Icemaker appliance and method for acoustic harvest detection

Abstract

An ice maker appliance includes a frame and a mold tray selectively supported by the frame. The mold tray includes one or more ice forming shapes defined therein. A motor is coupled to the frame and operably coupled with the mold tray to selectively rotate the mold tray with respect to the frame in each of a first direction and a second direction. A controller is operably coupled with the motor and an acoustic sensor. The controller is configured to perform an operation. The operation includes initiating a first harvest routine; obtaining an acoustic signal during the first harvest routine; determining similarity or dissimilarity between the acoustic signal and a baseline signal; and initiating a second harvest routine if dissimilarity between the acoustic signal and the baseline signal is determined.

Description

FIELD OF THE INVENTION

[0001] The present subject matter relates generally to refrigerator appliances, and more particularly to ice makers within refrigerator appliances.BACKGROUND OF THE INVENTION

[0002] Refrigerator appliances generally include a cabinet that defines one or more chilled chambers for receipt of food articles for storage. Typically, one or more doors are rotatably hinged to the cabinet to permit selective access to food items stored in the chilled chamber. Further, refrigerator appliances commonly include an ice maker mounted within an icebox on one of the doors or in a freezer compartment or fresh food compartment. To produce ice, liquid water is directed to the ice maker and frozen. For example, certain ice makers include an ice tray, for example, a mold body for receiving liquid water.

[0003] After ice is formed in the ice tray, it may be harvested from the ice tray and stored within an ice storage bin within the refrigerator appliance. Ice stored in the ice storage bin is accessible from within the freezer chamber or may be discharged through a dispenser recess defined on a front of the refrigerator door. A common issue for ice makers involves adherence of the ice shapes to a mold tray during the harvesting operation. Often, ice makers utilize plastic or silicon ice trays to which the water adheres throughout the ice making process. Water held within the ice tray can then become stuck to the tray, resulting in incomplete harvesting or harvesting failures due to adhesion.

[0004] Accordingly, a refrigerator appliance that obviates one or more of the above-mentioned drawbacks would be beneficial. In particular, a method for ice harvest detection and operation would be beneficial.BRIEF DESCRIPTION OF THE INVENTION

[0005] Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

[0006] An aspect of the present disclosure is directed to an ice maker appliance including a frame, a mold tray selectively supported by the frame, the mold tray including one or more ice forming shapes defined therein, a motor coupled to the frame and operably coupled with the mold tray to selectively rotate the mold tray with respect to the frame in each of a first direction and a second direction, and an acoustic sensor. A controller is operably coupled with the motor and the acoustic sensor. The controller is configured to perform an operation, the operation including initiating a first harvest routine; obtaining an acoustic signal during the first harvest routine; determining similarity or dissimilarity between the acoustic signal and a baseline signal; and initiating a second harvest routine if dissimilarity between the acoustic signal and the baseline signal is determined.

[0007] An aspect of the present disclosure is directed to a refrigerator appliance including an ice maker appliance. The refrigerator appliance includes a freezer compartment in which an ice maker appliance is provided. The ice maker appliance defines a vertical direction, a lateral direction, and a transverse direction. The ice maker appliance includes a frame and a mold tray selectively supported by the frame. The mold tray includes one or more ice forming shapes defined therein. A motor is coupled to the frame and operably coupled with the mold tray to selectively rotate the mold tray with respect to the frame in each of a first direction and a second direction. A controller is operably coupled with the motor and an acoustic sensor. The controller is configured to perform an operation. The operation includes initiating a first harvest routine; obtaining an acoustic signal during the first harvest routine; determining similarity or dissimilarity between the acoustic signal and a baseline signal; and initiating a second harvest routine if dissimilarity between the acoustic signal and the baseline signal is determined.

[0008] These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.

[0010] FIG. 1A provides a perspective view of a refrigerator appliance according to one or more exemplary embodiments of the present subject matter.

[0011] FIG. 1B provides a front view of an embodiment of a dispenser assembly for a refrigerator appliance according to one or more exemplary embodiments of the present subject matter.

[0012] FIG. 2 provides a perspective view of the exemplary refrigerator appliance of FIG. 1A, with the doors of the fresh food chamber shown in an open position.

[0013] FIG. 3 provides an interior perspective view of a dispenser door of the exemplary refrigerator appliance of FIG. 1A.

[0014] FIG. 4 provides an interior elevation view of the door of FIG. 3 with an access door of the dispenser door shown in an open position.

[0015] FIG. 5 provides a lower perspective view of a frame and ice mold with the ice mold in a first position according to exemplary embodiments of the present disclosure.

[0016] FIG. 6 provides a lower perspective view of the exemplary frame and ice mold of FIG. 5, with the ice mold in a second position.

[0017] FIG. 7 provides a lower perspective view of the exemplary frame and ice mold of FIG. 5, with the ice mold in a third position.

[0018] FIG. 8 provides a flow chart illustrating a method of operating a refrigerator appliance according to exemplary embodiments of the present disclosure.

