WO2014120845A1

WO2014120845A1 - Apparatus and method for sensing ice thickness in an ice maker

Info

Publication number: WO2014120845A1
Application number: PCT/US2014/013700
Authority: WO
Inventors: Steven L. Trulaske, Sr.; John Broadbent
Original assignee: True Manufacturing Co Inc
Current assignee: True Manufacturing Co Inc
Priority date: 2013-01-29
Filing date: 2014-01-29
Publication date: 2014-08-07
Anticipated expiration: 2015-07-29
Also published as: JP2016505128A; CN104995466B; EP2951513B1; US20140208781A1; EP2951513A1; JP6250069B2; US9644879B2; HK1212014A1; KR20150111926A; MX2015009321A; CN104995466A; MX358933B; EP2951513A4; EP2951513C0

Abstract

A method of controlling an ice maker having the steps of filling a sump of the ice maker with water, cascading the water across a freeze plate to make ice cubes, during an estimated sensible cooling time period for the water, sensing whether the water level in the sump has decreased, and indicating that a malfunction exists in the ice maker if during the sensible cooling time period the water level within the sump is sensed to have changed more than a predetermined amount.

Description

APPARATUS AND METHOD FOR SENSING ICE

THICKNESS IN AN ICE MAKER

This application claims priority to U.S. Provisional Patent Application No. 61/758,080, the contents of which are expressly incorporated herein by reference.

FIELD OF THE INVENTION

This invention relates to ice makers generally and in particular to an ice maker comprising system and method for more accurately and controllably determining when to initiate a harvest cycle.

BACKGROUND OF THE FNVENTION

Commercial ice-making machines produce clear ice cubes rather than cloudy ice cubes. Residential, in-your-freezer type ice makers generally produced cloudy ice cubes. This is because residential ice makers form ice cubes by depositing water into a mold attached to an evaporator or an ice tray and allowing the water to freeze in a sedentary state. Ice cubes formed in this manner are cloudy because air and impurities become trapped in the water as it freezes. Commercial ice-making machines form ice by flowing water over a chilled surface called a freeze plate. As the water flows over the chilled surface, layers of ice are formed without trapping air or many minerals within the layers of ice.

In typical commercial ice-making machines, water cascades over a surface of the vertically disposed freeze plate. The freeze plate includes a plurality of pockets or cells in which ice cubes are formed. The water that cascades down the freeze plate but does not freeze is caught in a sump located below the freeze plate and is eventually pumped from the sump back to the top of the freeze plate and allowed to cascade down the freeze plate again and again until the water cools to its freezing point and then is gradually frozen into ice cubes. At an appropriate point, the freeze plate is heated and the formed ice is released from the freeze plate and dropped into an ice storage bin.

After each cell of the freeze plate fills with frozen water, the cells begin to become interconnected to form a slab of frozen ice. When the harvest cycle initiates to release the slab from the freeze plate, the ice that bridges the individual cells tends to break to form smaller pieces of ice and individual cubes of ice.

It is important to determine when the ice has formed to a sufficient thickness such that it can be harvested. Harvesting too early yields small cubes of ice or, in some cases, no ice at all since the small cubes melt before they can be harvested. Harvesting too late yields large chunks of ice that do not easily separate into smaller pieces or individual cubes. An ice thickness sensor detects the thickness of the ice forming on the freeze plate. When a desired thickness is reached, the sensor signals the ice maker to terminate the freeze cycle and begin a harvest cycle. In the harvest cycle, the refrigeration cycle is reversed and the freeze plate is heated to melt the formed ice cubes away from the freeze plate.

Different devices have been used over the years to determine the ice thickness and thus the appropriate harvest point. Most commercial cube ice machines sold in the United States utilize a hinged sensor located in front of the freeze plate and evaporator to determine when the thickness of the ice has reached the desired point in order to initiate harvesting of the ice cubes. The hinged sensor approach has the advantage of directly measuring ice thickness as opposed to inferring the thickness from other measurements. This type of system is very common because it is relatively easy to mechanically adjust and provides a relatively accurate ice thickness measurement.

However, this approach has a number of drawbacks. Because the sensor is in the food zone, it must comply with National Sanitation Foundation's (NSF) rules for potable water. Thus, the sensor must be made of suitable material and have suitable geometry for use in the food zone of an ice machine, as defined by NSF. Also, the sensor is exposed to the flowing water, so care must be taken to ensure that it will not be adversely affected by the water or the scale that may be left on the sensor by the water.

