Ice Bin Motor Reverse Rotation to Reduce Torque and Prevent Overload
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Solution Overview
Problem
Existing refrigerator ice dispensing systems face issues with motor overload due to high torque requirements for crushing ice, potential damage from continuous operation without user input, and misdiagnosis of ice maker malfunction when ice is entangled or not dispensed properly.
Innovation Solution
A refrigerator system utilizing a BLDC motor with counter electromotive force detection and a controller that reversely rotates the motor to release restrictions, stops the motor when user input is not detected, and rearranges ice to reduce torque and prevent continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the motor operates to rotate the rotary blades in the first direction regardless of whether ice is dispensed, then the ice can be discharged from the ice bin, but the motor may be damaged due to overload when the rotary blade is not rotated normally
Solution Approach 1:
The controller detects the rotation state of the rotary blade and provides feedback to control the motor operation. When the rotary blade is not rotated normally (detected through rotation detection means), the controller stops the motor to prevent overload damage, while still enabling ice dispensing when rotation is normal
Solution Approach 2:
The motor operation is made dynamic and adaptive based on real-time rotation detection. The motor operates only when the rotary blade rotates normally, and stops when rotation is abnormal, creating a dynamic control system that adjusts motor operation based on actual mechanical conditions
2Productivity
If the torque of the motor is large for crushing ice, then the crushed ice can be dispensed, but overload of the motor may occur
Solution Approach 1:
The motor operates periodically with alternating rotation directions - first direction for crushing ice (high torque), then second direction for dispensing. This periodic action allows the motor to handle high torque demands only when necessary for crushing, reducing overall overload risk while maintaining ice crushing capability
Solution Approach 2:
The motor rotation direction is inverted between crushing and dispensing operations. The motor rotates in the first direction to crush ice with high torque, then reverses to the second direction for dispensing, utilizing the reverse rotation to reduce torque demands and prevent continuous overload
3Productivity
If the motor is operated continuously when an ice dispensing command is input, then ice can be dispensed, but the motor continues to operate and may be damaged if the detection part malfunctions
Solution Approach 1:
The rotation detection means provides continuous feedback to the controller about the rotary blade's rotation state. The controller uses this feedback to determine when to stop the motor - not just based on ice dispensing completion, but also on whether the rotary blade is actually rotating, preventing continuous operation even if the operation pad remains pressed due to detection part malfunction
Solution Approach 2:
The system uses the rotation detection mechanism to automatically control motor shutdown. When the rotary blade stops rotating (detected by the rotation detection means), the motor automatically stops without requiring the user to release the operation pad, making the system self-regulating and protecting against continuous operation
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
Prevents motor damage, ensures smooth ice dispensing, and reduces torque applied during subsequent dispensing, while preventing continuous operation due to detection part malfunctions.
Implementation Method 1
A refrigerator system utilizing a BLDC motor with counter electromotive force detection
Data Source
AI summary
A refrigerator includes: an ice maker for generating ice; an ice bin for storing the ice and including a rotational blade that is rotated in order to discharge the ice; a motor for generating power for rotating the rotational blade; a manipulation pad provided on the door of the refrigerator and manipulated to discharge the ice from the ice bin; a manipulation sensing part for detecting the manipulation of the manipulation pad; and a controller for operating the motor when the manipulation of the manipulation pad is detected by the manipulation sensing part, wherein the controller rotates the motor in one direction to discharge the ice from the ice bin and the controller rotates the motor in the other direction, which is the opposite direction of the one direction, for a set period of time when the manipulation of the manipulation pad is no longer detected.