Refrigerator Dispenser Optical Fill Sensing to Prevent Overflow
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Solution Overview
Problem
Existing refrigerator dispensers face issues with wear and tear from mechanical switches, inability to differentiate between containers and children's hands, and lack of automatic cut-off features, leading to potential overflow and increased complexity and cost.
Innovation Solution
An optical sensing system with a camera and ultrasonic sensors is integrated into the dispenser to detect container presence and size, allowing for hands-free dispensing and automatic cut-off, using a controller to optimize fill rates and prevent overflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical switches are used in the dispenser, then the dispensing operation can be controlled, but the switches wear out over time requiring replacement
Solution Approach 1:
The patent replaces mechanical switches with optical sensors that detect container presence and characteristics without physical contact. The optical sensor system uses light reflection properties to identify containers and trigger dispensing, eliminating mechanical wear and extending system lifespan while maintaining reliable control.
2Ease of operation
If active sensors are used to detect container presence, then automatic dispensing can be initiated, but the sensors cannot differentiate between a container and a child's hand
Solution Approach 1:
The patent employs multiple optical sensors positioned at different locations within the dispenser well, each detecting specific local characteristics of the inserted object. By analyzing the pattern of reflections across multiple sensor points, the system can distinguish between the geometric and optical properties of a container versus a hand, improving identification accuracy while maintaining automatic operation.
3Device complexity
If a single actuator is used to dispense both ice and water, then the dispenser structure is simplified, but additional control elements are required for users to select between ice and water
Solution Approach 1:
The patent uses the optical sensor system to automatically identify the type of container inserted and the desired product based on container characteristics. The system self-determines whether to dispense ice or water without requiring manual selection controls, simplifying the physical structure while maintaining ease of operation through automatic product selection.
4Ease of operation
If mechanical switches are used with pressure-sensitive operation, then the dispensing can be activated by pushing the container, but the physical interaction causes wear and tear on contact points, springs, and levers
Solution Approach 1:
The patent replaces pressure-sensitive mechanical switches with optical sensors that detect container presence and characteristics through light reflection without requiring physical contact or pressure application. This eliminates wear on contact points, springs, and levers while maintaining the convenient push-to-dispense operation through automatic sensor-triggered activation.
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
Enables efficient and accurate dispensing of ice and water to a desired level without manual intervention, accommodating various container shapes and sizes, while preventing spills and reducing wear and tear on components.
Implementation Method 1
an optical sensing system is provided including a camera located within a dispenser well
Implementation Method 2
another sensor, such as an ultrasonic sensor, can be utilized to detect the presence of the container
Data Source
AI summary
A refrigerator includes a dispenser having a dispenser well, a control for regulating a product dispensing operation, and an optical sensing system includes a camera within the dispenser well in communication with a controller for controlling the filling of a container within the dispenser well based on image data. The image data can used to detect at least one of a presence of a container in the dispenser well, a height of liquid within the container, a height of ice within the container and a shape of the container within the dispenser well, as well as to adjust a dispensing rate of product.