Twist-Type Icemaker Control Module for Low-Energy Ice Ejection
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Solution Overview
Problem
Existing automatic icemakers consume substantial power due to the use of AC power systems with electric mold heaters and rake-type ejection systems, which require both freezing and melting of ice cubes, leading to increased energy consumption and heat extraction from the freezer compartment.
Innovation Solution
A compact control system for automatic icemakers that includes a controller with a programmable digital microprocessor, an AC to DC power converter, and low-energy consumption thermistors to detect ice formation, along with a twist-style ice dispenser that ejects ice cubes without heating, allowing operation with only an AC outlet and water line, reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an AC power system with electric mold heater and rake-type ejection system is used, then ice cubes can be formed and ejected, but energy consumption increases substantially due to heating and melting requirements
Solution Approach 1:
The patent removes the electric heater component from the system entirely. Instead of using heat to melt and eject ice cubes, the invention employs a mechanical twist-style ejection mechanism that rotates the ice mold to release cubes directly, eliminating the energy-consuming heating and melting process while maintaining reliable ejection capability
Solution Approach 2:
The patent replaces the thermal field (heater-based melting system) with a mechanical field (twist-style rotation system). The ice mold is rotated mechanically to eject cubes without requiring thermal energy for melting, thereby substituting a high-energy thermal process with a low-energy mechanical process
2Measurement precision
If a thermostat control system is used to measure completion of ice formation, then ice formation can be monitored, but power consumption increases due to continuous temperature monitoring and heater control
Solution Approach 1:
The patent employs a DC motor with built-in control logic that operates autonomously based on simple sensors. The system self-regulates ice formation and ejection cycles using low-power DC sensing mechanisms rather than continuous AC thermostat monitoring, allowing the control system to service itself with minimal external power input
Solution Approach 2:
The patent changes the operating parameter from AC power with high-power thermostat control to DC power with low-power sensing. This parameter change reduces the energy consumption of the control system while maintaining adequate measurement capability for ice formation detection
3Adaptability or versatility
If an AC power supply is used directly by the icemaker control system, then the system can operate independently, but energy consumption increases and compatibility with basic refrigerators is limited
Solution Approach 1:
The patent changes the power supply parameter from AC to DC, enabling the icemaker to operate with lower power consumption. The DC motor and control system are designed to run on DC power from the refrigerator's existing supply, maintaining independent operation capability while reducing energy consumption and expanding compatibility to include basic refrigerators that provide only DC power
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 significantly reduces energy consumption, improving the energy rating of the refrigerator-freezer by eliminating the need for a heater and using a more efficient DC motor, resulting in cost savings and a higher energy star rating.
Implementation Method 1
converting the AC to DC for powering the control module
Implementation Method 2
utilizes low-energy consumption thermistors to detect temperatures associated with ice formation
Implementation Method 3
converting the AC to DC for powering the control module, and for further reducing the 12 volt DC to 5 volt DC for powering the control module microprocessor. The 12 volt DC power is then sent to the icemaker module for powering the DC motor which drives the icemaker
Implementation Method 4
employs a lower-energy consumption 'twist' style ice dispenser to eject formed ice cubes from the icemaker
Data Source
AI summary
A control system for an automatic icemaker including an icemaker module and a control module. The icemaker module includes a DC motor to drive rotation of a twist-type ice cube tray. The control module incorporates an integrated circuit with a programmable digital microprocessor for controlling the functions of the icemaker module. The control module accesses AC power and converts the AC power to DC power for powering a DC motor, an integrated circuit, and a microprocessor.