The present invention relates to commercial icemakers, and in particular to control systems therefore.
Commercial ice making machines are well known in the art and provide for the manufacture of ice in various forms, such as cubed and flaked. Cube type icemakers typically make ice by running a flow of water over a vertically oriented evaporator until ice of a sufficient thickness has formed thereon. When the ice is of harvest size, a hot gas defrosting procedure is typically used to remove the ice from the evaporator. It has long been recognized that icemakers are prone to a variety of malfunction events. In response thereto icemakers were first designed to include different control systems that shut down the icemaker in response to a sensor indicating that a problem exists. Examples of such malfunctions include the condenser being too cold or too hot, ice not being successfully harvested from the evaporator, or insufficient water in the water pan. It is also well understood that certain of the malfunctions can be due to causes that are transient in nature. Thus, control strategies have been proposed that allow the ice machine to shut down if a problem is sensed and then to restart and attempt to again make ice. In case the malfunction is not due to a transient problem, these restarts are usually limited to some predetermined number so that the icemaker does not vainly attempt an unlimited number of restarts. It is also well known to add a time delay between each restart in order to increase the total time period over which the limited number of restarts is attempted. This approach can provide more time for the transient problem to go away, while not increasing the number of restarts. At the end of the number of predetermined restart attempts after which a normal cycle of functioning is not restored, it is known to put the machine into a permanent shut-down and activate an indicator light to summon a service technician. Likewise, it is known to reset the counting of restarts to zero if a full ice making cycle results and is followed by a successful harvest.
A problem with the foregoing control approaches is that the restarts simply occur right after the error is sensed or after the predetermined time delays. In either case, the restart is essentially “mechanical”, that is, without any regard to the actual conditions of the machine. Thus, as long as the particular problem that initiated the shut down continues to exist, each restart attempt during that time is futile and can result in a needless waste of water and/or energy. Efficiency of energy and water use is of critical concern to owners and operators of ice making machines. Accordingly, it would be very desirable to have a control system that is better responsive to the actual operating condition of the ice maker so that restart attempts are minimized and are only initiated when there is a greater chance of a successful ice making cycle occurring. A further problem with the prior art controls concerns the fact that nothing is done in an attempt to actively remove or clear the problem causing the fault condition. Restart attempts are simply repeated in hopes that the error condition goes away or is somehow eliminated by the restart process itself Thus, it would also be desirable to have a more active control strategy that can take specific and more positive steps to eliminate an error condition.
The present invention concerns a control system for an ice maker wherein various operating condition thereof are continually monitored and where the ice maker is shut-down if a fault condition is sensed. A restart is attempted if sensors indicate that normal continued operation should be possible. Also, certain control steps are taken to actively remove the error condition.
A condenser routine is shown wherein operation of the ice maker is discontinued if a predetermined high temperature thereof is sensed. The ice maker is only restarted when a suitably low condenser temperature is sensed indicating that a subsequent full cycle ice making operation is attainable. If the predetermined high temperature is nevertheless again encountered, the control will again shut-down the ice maker and wait again for the desired low temperature to be sensed. A predetermined number of theses restarts will result in a permanent shut down condition being instructed. Thus, the control of the present invention does not attempt a restart unless and until the condenser temperature has come down to a predetermined low temperature. Thus, the restart has a much greater likelihood of leading to a successful completion of an ice making cycle.
A water fill rate routine is shown wherein a sensor monitors the rate of filling of a water pan below the evaporator. If the fill rate falls below a predetermined rate, the ice maker shuts off the compressor and the fill valve remains on. Once the rate increases above the predetermined rate or the high level is obtained, the compressor turns on, and the ice maker resumes a normal ice making cycle. If the water fill rate goes below a predetermined low fill rate the ice maker is shut off and water filling is discontinued. In this manner the control of the present invention conserves energy by turning off the compressor if the water fill rate is low but otherwise acceptable. The compressor is then restarted when the water does eventually reach the desired full level.
A failed harvest routine is shown and requires the monitoring of one or more proximity switches associated with a curtain that is pivotally positioned adjacent the evaporator. If ice is successfully harvested from the evaporator, it will fall there from into an ice bin there below, and in doing so, will contact and move the curtain to an open position. If the one or more curtain proximity switches do not all open in 4 minutes, thereby indicating a failed harvest, the compressor and hot gas valve shut off. The fill valve opens, allowing new warm water to enter the system and the circulating pump then runs for 10 minutes circulating that water over the evaporator. The control then causes the ice maker to enter into a hot gas cycle wherein hot gas from the compressor is sent through the evaporator. The control keeps track of the repeated failed harvests until a predetermined maximum value is reached and then stops any further restart attempts. Therefore, the control of the present invention includes the further and more aggressive steps of circulating warm water over the evaporator in order to more effectively dislodge ice that is resistant to being successfully harvested from the evaporator.