[0019] Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.DETAILED DESCRIPTION

[0020] Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

[0021] As used herein, the terms “first,”“second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”). In addition, here and throughout the specification and claims, range limitations may be combined and / or interchanged. Such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. The singular forms “a,”“an,” and “the” include plural references unless the context clearly dictates otherwise.

[0022] Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “generally,”“about,”“approximately,” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or machines for constructing or manufacturing the components and / or systems. For example, the approximating language may refer to being within a 10 percent margin, i.e., including values within ten percent greater or less than the stated value. In this regard, for example, when used in the context of an angle or direction, such terms include within ten degrees greater or less than the stated angle or direction, e.g., “generally vertical” includes forming an angle of up to ten degrees in any direction, e.g., clockwise or counterclockwise, with the vertical direction V.

[0023] The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” In addition, references to “an embodiment” or “one embodiment” does not necessarily refer to the same embodiment, although it may. Any implementation described herein as “exemplary” or “an embodiment” is not necessarily to be construed as preferred or advantageous over other implementations. Moreover, each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

[0024] FIG. 1A provides a perspective view of an appliance 100 according to one or more exemplary embodiments of the present subject matter. Appliance 100 may be configured as a refrigerator appliance or a standalone freezer appliance. Appliance 100 may define a vertical direction V, a lateral direction L, and a transverse direction T. Each of the vertical direction V, lateral direction L, and transverse direction T being mutually perpendicular to one another to form an orthogonal coordinate system. Appliance 100 may include a housing or a cabinet 102 that may extend between a top 104 and a bottom 106 along the vertical direction V, between a first side 108 and a second side 110 along the lateral direction L, and between a front side 112 and a rear side 114 along the transverse direction T.

[0025] Cabinet 102 may define one or more chilled chambers for receipt of food items for storage. In particular, cabinet 102 may define a fresh food chamber 122 positioned at or adjacent top 104 of cabinet 102 and a freezer chamber 124 arranged at or adjacent bottom 106 of cabinet 102. As such, appliance 100 may generally be referred to as a bottom mount refrigerator. It is recognized, however, that the benefits of the present disclosure apply to other types and styles of refrigerator appliances such as, e.g., a top mount refrigerator appliance, a side-by-side style refrigerator appliance, or a single door refrigerator appliance, or standalone freezer appliance. Consequently, the description set forth herein may be for illustrative purposes only and is not intended to be limiting in any aspect to any particular refrigerator chamber or freezer appliance configuration.

[0026] Appliance 100 may include refrigerator doors 128 that may be rotatably hinged to an edge of cabinet 102 for selectively accessing fresh food chamber 122. In addition, a freezer door 130 may be arranged below refrigerator doors 128 for selectively accessing freezer chamber 124. Freezer door 130 may be coupled to a freezer drawer (not shown) that may be slidably mounted within freezer chamber 124. Refrigerator doors 128 and freezer door 130 may be shown in the closed configuration in FIG. 1A. One skilled in the art will appreciate that other chamber and door configurations are possible and within the scope of the present invention.

[0027] Referring now to FIG. 2, a perspective view of appliance 100 shown with refrigerator doors 128 in the open position is provided. As shown in FIG. 2, various storage components may be mounted within fresh food chamber 122 to facilitate storage of food items therein as will be understood by those skilled in the art. In particular, the storage components may include bins 134 and shelves 136. Each of these storage components are configured for receipt of food items (e.g., beverages or solid food items, etc.) and may assist with organizing such food items. As illustrated, bins 134 may be mounted on refrigerator doors 128 or may slide into a receiving space in fresh food chamber 122. It should be appreciated that the illustrated storage components are used only for the purpose of explanation and that other storage components may be used and may have different sizes, shapes, and configurations.

[0028] Referring now generally to FIGS. 1A-1B, a dispensing assembly 140 will be described according to exemplary embodiments of the present subject matter. Dispensing assembly 140 may generally be configured for dispensing liquid water or ice bodies from the ice maker 180. Although an exemplary dispensing assembly 140 may be illustrated and described herein, it should be appreciated that variations and modifications may be made to dispensing assembly 140 while remaining within the present subject matter.

[0029] Dispensing assembly 140 and its various components may be positioned at least in part within a dispenser recess 142 defined on one of refrigerator doors 128. In this regard, dispenser recess 142 is defined on front side 112 of appliance 100 such that a user may operate dispensing assembly 140 without opening refrigerator door 128. In addition, dispenser recess 142 may be positioned at a predetermined elevation convenient for a user to access ice and enabling the user to access ice without the need to bend-over. In the exemplary embodiment, dispenser recess 142 may be positioned at a level that approximates the chest level of a user.

[0030] Dispensing assembly 140 may include an ice dispenser 144 that may include a discharging outlet 146 for discharging ice pieces from dispensing assembly 140. An actuating mechanism 148, shown as a paddle, may be mounted below discharging outlet 146 for operating ice or water dispenser 144. Discharging outlet 146 and actuating mechanism 148 may be an external part of ice dispenser 144 and may be mounted in dispenser recess 142.

[0031] In alternative exemplary embodiments, any suitable actuating mechanism may be used to operate ice dispenser 144. For example, ice dispenser 144 can include a sensor (such as an ultrasonic sensor) or a button rather than the paddle.