Because the sensor is placed in front of the evaporator and freeze plate, it must move out of the way when the ice is harvested so that the sensor does not get hit by the falling ice. Thus, the sensor is a moving part which could fail by not moving correctly. The thickness of the ice sensed is a function of how far the sensor is from the ice. Thus the sensor must be in exactly the right position or it will not work as desired. This distance is controlled by a set screw which must be manually adjusted and thus could be adjusted incorrectly or change over time, and because the ice thickness is controlled by the position of the set screw or other mechanical means, the ice thickness can only be adjusted mechanically, not electronically.

Another approach is to use electrical conductivity whereby an electrical probe is positioned closely adjacent the surface of the evaporator and freeze plate. When ice builds to a desired thickness the plate comes in contact with the flow of water completing an electrical circuit which can trigger the harvest cycle. This method is subject to fouling of the sensor with mineral or other contaminants that would adhere to the sensor and prevent electrical conductivity necessary to signal ice thickness. Additionally, the sensors must be protected from contaminants that would provide an alternatively conductivity path. This sensor must also be designed so that the sensor will detect the water even if the water has extremely low conductivity, as is the case with deionized or "DI" water.

An acoustic sensor for sensing the thickness of the formed ice is disclosed by U.S. Patent Application Publication No. 2012/0198864A1 to Rosenlund et al. The application proposes an acoustic transmitter which transmits acoustic waves at certain frequencies and an acoustic sensor which senses the reflection of the transmitted waves. When the sensed, reflected waves reach a certain expected amplitude, the system determines that the ice has reached the desired thickness. This sensor is still subject to NSF food zone requirements, still must be moved out of the way during the harvest cycle, is still subject to placement in the ice maker by mechanical means and therefore, the ice thickness can only be adjusted manually, not electronically. Similar to acoustic sensors, capacitive sensors may also be used but suffer from similar drawbacks.

Yet another system for measuring ice thickness is described in U.S. Patent

Nos. 6,405,546 and 6,705,090 granted to Billman et al. The contents of these patents are incorporated herein by reference. A process disclosed by Billman utilizes a pressure transducer to determine the height of water in the sump of the ice maker and can thus determine when the desired quantity of water is no longer in the sump and instead has been frozen into ice cubes on the freeze plate so that the ice harvesting can be started. A problem with Billman, though, is that because Billman does not measure ice thickness directly, Billman can mistake water leaks in the system as the formation or non-formation of ice on the freeze plate. For example, if water is leaking from the water circuit of the ice maker to the environment, Billman will presume such leakage is resulting from the formation of ice on the freeze plate. Undersized ice cubes will be the result.

If water is leaking from the water supply into the water circuit of the ice machine, oversized ice slabs (which may be difficult to separate into small pieces of ice or individual cubes) will result because the controller of Billman will incorrectly detect that insufficient water has formed as ice on the freeze plate. In the case of a serious leakage of water from the water supply to the ice maker water circuit, the sensor of Billman would continue to make ice long after the desired ice thickness has been reached and a major failure of the ice maker will result, which could include an uncontrolled water leakage into the ice machine's environment.

Rosenlund identifies three drawbacks to the system disclosed in Billman: 1) that the ice thickness may vary due to factors such as environmental conditions (temperature, humidity), 2) that the ice thickness may vary due to the level of total dissolved solids in the water (only the water freezes, not the minerals), 3) and water loss in the sump may cause incorrect readings. The first two criticisms of Billman are incorrect. As to the first criticism, the weight of the water missing from the sump is exactly equal to the weight of the ice on the freeze plate. Neither temperature nor humidity has any effect on this. As to the second criticism, while it is true that only the water freezes in icemakers with vertical freeze plates and minerals almost completely returns to the sump, it is also true that the weight of the water missing from the sump is exactly equal to the weight of the ice on the freeze plate and evaporator (thought the volume may be marginal different). This is no different than if the water was completely free of minerals. Therefore, criticism two is also incorrect. As discussed above, the last criticism remains a serious concern with the system of Billman.

