Method of operating a refrigerator appliance

Abstract

A refrigerator includes a damper assembly movable between positions. Additionally, the refrigerator includes a motor coupled to the assembly and operable to move the assembly between positions. Furthermore, the refrigerator includes a heating element to apply heat to the assembly. Moreover, the refrigerator includes a sensing device configured to generate data indicative of an electrical current associated with a torque applied by the motor. Additionally, the refrigerator includes a controller configured to receive the generated data from the sensing device. Furthermore, the controller is configured to monitor a magnitude of the electrical current occurring during a predetermined length of time based on the received generated data. Moreover, the controller is configured to determine a status of the assembly based on the monitored magnitude. Additionally, the controller is configured to operate at least one of the heating element or the motor based on the determined status of the assembly.

Description

FIELD

[0001] The present subject matter relates generally to refrigerator appliances and to methods of operating refrigerator appliances.BACKGROUND

[0002] Refrigerator appliances generally include a cabinet that defines chilled chambers for receipt of food items for storage. Insulated, sealing doors are provided for selectively enclosing the chilled food storage chambers.

[0003] Refrigerator appliances typically utilize sealed systems for cooling the chilled chambers. A typical sealed system includes an evaporator and a fan. However, moisture created when utilizing the sealed systems may sometimes undesirably freeze on components of the refrigerator and cause disruption of component operation.

[0004] Accordingly, a refrigerator appliance including features for detection and defrosting of components with disrupted operation would be beneficial.BRIEF DESCRIPTION

[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] In one exemplary embodiment, a method of operating a refrigerator appliance is provided. The refrigerator appliance includes a damper assembly. The moveable damper assembly is configured to move between a plurality of positions. Additionally, the refrigerator appliance includes a damper motor. The damper motor is operable to move the damper assembly between the plurality of positions. Furthermore, the refrigerator appliance includes a heating element. The heating element is configured to apply heat to the damper assembly. The method includes receiving, with a controller, sensing device data from a sensing device indicative of an electrical current associated with a torque applied by the damper motor. Moreover, the method includes monitoring, with the controller, a magnitude of the electrical current occurring during a predetermined length of time based on the received sensing device data. Additionally, the method includes determining, with the controller, a status of the damper assembly based on the monitored magnitude of the electrical current. Furthermore, the method includes operating, with the controller, at least one of the heating element or the damper motor based on the determined status of the damper assembly.

[0007] In another exemplary embodiment, a refrigerator appliance is provided. The refrigerator appliance includes a damper assembly. The damper assembly is configured to move between a plurality of positions. Additionally, the refrigerator appliance includes a damper motor. The damper motor is coupled to the movable damper assembly. Furthermore, the damper motor is operable to move the damper assembly between the plurality of positions. Moreover, the refrigerator appliance includes a heating element. The heating element is configured to apply heat to the damper assembly. Additionally, the refrigerator appliance includes a sensing device. The sensing device is configured to generate data indicative of an electrical current associated with a torque applied by the damper motor. Moreover, the refrigerator appliance includes a controller. The controller is operatively coupled to the sensing device, the damper motor, and the heating element. The controller is configured to receive the generated data from the sensing device. Additionally, the controller is configured to monitor a magnitude of the electrical current occurring during a predetermined length of time based on the received generated data. Furthermore, the controller is configured to determine a status of the damper assembly based on the monitored magnitude of the electrical current. Moreover, the controller is configured to operate at least one of the heating element or the damper motor based on the determined status of the damper assembly.

[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. 1 provides a front perspective view of a refrigerator appliance according to example embodiments of the present disclosure.

[0011] FIG. 2 provides a front perspective view of the example refrigerator appliance of FIG. 1, wherein the doors are shown in an open position.

[0012] FIG. 3 provides a schematic front section view of the exemplary refrigerator appliance of FIG. 1.

[0013] FIG. 4 provides a perspective view of an example damper assembly for a refrigerator appliance according to example embodiments of the present disclosure.

[0014] FIG. 5 provides a flowchart illustrating an exemplary method of operating a refrigerator appliance according to one or more exemplary embodiments of the present subject matter.

[0015] FIG. 6 illustrates a diagrammatic view of an electrical current magnitude plotted as a function of time according to one or more exemplary embodiments of the present subject matter.

[0016] 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

[0017] 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 or spirit 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.

[0018] 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”). The term “at least one of” in the context of, e.g., “at least one of A, B, and C” refers to only A, only B, only C, or any combination of A, B, and C. 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.

[0019] Terms such as “inner” and “outer” refer to relative directions with respect to the interior and exterior of the refrigerator appliance, and in particular the food storage chamber(s) defined therein. For example, “inner” or “inward” refers to the direction towards the interior of the refrigerator appliance. Terms such as “left,”“right,”“front,”“back,”“top,” or “bottom” are used with reference to the perspective of a user accessing the refrigerator appliance. For example, a user stands in front of the refrigerator to open the doors and reaches into the food storage chamber(s) to access items therein.

[0020] 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.

[0021] 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.

[0022] FIG. 1 provides a front, perspective view of a refrigerator appliance 100 according to an example embodiment of the present disclosure. FIG. 2 provides a front, perspective view of refrigerator appliance 100 with a refrigerator door 110 and a freezer door 112 of refrigerator appliance 100 shown in an open position to reveal a fresh food chamber 114 and a freezer chamber 116 of refrigerator appliance 100. Refrigerator appliance 100 defines a vertical direction V, a lateral direction L, and a transverse direction. The vertical direction V, lateral direction L, and transverse direction are mutually perpendicular and form an orthogonal direction system. Refrigerator appliance 100 extends between an upper portion 102 and a lower portion 104 along the vertical direction V. Refrigerator appliance 100 also extends between a first (right) side portion 106 and a second (left) side portion 108, e.g., along the lateral direction L.

