This patent application claims the benefit of and priority to German Patent Application No. 102023112104.9, filed on May 9, 2023, which is herein incorporated by reference in its entirety.
The invention relates to an ice maker for a household refrigeration appliance.
In order to produce ice cubes for domestic use in a household refrigeration appliance, for example, in a freezer compartment of a refrigerator, conventional ice makers have an ice making tray with a plurality of trays. These trays are used to fill with water, which freezes into one ice cube each during the freezing process. In certain conventional ice makers, the ice making tray is rotatably mounted. To empty the ice making tray of the frozen ice cubes, the ice making tray of these ice makers is rotated from a freezing position, in which the ice making tray is orientated substantially horizontally, so that the ice cubes can fall by gravity from the ice making tray into a collecting container below. In ice makers that work according to the so-called twisted tray principle, the ice making tray is not only twisted as a whole during the emptying process but also twisted in itself. This is intended to break the ice cubes, which can freeze to the surface of the ice making tray during the freezing process, away from the ice making tray and give them a kind of push to fall out of the ice making tray.
To control a drive unit that rotates the ice making tray from the freezing position and back, it is necessary to recognise when the desired final rotation state has been reached and, when it is subsequently rotated back, when the freezing position has been reached again. For this purpose, the ice maker can be equipped with electrical switches that change their electrical switching state when the respective rotational position of the ice making tray is reached. By wiring the switches accordingly using a harness, the electrical switching signals of the electrical switches can be fed to a control unit of the ice maker.
Ice makers of the type considered in the context of the invention are typically mass-produced products for which low-cost manufacture is of great importance. The provision of electrical switches for detecting the rotational position of the ice making tray and the necessary wiring of the switches result in an increased number of components, complicate the assembly of the ice maker and are thus cost drivers. One task of the present invention is therefore to provide an ice maker for use in a household refrigeration appliance which can be manufactured at low cost.
To solve this task, the invention provides an ice maker for a domestic refrigerating appliance, comprising an ice making tray arranged to rotate about an axis of rotation; a drive unit for driving the ice making tray in rotation, the drive unit comprising an electric motor; and a drive control system which is set up to control the operation of the electric motor as a function of its electric current consumption.
The invention is based on the idea of obtaining information about the rotational state of the ice making tray on the basis of the electric current consumption of the electric motor (i.e., the electric current flowing through the electric motor), and possibly using one or more further measured variables (e.g., motor voltage), and controlling the operation of the electric motor depending on the information thus obtained. In certain embodiments, the magnitude of the motor current (e.g., its instantaneous magnitude or magnitude averaged over a period of time or otherwise derived from a current measurement signal) is used to infer the rotational state of the ice making tray. At least during a part of the phase of an electric motor operation, the current can be used to control the electric motor independently of time (i.e., without considering the time factor). During another part of the phase of an operating run of the electric motor, the time factor can be taken into account in addition to the current strength (e.g., by measuring the current consumption of the electric motor at different times during an operating run and evaluating the time-dependent measured motor current with regard to one or more time-dependent defined motor current criteria). For example, a gradient of the time-dependent current consumption of the electric motor can be determined and compared with one or more gradient criteria.
The evaluation of the electric current consumption of the electric motor creates the prerequisite for dispensing with electrical switches for detecting the position of the ice making tray, thereby reducing the components and manufacturing costs for the ice maker.
According to certain embodiments, the drive control system is set up to stop the electric motor from running depending on whether a current behaviour is detected for the electric current consumption of the electric motor which is characteristic of the proper starting and/or reaching of a defined rotational state, in particular a final rotational state, of the ice making tray. These embodiments are based on the idea that the electric current consumption of the electric motor when the ice making tray is rotated in a certain direction of rotation is different for different rotational states of the ice making tray. If, for example, the final rotational state of the ice making tray is determined by a mechanical stop limiting the movement path of a component arranged in the power transmission path from the electric motor to the ice making tray, the current consumption of the electric motor will suddenly increase rapidly when this final rotational state is reached. This is because the mechanical stop limit then acts as an infinitely large mechanical load against which the electric motor must work. If such an increase in the motor current is detected, for example by evaluating the absolute magnitude of the motor current and/or by evaluating the time gradient of the motor current, the drive control system can conclude that the relevant final rotational state of the ice making tray has been reached and it can consequently stop the electric motor. Said component may be arranged upstream of the ice making tray in the power transmission path in the direction of power flow; for example, it may be a gear pinion of a reduction gear.
