Optical Ice Level Sensing for Movable Freezer Bins
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Solution Overview
Problem
Existing ice level sensing systems for ice makers in freezers face challenges with mechanical lever arm freezing and improper ice storage bin positioning, leading to inefficient ice production control and potential ice spillage due to movement.
Innovation Solution
An optical ice level sensing system with a transmitter and detector on the cavity wall, using a reflector to direct a light beam, allowing for angled placement and relative movement between the ice storage bin and sensing system, ensuring accurate ice level detection and preventing ice discharge when the bin is not properly positioned.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a mechanical lever arm is used to sense ice level, then the system is simple and reliable, but the moving parts are subject to freezing and may not function properly
Solution Approach 1:
The patent replaces the mechanical lever arm sensing system with an optical sensing system using a transmitter, detector, and reflector. The optical system uses light beams to detect ice level without moving parts that can freeze, thereby maintaining simplicity while eliminating the reliability issue of mechanical components freezing in the ice storage bin environment.
2Measurement precision
If optical sensing devices are disposed on opposite sides of the ice storage bin, then ice level can be detected, but precise positioning is required and relative movement must be prevented
Solution Approach 1:
The patent combines the transmitter and detector into a single mounting location on one wall of the ice storage bin, rather than placing them on opposite sides. This merging allows the system to tolerate relative movement between the bin and the optical components while maintaining accurate ice level detection, as the angled light beam geometry compensates for positional variations.
3Ease of operation
If the ice storage bin is movable, then accessibility is improved, but the bin can move away from the optical sensing system and ice may be discharged even when the bin is not positioned to catch discharged ice
Solution Approach 1:
The optical sensing system is designed with dynamic positioning tolerance, where the transmitter and detector are angled relative to each other so that the light beam geometry maintains functionality even when the ice storage bin moves within a certain range. This dynamic design allows the bin to be easily accessible while preventing false discharge by ensuring the optical path remains valid only when the bin is in the correct position.
4Measurement precision
If the mechanical lever arm extends into the ice storage bin, then ice level can be sensed, but movement of the ice storage bin becomes difficult and ice can be displaced
Solution Approach 1:
The patent replaces the mechanical lever arm that physically extends into the ice storage bin with a non-contact optical sensing system. The transmitter and detector mounted on the bin wall use light beams to sense ice level without any mechanical components extending into the bin, thereby maintaining sensing capability while fully preserving bin mobility and preventing ice displacement.
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 system effectively controls ice production based on ice level, preventing spillage and ensuring accurate ice collection by turning off the ice maker when the bin is full or improperly positioned, even with movement, thus maintaining operational efficiency and preventing jamming.
Implementation Method 1
A reflector is disposed relatively remote from the transmitter, where the transmitter is operative to project the light beam toward the reflector. The transmitter and detector are angled relative to each other so that the light beam reflected by the reflector is directed toward the detector.
Data Source
AI summary
An ice level sensing system for an appliance having a cavity with a cavity wall. An ice storage bin and an ice maker are disposed within the cavity. The ice storage bin is configured to hold ice discharged from the ice maker. The ice level sensing system includes a transmitter for transmitting a light beam and a detector for detecting the light beam. The transmitter and the detector are disposed on the cavity wall. A reflector is disposed relatively remote from the transmitter. The transmitter is operative to project the light beam toward the reflector. The transmitter and the detector are angled relative to each other so that the light beam reflected by the reflector is directed toward the detector.