[0023] Refrigerator appliance 100 includes a cabinet 120 that defines chilled chambers for receipt of food items for storage. In some embodiments, refrigerator appliance 100 defines fresh food chamber 114 at first side portion 106 of refrigerator appliance 100 and a freezer chamber 116 arranged next to fresh food chamber 114 at second side portion 108 of refrigerator appliance 100. As such, the illustrated refrigerator appliance 100 is generally referred to as a side-by-side style refrigerator appliance. However, using the teachings disclosed herein, one of skill in the art will understand that the present subject matter may be used with other types of refrigerator appliances (e.g., bottom mount or top mount style, quad door refrigerator appliances, and / or other similar refrigerator appliances) or a freezer appliance as well. Consequently, the description set forth herein is for illustrative purposes only and is not intended to be limiting in any aspect to any particular household appliance, such as the present subject matter is not limited to any particular refrigerator chamber configuration. Accordingly, it should be recognized that aspects of the present disclosure may be used with a variety of refrigerator appliances and / or freezer appliances.

[0024] In various embodiments, fresh food chamber 114 may be operable within a temperature range above the freezing point of water and below room temperature, such as between approximately thirty-three degrees Fahrenheit (33° F.) and approximately sixty degrees Fahrenheit (60° F.). Also, by way of example, the freezer chamber 116 may be operable within a temperature range including temperatures below the freezing point of water, e.g., less than thirty-two degrees Fahrenheit (32° F.), such as between approximately thirty degrees Fahrenheit (30° F.) and approximately zero degrees Fahrenheit (0° F.). For example, a temperature of the fresh food chamber 114 may be about forty degrees Fahrenheit (40° F.) or about forty-five degrees Fahrenheit (45° F.) and a temperature of the freezer chamber 116 may be about fifteen degrees Fahrenheit (15° F.) or about twenty-five degrees Fahrenheit (25° F.).

[0025] However, in some other embodiments, fresh food chamber 114 may be a first convertible chilled chamber 114 and / or the freezer chamber 116 may be a second convertible chilled chamber 116. As such, the chilled chambers 114 and / or 116 may be “chilled” in that the chilled chambers 114 and / or 116 are operable at temperatures between approximately zero degrees Fahrenheit (0° F.) and approximately sixty degrees Fahrenheit (60° F.). For example, one or both chilled chambers 114 and 116 may be adjusted between a “freezer” mode in which the corresponding chilled chamber 114 and / or 116 may be operable at freezing temperatures, e.g., between approximately zero degrees Fahrenheit (0° F.) and approximately thirty degrees Fahrenheit (30° F.), and a “refrigerator” mode in which the corresponding chilled chamber 114 and / or 116 may be operable at fresh food temperatures, e.g., between approximately thirty-three degrees Fahrenheit (33° F.) and approximately sixty degrees Fahrenheit (60° F.).

[0026] Refrigerator door 110 is rotatably hinged to an edge of cabinet 120 for accessing fresh food chamber 114. Similarly, freezer door 112 is rotatably hinged to an edge of cabinet 120 for accessing freezer chamber 116. Refrigerator door 110 and freezer door 112 may rotate between an open position (shown in FIG. 2) and a closed position (shown in FIG. 1) in order to permit selective access to fresh food chamber 114 and freezer chamber 116, respectively.

[0027] As shown in FIG. 2, in some embodiments, various storage components may be mounted within the fresh food chamber 114 to facilitate storage of food items therein. In particular, the storage components may include storage bins 117, drawers 118, and shelves 121 that may be mounted within the fresh food chamber 114. As such, the storage bins 117, drawers 118, and shelves 121 are configured for receipt of food items, for example, beverages or solid food items, and may assist with organizing such food items. As an example, the drawers 118 may receive fresh food items, for example, vegetables, fruits, or cheeses, and increase the useful life of such fresh food items.

[0028] In some embodiments, the refrigerator appliance 100 may also include a dispensing assembly 130 for dispensing liquid water and / or ice. As shown in FIG. 1, dispensing assembly 130 includes a dispenser 132 positioned on or mounted to an exterior portion of refrigerator appliance 100, e.g., on freezer door 112. Dispenser 132 includes a discharging outlet 134 for accessing ice and water. Any suitable actuator may be used to operate dispenser 132. For example, dispenser 132 may include a paddle or button for operating dispenser. Additionally, or alternatively, a sensor 136, such as an ultrasonic sensor, may be mounted below or beneath discharging outlet 134 for operating dispenser 132, e.g., during an auto-fill process of refrigerator appliance 100. A user interface panel 138 is provided for controlling the mode of operation. In some such embodiments, user interface panel 138 includes a water dispensing button (not labeled) and an ice-dispensing button (not labeled) for selecting a desired mode of operation such as crushed or non-crushed ice.

[0029] As shown, discharging outlet 134 and sensor 136 are an external part of dispensing assembly 130. One or both of discharging outlet 134 and sensor 136 are mounted in a dispenser recess 140 defined in an outside surface of freezer door 112. In some embodiments, dispenser recess 140 is positioned at a predetermined elevation convenient for a user to access ice or water and enabling the user to access ice without the need to bend-over and without the need to access freezer chamber 116. In the illustrated embodiment of FIG. 1, dispenser recess 140 is positioned at a level that approximates the chest level of a user.