[0032] By contrast, inside appliance 100, refrigerator door 128 may define an icebox 150, see, for example, FIGS. 2 through 4, that may house an ice maker appliance 180 and an ice storage bin 182 that may be configured to supply ice pieces to dispenser recess 142. In this regard, for example, icebox 150 may define an ice making chamber 154 for housing an ice making or ice maker assembly, a storage mechanism, and a dispensing mechanism. However, it should be appreciated that, in various embodiments, the ice maker and ice storage bin may be placed in alternative locations, or as a separate appliance (e.g., a standalone freezer appliance).

[0033] A control panel 160 may be provided for controlling the mode of operation. For example, control panel 160 may include one or more selector inputs 162, such as knobs, buttons, touchscreen interfaces, for selecting a desired mode of operation, for example an ice-dispensing button that may be provided for selecting crushed or non-crushed ice pieces. In addition, the one or more selector inputs 162 may be used to specify a fill volume or method of operating dispensing assembly 140. In this regard, the one or more selector inputs 162 may be in communication with a processing device or controller 164. Signals generated in controller 164 may operate the appliance 100 and the dispensing assembly 140 in response to the one or more selector inputs 162. Additionally, a display 166, such as an indicator light or a screen, may be provided on control panel 160. Display 166 may be in communication with controller 164 and may display information in response to signals from controller 164.

[0034] As used herein, “processing device” or “controller” may refer to one or more microprocessors or semiconductor devices and is not restricted necessarily to a single element. The processing device can be programmed to operate appliance 100 and dispensing assembly 140. The processing device may include, or be associated with, one or more memory elements (e.g., non-transitory storage media). In some such embodiments, the memory elements include electrically erasable, programmable read only memory (EEPROM). Generally, the memory elements can store information accessible to the processing device, including instructions that can be executed by processing device. Optionally, the instructions can be software or any set of instructions or data that when executed by the processing device, cause the processing device to perform operations.

[0035] In various embodiments, the appliance 100 includes an acoustic sensor 168, such as a microphone, configured to obtain, detect, or process sound, noise, or acoustic signals. The acoustic sensor 168 is operably coupled to the controller 164 to send acoustic signals to the controller 164, such as in accordance with one or more steps of method 1000 further described herein. The acoustic sensor 168 may be included at the display 166, at the control panel 160, at the dispensing assembly 140, or other portions of the appliance 100. For instance, one or more acoustic sensors may be positioned within the cabinet 102. The acoustic sensor 168 is positioned to receive acoustic signals corresponding to ice harvesting, such as further described herein in regard to method 1000. In some embodiments, the acoustic sensor 168 is positioned to receive acoustic signals associated with a user voice or other operations associated with the control panel 160 and controller 164.

[0036] Referring now to FIGS. 3 and 4, FIG. 3 provides an interior perspective view of one of the refrigerator doors 128 and FIG. 4 provides an interior elevation view of refrigerator door 128 with an access door 170 shown in an open position. In some embodiments, appliance 100 includes an icebox 150, for example, a sub-compartment, that may be defined on one of the refrigerator doors 128. In the illustrated exemplary embodiment, icebox 150 extends into fresh food chamber 122 when refrigerator door 128 is in the closed position. Chilled air from a sealed system (not shown) of appliance 100 may be directed into components within icebox 150, e.g., ice maker 180 or ice storage bin 182. As shown schematically in FIG. 4, ice maker 180 may be positioned within icebox 150. Ice maker 180 may generally be configured for freezing liquid water to form ice pieces, for example, ice cubes, which may be collected and stored in ice storage bin 182 positioned below ice maker 180. The ice pieces stored within ice storage bin 182 may be dispensed through discharging outlet 146 by dispensing assembly 140. Additionally or alternatively, the ice pieces may be stored in a separate ice storage box or compartment where they may be manually retrieved by a user. For instance, ice maker 180 may be configured to produce (e.g., freeze) designer or custom ice shapes (e.g., spheres, stars, geometric shapes, etc.) that may not be suitable for dispensation through dispensing assembly 140.

[0037] In some embodiments, appliance 100 may include a water fill assembly 190 in upstream fluid communication with ice maker 180. Water fill assembly 190 may be in operative communication with controller 164 to selectively deliver a fill of liquid water to ice maker 180. In some embodiments, water fill assembly 190 includes a water source 192, a flow regulator 194, a water valve 196, and a fill tube 198. Water source 192 may be any suitable water source for supplying water to ice maker 180. For example, water source 192 may be a municipal water network or well. Flow regulator 194 may be configured to regulate a flow rate of liquid water delivered from water source 192. Water valve 196 may be configured to selectively allow the flow of liquid water to be delivered to fill tube 198. For instance, water valve 196 may be in operative communication with controller 164 to selectively open or close water valve 196 such that the flow of liquid water from water source 192 can be selectively delivered to fill tube 198.