Therefore, there is a need in the art for an ice maker comprising apparatus and incorporating a method for accurately detecting ice thickness in an ice machine where: the ice thickness sensor is not located in the food zone, the ice thickness sensor is not subject to the impurities of the water supply, the ice thickness sensor need not be moved clear of falling ice during the ice harvest cycle, the ice thickness sensor is not required to be precisely mechanically located and adjusted, the ice thickness sensor is electronically adjustable, and the ice thickness sensor includes safeguards for water leakage into and out of the ice machine water circuit to prevent malformed ice and also major ice machine failure that can result in damage to the ice machine and the ice machine's environment. SUMMARY OF THE INVENTION

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of an ice maker according to an embodiment of the present invention;

FIG. 2 is a control diagram of an ice maker according to an embodiment of the present invention;

FIG. 3 is a diagram of a circuit board incorporating a pressure sensor according to an embodiment of the present invention;

FIG. 4 is a cross-sectional view of a sump according to an embodiment of the present invention; and

FIG. 5A-C are a flow chart describing the operation of a controller for an ice machine according to an embodiment of the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENT

While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail a preferred embodiment of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiment illustrated.

The preferred embodiment of the present invention comprises a unique system for the detection of the thickness of formation of ice on a freeze plate in an ice machine. The preferred embodiment incudes a piezoresistive transducer formed of a monolithic silicon pressure sensor. Most preferably, the transducer provides an analog signal to a microcontroller or microprocessor with A/D inputs.

In the preferred embodiment, the sensor uses a strain gauge to provide an analog output signal that is proportional to the applied pressure of water within the ice maker sump. By doing so, the microcontroller or microprocessor can determine the amount of water that has been converted to ice and determine the appropriate time at which to initiate an ice harvest cycle.

Advantageously, the sensor is not located in the food zone. The sensor is not affected by the minerals or scale that the supply water can leave behind because the sensor is not subjected to flowing water. The sensor is not affected by the electrical properties of the water. That is, it can equally sense ice thickness for de-ionized supply water as it can for water with a heavy ionized mineral content. Also, the sensor has no moving parts so it is not subject to inconsistencies in its placement within ice maker or changes over time as the ice maker ages. The position of the sensor is fixed, is not adjustable and the ice thickness can be controlled and adjusted electronically.

This type of water level measurement system has additional advantages. First of all, the system can use a low-cost, high-reliability pressure transducer, such as part number MPXV5004 from Freescale Semiconductor of Austin, Texas. This component is also used in the appliance industry for sensing the level of wash water in a washing machine and is available in quantity at low cost. Because the sensor detects the water level in the sump of the ice machine, it can be used both to initiate the harvest sequence and also to control the fill and purge functions. That is, when the ice machine is filling, the sensor can control the timing of the closing of the water supply valve when the sump reaches the desired water level. When purging the remaining mineral-concentrated water that remains in the sump when the harvest cycle begins, the sensor can provide an indication of when all remaining water has been purged to a drain from the sump. Thus this system can replace both the ice thickness sensor as well as the sump water level sensor typically found in ice makers.

To detect and protect against water leakage into or out of the ice maker water circuit, the preferred embodiment of the present invention monitors the water level of the sump during the period which the level of the sump is not expected to rise or fall. Specifically, each freeze cycle consists of a first period during which the water is cooled (the sensible cooling period) just to be point of water freezing. Stated otherwise, during the sensible cooling period the energy removed from the water contributes to only temperature change of the water and not to changing the state of the water from liquid to solid.

During a second period of time after the first period of time (when the water begins reaching the freezing point), energy removed from the water begins to contribute to change of state from liquid to solid instead of reduction of temperature (the latent cooling period).

The water level of the sump should not change during the first, sensible cooing period unless there is a water leak into or out of the water circuit. In a typical ice maker, that first period lasts a minimum of 3 minutes after the sump is filled and the refrigeration process starts. The length of time for the first period is highly dependent upon the temperature of the water supplied to the ice maker. Obviously, the warmer water supplied in warmer climates takes longer to cool to its freezing point.

Thus any increase or decrease in water level that occurs during about the sensible cooling period of each freeze cycle (beyond the acceptable level variation due to water turbulence) is due to a leak. According to the preferred embodiment of the present invention, an unacceptable variation in the water level measurement system will result in the microcontroller or microprocessor shutting the ice machine off. Alternatively or additionally, the controller may provide a signal to an indicator that indicates that a leak has been detected. In yet another alternative embodiment, the microcontroller or microprocessor (upon the detection of a leak) may determine if the leak is within an acceptable limit, provide a signal to an indicator that a leak exists, but continue to operate to make ice. In the preferred embodiment, the system continues to monitor the water level for a predetermined period of time after the ice machine has stopped operation as a result of a detected leak. If the water level remains constant during this period, the system will restart freeze cycle of the ice maker. In this manner, the machine would restart if the sensed water level variation that caused the shutdown was due to a transient event (for example, a splashing in the sump caused by a person or other external factor).