[0030] As shown in FIG. 2, certain components of dispensing assembly 130 are illustrated. Dispensing assembly 130 includes a housing 142 mounted, as an example, on or within freezer door 112. As freezer door 112 opens and closes, housing 142 may be selectively positioned within and out of freezer chamber 116, respectively. Generally, housing 142 is constructed and arranged to facilitate production and storage of ice. More particularly, housing 142 includes or contains an ice maker for creating ice and / or feeding the same to a container 144. In some such embodiments, container 144 is mounted on freezer door 112, e.g., below or beneath housing 142. As illustrated in FIG. 2, container 144 is placed at a vertical position on freezer door 112 that will allow for the receipt of ice from a discharge opening of container 144 and into an entrance of container 144. As freezer door 112 is closed or opened, housing 142 and container 144 may be moved together in and out of freezer chamber 116.

[0031] Refrigerator appliance 100 further includes a controller 150. Operation of the refrigerator appliance 100 is regulated by controller 150 that is operatively coupled to user interface panel 138 and / or sensor 136. In some exemplary embodiments, user interface panel 138 may represent a general purpose I / O (“GPIO”) device or functional block. In some exemplary embodiments, user interface panel 138 may include input components, such as one or more of a variety of electrical, mechanical or electro-mechanical input devices including rotary dials, push buttons, touch pads, and touch screens. User interface panel 138 may be communicatively coupled with controller 150 via one or more signal lines or shared communication busses. User interface panel 138 provides selections for user manipulation of the operation of refrigerator appliance 100, e.g., whereby a user may provide one or more set point temperatures for the various chilled chambers 114 and 116. In response to user manipulation of the user interface panel 138, controller 150 operates various components of refrigerator appliance 100. For example, controller 150 is operatively coupled or in communication with various airflow components, e.g., dampers and fans, as discussed below. Controller 150 may also be communicatively coupled with a variety of sensors, such as, for example, chamber temperature sensors or ambient temperature sensors. Such chamber temperature sensors and / or ambient temperature sensors may be or include thermistors, thermocouples, or any other suitable temperature sensor. Controller 150 may receive signals from these temperature sensors that correspond to the temperature of an atmosphere or air within their respective locations.

[0032] As used herein, the terms “processing device,”“computing device,”“controller,” or the like may generally refer to any suitable processing device, such as a general or special purpose microprocessor, a microcontroller, an integrated circuit, an application specific integrated circuit (ASIC), a digital signal processor (DSP), a field-programmable gate array (FPGA), a logic device, one or more central processing units (CPUs), a graphics processing units (GPUs), processing units performing other specialized calculations, semiconductor devices, etc. In addition, these “controllers” are not necessarily restricted to a single element but may include any suitable number, type, and configuration of processing devices integrated in any suitable manner to facilitate appliance operation. Alternatively, controller 150 may be constructed without using a microprocessor, e.g., using a combination of discrete analog and / or digital logic circuitry (such as switches, amplifiers, integrators, comparators, flip-flops, AND / OR gates, and the like) to perform control functionality instead of relying upon software.

[0033] Controller 150 may include, or be associated with, one or more memory elements or non-transitory computer-readable storage mediums, such as RAM, ROM, EEPROM, EPROM, flash memory devices, magnetic disks, or other suitable memory devices (including combinations thereof). These memory devices may be a separate component from the processor or may be included onboard within the processor. In addition, these memory devices may store information and / or data accessible by the one or more processors, including instructions that may be executed by the one or more processors. It should be appreciated that the instructions may be software written in any suitable programming language or may be implemented in hardware. Additionally, or alternatively, the instructions may be executed logically and / or virtually using separate threads on one or more processors.

[0034] For example, controller 150 may be operable to execute programming instructions or micro-control code associated with an operating cycle of refrigerator appliance 100. In this regard, the instructions may be software or any set of instructions that when executed by the processing device, cause the processing device to perform operations, such as running one or more software applications, displaying a user interface, receiving user input, processing user input, etc. Moreover, it should be noted that controller 150 as disclosed herein is capable of and may be operable to perform any methods, method steps, or portions of methods as disclosed herein. For example, in some embodiments, methods disclosed herein may be embodied in programming instructions stored in the memory and executed by controller 150.

[0035] The memory devices may also store data that may be retrieved, manipulated, created, or stored by the one or more processors or portions of controller 150. The data may include, for instance, data to facilitate performance of methods described herein. The data may be stored locally (e.g., on controller 150) in one or more databases and / or may be split up so that the data is stored in multiple locations. In addition, or alternatively, the one or more database(s) may be connected to controller 150 through any suitable network(s), such as through a high bandwidth local area network (LAN) or wide area network (WAN). In this regard, for example, controller 150 may further include a communication module or interface that may be used to communicate with one or more other component(s) of refrigerator appliance 100, controller 150, an external appliance controller, or any other suitable device, e.g., via any suitable communication lines or network(s) and using any suitable communication protocol. The communication interface may include any suitable components for interfacing with one or more network(s), including for example, transmitters, receivers, ports, controllers, antennas, or other suitable components.

[0036] Referring now to FIG. 3 generally, the refrigerator appliance 100 may include an insulated mullion 170 between the fresh food chamber 114 and the freezer chamber 116. For example, the freezer chamber 116 may be spaced apart from the fresh food chamber 114 and separated from the fresh food chamber 114 by the insulated mullion 170, such that the insulated mullion 170 partially defines each of the fresh food chamber 114 and the freezer chamber 116, and where the thermal insulation of the insulated mullion 170 promotes operation of the fresh food chamber 114 and the freezer chamber 116 at distinct temperatures, as is understood by those of ordinary skill in the art.

