Apparatus and method for sensing ice thickness and detecting failure modes of an ice maker
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Solution Overview
Problem
Existing ice making machines face challenges in accurately detecting ice thickness and failure modes, such as water leaks, due to sensors being in the food zone, prone to contamination, and requiring mechanical adjustment, which can lead to improper ice harvesting and machine failure.
Innovation Solution
An ice maker system with a controller and air pressure sensor that measures water level in the sump to determine ice thickness and initiate harvest cycles, while also detecting failure modes like water leaks and component malfunctions, using a pneumatic tube and air fitting to sense air pressure corresponding to water level, allowing for electronic control and adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a hinged sensor is used to directly measure ice thickness, then measurement precision is improved, but the sensor is exposed to water and scale contamination, and requires mechanical adjustment which reduces reliability
Solution Approach 1:
The sensor is extracted from the food zone and water exposure environment. The patent uses a water level sensor that measures the position of the water line in the sump, which indirectly indicates ice thickness without requiring the sensor to be in contact with water or ice. This eliminates contamination risks and mechanical adjustment needs while maintaining measurement capability.
2Measurement precision
If a hinged sensor is placed in front of the evaporator assembly, then ice thickness can be detected, but the sensor must move out of the way during harvest to avoid damage from falling ice
Solution Approach 1:
The sensor is extracted from the harvest zone where falling ice could damage it. The patent positions the water level sensor in the sump away from the evaporator assembly and ice harvest path. The sensor remains stationary while still providing accurate ice thickness information through water level measurement, eliminating the need for moving parts or protective mechanisms.
3Measurement precision
If the sensor position is mechanically adjusted using a set screw, then ice thickness measurement can be calibrated, but the adjustment can be incorrect or change over time, reducing consistency
Solution Approach 1:
The mechanical adjustment system (set screw) is replaced with an electronic control system. The patent uses a controller that receives signals from the water level sensor and automatically determines when ice has reached the desired thickness. The system electronically controls the harvest timing based on water level position, eliminating manual mechanical adjustment and its associated problems of incorrect positioning and drift over time.
4Device complexity
If the ice thickness is controlled by mechanical means, then the system is simple, but the ice thickness cannot be adjusted electronically, reducing adaptability
Solution Approach 1:
The mechanical ice thickness control system is replaced with an electronic control system. The patent employs a controller that processes sensor signals and electronically determines harvest timing. This electronic system can be programmed with different ice thickness parameters and can adapt to varying operating conditions, providing greater versatility while maintaining system simplicity through integrated control logic.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables accurate ice thickness measurement and detection of failure modes without mechanical adjustments, reducing the risk of improper ice harvesting and machine failure, ensuring consistent ice production and operational reliability.
Implementation Method 1
an air pressure sensor adapted to sense an air pressure from water in the sump compressing air in the air fitting, wherein the sensed pressure corresponds to a water level in the sump
Implementation Method 2
sense an air pressure from water in the sump compressing air in the air fitting
Implementation Method 3
an evaporator assembly, a freeze plate thermally coupled to the evaporator assembly
Implementation Method 4
the refrigeration cycle is reversed and the freeze plate is heated to melt the formed ice cubes away from the freeze plate
Data Source
AI summary
An ice maker includes a refrigeration system, a water system, and a control system. The control system includes an air fitting disposed in the sump of the water system, a pneumatic tube, and a controller including a processor and an air pressure sensor. The air fitting defines a chamber in which air may be trapped and includes openings through which water in the sump is in fluid communication with the air in the chamber. The pneumatic tube is in fluid communication with the air pressure sensor and the air fitting. The air pressure sensor is adapted to sense a pressure corresponding to a sump water level. The controller is adapted to control the operation of the refrigeration system and the operation of the water system based upon the sump water level and to detect one or more failure modes of the water system based upon the sump water level.