Flexing tray ice-maker with AC drive
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Solution Overview
Problem
Existing ice-making machines in refrigerators often require DC power and sophisticated control electronics, which are not available in all refrigerator models, limiting the use of flexible ice trays for efficient ice cube ejection.
Innovation Solution
An ice-maker system using a flexible tray with an AC motor, featuring a bi-directional AC motor with interacting stops and a position sensor for precise control, eliminating the need for DC power processing and incorporating a simple user interface, error code output, and adjustable tray fill level, along with a mechanical and electrical connector for easy replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a flexible ice tray with DC motor is used for ice cube ejection, then energy savings are achieved, but DC power processing and sophisticated control electronics are required which are not available in all refrigerator models
Solution Approach 1:
The invention changes the power parameter from DC to AC, allowing the ice maker to operate with standard AC power already available in the refrigerator without requiring DC power processing circuitry. This resolves the contradiction by maintaining energy efficiency while eliminating the need for complex power conversion electronics.
Solution Approach 2:
The AC motor design with interacting stops makes the ice maker compatible with all refrigerator lines regardless of their power supply configuration. By using universal AC power instead of requiring specific DC power infrastructure, the invention achieves broad applicability across different refrigerator models without additional complexity.
2Reliability
If a metal die-cast ice tray with electrical resistance heater is used, then ice release is achieved, but the tray cannot be easily replaced and requires sophisticated control electronics
Solution Approach 1:
The invention replaces the electrical resistance heater system with a mechanical flexing mechanism. The flexible tray warped by AC motor-driven interaction with stops provides ice release through mechanical deformation rather than thermal heating, eliminating the need for heater control electronics while maintaining reliable ice release.
Solution Approach 2:
The flexible tray design allows users to manually flex and release ice cubes without electrical heating, and the tray can be easily removed and replaced by the user. This self-service approach eliminates complex control electronics while maintaining functional reliability.
3Device complexity
If an AC motor with interacting stops is used for tray rotation, then bidirectional control is achieved without DC power, but precise position control must be implemented mechanically
Solution Approach 1:
The interacting stops act as mechanical intermediaries that translate AC motor rotation into precise tray positioning. The stops physically limit and define the tray's angular positions, providing inherent position control without requiring sensors or complex electronic control systems. This resolves the contradiction by using simple mechanical elements to achieve precise positioning.
Solution Approach 2:
The mechanical stop system automatically provides position feedback and control through its physical interaction with the AC motor shaft. The stops self-regulate the tray position through mechanical constraint, eliminating the need for external position sensing or control electronics.
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 ice cube ejection with energy savings, automatic reversal of the AC motor for full bin detection, and user-friendly operation, while being compatible with all refrigerator lines by using line power directly without additional voltage regulation.
Implementation Method 1
an AC motor operable to rotate the connector bi-stably in two directions
Implementation Method 2
a position sensor sensing at least one rotated location of the tray
Implementation Method 3
A controller responds to the position sensor to control power to the AC motor to provide a cycling of the tray between the first and second positions
Data Source
AI summary
An ice-maker provides a reversible AC motor whose direction is changed at a first and second stop positioning the tray in a filling position and an ice cubes discharging position, respectively. A bail arm may introduce an additional stop preventing discharge of ice when an ice bin is full. User controls may allow the user to set a water fill time based on local water pressure conditions. An ice tray incorporating an ice sensor may releasably connect to the ice-making machine for ready replacement.