[0037] In some embodiments, the refrigerator appliance 100 may further include a bridge chamber 200. The bridge chamber 200 may be partially, e.g., on at least one side, defined by the insulated mullion 170. The bridge chamber 200 may further be defined by one or more additional insulated partitions 202, such that the bridge chamber 200 may be operated at a distinct temperature from the operating temperature of one or both of the fresh food chamber 114 and freezer chamber 116. The bridge chamber 200 may include a first aperture 204 in fluid communication with the fresh food chamber 114 and a second aperture 208 in fluid communication with the freezer chamber 116. The refrigerator appliance 100 may further include one or more movable damper assemblies, such as two rotatable damper assemblies that each include a damper 212, e.g., a first rotatable damper 214 positioned at the first aperture 204 and a second rotatable damper 216 positioned at the second aperture 208. The configuration of a damper assembly that includes the damper 212 will be described below. The movable damper assemblies may each be movable, e.g., rotatable, between a plurality of positions, such as between a closed position, a fully open position, and a plurality of partially open positions. For example, the first rotatable damper 214 may be movable between a first position, e.g., for a fresh food mode, and a second position, e.g., for a freezer mode, while the second rotatable damper 216 may be movable between a first position, e.g., for the freezer mode, and the second position, e.g., for the fresh food mode. As such, the second rotatable damper 216 may be in a closed position relative to the freezer chamber 116 while in the second position and the first rotatable damper 214 may be in a fully open position relative to the fresh food chamber while in the first position. Likewise, the first rotatable damper 214 may be in a closed position relative to the fresh food chamber 114 while in the second position and the second rotatable damper 216 may be in a fully open position relative to the freezer chamber 116 while in the first position.

[0038] The refrigerator appliance 100 may further include two damper motors 213, e.g., a stepper motor, each coupled to one of the rotatable dampers 214 or 216. The damper motors 213 may operate to move the rotatable dampers 214, 216 between the plurality of positions. Controller 150 may be operatively or communicatively coupled to damper motors 213. As such, controller 150 may operate or activate the damper motors 213 to move rotatable dampers 214, 216 between the plurality of positions.

[0039] Additionally, refrigerator appliance 100 may further include one or more heating elements, such as heaters 215. The heaters 215 may be any suitable type of heater, such as radiation heaters, convection heaters, and / or the like. The heaters 215 may be positioned proximate or adjacent to the rotatable dampers 214, 216 and / or damper motors 213 for applying heat to the rotatable dampers 214, 216 and / or damper motors 213 during operation / activation of the heaters 215. As will be described below, the heaters 215 may be part of, e.g., positioned on / attached to, a damper 212, such as the first rotatable damper 214 and / or the second rotatable damper 216. As such, the heaters 215 may melt frozen moisture on the rotatable dampers 214, 216 and / or damper motors 213. Controller 150 may be operatively or communicatively coupled to the heaters 215. As such, controller 150 may operate or activate the heaters 215 to apply heat to the rotatable dampers 214, 216 and / or damper motors 213. As will be described below, in some embodiments, controller 150 may operate the heaters 215 based on a determined status of the damper assembly, e.g., a damper fault status.

[0040] Furthermore, an electrical current sensing device 217 may be provided in operative association with the damper motors 213. To move the rotatable dampers 214, 216 between the plurality of positions, each of the damper motors 213 apply a torque to one of the rotatable dampers 214 or 216. The sensing device 217 may generate data indicative of an electrical current associated with the torque applied by one or both of the damper motors 213. For example, the generated data may be current values, power values, and / or the like associated with the torque applied by one of the damper motors 213. In some embodiments, sensing device 217 may be a current sensing resistor. However, it should be appreciated that sensing device 217 may be any suitable current sensing device, such as a Hall effect sensor, a current transformer (CT), and / or the like. Moreover, controller 150 may be operatively or communicatively coupled to sensing device 217. In this respect, as will be described below, controller 150 may monitor a magnitude of the electrical current, such as during operation of the damper motors 213. The monitored magnitude of the electrical current may be utilized to determine the status of the damper assembly, e.g., a blocked damper status.

[0041] The refrigerator appliance 100 may further include a sealed cooling system, as is generally understood by those of ordinary skill in the art. For example, the sealed cooling system may include a sealed refrigerant loop with heat exchangers coupled in line with the sealed refrigerant loop (e.g., for series flow through the sealed refrigerant loop and successively through the heat exchangers). The heat exchangers may include a condenser (not shown), in which vapor phase refrigerant condenses to liquid phase, thereby releasing heat to the external environment at the condenser, and an evaporator 220, in which liquid phase refrigerant absorbs heat from the external environment (e.g., air around the evaporator 220) and thereby vaporizes, such that a flow of chilled air may be generated at and around the evaporator 220. A fan 222 may be positioned proximate to the evaporator 220, such that the fan 222 is sufficiently close to the evaporator 220 to urge the chilled air generated at the evaporator 220 to or towards one of the chilled chambers (fresh food chamber 114 and freezer chamber 116) of the refrigerator appliance 100.

[0042] In particular, the evaporator 220 and the fan 222 may be positioned in the bridge chamber 200, such that the flow of chilled air urged by the fan 222 may be directed from the bridge chamber 200 to one or the other of the fresh food chamber 114 and the freezer chamber 116. For example, the flow of chilled air from the bridge chamber 200 (urged by fan 222) may be obstructed from one of the chambers and directed to the other of the chambers by the rotatable dampers 214, 216. As mentioned above, the rotatable dampers 214, 216 may be movable between first and second positions, such as the first rotatable damper 214 may obstruct the first aperture 204 in the second position (not shown) and the second rotatable damper 216 may obstruct the second aperture 208 in the second position (FIG. 3). Thus, the flow of chilled air between the bridge chamber 200 and the freezer chamber 116 may be obstructed while the second rotatable damper 216 is in the second position (FIG. 3) and the flow of chilled air from the bridge chamber 200 may be directed into the fresh food chamber 114 while the first rotatable damper 214 is in the first position (FIG. 3). Similarly, the flow of chilled air between the bridge chamber 200 and the fresh food chamber 114 may be obstructed while the first rotatable damper 214 is in the second position (not shown) and the flow of chilled air from the bridge chamber 200 may be directed into the freezer chamber 116 while the second rotatable damper 216 is in the first position (not shown).