More specifically and referring to FIG. 1 of the drawings, an ice making machine 10 according to a preferred embodiment of the present invention is housed in a cabinet 12 which is located on top of an ice bin 15 with a housing 14 that forms an ice receiving and storing compartment accessible through door 16 and an upper section 20 comprising a refrigeration compartment housing the compressor and condenser units of a closed refrigeration circuit. The upper section 20 of the ice making machine 10 further includes evaporator tubing (not shown) attached to an ice making grid 21, which is located above a water pump 19 and sump 24. The various compartments of the ice maker cabinet 12 are closed by suitable fixed and removable panels to provide temperature integrity and compartmental access, as will be understood by those in the art.

The closed refrigeration system housed in compartment 20 includes the refrigeration compressor and the air-cooled condenser. The high pressure discharge side of the compressor is connected by a discharge line to the condenser. Saturated liquid refrigerant flows from the condenser through liquid line having a filter/drier unit therein and is connected to a typical thermostatic expansion valve which meters refrigerant into an inlet of the evaporator unit 21 in the freeze compartment. An outlet of the evaporator is connected by a suction line to a suction side of the compressor. The refrigeration cycle is typical— the compressor supplies high pressure hot refrigerant gas to the condenser, where it is cooled to its saturation temperature and liquefied refrigerant flows to the evaporator 21 through the expansion valve. The expanding vaporization of liquid refrigerant in the evaporator removes heat from the water on the evaporator and freeze plate 21 thereby forming the ice cubes in the lattice molds thereon, and the gaseous refrigerant is returned to the compressor suction side to complete the refrigeration and freeze cycle.

The system also includes a hot gas by-pass line connected between the discharge line and the evaporator inlet side downstream of expansion valve, and being controlled by solenoid valve to initiate an ice harvest cycle. When this solenoid valve is energized, the hot gas bypass line warms the freeze plate 21 to thaw ice cubes that have been formed thereon. The result is that the ice cubes melt away from the freeze plate 21 and fall through an ice hole 22 into the ice bin 15 from where it can be retrieved and used.

Referring to FIG. 2, in the preferred embodiment, ice maker 10 comprises a control system 30. In the control system 30, an ice maker controller 32 is electrically connected to a plurality of elements which provide input signals and/or respond to output signals from the controller 32. A water supply valve 34 is connected to the controller 32 such that the controller 32 can initiate and end the flow of supply water to the sump 24. A refrigeration compressor 36 and water circulation pump 38 are electrically connected to the controller 32 such that the controller 32 can initiate and end a freeze cycle by starting or stopping the refrigeration compressor 36 and the water circulation pump 38 that pumps water from the sump 24 to the freeze plate. The controller 32 is further electrically connected a harvest solenoid 42 for initiating the harvest cycle and a purge solenoid 43 for draining the sump 24 at the end of a freeze cycle.

As shown in FIG. 3, an electronic control board 44 includes the controller 32 for controlling the operation of the ice maker 10. Board 44 comprises a pressure sensor 40 (see also FIG. 2), such as the MPXV5004G described above. As understood by also viewing FIG. 4, a pneumatic tube 48 is connected to the pressure sensor 40 and is submerged underneath the water in sump 24 on its opposite end.

During filling of the sump 24 with water, the pressure of the air trapped in tube 48 increases with the pressure created by the water in which tube 48 is submerged. .

The preferred embodiment of the invention operates according to the diagram of FIGS. 5A-5C. Specifically, operation begins at step 62 when the controller 32 signals to water supply valve 34 to open and fill the sump 24. In step 64, the controller 32 decides whether the signal from the pressure sensor 40 indicates that the sump 24 is sufficiently full. If the sump 24 is not sufficiently full, the water supply valve 34 remains open until the pressure sensor 40 provides an indication that the sump 24 is sufficiently full. When the pressure sensor 40 determines the sump 24 is sufficiently full, the controller 32 proceeds to step 66 where a signal is provided to the water supply valve 34 to close.