[0038] As mentioned above, the present disclosure may also be applied to other types and styles of refrigerator appliances such as a top mount refrigerator appliance, a side-by-side style refrigerator appliance or a standalone ice maker appliance. Additionally, variations and modifications may be made to ice maker 180 while remaining within the scope of the present subject matter. Accordingly, the description herein of icebox 150 on refrigerator door 128 of fresh food chamber 122 may be provided by way of example only. In other example embodiments, ice maker 180 may be positioned in freezer chamber 124, e.g., of the illustrated bottom-mount refrigerator, of a side-by-side refrigerator, of a top-mount refrigerator, or any other suitable refrigerator appliance. As another example, ice maker 180 may also be provided in a standalone ice maker appliance. As used herein, the term “standalone ice maker appliance” may refer to an appliance of which the sole or primary operation is generating or producing ice, whereas the more general term “ice maker appliance” may include such appliances as well as appliances with diverse capabilities in addition to making ice, such as a refrigerator appliance equipped with an ice maker, or a standalone freezer appliance, among other possible examples.

[0039] As mentioned above, access door 170 may be hinged to the inside of refrigerator door 128. Access door 170 may permit selective access to icebox 150. Any manner of suitable latch 172 may be configured with icebox 150 to maintain access door 170 in a closed position. As an example, latch 172 may be actuated by a user, such as a consumer, in order to open access door 170 for providing access into icebox 150. Access door 170 may also assist with insulating icebox 150, e.g., by thermally isolating or insulating icebox 150 from fresh food chamber 122.

[0040] According to some embodiments of the present subject matter, ice maker 180 may advantageously include a twist ice tray assembly 200. Twist ice tray assembly 200 may define a vertical direction V, a lateral direction L, and a transverse direction T. Each of vertical direction V, lateral direction L, and transverse direction T may be the same as vertical direction V, lateral direction L, and transverse direction T of appliance 100. As would be appreciated, twist ice tray assembly 200 may provide two or more twist ice trays (e.g., a first ice tray and a second ice tray, not shown) positioned in a side-by-side arrangement. Additionally or alternatively, twist ice tray assembly 200 may be configured to accommodate different ice molds (described below) such that a variety of different shapes may be selectively formed or frozen therein.

[0041] Referring now to FIGS. 5-7, an exemplary twist ice tray assembly 200 will be described in detail. Twist ice tray assembly 200 may include a frame 202. For instance, frame 202 may be positioned within ice maker 180. Frame 202 may include one or more frame members, such as a rear frame member 204, a first side frame member 206, a second side frame member 208, and a front frame member 210. Rear frame member 204 may extend along the vertical direction V and the transverse direction T. Each of first side frame member 206 and second side frame member 208 may extend along the vertical direction V and the lateral direction L. For instance, first side frame member 206 may protrude from a first end 2041 of rear frame member 204. Second side frame member 208 may protrude from a second end 2042 of rear frame member 204 opposite first end 2041. Front frame member 210 may be spaced apart from rear frame member 204 along the lateral direction L. Additionally or alternatively, front frame member 210 may connect first side frame member 206 to second side frame member 208.

[0042] Twist ice tray assembly 200 may include a mold tray 212. Mold tray may be selectively supported by frame 202. For instance, mold tray 212 may be movably (e.g., rotatably) positioned within frame 202 (e.g., between rear frame member 204, first side frame member 206, second side frame member 208, and front frame member 210. Mold tray 212 may include one or more ice forming shapes 214 formed therein. In detail, the one or more ice forming shapes 214 may define pockets or receiving spaces in which water is supplied to be frozen into ice shapes. The one or more ice forming shapes 214 may define predetermined geometric shapes or patterns. Thus, certain unique shapes and patterns may be formed in ice via ice forming shapes 214.

[0043] In some embodiments, the mold tray 212 is configured to receive between approximately fifteen (15) cubic centimeters of water and approximately one-hundred (100) cubic centimeters of water per ice shape 214. In still some embodiments, the mold tray 212 is configured to form up to seven (7) ice shapes 214 per harvest.

[0044] Mold tray 212 may include an edge frame 216. For instance, edge frame 216 may support each of the one or more ice forming shapes 214. In some instances, edge frame 216 forms a peripheral boundary of mold tray 212. Thus, edge frame 216 may have a generally rectangular or quadrilateral shape. As will be described, mold tray 212 may selectively rotate within frame 202. While performing an ice forming or freezing operation or cycle, mold tray 212 may be in a neutral position. When in the neutral position, edge frame 216 may be predominantly parallel with frame 202. For instance, a top plane of edge frame 216 (e.g., defined along the lateral direction L and the transverse direction T) may be parallel with a top plane of frame 202 (e.g., defined along the lateral direction L and transverse direction T).

[0045] Mold tray 212 may include or define a driveshaft 218. As mentioned above, mold tray 212 may be rotatable within frame 212. An axis of rotation may be defined along the transverse direction T. Accordingly, the axis of rotation may be parallel with rear frame member 204 and front frame member 210. Driveshaft 218 may be rotatably supported by frame 202. For at least one example, a first end 2181 of driveshaft 218 is supported by first side frame member 206. For instance, first end 2181 may be received within a bearing defined in an interior surface 2061 of first side frame member 206. Driveshaft 218 may thus rotate with respect to first side frame member 206 (and second side frame member 208).