[0043] In at least some embodiments, the evaporator 220 in the bridge chamber 200 may be the only evaporator 220 in the sealed cooling system, such as the evaporator 220 in the bridge chamber 200 may be the only evaporator of the refrigerator appliance 100. Thus, for example, the rotatable dampers 214, 216 may provide selective cooling to one or the other of the fresh food chamber 114 and the freezer chamber 116, such that the single evaporator 220 for the entire refrigerator appliance 100 may provide cooling to both chilled chambers 114 and 116.

[0044] In at least some embodiments, one or both rotatable dampers 214, 216 may also be movable to one or more intermediate or partially open positions between the first position and the second position, such that chilled air from the bridge chamber 200 may be directed to both chilled chambers 114 and 116 at the same time, such as in a cool down mode. For example, the cool down mode may be implemented when the refrigerator appliance is first commissioned, after a power outage, or in other cases when a temperature in each chilled chamber 114 and 116 (such as may be measured by chamber temperature sensor(s), as described above) is significantly greater than a respective set temperature or target temperature for each chilled chamber 114 and 116.

[0045] In some embodiments, the refrigerator appliance 100, e.g., the sealed cooling system thereof, may further include a variable speed compressor 224 (FIG. 3) coupled to the evaporator 220. The controller 150 may be in operative communication with the variable speed compressor 224, such as to operate the variable speed compressor 224 at a plurality of speeds within an operating range of the variable speed compressor 224. The operating speed of the variable speed compressor 224 may control a flow rate of liquid phase refrigerant to the evaporator 220 and thus control the rate of cooling provided by the sealed cooling system. In such embodiments, the controller 150 may be configured to operate the variable speed compressor 224 at a first speed when the first rotatable damper 214 is in the first position and the second rotatable damper 216 is in the second position and to operate the variable speed compressor 224 at a second speed different from the first speed when the first rotatable damper 214 is in the second position and the second rotatable damper 216 is in the first position. For example, the variable speed compressor 224 may be operated at a higher rate to provide increased cooling when in freezer mode (e.g., when the first rotatable damper 214 is in the second position and the second rotatable damper 216 is in the first position) and may be operated at a lower rate to provide increased efficiency when in fresh food mode (e.g., when the first rotatable damper 214 is in the first position and the second rotatable damper 216 is in the second position).

[0046] Referring now to FIG. 4, a perspective view of a damper assembly is provided, such as one of the damper assemblies described above with respect to FIG. 3. As illustrated, the damper assembly includes a damper 212. Additionally, the damper assembly may include a damper housing 230 within which the damper 212 is positioned. The damper 212, which may be the first rotatable damper 214 or the second rotatable damper 216, may be rotatably coupled to one or more interior surfaces 232 of the damper housing 230. As such, the damper 212 may be rotatable about an axis A between the closed position and the fully open position as described above. Furthermore, an air flow passage (as indicated by arrows 234) may be defined through the damper housing 230 as shown in FIG. 4. The damper housing 230 may be positioned within the bridge chamber 200 (FIG. 3) such that the air flow passage 234 is aligned with one of the first aperture 204 or the second aperture 208 of the bridge chamber 200. In this respect, air may flow between an interior of the damper housing 230, the bridge chamber 200, and one of the fresh food chamber 114 or the freezer chamber 116 while the damper 212 is rotated to the fully open position or one of a plurality of partially open positions (FIG. 4). When the damper 212 is rotated to the closed position, the damper 212 seals a damper housing aperture 236 of the damper housing 230, effectively blocking the air flow passage 234 and, thus, the flow of air between the corresponding compartment, e.g., the fresh food chamber 114 or the freezer chamber 116, and the bridge chamber 200 and the interior of the damper housing 230.

[0047] Moreover, as shown in FIG. 4, two of the heaters 215 briefly described above are positioned proximate / adjacent to and attached to the damper 212. Specifically, a first coil heater 238 may be positioned on a portion of the damper housing 230 within the interior of the damper housing 230. The first coil heater 238 may be positioned adjacent to the damper housing aperture 236 such that the first coil heater 238 applies greater heat to the damper 212 while the damper 212 is in the closed position than while the damper 212 is in the fully open position or in one of the partially open positions. When activated, an electrical current may pass through a coil of the first coil heater 238. The coil of the first coil heater 238 may include an electrical resistance that resists the flow of the electrical current through the coil, thus generating heat that radiates from the coil. Additionally, a second coil heater 239 may be attached to the damper 212, e.g., positioned within an interior of the damper 212 as shown in FIG. 4. When activated, an electrical current may pass through a coil of the second coil heater 239. The coil of the second coil heater 239 may include an electrical resistance that resists the flow of the electrical current through the coil, thus generating heat that radiates from the coil.

[0048] Turning now to FIG. 5, embodiments of the present disclosure may also include methods of operating a refrigerator appliance, such as the exemplary method 500. Such methods may be usable with any suitable refrigerator appliance and / or freezer appliance, such as but not limited to the exemplary refrigerator appliance 100 described hereinabove. For example, the methods may be usable with top mount or bottom mount refrigerator appliance, a quad door refrigerator appliance, and / or other refrigerator appliances and / or freezer appliances. Furthermore, the methods may be usable with a variety of refrigerator appliances and / or freezer appliances having different numbers, sizes, and / or types of dampers. Additionally, the methods may be usable with a variety of refrigerator appliances and / freezer appliances with two or more chilled chambers, such as three chilled chambers.

