Apparatus and method for sensing water level
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Solution Overview
Problem
Existing ice makers face challenges in accurately determining ice thickness for harvesting, as traditional sensors are often located in the food zone, prone to contamination, require mechanical adjustment, and are not electronically adjustable, leading to inconsistencies in ice cube size and production.
Innovation Solution
An ice maker system utilizing an air pressure sensor and pneumatic tube to measure water level changes in the sump, allowing for electronic adjustment and accurate detection of ice thickness without being in the food zone, thus avoiding contamination and mechanical adjustment issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a hinged sensor is used to directly measure ice thickness, then measurement precision is improved, but the sensor is exposed to water and scale contamination, and requires mechanical adjustment
Solution Approach 1:
The patent uses an air pressure sensor as an intermediary device to measure ice thickness indirectly. The sensor measures air pressure in a chamber above the water level, which corresponds to the water level height, and from this the ice thickness is calculated. This intermediary measurement approach allows the sensor to remain outside the food zone, avoiding direct exposure to water and scale contamination while still providing accurate ice thickness data.
Solution Approach 2:
The patent replaces the mechanical hinged sensor system with an electronic air pressure sensing system. Instead of using a physical sensor that moves or contacts the ice directly, the system uses air pressure measurements taken from a sealed chamber. This substitution eliminates the need for mechanical adjustment and removes the sensor from the food zone, preventing contamination while maintaining measurement accuracy.
2Measurement precision
If the sensor is placed in the food zone for direct measurement, then measurement accuracy is improved, but the sensor requires mechanical adjustment and cannot be electronically adjusted
Solution Approach 1:
The patent replaces the mechanical sensor positioning system with an electronic control system. The air pressure sensor is fixed in position outside the food zone, and ice thickness measurements are obtained electronically through air pressure readings. The controller processes these readings and can electronically adjust operational parameters without requiring any mechanical movement or manual adjustment of the sensor itself, thereby achieving full electronic adjustability.
Solution Approach 2:
The system uses the natural relationship between air pressure and water level to provide self-measuring capability. The air pressure sensor automatically detects changes in air pressure as the water level changes during the ice making process, and the controller automatically calculates ice thickness from these readings without requiring manual intervention or mechanical adjustment.
3Ease of operation
If air pressure sensor is used to measure water level, then electronic adjustment capability is achieved, but temperature changes may affect measurements
Solution Approach 1:
The patent uses the air column in the sealed chamber as an intermediary medium between the water level and the temperature-sensitive electronic sensor. The air pressure transmits the water level information to the sensor without requiring the sensor to be exposed to temperature extremes. Additionally, the air column acts as a thermal buffer, isolating the sensor from rapid temperature changes in the surrounding environment, thereby reducing temperature sensitivity while maintaining electronic adjustability.
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 solution enables precise control of ice thickness and water level detection, ensuring consistent ice cube size and efficient operation, regardless of temperature changes, and reduces the risk of sensor failure and contamination.
Implementation Method 1
an air pressure sensor, wherein the air inside the proximal end of the pneumatic tube is in fluid communication with the air pressure sensor. The air pressure sensor measures an air pressure from the air chamber of the air fitting
Implementation Method 2
the air fitting comprises one or more openings through which water in the sump is in fluid communication with the air in the chamber
Data Source
AI summary
An ice maker includes a refrigeration system, a water system, and a control system. The control system includes an air fitting disposed above the sump of the water system, a pneumatic tube, and a controller including a processor and an air pressure sensor. The air fitting defines a chamber in which air may be trapped and includes one or more openings through which water in the sump is in fluid communication with the air in the chamber. The pneumatic tube is in fluid communication with the air pressure sensor and the air fitting. The air pressure sensor is adapted to sense a pressure corresponding to a sump water level. The controller is adapted to control the operation of the refrigeration system and the operation of the water system based upon the sump water level. To avoid errors in water level measurements due to temperature changes, the system uses the pressure sensor data's noise level to detect when the water level reaches the bottom of the air fitting.