[0046] In some instance, driveshaft 218 defines first end 2181 and a second end 2182 (FIG. 7) opposite first end 2181 (e.g., along the transverse direction T). As mentioned, first end 2181 may be supported by first side frame member 206. Thus second end 2182 may be positioned at or near second side frame member 208. In some embodiments, for instance, as best shown in FIG. 7, first end 2181 is separated from second end 2182. For one example, each of first end 2181 and second end 2182 is a separate, individual piece attached independently to edge frame 216. As will be described, second end 2182 may be coupled to a motor.

[0047] Mold tray 212 may include a temperature sensor 213. Temperature sensor 213 may be attached at mold tray at at least one of the ice forming shapes 214. Temperature sensor 213 may be operably connected with controller 164. For instance, temperature sensor 213 may monitor (e.g., sense, measure, etc.) a temperature at mold tray 212. Accordingly, temperature sensor 213 may approximate a temperature of the water contained within ice forming shapes 214 during an ice making operation or cycle.

[0048] As used herein, “temperature sensor” or the equivalent is intended to refer to any suitable type of temperature measuring system or device positioned at any suitable location for measuring the desired temperature. Thus, for example, temperature sensor 213 may each be any suitable type of temperature sensor, such as a thermistor, a thermocouple, a resistance temperature detector, a semiconductor-based integrated circuit temperature sensors, etc. In addition, temperature sensor 213 may be positioned at any suitable location and may output a signal, such as a voltage, to a controller that is proportional to and / or indicative of the temperature being measured. Although exemplary positioning of temperature sensors is described herein, it should be appreciated that appliance 100 (e.g., ice maker 180) may include any other suitable number, type, and position of temperature, humidity, and / or other sensors according to alternative embodiments.

[0049] Twist ice tray assembly 200 may include a motor 220. Motor 220 may be coupled directly to second end 2182 of the driveshaft 218. For instance, motor 220 may be configured to provide a rotational force to mold tray 212 via second end 2182 of driveshaft 218. Motor 220 may be any suitable type of motor 208 operable of driving rotation of driveshaft 218. For example, motor 220 may be an AC induction motor or a DC motor. Motor 220 may be in operative communication with controller 164. In this regard, controller 164 may selectively energize motor 220 to selectively drive rotation of mold tray 212, for example, during a harvest operation of ice maker 180.

[0050] Frame 202 may include a stopper 222. Stopper 222 may be attached to frame 202 adjacent to mold tray 212. For instance, stopper 222 may be attached to interior surface 2061 of first side frame member 206. Stopper 222 may extend inward (e.g., along the transverse direction T) from first side frame member 206. For instance, stopper 222 may extend from first side frame member 206 toward second side frame member 208. Stopper 222 may be offset from the axis of rotation of mold tray 212. For instance, stopper 222 may be positioned offset along at least one of the vertical direction V and the lateral direction L from the axis of rotation. In some instances, stopper 222 is positioned in contact with mold tray 212. In detail, when mold tray 212 is in the neutral position, stopper 222 contacts at least a portion of edge frame 216 when mold tray is in the neutral position. Stopper 222 may contact a lower or bottom surface of edge frame 216 at a first side thereof. For instance, stopper 222 may be positioned closer to rear frame member 204 (e.g., along the lateral direction L) than the axis of rotation of mold tray 212 and below (e.g., along the vertical direction V) the axis of rotation. Thus, when mold tray 212 is in the neutral position, stopper 222 may restrict a rotation of mold tray 212 about a first direction (described below).

[0051] In some instances, stopper 222 is a separate piece (e.g., from frame 202) that is removably coupled to frame 202. For example, different styles, shapes, sizes, or the like of stoppers may be attached to frame 202 based on a particular mold tray 212 attached thereto. In some embodiments, however, stopper 222 is formed integrally with frame 202. Stopper 222 may thus be adjustable with respect to frame 202. For instance, a position or location of stopper 222 may be adjusted to vary a contact point between mold tray 212 and stopper 222.

[0052] Ice maker 180 may be configured to selectively perform a harvesting operation. For instance, when water supplied to ice forming shapes 114 freezes (e.g., after a predetermined length of time), mold tray 212 may be rotated (e.g., via motor 220). Motor 220 may be a bi-directional motor such that rotation may be initiated in either the first direction (e.g., a clockwise direction) or the second direction (e.g., a counterclockwise direction). As mentioned, stopper 222 may contact an underside of mold tray 212 in the neutral position. During the harvesting operation, mold tray 212 may be rotated (e.g., in the first direction). The first direction may be referred to as a forward direction. The forward direction may be away from stopper 222 (e.g., edge frame 216 may rotate up and away from contact with stopper 222). As shown in FIG. 7, for instance, mold tray 212 may be rotated such that a portion of mold tray 212 (e.g., at edge frame 216) contacts stopper 222. The portion of mold tray 212 contacting the stopper after the rotation in the first direction may be different from the portion of mold tray 212 contacting the stopper in the neutral position. According to some embodiments, during the harvesting operation, mold tray is rotated between about 120 degrees and about 160 degrees in the forward direction.