[0049] As illustrated in FIG. 5, the method 500 includes activating a damper motor, whereby torque is applied to a damper assembly to move the damper assembly, e.g., as indicated at (502) in FIG. 5. Specifically, controller 150 may activate one of damper motors 213, whereby the damper motor 213 applies torque to one of the dampers 212, e.g., the first rotatable damper 214 or the second rotatable damper 216, to move damper 212 between the plurality of positions, e.g., to the first position described above, such as during cooling operations of the refrigerator appliance 100. However, in some embodiments, the damper motor 213 may be activated during an overdrive operation of the damper assembly to verify that the damper 212 is either in a closed position or a fully open position. As such, it should be appreciated that the damper 212 may sometimes have limited or no movement when torque is applied by the damper motor 213, such as during an overdrive operation and / or when something else is blocking / preventing the damper 212 from moving, e.g., ice from the damper 212 being frozen.

[0050] Additionally, the method 500 includes receiving sensing device data from a sensing device indicative of an electrical current associated with the torque applied by the damper motor, e.g., as indicated at (504) in FIG. 5. Specifically, sensing device 217 may generate and transmit, and controller 150 may receive, data indicative of the electrical current associated with the torque applied by the damper motor 213 at (502). The data may be electrical current values, power values, and / or the like that are outputs of the damper motor 213 applying the torque to the damper assembly. For example, the damper motor 213 may encounter resistance from the damper assembly. The resistance encountered from the damper assembly may be proportional to the outputs, e.g., electrical current, power, and / or the like, of the damper motor 213.

[0051] Thereafter, the method 500 includes monitoring a magnitude of the electrical current occurring during a predetermined length of time based on the received sensing device data, e.g., as indicated at (506) in FIG. 5. Specifically, controller 150 may monitor the magnitude of the electrical current occurring during the predetermined length of time based on the sensing device data received at (504). The predetermined length of time may be a predetermined or preset maximum length of time stored within the memory of controller 150 at which the damper motor 213 is operated for. For example, FIG. 6 illustrates a diagrammatic view of the magnitude of the electrical current plotted as a function of time. As illustrated in FIG. 6, the waveform 300 of the electrical current magnitude may be monitored for the predetermined length of time, which is between an initial time ti and a final time tf.

[0052] Furthermore, the method 500 includes determining a status of the damper assembly based on the monitored magnitude of the electrical current, e.g., as indicated at (508) in FIG. 5. During faulty operation of the damper assembly, the damper 212 may sometimes become frozen or blocked and, thus, normal movement of the damper 212 is inhibited. In such scenarios, damper motor 213 may encounter resistance during activation as it applies torque to the damper 212 and, thus, the electrical current magnitude may be increased relative to the electrical current magnitude during normal operations. As such, controller 150 may determine the status of the damper 212, such as the fault status, based on the magnitude of the electrical current monitored at (506). For example, in some embodiments, controller 150 may determine the average of the magnitude monitored at (506) over the predetermined length of time. As such, controller 150 may utilize a mathematical model, such simple moving average (SMA), exponential moving average (EMA), and / or the like to determine the average of the monitored magnitude over the predetermined length of time. Controller 150 may then compare the determined average of the magnitude monitored at (506) to a predetermined average magnitude threshold range. The predetermined average magnitude threshold range may be a threshold range within which the electrical current magnitude falls during desired operation of damper motor 213. The predetermined average magnitude threshold range may be stored within the memory of controller 150. Thereafter, controller 150 may detect a blocked damper status in response to the magnitude monitored at (506) exceeding the predetermined average magnitude threshold range. The blocked damper status may be due to a blocked damper 212, which may occur when moisture freezes and limits or prevents movement of damper 212. Alternatively, controller 150 may detect a no-fault damper status in response to the magnitude monitored at (506) equaling or falling below the predetermined average magnitude threshold range.

[0053] Additionally, or alternatively, in some embodiments, controller 150 may determine a number of standard deviations by which each discrete magnitude value of a plurality of discrete magnitude values of the magnitude monitored at (506) that exceeds the determined average of the magnitude is above the determined average of the magnitude. More simply, controller 150 determines the discrete magnitude values that exceed the determined average of the magnitude as described above and determines the number of standard deviations that each of those values is above the determined average of the magnitude. Then, controller 150 may compare the determined number of standard deviations the values to a predetermined standard deviation threshold range. The predetermined standard deviation threshold range may be a threshold range within which the standard deviations of the values of the magnitudes fall during desired operation of damper motor 213. The predetermined standard deviations threshold range may be stored within the memory of controller 150. Thereafter, controller 150 may detect the blocked damper status in response to the determined number of standard deviations that exceeds the determined average of the magnitude exceeding the predetermined standard deviation threshold range. Alternatively, controller 150 may detect a no-fault damper status in response to the determined number of standard deviations that exceeds the determined average of the magnitude equaling or falling below the predetermined standard deviation threshold range.

[0054] Additionally, or alternatively, in some embodiments, controller 150 may compare a plurality of discrete magnitude values of the magnitude monitored at (506) to a predetermined threshold magnitude value range. The predetermined threshold magnitude value range may be a threshold range within which discrete magnitude values fall during desired operation of damper motor 213. The predetermined threshold magnitude value range may be stored within the memory of controller 150. Then, controller 150 may determine a number of discrete time-consecutive values of the plurality of discrete magnitude values that exceed the predetermined threshold magnitude value range. More simply, controller 150 may count the number of time-consecutive values that exceed the predetermined threshold magnitude value range. Thereafter, controller 150 may detect the blocked damper status in response to the number of discrete time-consecutive values that exceed the predetermined threshold magnitude value range exceeding a threshold number of discrete values range. More simply, when the count of time-consecutive values exceeds the threshold number of discrete values, controller 150 detects the blocked damper status. In such embodiments, the threshold number of discrete values range may be a first threshold number of discrete values range. The number / count of time-consecutive values exceeding the first threshold number of discrete values range indicates that the damper motor 213 is receiving torque resistance for too long for a normal movement of damper 212, as the magnitude of the electrical current is too high for normal movement of damper 212 over a continuous period of time. The first threshold number of discrete values range may be a threshold number range equal to or below which the number of discrete time-consecutive values fall during desired operation of damper motor 213. The first threshold number of discrete values range may be stored within the memory of controller 150. Alternatively, controller 150 may detect a no-fault damper status in response to the number of discrete time-consecutive values that exceed the predetermined threshold magnitude value range fall within or below the first threshold number of discrete values range.

