Ice Maker Pulsed Fill Routine for Consistent Batch Volume Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional ice makers face inconsistencies in ice batch volume due to variations in water supply pressure and splashing, leading to potential undershoot or overshoot in water levels during the freeze routine, which affects the reliability and consistency of ice production.
Innovation Solution
The proposed ice maker employs a control system that includes a water level sensor and a controller to execute a pulsed fill routine and a differential freeze routine, where the water level is managed by pulsing water to a fill-approach level and then to a freeze routine starting level, and the differential freeze routine adjusts based on a predefined differential amount from a high control water level, ensuring consistent ice batch production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional continuous fill routine is used, then filling speed is fast, but water level precision deteriorates due to overshoot and splashing
Solution Approach 1:
The fill routine uses periodic pulsing of the water inlet valve instead of continuous opening. The valve opens for a predetermined time period, closes, waits for a predetermined time, then repeats the cycle. This periodic action allows water to be added in controlled increments, preventing overshoot and splashing while maintaining acceptable filling speed.
Solution Approach 2:
The fill routine is segmented into multiple phases: initial rapid fill phase, pulsing fill phase, and final adjustment phase. This segmentation allows the system to combine fast filling when water level is low with precise control when approaching the target level, resolving the contradiction between speed and precision.
2Adaptability or versatility
If water supply pressure varies, then adaptability is improved, but manufacturing precision deteriorates due to inconsistent ice batch volume
Solution Approach 1:
The system uses a water level sensor to provide feedback on the actual water level in the sump during the fill routine. The controller compares the sensed level with the desired level and adjusts the valve pulsing duration accordingly. This feedback mechanism compensates for variations in water supply pressure, ensuring consistent water level and ice batch volume regardless of pressure fluctuations.
Solution Approach 2:
The fill routine dynamically adjusts the valve opening duration based on real-time water level conditions. When water supply pressure is high, the valve opens for shorter periods; when pressure is low, it opens for longer periods. This dynamic adaptation maintains manufacturing precision across varying pressure conditions.
3Ease of operation
If water is added continuously to reach fill level, then operation simplicity is maintained, but reliability deteriorates due to undershoot and overshoot
Solution Approach 1:
The automated pulsing fill routine maintains simplicity from the operator's perspective while internally implementing periodic valve activation. The controller automatically manages the complex pulsing sequence without user intervention, achieving both ease of operation and high reliability through automated periodic control.
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 approach ensures consistent ice batch volume by minimizing material differences and splashing effects, thereby improving the reliability and efficiency of ice production by maintaining precise control over water levels and temperature thresholds.
Implementation Method 1
a water level sensor configured to output a signal representative of water level in the sump to the controller
Implementation Method 2
A refrigeration system is configured to cool the ice formation device for forming at least some of the water circulated by the water system into ice
Data Source
AI summary
A batch ice maker can execute a pulsed fill routine in which a control system pulses water from a water supply into the sump until the sump reaches a predefined freeze routine starting level. Pulsing may begin after continuously filling the sump to a fill-approach level. A batch ice maker can execute a differential freeze routine in which the control system circulates water from a sump to an ice formation device until water level decreases by a predefined differential amount from a high control water level based on the water level in the sump at a point in time after the sump was filled to a freeze routine starting level. The high control water level can be set based on water level in the sump when sump water temperature reaches a predefined pre-chill temperature. The predefined pre-chill temperature can be associated with a switchover from sensible cooling to latent cooling.