[0053] Now that the general descriptions of an exemplary appliance have been described in detail, a method 1000 of operating an appliance (e.g., appliance 100 or ice maker 180) will be described in detail. Although the discussion below refers to the exemplary method 1000 of operating ice maker 180, one skilled in the art will appreciate that the exemplary method 1000 is applicable to any suitable domestic appliance capable of performing an ice making operation (e.g., such as a clear ice maker, a stand-alone ice maker, etc.). In exemplary embodiments, the various method steps as disclosed herein may be performed by controller 164 and / or a separate, dedicated controller. For instance, one or more steps may be stored as instructions at the controller 164 that, when executed, causes an appliance (e.g., appliance 100) or ice maker (e.g., ice maker 180) to perform operations in accordance with steps of method 1000. FIG. 8 provides a flow chart illustrating a method of operating an ice maker. In various embodiments, method 1000 provides a method for ice harvest detection and operation. Hereinafter, method 1000 will be described with reference to FIG. 8.

[0054] Method 1000 includes at 1010 initiating a first harvest routine. The first harvest routine includes operations for removing or extracting ice from an ice tray, such as described in regard to ice tray assembly 200. For instance, the first harvest routine may include operations for selectively energizing motor 220 to generate a rotational force to mold tray 212. The first harvest routine includes one or more adjustable harvest routine parameters, such as may be altered by controller 164 by adjusting voltage, current, duration, or frequency. For instance, the harvest routine parameter may include a twist angle (e.g., up to between approximately 120 degrees and approximately 160 degrees), a direction of rotation (e.g., a first direction, a second direction opposite of the first direction, clockwise, counterclockwise, forward, reverse, etc.), a quantity of twists, a frequency of twists (e.g., period of time for each twist, or period of time between twists, or both), a heat input (e.g., an increase in temperature applied to the ice tray to promote detachment of ice from the ice tray), a heat cycle (e.g., a period of time, or frequency, for which heat is applied), or combinations thereof.

[0055] Method 1000 includes at 1020 obtaining an acoustic signal during the first harvest routine. Obtaining the acoustic signal includes obtaining, via an acoustic sensor (e.g., acoustic sensor 168), sounds, noises, pressure waves, etc. during the first harvest routine.

[0056] Method 1000 includes at 1030 determining similarity between the acoustic signal and a baseline signal. However, it should be appreciated that method 1000 at 1030 may include determining dissimilarity between the acoustic signal and a baseline signal. In various embodiments, method 1000 at 1030 includes any appropriate method for signal comparison or correlation, such as, but not limited to, cross-correlation, sliding dot product, or convolution. For instance, determining similarity or dissimilarity, can include determining a relationship between the acoustic signal obtained from a present time of ice harvest operation (e.g., at step 1020) versus an acoustic signal obtained from a prior time of ice harvest operation associated with new, desired, or engineered conditions. The baseline signal includes an acoustic signal, or representation thereof, corresponding to a desired ice harvest operation and output. For instance, the baseline signal corresponds to acoustic signals generated when the ice harvest routine is performed and releases, or extracts, all of the desired ice within a desired period of time, with desired power input (or current, or voltage, etc.), or other parameters associated with a desired ice harvest routine. The desired ice harvest routine provides a baseline acoustic signal against which obtained acoustic signals in subsequent ice harvest operations (e.g., step 1020) is compared.

[0057] In some embodiments, determining similarity, or dissimilarity, includes comparing the acoustic signal and the baseline signal relative to a similarity threshold. The similarity threshold includes a quantity beyond which the compared or correlated acoustic signal and baseline signal is determined to be dissimilar. In still some embodiments, determining similarity or dissimilarity includes at 1032 determining error between the acoustic signal and the baseline signal, and at 1034 comparing the error to an error range or similarity threshold.

[0058] Method 1000 may include at 1036 determining a change in the error between the acoustic signal to the baseline signal over time. Determining the change in the error can include trending, over time, iterations of determined error (e.g., step 1030, 1032, or 1034). Method 1000 at 1036 may include comparing the determined change to a baseline or performing a rolling average, such as may determine drift from initial operation of the ice harvest routine to a present state operation of the ice harvest routine.

[0059] In various embodiments, method 1000 includes at 1040 initiating a second harvest routine if dissimilarity between the acoustic signal and the baseline signal is determined. Method 1000 at 1040 may include initiating a second harvest routine if the error range or similarity threshold is exceeded. The dissimilarity is associated with an incomplete ice harvest, such as one or more pieces of ice remaining in the mold tray (e.g., mold tray 212) after performing the first harvest routine. The second harvest routine provides an additional instance of performing the harvest routine after performing the first harvest routine. Alternatively, the second harvest routine extends operation of the first harvest routine beyond a baseline time period over which the first harvest routine operates.

[0060] In some embodiments, method 1000 includes at 1050 adjusting a harvest routine parameter if dissimilarity between the acoustic signal and the baseline signal is determined. Adjusting the harvest routine parameter may include adjusting heat input, heat cycle, twist angle, or direction of rotation at the mold tray, such as described herein. Method 1000 at 1050 may include adjusting the harvest routine parameter for operation during the second harvest routine. As such, method 1000 at 1040 may include initiating or performing the second harvest routine different from the first harvest routine based on the one or more adjusted harvest routine parameters.