[0055] Additionally, or alternatively, in some embodiments, controller 150 may detect that damper 212 has reached one of a fully open position or a closed position in response to the number of discrete time-consecutive values that exceed the predetermined threshold magnitude value range falling within a second threshold number of discrete values range. The second threshold number of discrete values range may be lesser than the first threshold number of discrete values range. More simply, when the count of time-consecutive values falls within the second threshold number of discrete values, controller 150 detects the that the damper 212 has reached the fully open position or the closed position. The number / count of time-consecutive values falling within the second threshold number of discrete values range indicates that the damper motor 213 is briefly receiving high torque resistance, which is encountered by damper motor 213 briefly overdriving the damper 212 once the damper 212 has reached the fully open position or the closed position. Once the damper 212 has been briefly overdriven, the operation of damper motor 213 is halted. Alternatively, controller 150 may detect that the damper 212 has not reached either the fully open position or the closed position, such as when the number of time-consecutive values that exceed the predetermined threshold magnitude value range exceeds the first threshold number of discrete values range as described above, thus indicating a blocked damper 212.

[0056] Moreover, the method 500 includes operating at least one of a heating element of the refrigerator appliance or the damper motor based on the determined status of the damper assembly, e.g., as indicated at (510) in FIG. 5. Specifically, controller 150 may operate the heater 215, e.g., the first coil heater 238 or the second coil heater 239, and / or the damper motor 213 based on the status of the damper assembly determined at (508). For example, controller 150 may activate heater 215, whereby heat is applied to damper 212 and / or damper motor 213, and / or pause operation of damper motor 213 in response to detecting the blocked damper status. Additionally, controller 150 may pause the operation of damper motor 213 in response to detecting that the damper 212 has reached one the fully open or the closed position in order to prevent excessive overdriving of damper 212.

[0057] Additionally, or alternatively, in some embodiments, the method 500 may include providing a user notification indicating the status of the damper assembly. Specifically, controller 150 may provide the user notification indicating the status of the damper. For example, in some embodiments, controller 150 may be wirelessly connected to a network, e.g., local area network (LAN), via BLUETOOTH® or WI-FI®, and / or directly to a remote user interface device, e.g., smartphone, laptop, tablet, and / or the like. As such, controller 150 may wirelessly provide the user notification to the remote user interface device. Additionally, or alternatively, in some embodiments, the user notification may be provided in the form of a sound, visual display, and / or the like on / from the refrigerator appliance 100, such as on / from the user interface panel 138.

[0058] 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 claim.

Claims

1. A method of operating a refrigerator appliance, the refrigerator appliance including a damper assembly configured to move between a plurality of positions, a damper motor operable to move the damper assembly between the plurality of positions, and a heating element configured to apply heat to the damper assembly, the method comprising:receiving, with a controller, sensing device data from a sensing device indicative of an electrical current associated with a torque applied by the damper motor;monitoring, with the controller, a magnitude of the electrical current occurring during a predetermined length of time based on the received sensing device data;determining, with the controller, a status of the damper assembly based on the monitored magnitude of the electrical current; andoperating, with the controller, at least one of the heating element or the damper motor based on the determined status of the damper assembly.

2. The method of claim 1, wherein determining the status of the damper assembly comprises:determining, with the controller, an average of the monitored magnitude of the electrical current over the predetermined length of time;comparing, with the controller, the determined average of the monitored magnitude of the electrical current to a predetermined average magnitude threshold range; anddetecting, with the controller, a blocked damper status in response to the monitored magnitude of the electrical current exceeding the predetermined average magnitude threshold range.

3. The method of claim 2, wherein operating at least one of the heating element or the damper motor comprises:activating, with the controller, the heating element, whereby heat is applied to the damper assembly, in response to detecting the blocked damper status.

4. The method of claim 2, wherein determining the status of the damper assembly comprises:determining, with the controller, a number of standard deviations by which each discrete magnitude value of a plurality of discrete magnitude values of the monitored magnitude of the electrical current that exceeds the determined average of the magnitude is above the determined average of the magnitude;comparing, with the controller, the determined number of standard deviations that exceeds the determined average of the magnitude to a predetermined standard deviation threshold range; anddetecting, with the controller, a blocked damper status in response to the determined number of standard deviations that exceeds the determined average of the magnitude exceeding the predetermined standard deviation threshold range.

5. The method of claim 1, wherein determining the status of the damper assembly comprises:comparing, with the controller, a plurality of discrete magnitude values of the monitored magnitude of the electrical current to a predetermined threshold magnitude value range;determining, with the controller, a number of discrete time-consecutive values of the plurality of discrete magnitude values that exceed the predetermined threshold magnitude value range; anddetecting, with the controller, a blocked damper status in response to the number of discrete time-consecutive values of the plurality of discrete magnitude values that exceed the predetermined threshold magnitude value range exceeding a threshold number of discrete values range.

