Cone-Drum Ice Dispenser With Sensor-Based Refill Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current standalone ice dispensers have complex ice storage and advancing systems, leading to high manufacturing costs and frequent service visits due to increased failure rates, resulting in higher operating expenses and potential revenue loss during malfunctions.
Innovation Solution
A simplified ice storage and advancing system with a cone-shaped drum, weight sensors, and a motor-driven mechanism that uses a bagging unit with air cylinders and sensors to manage ice dispensing and production, reducing complexity and maintenance needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a complex ice storage and advancing system is used, then ice dispensing capability is improved, but manufacturing cost increases and reliability decreases
Solution Approach 1:
The ice storage system is segmented into multiple storage bins, each with independent advancing mechanisms. This segmentation allows each bin to operate independently, so if one bin or its advancing mechanism fails, other bins continue to function, thereby improving overall system reliability while maintaining ice dispensing capability.
Solution Approach 2:
The advancing mechanism is extracted and simplified to use a basic auger design with minimal moving parts. By removing complex components from the advancing system and keeping only the essential elements needed to move ice, the mechanism becomes more reliable while still achieving effective ice dispensing.
2Productivity
If a complex ice storage and advancing system is used, then ice dispensing capability is improved, but manufacturing cost increases
Solution Approach 1:
The advancing mechanism uses simple, inexpensive components that can be easily manufactured and replaced if needed. The design prioritizes using cheap, readily available materials and standard components over complex, custom-engineered parts, thereby reducing manufacturing costs while maintaining functional capability.
Solution Approach 2:
The system is divided into modular segments (storage bins with individual advancing mechanisms) that can be manufactured separately and assembled. This modular segmentation allows for simpler, more cost-effective manufacturing of each individual component using standard production techniques, rather than requiring complex integrated systems.
3Productivity
If a complex ice storage and advancing system is used, then ice dispensing capability is improved, but service visit frequency increases
Solution Approach 1:
The ice storage system is divided into multiple independent bins, each with its own simple advancing mechanism. This segmentation isolates potential failures to individual bins rather than affecting the entire system, reducing the frequency and scope of service visits needed while maintaining overall ice dispensing capability.
Solution Approach 2:
The system includes sensors and control mechanisms that automatically monitor ice levels and advancing mechanism operation, enabling self-diagnosis and automatic refilling operations. This reduces the need for manual service intervention and decreases service visit frequency while maintaining reliable ice dispensing.
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
The simplified system lowers manufacturing costs, reduces service visit frequency, and increases machine uptime by making the device less prone to failures and reducing revenue-robbing downtime.
Implementation Method 1
An ice maker is attached to the housing such that the ice maker receives water and turns the water into ice
Implementation Method 2
Once the ice is made, it is gravitationally discharged from the ice maker into the mouth of the drum
Implementation Method 3
the drum rotates such that the advancing fin causes the ice disposed within the internal cavity of the drum to advance out of the mouth
Implementation Method 4
The weight sensor measures the weight of the drum so that when the weight of the drum is below a lower limit, the ice maker is activated
Implementation Method 5
The first air cylinder extends toward the bag rack such that the suction cups suctionally engage a side of the bag and thereafter the first air cylinder retracts thereby opening the bag
Data Source
AI summary
A standalone ice dispenser delivers ice in either bagged form or bulk form to a user. The device uses a cone-shaped drum with an upwardly oriented mount that receives and stores the ice which ice is gravitationally delivered to the drum from an ice maker. When ice is to be dispensed, a motor rotates the drum such that a fin within the drum cause ice therein to advance toward and eventually out of the mouth of the drum into either a bagging system or directly out of the device via a chute. Weight sensors attached to the drum determine whether the drum is relatively empty or relatively full and control operation of the ice maker as a result and/or a proximity sensor measures the volume of ice in the drum and controls the operation of the ice maker.