According to certain embodiments, a nominal current behaviour of the current consumption of the electric motor can be stored in a memory of the drive control system in a tabular, algorithmic or otherwise suitable manner, which is characteristic of a proper rotation of the ice making tray from a first final rotational state to a second final rotational state and which, at least in certain embodiments, indicates a nominal time-dependent course of the motor current during such a rotational movement. By evaluating the time-dependent measured motor current, the drive control system can determine matches and deviations between the measured current behaviour and the nominal current behaviour and control the operation of the electric motor depending on the matches or deviations determined.
In certain embodiments, two final rotational states are defined for the ice making tray by mechanical stop limitation. In these embodiments, one of these final rotational states corresponds to a horizontal position of the ice making tray (freezing position), in which the ice making tray is ready for the filling of fresh water into the troughs of the ice making tray. The other of the final rotational states is a rotational state of the ice making tray that is rotated in relation to the horizontal position, which allows the frozen ice cubes to fall out of the ice making tray due to gravity. In this other final rotational state, the ice making tray can have a forced, automatically reversible internal torsion.
In certain embodiments, in association with each of two predetermined final rotational states of the ice making tray, a different nominal current behaviour of the current consumption of the electric motor is predetermined for the proper moving towards and/or reaching of the respective final rotational state. In such embodiments, the current consumption of the electric motor exhibits different behaviour depending on whether the ice making tray is rotated from one final rotational state to the other or vice versa. This difference can manifest itself in particular in a different time behaviour of the electric motor's current consumption. For example, when the ice making tray is rotated from a horizontal position (freezing position) to an emptying rotational state, the current consumption of the electric motor can show a characteristic increase even before the emptying rotational state is reached. This increase in current can be caused by a forced twisting of the ice making tray, which increases the mechanical load acting on the electric motor. If the ice making tray is rotated in reverse (from the emptying rotational state to the horizontal position), on the other hand, the current consumption of the electric motor can remain largely constant until the horizontal position is reached, after the twisting of the ice making tray described above has disappeared, and only increase abruptly when the horizontal position is reached. The nominal time behaviour of the current consumption of the electric motor can be correspondingly different for the two directions of rotation of the ice making tray.
According to certain embodiments, the drive control system is set up to stop the electric motor from running when the ice making tray rotates from a horizontal position towards an emptying rotational state, depending on the fact that a current increase behaviour characteristic of the characteristic moving towards and/or reaching of the emptying rotational state is determined for the electric current consumption of the electric motor. In this case, the drive control system can be set up to take into account a current increase behaviour during such a part of the rotational movement path of the ice making tray on which the ice making tray undergoes a twisting that ensures or promotes the breaking away of pieces of ice from the ice making tray in order to assess whether a current increase behaviour characteristic of the proper moving towards and/or reaching of the emptying rotational state is present. By the drive control system monitoring the measured electric current consumption of the electric motor for the occurrence of a rise behaviour characteristic of a torsion of the ice making tray, it can be ensured that in the emptying rotational state of the ice making tray a complete emptying of the ice making tray is possible because the frozen ice cubes were previously able to break away from the ice making tray due to the torsion of the ice making tray.
In certain embodiments, the drive control system is set up to determine a current angle of rotation of the electric motor and/or the ice making tray based on the current consumption of the electric motor and to control the electric motor depending on the current angle of rotation. For example, the horizontal position of the ice making tray is assigned a first angle of rotation (e.g., 0°), and the emptying rotation state of the ice making tray is assigned a different second angle of rotation (e.g., 180°). The drive control system can then be set up to stop the electric motor from running during an emptying process depending on whether the second angle of rotation has been reached. Accordingly, the electric motor can be stopped during the return movement of the ice making tray towards the horizontal position depending on whether the first angle of rotation has been reached. This rotation angle-dependent control can also be combined with the control described above based on the characteristic current behaviour, for example to interrupt motor operation before the desired rotation angle is reached if an unexpected abrupt increase in current occurs. The information about the current angle of rotation can also be used by the drive control system for fault diagnosis.