6. The method of claim 1, wherein determining the status of the damper assembly comprises:comparing, with the controller, a plurality of discrete magnitude values of the monitored magnitude of the electrical current to a predetermined threshold magnitude value range;determining, with the controller, a number of discrete time-consecutive values of the plurality of discrete magnitude values that exceed the predetermined threshold magnitude value range; anddetecting, with the controller, a no-fault damper status in response to the number of discrete time-consecutive values of the plurality of discrete magnitude values that exceed the predetermined threshold magnitude value range falling within or falling below a threshold number of discrete values range.

7. The method of claim 6, wherein the threshold number of discrete values range is a first threshold number of discrete values range, determining the status of the damper assembly further comprising:detecting, with the controller, that the damper assembly has reached one of a fully open position or a closed position in response to the number of discrete time-consecutive values that exceed the predetermined threshold magnitude value range falling within a second threshold number of discrete values range lesser than the first threshold number of discrete values range.

8. The method of claim 1, wherein:determining the status of the damper assembly comprises:comparing, with the controller, discrete magnitude values of the monitored magnitude of the electrical current to a predetermined threshold magnitude value range as the magnitude of the electrical current is monitored; anddetecting, with the controller, that the damper assembly has reached one of a fully open position or a closed position in response to at least one of the discrete magnitude values exceeding a predetermined threshold magnitude value range; andoperating at least one of the heating element or the damper motor comprises:pausing, with the controller, operation of the damper motor upon detecting that the damper assembly has reached one of the fully open position or the closed position.

9. The method of claim 1, further comprising:providing, with the controller, a user notification indicating the status of the damper assembly.

10. A refrigerator appliance, the refrigerator appliance comprising:a damper assembly configured to move between a plurality of positions;a damper motor coupled to the movable damper assembly, the damper motor operable to move the damper assembly between the plurality of positions;a heating element configured to apply heat to the damper assembly;a sensing device configured to generate data indicative of an electrical current associated with a torque applied by the damper motor; anda controller operatively coupled to the sensing device, the damper motor, and the heating element, the controller configured to:receive the generated data from the sensing device;monitor a magnitude of the electrical current occurring during a predetermined length of time based on the received generated data;determine a status of the damper assembly based on the monitored magnitude of the electrical current; andoperate at least one of the heating element or the damper motor based on the determined status of the damper assembly.

11. The refrigerator appliance of claim 10, wherein determining the status of the damper assembly comprises:determining an average of the monitored magnitude of the electrical current over the predetermined length of time;comparing the determined average of the monitored magnitude of the electrical current to a predetermined average magnitude threshold range; anddetecting a blocked damper status in response to the monitored magnitude of the electrical current exceeding the predetermined average magnitude threshold range.

12. The refrigerator appliance of claim 11, wherein operating at least one of the heating element or the damper motor comprises:activating the heating element, whereby heat is applied to the damper assembly, in response to detecting the blocked damper status.

13. The refrigerator appliance of claim 11, wherein determining the status of the damper assembly comprises:determining a number of standard deviations by which each discrete magnitude value of a plurality of discrete magnitude values of the monitored magnitude of the electrical current that exceeds the determined average of the magnitude is above the determined average of the magnitude;comparing the determined number of standard deviations that exceeds the determined average of the magnitude to a predetermined standard deviation threshold range; anddetecting a blocked damper status in response to the determined number of standard deviations that exceeds the determined average of the magnitude exceeding the predetermined standard deviation threshold range.

14. The refrigerator appliance of claim 10, wherein determining the status of the damper assembly comprises:comparing a plurality of discrete magnitude values of the monitored magnitude of the electrical current to a predetermined threshold magnitude value range;determining a number of discrete time-consecutive values of the plurality of discrete magnitude values that exceed the predetermined threshold magnitude value range; anddetecting a blocked damper status in response to the number of discrete time-consecutive values of the plurality of discrete magnitude values that exceed the predetermined threshold magnitude value range exceeding a threshold number of discrete values range.

15. The refrigerator appliance of claim 10, wherein determining the status of the damper assembly comprises:comparing a plurality of discrete magnitude values of the monitored magnitude of the electrical current to a predetermined threshold magnitude value range;determining a number of discrete time-consecutive values of the plurality of discrete magnitude values that exceed the predetermined threshold magnitude value range; anddetecting a no-fault damper status in response to the number of discrete time-consecutive values of the plurality of discrete magnitude values that exceed the predetermined threshold magnitude value range falling within or falling below a threshold number of discrete values range.

16. The refrigerator appliance of claim 15, wherein the threshold number of discrete values range is a first threshold number of discrete values range, determining the status of the damper assembly further comprising:detecting that the damper assembly has reached one of a fully open position or a closed position in response to the number of discrete time-consecutive values that exceed the predetermined threshold magnitude value range falling within a second threshold number of discrete values range lesser than the first threshold number of discrete values range.

17. The refrigerator appliance of claim 10, wherein:determining the status of the damper assembly comprises:comparing discrete magnitude values of the monitored magnitude of the electrical current to a predetermined threshold magnitude value range as the magnitude of the electrical current is monitored; anddetecting that the damper assembly has reached one of a fully open position or a closed position in response to at least one of the discrete magnitude values exceeding a predetermined threshold magnitude value range; andoperating at least one of the heating element or the damper motor comprises:pausing operation of the damper motor upon detecting that the damper assembly has reached one of the fully open position or the closed position.

18. The refrigerator appliance of claim 10, further comprising:a fresh food chamber; anda freezer chamber,wherein, the movable damper assembly is moved between a plurality of positions for cooling the fresh food chamber and the freezer chamber.

19. The refrigerator appliance of claim 10, further comprising:a first chilled chamber; anda second chilled chamber,wherein:at least one of the first chilled chamber or the second chilled chamber is a convertible chilled chamber; andthe movable damper assembly is moved between a plurality of positions for cooling the first chilled chamber and the second chilled chamber.

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