ICE MAKER WITH CAPACITIVE WATER LEVEL SENSING

Abstract

An ice maker comprising a refrigeration system, a water system, and a control system. The control system includes a controller comprising a processor and a water level sensor. The water level sensor is adapted to externally sense a capacitance corresponding to a sump water level. The controller is adapted to control the operation of the refrigeration system and the operation of the water system based upon the sump water level and to detect one or more failure modes of the water system based upon the sump water level.

Claims

1. An ice maker for forming ice using a refrigerant capable of transitioning between liquid and gaseous states, the ice maker comprising: (i) a refrigeration system comprising a compressor, a condenser, a thermal expansion device, an evaporator assembly, a freeze plate thermally coupled to the evaporator assembly, and a hot gas valve; (ii) a water system comprising a water pump, a water distribution tube, a purge valve, a water inlet valve, and a sump located below the freeze plate adapted to hold water; and (iii) a control system comprising a processor and a water level sensor, wherein the water level sensor is adapted to externally sense a capacitance from the water in the sump, wherein the sensed capacitance corresponds to a water level in the sump and wherein the controller is adapted to control the operation of the refrigeration system and the operation of the water system based upon the water level in the sump and to detect one or more failure modes of the water system based upon the water level in the sump.

2. The ice maker of claim 1 wherein the water level sensor comprises a capacitive sensor positioned alongside the sump and separated from the water by a wall of the sump.

3. The ice maker of claim 1 wherein the controller is adapted to detect a water pump failure mode when the water level in the sump does not decrease when the water pump is turned on.

4. The ice maker of claim 1 wherein the controller is adapted to detect an insufficient water failure mode when the water level in the sump does not increase when the water inlet valve is turned on.

5. The ice maker of claim 1 wherein the controller is adapted to detect a purge valve failure mode when the water level in the sump does not decrease when the purge valve is turned on.

6. The ice maker of claim 1 wherein the controller is adapted to detect a leak failure mode when the water level in the sump varies beyond an acceptable range during a sensible cooling cycle.

7. The ice maker of claim 1 wherein when the controller detects a failure mode, the ice maker is adapted to indicate that the failure mode has been detected.

8. A method of controlling an ice maker, the ice maker comprising (i) a refrigeration system comprising a compressor, a condenser, a thermal expansion device, an evaporator assembly, a freeze plate thermally coupled to the evaporator assembly, and a hot gas valve, (ii) a water system comprising a water pump, a water distribution tube, a purge valve, a water inlet valve, and a sump located below the freeze plate adapted to hold water, and (iii) a control system comprising a controller comprising a processor and a water level sensor, wherein the water level sensor is adapted to externally sense a capacitance from the water in the sump, wherein the sensed capacitance corresponds to a water level in the sump and wherein the controller is adapted to control the operation of the refrigeration system and the operation of the water system based upon the water level in the sump and to detect one or more failure modes of the water system based upon the water level in the sump, the method comprising: measuring the water level in the sump during a sensible cooling cycle to determine if the water level is varying beyond an acceptable range; and detecting a leak failure mode if the water level in sump varies beyond the acceptable range during the sensible cooling cycle.

9. The method of claim 8 further comprises indicting the leak failure mode if the leak failure mode is detected.

10. The method of claim 8 further comprising: turning the water pump on; measuring the water level in the sump to determine if the water level is decreasing; and detecting a water pump failure mode if the water level in sump does not decrease when the water pump is on.

11. The method of claim 10 further comprising indicating the water pump failure mode if the water pump failure mode is detected.

12. The method of claim 10 further comprising: turning off the refrigeration and water systems; waiting for a period of time; turning on the water pump; measuring the water level in the sump to determine if the water level is decreasing; and turning on the compressor and the condenser fan if the water level in sump decreases when the water pump is on.

13. The method of claim 12 further comprising repeating the steps of claim 11 if the water level in sump does not decrease when the water pump is on.

14. The method of claim 8 further comprising: opening the water inlet valve; measuring the water level in the sump to determine if the water level has reached an ice making level before a sensible cooling time has elapsed; and detecting an insufficient water failure mode if the water level in sump has not reached the ice making level before the sensible cooling time has elapsed.

15. The method of claim 14 wherein the method further comprises indicating the insufficient water failure mode if the insufficient water failure mode is detected.