The drive control system can be set up to determine the current angle of rotation based on the cumulative current consumption of the electric motor within a past time interval. For example, the drive control system can determine the current angle of rotation on the basis of the cumulative current consumption of the electric motor and the motor voltage in the past time interval, in particular on the basis of the cumulative power consumption of the electric motor in the past time interval. The current rotation angle is defined, for example, relative to a reference position (e.g., relative to the horizontal position of the ice making tray or relative to the emptying rotation state of the ice making tray). The elapsed time interval can begin at a point in time at which this reference position is left.
The drive control system can be set up to determine a rotational speed of the electric motor and/or the ice making tray for each of the measurement times based on the current consumption of the electric motor at a plurality of measurement times within a past time interval, and to determine the current angle of rotation on the basis of the rotational speeds. In particular, the drive control system can be set up to determine the rotational speeds on the basis of the current consumption and the motor voltage at the respective measurement times, in particular on the basis of the power consumption of the electric motor at the respective measurement times.
According to certain embodiments, an assignment of current consumption values, motor voltage values and/or power consumption values of the electric motor to rotational speed values of the electric motor and/or the ice making tray can be stored in a memory of the drive control system in a tabular, algorithmic or otherwise suitable manner. The assignment can be determined and stored using measured current consumption values and/or power consumption values of the electric motor during a reference operating phase of the electric motor. The reference operating phase can cause the ice making tray and/or the electric motor to rotate between the first angle of rotation and the second angle of rotation. It is therefore conceivable that the ice making tray is rotated from the horizontal position during the reference operating phase of the electric motor until the characteristic current behaviour described above is used to detect that the second angle of rotation has been reached and the electric motor is stopped. The first angle of rotation, the second angle of rotation and/or the duration of the reference operating phase can now be correlated with the current consumption values measured during the reference operating phase in order to determine or adjust the above-mentioned assignment.
Certain embodiments provide for the drive unit to be installed in a module housing of a drive module, which is designed with a coupling piece rotatably mounted on the module housing and in rotary drive connection with the drive unit. The coupling piece forms a mechanical interface accessible from outside the drive module for the detachable, torque-transmitting coupling of the ice making tray to the drive module. The module housing has an opening through which an electrical conductor arrangement connected to the drive unit is led out of the module housing. At least one of the following measures is taken: the interface and the opening are formed on opposite sides of the module housing; the conductor arrangement is formed by a circuit board; and the module housing has at least one positioning formation, in particular a pin-like positioning formation, on the outside of the housing near the opening for positioning a control board that is in electrical contact with the conductor arrangement.
The invention is explained further below with reference to the accompanying drawings. They show:
Reference is first made to
Insofar as the term ice cube is used in the context of the present disclosure, this is in no way intended to be limited to a geometric cube shape of the ice pieces produced. Rather, the term is to be understood in the colloquial sense as designating any geometric shape of ice pieces, such as may be provided by recesses in an ice making tray.
In
The twisting of the ice making tray 12 is effected by blocking it against further rotation from a certain angle of rotation in the area of a tray longitudinal end remote from the drive. In the area of a tray longitudinal end close to the drive end, on the other hand, the ice making tray 12 can be rotated beyond this angle of rotation into the emptying rotation state. In
The drive module 20 has a module housing 22 in which a drive unit 23 (see
In the example shown, the pinion 28 of the reduction gear 26 has an arc-shaped recess 38 (
For this purpose, for example, a stop not shown in detail can be formed on the frame 16, against which the ice making tray 12 abuts in the region of its tray longitudinal end remote from the drive, after it has been rotated from the horizontal position by a certain angle of rotation, which is less than the angular length of the arc-shaped recess 38. For example, the available range of rotation angles in the region of the tray longitudinal end remote from the drive can be only about 90 degrees. It will be understood that the figures disclosed herein for the range of angular rotation of the ice making tray 12 in the region of its two tray longitudinal ends are exemplary only and are not to be construed as limiting in any way.
The mentioned emptying rotational state of the ice making tray 12 means the rotational state in which the ice making tray 12 has been rotated as far as possible from the horizontal position in the area of its tray longitudinal end close to the drive. The horizontal position and the emptying rotational state therefore correspond to the two arc ends of the arc-shaped recess 38 in the embodiment example shown.