Next, in step 70, controller 32 determines whether the pressure sensor 40 indicates that that water level in the sump 24 has increased or decreased beyond an acceptable tolerance. If it has not, the controller 32 proceeds to step 72 where the controller 32 determines whether the water cooling period time limit has expired. If water cooling period time limit has not expired, the controller returns to step 70.

If in step 70, the controller 32 determines that the water level has increased or decreased by an unacceptable amount, the controller 32 proceeds to step 74 where it stops the refrigeration compressor 36 and the pump 38 and provides an error indication indicative of a leak into or out of the water circuit.

Referring to FIG. 5C, in step 76 the controller determines whether a predefined wait period, for example 1 minute, has expired. If it has expired, in step 78, the controller 32 rechecks to determine whether the settled water within the sump 24 still indicates a water level outside the tolerance, indicating a water level increase or decrease. If the water level is within the tolerance, the controller 32 returns to step 63 and reinitiates the freeze cycle. In this instance, the previous sense of a water level out of tolerance is the result of an anomaly, rather than a leak.

If the water level change remains above or below the tolerance for an acceptable sump 24 water level, the controller 32 proceeds to step 80, where the controller continues to provide the error indication and discontinues the freeze cycle.

Referring back to step 72 in FIG. 5 A, if the cooling time has expired, the controller 32 proceeds to step 84 where the controller 32 next monitors the water level in the sump 24 until the controller 32 determines the water level has dropped to a predetermined harvest level. When the water level in the sump 24 has dropped to the predetermined harvest level, the controller proceeds to step 86, where the harvest solenoid 42 and the purge solenoid 43 are activated. In step 88, the controller determines whether a harvest has occurred, then proceeds to step 90 where the harvest solenoid 42 is deactivated and the purge solenoid 43 is deactivated. The controller now continues to step 63 (FIG. 5A) and restarts a new freeze cycle.

The above example shows that the invention, as will be defined by the claims, has far ranging application and should not be limited merely to the embodiment shown and described in detail. Instead the invention should be limited only to the words of the claims. Aspects of the preferred embodiment not claimed are not intended to be part of the claimed invention. Applicant intends the scope of the protection to be only limited by the scope of the patent claims.

Claims

We claim:

1. A method of controlling an ice maker comprising the steps of:

filling a sump of the ice maker with water;

cascading the water across a freeze plate to make ice cubes;

during an estimated sensible cooling time period for the water, sensing whether the water level in the sump has decreased;

indicating that a malfunction exists in the ice maker if during the sensible cooling time period the water level within the sump is sensed to have changed more than a predetermined amount.

2. The method of claim 1 wherein the step of filling a sump comprises the steps of:

opening a water inlet valve;

sensing the water level of water within the sump;

closing the water inlet valve when the water level within the sump reaches a desired level.

3. The method of claim 1 wherein indicating a malfunction exists comprises the step of:

indicating that a leak exists in the ice maker if during the sensible cooling time period the water level within the sump is sensed to have decreased more than a predetermined amount.

4. The method of claim 1 wherein indicating a malfunction exists comprises the step of:

indicating that a malfunction exists in the ice maker if during the sensible cooling time period the water level within the sump is sensed to have increased more than a predetermined amount.

5. The method of claim 1 further comprising the step of:

if a malfunction is indicated, waiting a predetermined period of time and re-determining whether the water level within the sump is still sensed to have changed more than a predetermined amount.

6. The method of claim 5 further comprising the step of:

if after waiting a predetermined period of time and re-determining whether the water level within the sump is still sensed to have changed more than a predetermined amount, the water level is now sensed to be less than the predetermined amount, performing a step selected from the group consisting of: a. not performing the indicating a malfunction exists step; and b. removing a previously provided indication of a malfunction.

7. The method of claim 5 further comprising the step of:

if after waiting a predetermined period of time and re-determining whether the water level within the sump is still sensed to have changed more than a predetermined amount, the water level is still sensed to be less than the predetermined amount, performing a step selected from the group consisting of: a. continuing to provide an indication a malfunction

b. initially indicating that a malfunction exists

8. The method of claim 1 further comprising the step of:

if the sensible cooling time has expired, monitoring the water level in the sump to determine whether the water level has dropped to a predetermined harvest level; and

initiating a harvest cycle when the water level has dropped to a predetermined harvest level.