16. The method of claim 14 further comprising: turning off the compressor and the condenser fan and closing the water inlet valve; waiting for a period of time; opening the water inlet valve; measuring the water level in the sump to determine if the water level is increasing; and turning on the compressor and the condenser fan if the water level in sump increases when the water inlet valve is open.

17. The method of claim 16 further comprising repeating the steps of claim 15 if the water level in sump does not increase when the water inlet valve is open.

18. The method of claim 8 further comprising: measuring the water level in the sump after the sensible cooling cycle has elapsed to determine if the water level is at the harvest level; turning off the condenser fan, opening the hot gas valve, and opening the purge valve; measuring the water level in the sump to determine if the water level is decreasing; and detecting a purge valve failure mode if the water level in sump does not decrease when the purge valve is open.

19. The method of claim 18 wherein the method further comprises indicating the purge valve failure mode if the purge valve failure mode is detected.

20. The method of claim 8 further comprising: turning off the condenser fan, opening the hot gas valve, and opening the purge valve after the expiration of a maximum freeze time; measuring the water level in the sump to determine if the water level is decreasing; and detecting a purge valve failure mode if the water level in sump does not decrease when the purge valve is open.

21. The method of claim 20 wherein the method further comprises indicating the purge valve failure mode if the purge valve failure mode is detected.

22. A method of controlling an ice maker, the ice maker comprising (i) a refrigeration system comprising a compressor, a condenser, a thermal expansion device, an evaporator assembly, a freeze plate thermally coupled to the evaporator assembly, and a hot gas valve, (ii) a water system comprising a water pump, a water distribution tube, a purge valve, a water inlet valve, and a sump located below the freeze plate adapted to hold water, and (iii) a control system comprising a controller comprising a processor and a water level sensor, wherein the water level sensor is adapted to externally sense a capacitance from the water in the sump, wherein the sensed capacitance corresponds to a water level in the sump and wherein the sensed capacitance corresponds to a water level or a scale amount within the sump, the method comprising: measuring the scale amount in the sump; and determining the need for a cleaning cycle based on the measured amount of scale.

23. The method of claim 22 further comprising the controller signaling that a cleaning cycle is needed.

24. The method of claim 22 further comprising initiating multiple cleaning cycles until the measured amount of scale falls below a predetermined threshold.

25. The method of claim 22 further comprising automatically adapting the frequency of the cleaning cycle based on the rate of scale measured between cleaning cycles.

26. The method of claim 22 further comprising notifying a user to increase the concentration of a descaling chemical used during the cleaning cycle.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0023] These and other features, aspects and advantages of the invention will become more fully apparent from the following detailed description, appended claims, and accompanying drawings, wherein the drawings illustrate features in accordance with exemplary embodiments of the invention, and wherein:

[0024] FIG. 1 is a schematic drawing of an ice maker having various components according to one embodiment of the invention;

[0025] FIG. 2 is a schematic drawing of a controller for controlling the operation of the various components of an ice maker;

[0026] FIG. 3 is a right perspective view of an ice maker assembly with an ice maker disposed within a cabinet wherein the cabinet is disposed on an ice storage bin assembly according to one embodiment of the invention;

[0027] FIG. 4 is a right perspective view of an ice maker assembly with an ice maker disposed within a cabinet wherein the cabinet is disposed on an ice storage bin assembly according to one embodiment of the invention;

[0028] FIG. 5 is a section view of a capacitive water level sensor according to one embodiment of the invention;

[0029] FIG. 6A is flow chart describing the operation of an ice maker according to one embodiment of the invention;

[0030] FIG. 6B is flow chart describing the operation of an ice maker according to one embodiment of the invention;

[0031] FIG. 6C is flow chart describing the operation of an ice maker according to one embodiment of the invention;

[0032] FIG. 6D is flow chart describing the operation of an ice maker according to one embodiment of the invention; and

[0033] FIG. 7 is a section view of a capacitive water sensor and the potential scale buildup that remains at the initial surface as the water level falls during ice making.

DETAILED DESCRIPTION

[0034] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.