It will be understood that a mechanical rotation limiting device for the drive end of the ice making tray 12 can alternatively be provided elsewhere in the power transmission path leading from the electric motor 24 to the ice making tray 12. For example, such a mechanical rotation limitation can be realised at a pinion of the reduction gear 26 other than the pinion 28. According to yet another alternative, a suitable stop formation could be formed on the frame 16 in spatial association with the longitudinal end of the ice making tray 12 close to the drive, which serves as a rotation limiting stop for the ice making tray 12.
In the embodiment example of the ice maker 10 shown, a control board 42 (
For precise positioning of the control board 42 relative to the circuit board 48 during assembly of the ice maker 10, a positioning pin 56 protrudes from the module housing 22 of the drive module 20 in close proximity to the circuit board 48. When the control board 42 is installed, this engages in a cross-sectionally complementary positioning hole 58 (
In other embodiments, not shown in detail, the circuit board 48 may be omitted and another form of electrical contacting of the electric motor 24 with the control board 42 may be provided. For example, it is conceivable to use electrically conductive pin bodies, spring elements or similar components.
The control board 42 with its components 43 mounted thereon has a measuring function for measuring the electric current consumption of the electric motor 24. For this purpose, it can either directly measure the current flowing to the electric motor 24 via the circuit board 48 or measure the current in another circuit branch of the electrical circuit formed on the control board 42, provided that the current flowing there is representative of the current consumption of the electric motor 24. Depending on the measured current, the drive control unit 44 is set up to control the operation of the electric motor 24 and, in particular, to cause the electric motor 24 to stop if, when the ice making tray 12 rotates from one of its final rotational states (horizontal position, emptying rotational state) to the respective other final rotational state, the measured current consumption of the electric motor 24 is used to recognise that this other final rotational state has been reached or an unforeseen malfunction event has occurred. For this purpose, the drive control unit 44 can compare the time course of the measured current consumption of the electric motor 24 with one or more predetermined characteristic curves, which are characteristic of the proper starting and/or reaching of the respective final rotational state of the ice making tray 12, at least in certain rotational angle ranges of the ice making tray 12. In this regard, reference is now made to
Characteristic curves such as those shown in
In certain embodiments, this further information may relate to the time dimension. For example, a certain (minimum) time period from the start of the rotation process until the emptying rotation state is reached may be defined for a proper emptying process of the ice making tray 12. If a current magnitude and/or a current increase is measured before this time period has elapsed, which indicates a mechanical blockage in the power transmission train from the electric motor 24 to the ice making tray 12 (as in
Consideration of the time dimension alone may be prone to errors if the electric motor 24 does not exhibit sufficiently stable speed behaviour. If the speed behaviour of the electric motor 24 fluctuates, the current rotational state of the ice making tray 12 cannot always be reliably inferred from the elapsed time alone. Certain embodiments therefore provide for alternatively or additionally using one or more other measurable parameters in the determination in order to draw conclusions about the current rotational state of the ice making tray 12. For example, it is conceivable to calculate the current angle of rotation of the ice making tray 12 on the basis of the motor current and the voltage. In particular, the motor current and the motor voltage can be recorded at periodic points in time (e.g., every millisecond), and a respective rotational speed can be determined for each of the points in time using a predetermined assignment of motor current and motor voltage values to rotational speed values. This makes it possible to determine the rotation speed over time, which in turn makes it possible to determine the current rotation angle, provided that the rotation angle at a previous point in time is known (e.g., a rotation angle of 0° at the start of the rotation of the ice making tray from its horizontal position). The predetermined mapping can also be adjusted, for example if it is determined that the mapping indicates a current rotation angle that is greater than a maximum possible rotation angle of the ice making tray 12 (e.g., a maximum rotation angle of) 180°. Such readjustment of the assignment or correlation between power consumption and rotational speed is particularly advantageous if a low-cost electric motor is used whose speed behaviour changes over time with the same power consumption.
If a significantly increased current magnitude and/or a significantly increased gradient of the motor current is measured during the rotary operation of the ice making tray 12, it can be concluded from the calculated current angle of rotation of the ice making tray 12 whether one of the nominal final rotational states of the ice making tray 12 (horizontal position, emptying rotational state) has been properly reached or whether an irregular blockage has occurred. The current angle of rotation can therefore also be used to analyse faults.
In the embodiment example shown in
Number | Date | Country | Kind |
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102023112104.9 | May 2023 | DE | national |