[0061] In still some embodiments, method 1000 includes at 1012 determining an elapsed time between initiating the first harvest routine and obtaining an acoustic peak associated with ice harvest during the first harvest routine. For instance, from time of initiation of the first harvest routine (e.g., t0), or furthermore, initiation acquisition of the acoustic signal, a time at which an acoustic peak in the acoustic signal associated with ice harvest is obtained (e.g., tpeak1, in which tpeak1>t0). One or more acoustic peaks is associated with ice detachment and release from the mold tray (e.g., peak2, peak3, . . . peakn, in which “n” correlates to a quantity of ice pieces at the mold tray).

[0062] Method 1000 may include at 1014 determining similarity, or dissimilarity, between the elapsed time and a baseline initiation elapsed time. For instance, similarity, or dissimilarity, between tpeak1 and tpeakbaseline1 may be determined, in which tpeakbaseline1 is a time associated with the baseline acoustic signal at which a first ice harvest peak is obtained. Beyond an error range or similarity threshold associated with the timing of the peaks from initiation (e.g., t0), dissimilarity is determined. Method 1000 may include adjusting a harvest routine parameter if dissimilarity is determined (e.g., step 1050). In some embodiments, the harvest routine parameter associated with the first harvest routine, or during operation of the first harvest routine, may be adjusted. In some embodiments, method 1000 includes at 1016 initiating the second harvest routine if dissimilarity between the elapsed time and the baseline initiation elapsed time is determined.

[0063] In still some embodiments, method 1000 includes at 1013 determining an elapsed time between termination of the first harvest routine and obtaining an acoustic peak associated with ice harvest during the first harvest routine. For instance, from time of termination of the first harvest routine (e.g., tend), a time at which an acoustic peak in the acoustic signal associated with ice harvest is obtained (e.g., tpeakn, tpeakn-1, . . . tpeakn-x, in which “x” is a difference in total “n” and a quantity of ice harvested prior to tpeakn-x).

[0064] Method 1000 may include at 1015 determining similarity, or dissimilarity, between the elapsed time and a baseline termination elapsed time. For instance, similarity, or dissimilarity, between tpeak1 and tpeakbaseline-end may be determined in which tpeakbaseline=end is a time associated with the baseline acoustic signal at which a last ice harvest peak is obtained. Beyond an error range or similarity threshold associated with the timing of the peaks, dissimilarity is determined. Method 1000 may include adjusting a harvest routine parameter if dissimilarity is determined (e.g., step 1050). In some embodiments, the harvest routine parameter associated with a future iteration of the first harvest routine, or the second harvest routine, may be adjusted. In some embodiments, method 1000 includes at 1017 initiating the second harvest routine if dissimilarity between the elapsed time and the baseline termination elapsed time is determined.

[0065] In an exemplary operation of method 1000 and appliance 100, an ice harvest mode (e.g., step 1010) is initiated and one or more microphones or acoustic sensor(s) (e.g., acoustic sensor 168) enters a harvest monitoring mode in which acoustic signals are obtained via the acoustic sensor (e.g., step 1020). Method 1000 and appliance 100 determines similarity, or dissimilarity, of the obtained acoustic signals to one or more baseline signals. If similarity between the obtained acoustic signal and the baseline signal is determined, the first harvest routine may initiate and terminate without changes to harvest routine parameter or without initiating the performing the second harvest routine. If dissimilarity is determined, the second harvest routine is performed. In some embodiments, the second harvest routine may include re-performing the first harvest routine. In still some embodiments, the second harvest routine may include adjusting one or more harvest routine parameters and performing the harvest routine to complete extraction of ice from the mold tray. In still some embodiments, method 1000 may include generating and transmitting a communication signal indicative with performing a maintenance or repair of the ice tray assembly or appliance.

[0066] In some embodiments, a machine learning routine may be utilized to determine trends, deviations, correlations, or comparisons between baseline and acquired signals. In still some embodiments, the machine learning routine may be utilized to identify one or more harvest routine parameters, or combinations thereof, for adjustment based on the acquired signals or comparisons to baseline.

[0067] Sizes and quantities of ice shapes, or ranges thereof, provided herein may facilitate obtaining and comparing acoustic signals such as provided in regard to method 1000. For instance, sizes and quantities of ice shapes provided herein may correspond to craft ice makers, such as may be configured to generate “clear ice” having desired thresholds or ranges of total dissolved solids (TDS), or generate various desired ice shapes. Craft ice makers may contrast with large-quantity ice makers, such as configured to generate quantities of ice greater than ranges or thresholds provided herein, or configured to generate sizes less than ranges or threshold provided herein.

[0068] Combinations of acoustic sensor associated with a display or control panel and sizes or quantities of ice shapes provided herein may facilitate obtaining and comparing acoustic signals such as provided in regard to method 1000. For instance, acoustic sensor 168 may be configured to obtain user voice commands or other acoustic signals, and furthermore, obtain acoustic signals such as described herein.

