Patent Application
20080098753
The present disclosure generally relates to a method and ice-making machine that tracks performance history including ice-making cycles, compressor run hours, system performance data, error codes, etc.
Conventional ice-making machines do not provide users with an ability to quickly diagnose machine status or condition. It would be useful for both machine operators and service technician if there was a quick and easy way to diagnose machine status or condition, thereby allowing appropriate action to be taken to reduce delays normally associated with a more manual diagnosis.
Thus, there is a need for an improved ice-making machine and method that aids diagnosis of ice making performance.
The present inventors have developed a novel ice-making machine and method which provides users and service technicians with ready access via a USB port on an advance feature board to a log file containing status and condition information related to the performance of an ice-making machine, thereby allowing the user and/or service technician to rapidly diagnose the machine's condition.
An ice-making machine of the present invention comprises an assembly that performs an operation of making ice, a processor and a data log program that when executed by the processor writes in a log memory current values of a set of operational parameters of the operation.
In one embodiment of the present invention, the log program periodically repeats the writing of current values in the log memory so that the log memory contains a history of ice making cycles, compressor run time and system performance.
In another embodiment of the present invention, the log program causes the processor to send the values stored in the log memory to an external device.
In another embodiment of the present invention, the values are sent to the external device periodically or earlier if the current values being written contain an error or in response to a received request.
In another embodiment of the present invention, the request is received from the external device.
In another embodiment of the present invention, when the log memory is full, the current values are written over the oldest logged current values in the log memory.
A method of the present invention comprises performing an operation of making ice and writing in a log memory current values of a set of operational parameters of the operation.
In one embodiment of the method of the present invention, the log program periodically repeats the writing of the current values in the log memory so that the log memory contains a history of ice making cycles, compressor run time and system performance.
In another embodiment of the method of the present invention, the log program causes the processor to send the values stored in the log memory to an external device.
In another embodiment of the method of the present invention, the values are sent to the external device periodically or earlier if the current values being written contain an error or in response to a received request.
In another embodiment of the method of the present invention, the request is received from the external device.
In another embodiment of the method of the present invention, when the log memory is full, the current values are written over the oldest logged current values in the log memory.
The present invention also provides many additional advantages, which shall become apparent as described below.
Other and further objects, advantages and features of the present invention will be understood by reference to the following specification in conjunction with the accompanying drawings, in which like reference characters denote like elements of structure and:
The ice-making machine according to the present disclosure regulates ice making based on time variable electrical power rates and logs data records of the performance of the ice-making machine.
Some utility companies vary power rates during the day to lower demand during peak use hours. Typical ice-making machines are mounted on or above ice storage bins. When power rates are low, the ice-making machine of the present disclosure runs to fill the storage bin. When power rates are high, the ice-making machine lets the ice level in the bin drop to lower levels and maintains them at the lower levels until power rates drop again. Alternatively, if through monitoring the usage rate of the ice, the ice-making machine determines that at the lower levels the customer will run out of ice, the ice-making machine will make ice regardless of electricity rates.
By way of example and completeness of description, the present invention will be described in a preferred embodiment that comprises a field add on or retrofit to an existing ice-making machine. Referring to
Control board assembly 36 comprises a mounting bracket 38 and a main control board 40. A controller 42 and an interface 44 are mounted on main control board 40.
A field add on assembly 50 comprises a bin level control board 52, an advance feature control board 54, a communication cable 56 and a bin level sensing device 58. Bin level sensing device 58 comprises a sensor 60, a mount 62 and a wire 64. Sensor 60 is any suitable sensor that senses a level of ice in ice bin 46. Preferably, sensor 60 is an ultrasonic sensor.
Bin level control board 52 includes circuitry to monitor the current ice level in ice bin 46, a plug (not shown) and a user interface knob 66. Bin level control board 52 plugs into main control board 40. Advance feature control board 54 also plugs into main control board 40 via communication cable 56.
Referring to
User interface 72 comprises USB port 74, a display area 76, a scroll down button 78, a scroll up button 80, a select button 82, an escape button 84 and an enter button 86. A display program 102 is also stored in memory 94 and when run causes processor 70 to present menus in display area 76. Display program 102 responds to manual operation of scroll down and up buttons 78 and 80 to scroll down and up through a list of menu items on a menu presented in display area 76. Display program 102 responds to manual operation of select button 82 to make changes to settings, such as electricity rates and the times of day when applicable or other parameters. Display program 102 responds to manual operation of enter button 86 to change from a main menu list to a sub-menu list. Display program 102 responds to manual operation of escape button 84 to back up through the menu. Display program 102 can also display alerts and data in display area 76. Examples of alerts are “service ice machine soon”, “slow water fill”, “long freeze cycle”, “long harvest cycle”, and “high discharge temperature”.
A log program 104 is also stored in memory 94. Log program 104 is executed by processor 70 on a periodic basis to obtain data records of operational parameters at sample times. Log program 104 causes each data record to be written to log memory 98. Log memory 98 is preferably a non-volatile memory that retains stored data records in the event of turn off of ice-making machine 20 by operator action or power failure. Real time clock 96 provides time and date stamping information for log program 104. When log memory 98 is full, log program 104 writes the data records over the oldest records. The logged data can be downloaded to external device 106 that comprises a data analysis tool 108 that downloads the logged data and presents views and charts of the logged data to a user, such as a technician
Advance feature board 54 is an add-on board to the base control system of conventional ice-making machines. It provides additional features that are not incorporated into main control board 40.
Log program 104 tracks the ice machine performance including ice making cycles, compressor run hours, system performance data, error codes, etc. In one embodiment, log memory 98 has the capacity to store a cycle history of 12 hours minimum to 720 hours maximum history, depending on sample rate setting, which is adjustable from one second to 60 seconds. As memory 98 becomes full, log program 104 writes new data records over the oldest data records. Log program 104 has the ability to clear memory 98. Assuming ice-making machine 20 is operating without any type of error condition, log program 104 will cause a basic log of data to be sent out every hour via USB port 74 to external device 106. If an error occurs, log program 104 will cause the logged data up to the occurrence of the error condition to be sent out. A user of external device 106 can at any time request a download of the logged data.
Referring to
The table below lists exemplary variables for which the ice-making machine can log cycle history. By charting these variables out over time, the user can determine if various components are turning on and off at the appropriate time within each ice making cycle.
The present invention having been thus described with particular reference to the preferred forms thereof, it will be obvious that various changes and modifications may be made therein without departing from the spirit and scope of the present invention as defined in the appended claims.
This application claims the benefit of U.S. Provisional Patent Application No. 60/862,304, filed Oct. 20, 2006, the entire contents of which are incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 60862304 | Oct 2006 | US |