A better understanding of the construction and operation of the present invention as well as the objects and advantages thereof can be had by reference to the following detailed description which refers to the following figures, wherein:
The ice maker of the present invention is seen in
A solenoid operated dump valve 36 is fluidly connected to line 34 and serves, when open, to direct water pumped thereto to a drain, not shown. An evaporator curtain 37 is pivotally positioned closely adjacent evaporator 16 and includes a magnetic switch 38 for indication when it has moved away from evaporator 16 to an open position indicated by the dashed line representation thereof. For purposes of clarity of the view of
As particularly seen in
Fitting 48 resides in pan 26 at the bottom thereof and is press fit within a circular ridge 49 that is formed as an integral molded portion of the bottom surface of pan 26. Fitting 48 includes an outer housing 48a defining an inner air trapping area 48b and a tube connecting portion 48c. Four water flow openings 50 exist around a bottom perimeter of housing 48a.
The operation of the present invention can be better understood by referring to the flow diagram of
At block 72 control 40 monitors for the attainment of a maximum fill level for pan 26 indicated by the level line denoted by letters MX. When this highest pressure level is sensed, then at block 74 fill valve 30 is closed. At block 76, a 45 second clock is initiated to provide for some pre-cooling of the water delivered to pan 26 through flow over evaporator 16. At block 78 pump 32 is again turned on. A further 45 second clock is set at block 80, and when that has timed out, fill valve 30 is opened. It will be understood by those of skill that action of pump 32 will serve to fill fluid line 34 and distribution tube 28 which will slightly lower the level of water in pan 26 below that of the desired maximum water volume indicated by level MX. Thus, fill valve 30 is opened at block 82, to replenish that volume as is determined at block 84. At block 86, fill valve 30 is closed when the desired starting maximum level MX is again attained.
At this point pump 32 is operating to flow water over evaporator 16 as such is being cooled by the action of compressor 20, condenser and fan 18 and expansion valve 22, all as operated by control 40. As ice forms on evaporator 16, the water level in pan 26 goes down as does the pressure sensed by sensor 44. When a predetermined harvest water level is reached, as indicated by the level line denoted H, a corresponding predetermined pressure value is sensed by control 40 at block 88. When the harvest point is indicated, pump 32 is stopped and hot gas valve 24 is opened at block 90, causing evaporator 16 to warm resulting in the release of the ice slab formed thereon. Of course, those of skill will understand that other heating means known in the art could be employed, such as, an electrical heater integral with the ice forming evaporator. As is well understood, when the slab of ice falls from evaporator 16, curtain 37 is opened and switch 38 is closed, signaling to the control 40 the release of the ice slab from evaporator 16. As is also known, to insure that the slab of ice has fallen into bin 12 and is no longer in the vicinity of evaporator 16, at block 96, the control herein awaits the remaking of switch 38 which occurs when curtain 36 is free to swing back to its normal closed position unobstructed by any ice. At block 98 the control returns to start and initiates a further ice making cycle.
It was found that the pressure-based water level sensing as described herein provides for very accurate and repeatable determination and control thereof, and hence, for very reliable control of the harvest cycle of an ice maker. In particular, the physical isolation of the pressure sensor 44 from pan 26 contributes to this improved performance by serving to prevent any degradation of the sensor due to the presence of water and/or the corrosive impact thereof.
The operation of the high condenser temperature error control can best be understood by reference to
The water fill cycle control of the present invention is best understood by referring to the flow diagram of
It can now be understood that the water safety control of the present invention actively looks at the fill rate of pan 26 and has a built in tolerance for that fill rate. If the fill rate is above a certain predetermined rate, the compressor is left on. If the fill rate is low but otherwise acceptable, i.e. the filling of the pan will occur in a slower but nevertheless reasonable period of time, then that filling is allowed to continue. However, the compressor is turned off so as not to waste energy during the longer fill cycle. The water fill routine of the present invention is also an improvement over the prior art wherein a simple timer is used without regard to the actual fill rate. Thus, the water fill routine herein will not recognize as a “fault” what other systems may otherwise determine as such based upon the simple timing out of a timer. A threshold low or no fill rate is also determined below which the filling of pan 26 is exceedingly slow or not occurring at all, whereupon a manual restart should be required. If less than one quarter of an inch of water is seen in pan 26, that would indicate that no water is flowing or that, for example, pan 28 is leaking water and not filling.
The improved harvest cycle control of the present invention can best be understood in view of
It can be appreciated that the harvest control of the present invention uses a novel approach to circulate warm water over the evaporator for a predetermined period of time in order to melt and remove any recalcitrant ice from the evaporator. Thus, the control herein takes active measures to eliminate a fault resulting from a failed harvest, wherein ice is not seen to have fallen from the evaporator.
While embodiments of the invention have been described in detail, one skilled in the art can devise various modifications and other embodiments without departing from the spirit and scope of the invention, as defined in the accompanying claims.
This application claims benefit of provisional application Ser. No. 60/455,103, filed Mar. 13, 2003.
Filing Document | Filing Date | Country | Kind | 371c Date |
---|---|---|---|---|
PCT/US04/07775 | 3/13/2004 | WO | 11/8/2006 |
Number | Date | Country | |
---|---|---|---|
60455103 | Mar 2003 | US |