[0069] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

1. An ice maker appliance, the ice maker appliance comprising:a frame;a mold tray selectively supported by the frame, the mold tray comprising one or more ice forming shapes defined therein;a motor coupled to the frame and operably coupled with the mold tray to selectively rotate the mold tray with respect to the frame in each of a first direction and a second direction;an acoustic sensor; anda controller operably coupled with the motor and the acoustic sensor, the controller configured to perform an operation, the operation comprising:initiating a first harvest routine;obtaining an acoustic signal during the first harvest routine;determining similarity or dissimilarity between the acoustic signal and a baseline signal; andinitiating a second harvest routine if dissimilarity between the acoustic signal and the baseline signal is determined.

2. The ice maker appliance of claim 1, the operations comprising:adjusting a harvest routine parameter if dissimilarity between the acoustic signal and the baseline signal is determined.

3. The ice maker appliance of claim 2, wherein adjusting the harvest routine parameter comprises adjusting heat input, heat cycle, twist angle, or direction of rotation at the mold tray.

4. The ice maker appliance of claim 1, wherein determining similarity or dissimilarity comprises determining error between the acoustic signal to the baseline signal and comparing the error to an error range.

5. The ice maker appliance of claim 4, the operations comprising:determining a change in the error between the acoustic signal and the baseline signal over time.

6. The ice maker appliance of claim 1, the operations comprising:determining an elapsed time between initiating the first harvest routine and obtaining an acoustic peak associated with ice harvest during the first harvest routine;determining similarity or dissimilarity between the elapsed time and a baseline initiation elapsed time; andinitiating the second harvest routine if dissimilarity between the elapsed time and the baseline initiation elapsed time is determined.

7. The ice maker appliance of claim 1, the operations comprising:determining an elapsed time between termination of the first harvest routine and obtaining an acoustic peak associated with ice harvest during the first harvest routine; anddetermining similarity or dissimilarity between the elapsed time and a baseline termination elapsed time; andinitiating the second harvest routine if dissimilarity between the elapsed time and the baseline termination elapsed time is determined.

8. The ice maker appliance of claim 1, wherein the mold tray is configured to receive between approximately 15 cubic centimeters of water and approximately 100 cubic centimeters of water per ice shape.

9. The ice maker appliance of claim 8, wherein the mold tray is configured to form up to seven ice shapes per harvest.

10. A refrigerator appliance, the refrigerator appliance comprising a freezer compartment in which an ice maker appliance is provided, the ice maker appliance defining a vertical direction, a lateral direction, and a transverse direction, the ice maker appliance comprising:a frame and a mold tray selectively supported by the frame, the mold tray comprising one or more ice forming shapes defined therein;a motor coupled to the frame and operably coupled with the mold tray to selectively rotate the mold tray with respect to the frame in each of a first direction and a second direction;an acoustic sensor; anda controller operably coupled with the motor and the acoustic sensor, the controller configured to perform an operation, the operation comprising:initiating a first harvest routine;obtaining an acoustic signal during the first harvest routine;determining similarity or dissimilarity between the acoustic signal and a baseline signal; andinitiating a second harvest routine if dissimilarity between the acoustic signal and the baseline signal is determined.

11. The refrigerator appliance of claim 10, comprising:a control panel comprising the controller and the acoustic sensor.

12. The refrigerator appliance of claim 10, comprising:a dispensing assembly comprising an ice dispenser, the ice dispenser comprising a discharging outlet for outputting ice bodies from the ice maker.

13. The refrigerator appliance of claim 10, the operations comprising:adjusting a harvest routine parameter if dissimilarity between the acoustic signal and the baseline signal is determined.

14. The refrigerator appliance of claim 13, wherein adjusting the harvest routine parameter comprises adjusting heat input, heat cycle, twist angle, or direction of rotation at the mold tray.

15. The refrigerator appliance of claim 10, wherein determining similarity or dissimilarity comprises determining error between the acoustic signal to the baseline signal and comparing the error to an error range.

16. The refrigerator appliance of claim 15, the operations comprising:determining a change in the error between the acoustic signal to the baseline signal over time.

17. The refrigerator appliance of claim 10, the operations comprising:determining an elapsed time between initiating the first harvest routine and obtaining the acoustic signal during the first harvest routine;determining similarity or dissimilarity between the elapsed time and a baseline initiation elapsed time; andinitiating the second harvest routine if dissimilarity between the elapsed time and the baseline initiation elapsed time is determined.

18. The refrigerator appliance of claim 10, the operations comprising:determining an elapsed time between termination of the first harvest routine and obtaining the acoustic signal during the first harvest routine; anddetermining similarity or dissimilarity between the elapsed time and a baseline termination elapsed time; andinitiating the second harvest routine if dissimilarity between the elapsed time and the baseline termination elapsed time is determined.

19. The refrigerator appliance of claim 10, wherein the mold tray is configured to receive between approximately 15 cubic centimeters of water and approximately 100 cubic centimeters of water per ice shape.

20. The refrigerator appliance of claim 19, wherein the mold tray is configured to form up to seven ice shapes per harvest.

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