Ice Diverter Valve Control for Multi-Bin Delivery Back-Up Prevention
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Solution Overview
Problem
Existing ice making and delivery systems lack the ability to efficiently divert ice from a single source to multiple receptacles while the ice making machine operates, especially under high force conditions, and fail to manage ice build-up effectively in delivery conduits.
Innovation Solution
A computer-controlled ice diverter valve system that operates during dwell periods to divert ice from one discharge line to another, utilizing level sensors, motor-driven vanes, and magnetic switches to manage ice distribution and prevent back-up, with an operator override mechanism for manual control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a diverter valve is used to divert ice to multiple receptacles during operation, then ice distribution efficiency is improved, but the complexity of the control system increases
Solution Approach 1:
The control system activates the diverter valve during the dwell period, which is the time interval between auger strokes when ice is not being pushed into the conduit. By performing the valve activation in advance during this idle period rather than during active ice delivery, the system achieves multi-receptacle distribution without requiring complex real-time coordination during high-force ice delivery operations.
2Force
If the diverter valve operates under high force conditions to divert ice, then ice diversion capability is improved, but the reliability of valve operation deteriorates
Solution Approach 1:
The diverter valve is activated during the dwell period before the auger delivers ice under high force. This timing ensures the valve is already in the correct position to receive and direct the incoming ice stream, allowing the valve to operate under low-force conditions during positioning while still achieving effective ice diversion when the ice arrives.
Solution Approach 2:
The control system acts as an intermediary that coordinates between the auger operation cycle and the diverter valve activation. It detects the dwell period and triggers valve activation at the optimal moment, mediating between the high-force ice delivery mechanism and the diverter valve to ensure reliable operation without direct force interference.
3Reliability
If level sensors and automated controls are used to prevent ice back-up, then ice management reliability is improved, but the device complexity increases
Solution Approach 1:
Level sensors are installed in the ice receptacles to detect ice accumulation levels and provide feedback to the control system. When a receptacle reaches its maximum capacity, the sensor signal triggers the control system to activate the diverter valve during the next dwell period, redirecting ice flow to alternative receptacles and preventing ice back-up in the full receptacle.
Solution Approach 2:
The system uses the existing dwell period in the ice delivery cycle as a self-service opportunity to perform valve activation without requiring additional operational time or external intervention. The control system automatically detects and utilizes this inherent idle period in the auger operation to execute the diverter valve activation, making the complexity management self-contained within the existing operational framework.
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 controlled and efficient diversion of ice to multiple receptacles, preventing ice back-up in delivery conduits and ensuring continuous operation of the ice making machine by sensing ice levels and activating the diverter valve during dwell periods, thus maintaining optimal ice distribution.
Implementation Method 1
a force multiplication means for moving the diverter valve from one position to another
Implementation Method 2
motor-driven vanes are used, in connection with magnetic switches
Data Source
AI summary
An ice making, and delivery apparatus for making and delivering ice to different ones of a plurality of receptacle units is provided, in which ice delivered via a conduit to a diverter valve mechanism, is diverted from alignment with one ice discharge line to another, depending upon sensors in ice receptacles recognizing a level of build-up of ice in any given receptacle, for computer control of a gearmotor for moving the diverter valve from one position to another. Various controls are provided for preventing ice build-up, and for operating the diverter valve during a “dwell” period of ice movement in the conduit, as distinguished from a “push” period of ice movement in the conduit to the diverter valve. A force multiplication technique is employed for moving the diverter valve notwithstanding the presence of ice therein.