[0035] Embodiments of the ice maker described herein comprise a controller and a capacitive water level sensor which permit the detection of the amount of water in a sump reservoir of an ice maker. Additionally, the controller and water level sensor allow the controller to determine the amount of water that has been converted to ice and determine the appropriate time at which to initiate an ice harvest cycle. By monitoring the water level throughout the ice making cycle, the controller can also determine and control the thickness of the ice cubes produced, the amount of remaining ice making water purged each cycle, when to open and close the inlet water valve to maintain the proper levels of water in the ice maker, whether water is leaking into or out of the ice maker and whether or not the water pump or other components of the ice maker are functioning properly. Accordingly, the controller can detect one or more failure modes of the ice maker.

[0036] FIG. 1 illustrates certain principal components of one embodiment of ice maker 10 having a refrigeration system and ice making or water system. The refrigeration system of ice maker 10 may include compressor 12, condenser 14 for condensing compressed refrigerant vapor discharged from the compressor 12, thermal expansion device 18 for lowering the temperature and pressure of the refrigerant, evaporator assembly 20, freeze plate 60 thermally coupled to evaporator assembly 20, and hot gas valve 24. In certain embodiments, freeze plate 60 may contain a large number of pockets (usually in the form of a grid of cells) on its surface where water flowing over the surface can collect (see FIG. 4).

[0037] Thermal expansion device 18 may include, but is not limited to, a capillary tube, a thermostatic expansion valve or an electronic expansion valve. In certain embodiments, where thermal expansion device 18 is a thermostatic expansion valve or an electronic expansion valve, ice maker 10 may also include a temperature sensing bulb 26 placed at the outlet of the evaporator assembly 20 to control thermal expansion device 18. In other embodiments, where thermal expansion device 18 is an electronic expansion valve, ice maker 10 may also include a pressure sensor (not shown) placed at the outlet of the evaporator assembly 20 to control thermal expansion device 18 as is known in the art. In certain embodiments that utilize a gaseous cooling medium (e.g., air) to provide condenser cooling, a condenser fan 15 may be positioned to blow the gaseous cooling medium across condenser 14. As described more fully elsewhere herein, a form of refrigerant cycles through these components via lines 23, 25, 27, and 28.

[0038] The water system of ice maker 10 may include water pump 62, water line 63, water distribution manifold or tube 66, and sump 70 located below freeze plate 60 adapted to hold water. During operation of ice maker 10, as water is pumped from sump 70 by water pump 62 through water line 63 and out of distributor manifold or tube 66, the water impinges on freeze plate 60, flows over the pockets of freeze plate 60 and freezes into ice. Sump 70 may be positioned below freeze plate 60 to catch the water coming off of freeze plate 60 such that the water may be recirculated by water pump 62 (see FIGS. 4 and 5). In addition, hot gas valve 24 may be used to direct warm refrigerant from compressor 12 directly to evaporator assembly 20 to remove or harvest ice cubes from freeze plate 60 when the ice has reached the desired thickness.

[0039] Ice maker 10 may further include water supply line 50 and water inlet valve 52 disposed thereon for filling sump 70 with water from a water source (not shown), wherein some or all of the supplied water may be frozen into ice. Ice maker 10 may further include purge line 54 and purge valve 56 disposed thereon. Water and/or any contaminants remaining in sump 70 after ice has been formed may be purged via purge line 54 and purge valve 56. In various embodiments, purge line 54 may be in fluid communication with water line 63. Accordingly, water in sump 70 may be purged from sump 70 by opening purge valve 56 when water pump 62 is running.

[0040] As illustrated in FIG. 5, ice maker 10 may also include harvest sensor 58 which may sense when door 59 is opened by ice as it is harvested from freeze plate 60. In certain embodiments, for example, as illustrated in FIG. 5, harvest sensor 58 may sense when door 59 is open or closed by sensing rotation of door 59. In other embodiments, for example, harvest sensor 58 may sense when door 59 is open or closed by whether door 59 contacts or is in proximity to harvest sensor 58. It will be understood that any type of harvest sensor which can sense whether door 59 is open or closed may be used without departing from the scope of the invention. Ice maker 10 may have other conventional components not described herein without departing from the scope of the invention.

