Icemaker Control Circuit With Direct AC-to-DC Motor Drive

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Solution Overview

Problem

Current control circuits for devices like icemakers are inefficient and costly, requiring complex mechanical parts and inefficiently converting AC power to DC for motor operation.

Innovation Solution

A DC motor control circuit that interfaces directly with AC signals, using a thyristor or TRIAC to convert AC power to a DC output without needing additional signal interfaces, employing a zero cross detection circuit for efficient power conversion and minimizing mechanical components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If current control circuit designs are used, then the icemaker can operate with AC power input, but the system requires complex mechanical parts and has poor energy efficiency

Engineering Contradiction:

Improveenergy efficiencyVSAvoidmechanical parts complexity

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical control mechanisms with an electronic control circuit that directly interfaces AC power input with a DC motor. The control circuit uses electronic switching components (such as transistors or thyristors) to convert AC power to DC power and control motor operation, eliminating the need for mechanical converters, clutches, or other moving mechanical parts that were required in traditional designs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the electrical parameters of the power conversion process by directly converting AC power to DC power through electronic switching and rectification within the control circuit. This allows the system to operate efficiently by matching the DC motor's electrical requirements with AC power input, improving energy efficiency while reducing mechanical complexity.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If traditional AC to DC conversion methods are used, then the motor can be powered, but additional signal interfaces and conversion components are required

Engineering Contradiction:

Improvecost effectivenessVSAvoidsignal interface requirements

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The control circuit is designed to perform multiple functions within a single integrated unit: it accepts AC power input, converts it to DC power, and directly controls the DC motor operation. This multi-functional design eliminates the need for separate signal interfaces, conversion components, and additional control circuits, reducing both cost and complexity while improving ease of manufacture.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Duration of action of moving object

If complex mechanical parts are used in the control circuit, then the icemaker can be controlled, but power consumption increases and motor life decreases

Engineering Contradiction:

Improvemotor lifeVSAvoidpower consumption

Core Design Contradiction:

Duration of action of moving objectVSUse of energy by moving object

Solution Approach 1:

The patent replaces mechanical control parts with an electronic control circuit that uses solid-state switching components. This substitution eliminates friction, wear, and mechanical failures that reduce motor life, while also reducing power consumption since electronic switching requires minimal energy compared to mechanical actuators, relays, or contactors.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

The solution provides a cost-effective and energy-efficient method for icemaker operation, reducing power consumption and extending motor life by eliminating complex mechanical parts and heat usage, while ensuring reliable and adaptable performance.

Implementation Method 1

employing a zero cross detection circuit for efficient power conversion

Methodology Applied

Scientific EffectZero cross detection:

Implementation Method 2

A DC motor control circuit that interfaces directly with AC signals, using a thyristor or TRIAC to convert AC power to a DC output

Methodology Applied

Scientific EffectThyristor switching:

Data Source

PatentUS10006687B2Control circuit

Publication Date: 2018.06.26 ENVOLVE INTPROP LLC

AI summary

An icemaker control circuit may include an icemaker module and a DC motor. The icemaker module may include a control board that receives an AC power signal directly from an AC source that is external to the icemaker control circuit. The module may also include self-contained electronics and controls that allows icemaker operation without a need to interface to any signals other than AC power signal. The DC motor is provided for moving an output drive and is controlled by a DC output of the control circuit of the icemaker module in response to applying the AC signal to the icemaker module.