is activated to dispense product.

FIG. 5 shows a block diagram of the circuit used to implement the triangulation position detection device of FIG. 1. Clock 46 is connected to transmitter 10, synchronous checker 54 and ON delay 56. Transmitter 10 emits pulse light beam 28 in response to receiving a periodic clock pulse 47 from clock 46. Pulse light beam 28 is reflected off an object, for example a cup 48, as reflected light beam 32 toward receiver 12. Receiver 12 produces a light indicative signal 49 in response to receiving pulse light beam 32. Amplifier 50 is connected to receiver 12 and amplifies light indicative signal 49. Signal strength detector 52 receives the amplified light indicative signal 51 from amplifier 50 and compares amplified light indicative signal 51 against a predetermined parameter to detect whether a sufficient amount of light beam 32 was reflected into receiver 12. Signal strength detector 52 produces a signal strength signal 53 when the amplified light indicative signal 51 is greater than the predetermined parameter, and the synchronous checker 54 determines whether the signal strength signal 53 occurs substantially synchronously with the periodic clock pulse from clock 46. Synchronous checker 54 ensures that the light received in receiver 12 was indeed produced by transmitter 10 and produces a synchronous signal 55 in response. The synchronous signal 55 is received by ON delay 56 which is connected to clock 46 and dispenser 58, and delays activating dispenser 58 to ensure that container 48 has passed target intercept point 26 and occupies a majority of target window 30. In the preferred embodiment, it was found that a 100 millisecond delay was sufficient to ensure that the edge of cup 48 has passed target intercept point 26, which avoids spilling dispensed product over the leading edge of cup 48. ON delay 56 creates dispensing signal 57 to activate dispenser 58.

FIG. 6 is a system flow chart of the triangulation position detection device which would guide implementing the device with a microprocessor and software. At power up 60 the receiver is read 62 and checked to see if light is received 64. If light is received, it is interpreted as stray light and ignored by the system by resetting the ON delay timer 66 and disabling the dispenser 68 to ensure the dispenser is deactivated. The system then reads the receiver 62 again, ensures that no stray light is received 64, and transmits a pulse of light 70. The receiver is read 72, and a determination is made as to whether a sufficient amount of light is received 74. An insufficient amount of light received is an indication that the cup is not yet in position or a stray light signal was received. In those cases, the ON delay timer is reset 66, the dispenser is disabled 68, and the loop is started again by reading receiver 62. If sufficient light is received 74, the ON delay timer is enabled 76. The loop is repeated until the desired delay time is expired 78 which allows enough time to position the cup sufficiently under the dispenser. When the delay time has expired 78, the cup is in position and the dispenser is enabled 80. The entire flow chart is repeated checking to make sure that the cup stays in position while dispensing. If a pulse of light is transmitted 70 but not sufficiently received 72, 74, the ON delay timer is reset 66 and the dispenser is immediately disabled 68 which provides an instant OFF when the cup is no longer sufficiently in target window 30, FIG. 1.

FIG. 7 shows a timing diagram with various examples of operation. Clock (46) produces periodic clock pulses 47 having a period of 2 ms. and a pulse width of 150 .mu.s. Clock (46) enables transmitter (10) which provides a pulse of light 32 with the same periodicity as clock pulses 47. Transmitter (10) has a time of emission equal to the clock pulse width. The transmitter produces a pulse of light 32 substantially equal in time to the clock pulse 47 produced by the clock. Receiver (12) produces light indicative signals 49 when light is received. Signal strength detector (52) shows signal strength signals 53 coinciding with light indicative signals 49 only when light indicative signals 49 are greater than a predetermined parameter. For example, light indicative signal 49a is not greater than the predetermined parameter and therefore no corresponding signal strength signal 53 is shown. Light indicative signal 49a may indicate the preference of a stray or errant light source. Synchronous checker 54 has synchronous signals 55 only when the signal strength signals 53 are substantially synchronous with the periodic clock pulses 47. For example, signal strength signal 53a corresponding to light indicative signal 49b is not synchronous with any clock pulse 47 and therefore does not have a corresponding synchronous signal. Dispenser (58) receives dispensing signal 57 which is delayed 100 ms. from the first occurrence of a synchronous signal 55. Dispensing signal 57 has an ON pulse width dependent upon the reoccurrence of synchronous signals 55. ON delay 56, FIG. 5, holds dispenser 58 in the enable mode until a clock pulse 47, FIG. 7, occurs in the absence of a synchronous signal 55, at which point dispensing pulse 57 goes low disabling dispenser (58).

The method and device of the present invention is not limited to any particular light source but is functional with any electromagnetic radiation in the optical wavelength range including infrared, visible, and ultraviolet. The preferred embodiment uses an infrared transmitter and receiver because they are very reliable, readily available, long lasting, and relatively inexpensive.