Refrigerator Ice Bin Level Sensing for Precise Ice Supply Control
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Solution Overview
Problem
Existing ice suppliers in refrigerators lack efficient control mechanisms for maintaining a desired quantity of ice, leading to inefficiencies in ice production and storage management.
Innovation Solution
An ice supplier system with a sensing system that uses multiple senders and receivers at different heights to detect ice quantity, a heating element for defrosting, and a controller to manage ice production based on user input and sensed data, allowing for precise control of ice levels and display of storage status.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensing system with multiple senders and receivers at different heights is implemented to accurately detect ice quantity, then measurement precision of ice quantity is improved, but device complexity increases
Solution Approach 1:
The sensing system is segmented into multiple independent sender-receiver pairs positioned at different heights within the storage bin. Each pair independently detects ice presence at its specific height level, allowing the system to determine total ice quantity by counting active pairs. This segmentation enables accurate multi-level detection while keeping each individual sensing unit relatively simple.
Solution Approach 2:
The sensing system transitions from single-point detection to multi-level vertical detection by positioning senders and receivers at different heights. This dimensional expansion along the vertical axis enables the system to detect ice quantity more accurately by measuring presence at multiple elevation levels rather than relying on a single detection point.
2Reliability
If a heating element is added to defrost the senders and receivers, then reliability of sensing is improved, but use of energy increases
Solution Approach 1:
The controller continuously monitors the operation status of each sender-receiver pair and uses this feedback to determine when defrosting is needed. When a pair fails to detect ice presence despite ice being present (indicating frosting), the controller activates the heating element to defrost that specific area, then resumes normal sensing operations. This feedback-based control ensures the heating element operates only when necessary.
Solution Approach 2:
The heating element serves the sensing system by automatically removing frost accumulation that would otherwise impair detection. The system essentially self-corrects sensing failures caused by frosting through the heating element, maintaining reliable operation without requiring external intervention or complex manual defrosting procedures.
3Ease of operation
If the storage bin is made transparent to allow visual feedback on ice levels, then ease of operation is improved, but manufacturing precision requirements increase
Solution Approach 1:
The system utilizes the optical properties of transparent materials to enable visual monitoring of ice levels. Users can observe ice quantity and distribution through the transparent storage bin walls, providing immediate visual feedback without requiring additional display components. This approach maintains manufacturing simplicity while achieving the desired transparency function.
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 accurate control of ice quantity, reduces energy consumption by producing ice only when needed, and enhances user convenience through visual feedback on ice levels without visible storage bin obstruction.
Implementation Method 1
a heating element arranged to be in thermal communication with and produce heat to defrost the first receiver and the second receiver
Implementation Method 2
a first sender positioned at a first height with respect to the ice storage bin and configured to send a first signal used in sensing the quantity of ice, a first receiver positioned at the first height with respect to the ice storage bin and configured to receive the first signal
Data Source
AI summary
An ice supplier includes an ice maker configured to make ice, a case configured to store ice made by the ice maker, a sensing unit configured to sense a quantity of ice stored in the case, and a controller configured to control the ice maker according to a result of sensing from the sensing unit.