Ice Bin Optical Sensor Layout Using Drive Unit Heat

Solution Overview

Problem

Refrigerators using optical sensors to sense ice levels in ice bins often require a heater to prevent malfunction due to fog and frost, increasing costs and complexity.

Innovation Solution

The optical sensor emitter and receiver are installed on the first and second drive units, which are positioned at high temperature parts in the ice making chamber, allowing them to operate without a conventional heater by using the heat generated from the motors and controllers to prevent fog and frost interference.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an optical sensor heater is installed to prevent fog and frost interference, then the optical sensor can operate reliably, but the device complexity and production cost increase

Engineering Contradiction:

Improveoptical sensor operation reliabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The optical sensor is integrated directly into the drive unit housing, combining the sensing function with the existing motor housing structure. This eliminates the need for separate heater components and their associated control systems, reducing device complexity while maintaining reliable operation through the sensor's proximity to the warm motor housing

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The drive unit motor housing naturally generates heat during operation, which self-heats the optical sensor and prevents fog and frost formation without requiring an external heater. The system uses its own operational heat to maintain sensor functionality, eliminating additional heating components

Inventive Principle:

Principle #25Self-service

2Reliability

If an optical sensor heater is installed to prevent fog and frost interference, then the optical sensor can operate reliably, but production cost increases

Engineering Contradiction:

Improveoptical sensor operation reliabilityVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The optical sensor is integrated directly into the drive unit housing, combining the sensing function with the existing motor housing structure. This eliminates the need for separate heater components and their associated control systems, reducing device complexity while maintaining reliable operation through the sensor's proximity to the warm motor housing

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The drive unit motor housing naturally generates heat during operation, which self-heats the optical sensor and prevents fog and frost formation without requiring an external heater. The system uses its own operational heat to maintain sensor functionality, eliminating additional heating components

Inventive Principle:

Principle #25Self-service

3Reliability

If an optical sensor heater is installed to prevent fog and frost interference, then the optical sensor can operate reliably, but assembly efficiency decreases

Engineering Contradiction:

Improveoptical sensor operation reliabilityVSAvoidassembly efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The optical sensor is integrated directly into the drive unit housing, combining the sensing function with the existing motor housing structure. This eliminates the need for separate heater components and their associated control systems, reducing device complexity while maintaining reliable operation through the sensor's proximity to the warm motor housing

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The drive unit motor housing naturally generates heat during operation, which self-heats the optical sensor and prevents fog and frost formation without requiring an external heater. The system uses its own operational heat to maintain sensor functionality, eliminating additional heating components

Inventive Principle:

Principle #25Self-service

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

This configuration eliminates the need for an optical sensor heater, reducing production costs, improving reliability, and enhancing assembly efficiency while maintaining accurate ice level sensing.

Implementation Method 1

an emitter to output optical signals so as to sense whether or not the ice cubes in the ice bin are at a full ice level, and a receiver to receive the optical signals output from the emitter

Methodology Applied

Scientific EffectOptical signal transmission and detection: Light

Implementation Method 2

allowing them to operate without a conventional heater by using the heat generated from the motors and controllers to prevent fog and frost interference

Methodology Applied

Scientific EffectThermal heating to prevent condensation and frost: Heating

Data Source

PatentUS9506680B2Ice making apparatus and refrigerator having the same

Publication Date: 2016.11.29 SAMSUNG ELECTRONICS CO LTD

AI summary

Disclosed is an ice making apparatus and a refrigerator having the same. The refrigerator includes an ice making tray in which ice cubes are made, an ejector to discharge the ice cubes from the ice making tray, an ice bin to store the ice cubes discharged by the ejector, an auger to move the ice cubes in the ice bin, a first drive unit to provide the ejector with rotational force, a second drive unit to provide the auger with rotational force, an emitter to output optical signals so as to sense whether or not the ice cubes in the ice bin are at a full ice level, and a receiver to receive the optical signals output from the emitter, wherein any one of the emitter and the receiver is installed at the first drive unit, and the other one is installed at the second drive unit.