[0041] As illustrated in FIGS. 1 and 5, ice maker 10 may also include a control and water level measurement system having a capacitive fluid level sensor 90 disposed on the outer wall of sump 70 and controller 80. Controller 80 may be located remote from evaporator assembly 20 and sump 70. Controller 80 may include a processor 82 for controlling the operation of ice maker 10 and for determining if various components of the refrigeration and water systems of ice maker 10 have failed. The water level in sump 70 may be correlated to the thickness of ice on freeze plate 60. Using the output from the capacitive sensor 90, processor 82 can determine the water level in sump 70 throughout the cooling cycle. The use of water level sensor 90 also allows processor 82 to determine the appropriate time at which to initiate an ice harvest cycle, control the fill and purge functions, to automatically run a cleaning cycle due to scale buildup along the surface of the water, and to detect any failure modes of components of the water systems of ice maker 10 including, but not limited to, water supply failures, water inlet valve failures, water pump failures, purge failures, and water leaks.

[0042] The water level sensor 90 preferably includes a capacitive sensor positioned alongside the sump 70 and separated from the water by a vertical wall of the sump 70. The sensor 90 may include a flexible non-conductive, dielectric substrate provided as an elongated strip capable of conforming to the exterior of the sump 70. In order to determine the water level in the sump 70, the sensor 90 is provided with a plurality of conductive electrodes aligned along a longitudinal axis of the substrate. Preferably, the electrodes extend along the length of the substrate over the region of the sump 70 within which water may be stored. One end of each of the electrodes is preferably coupled to a connector 86b for providing an analog or digital signal to the controller 80 via interface 86 through connector 86a.

[0043] The dielectric effect of the water changes the effective capacitance of the sensing capacitor as the water rises and falls within the sump 70. The effective electrode area adjacent the water is directly related to the capacitance of the sensor 90. This change in effective capacitance is detected by electronic circuitry located either in the sensor 90 or in the controller 80.

[0044] The water level sensor 90 generates a signal to the controller 80 corresponding to dielectric changes in the sensor 90 as the water level in the sump 70 varies. Knowing the location of the sensor 90 and the geometry and dimensions of the sump 70, the quantity of water in the sump 70 at a given time is readily calculated from the measured capacitance.

[0045] The sump 70 is typically constructed of injection molded plastic—either Acrylonitrile Butadiene Styrene (ABS) or High Impact Polystyrene (HIPS). Provided the wall thickness of the sump 70 is designed within tolerance of the sensor 90 (usually 1/16.sup.th to 3/16.sup.th of an inch), the sensor 90 should be able to detect the change in capacitance due to the level of water on the opposite side of the wall. The sensor 90 may include a multi-capacitive array in certain embodiments to monitor multiple locations—or discrete levels of water. Unlike conductivity meters and floats, only one device would be required to measure multiple set points. One acceptable sensor 90 is manufactured by Molex sold as part number 131960001, which includes a polyimide circuit with a conformal coating, mounting adhesive, shielding layers, microcontroller and a wiring harness terminated with a connector. This particular fluid level sensor conforms to the industry standard I.sup.2C bus protocol, although other bus protocols are within the spirit of the present invention, such as Pulse Width Modulation (PWM). Using this sensor, controller 80 would control the initiation and timing of all I.sup.2C messages by communicating with the microcontroller within the sensor 90.

[0046] Processor 82 of controller 80 may include a processor-readable medium storing code representing instructions to cause processor 82 to perform a process. Processor 82 may be, for example, a commercially available microprocessor, an application-specific integrated circuit (ASIC) or a combination of ASICs, which are designed to achieve one or more specific functions, or enable one or more specific devices or applications. In yet another embodiment, controller 80 may be an analog or digital circuit, or a combination of multiple circuits. Controller 80 may also include one or more memory components (not shown) for storing data in a form retrievable by controller 80. Controller 80 can store data in or retrieve data from the one or more memory components. Controller 80 may also include a timer for measuring elapsed time. The timer may be implemented via hardware and/or software on or in controller 80 and/or processor 82 in any manner known in the art without departing from the scope of the invention.

[0047] In various embodiments, in reference to FIGS. 1 and 2, controller 80 may also comprise input/output (I/O) components (not shown) to communicate with and/or control the various components of ice maker 10. In certain embodiments, for example controller 80 may receive inputs from water level sensor 90, a harvest sensor 58 (see FIG. 5), an electrical power source (not shown), user control panel 102 (see FIG. 4), and/or a variety of sensors and/or switches including, but not limited to, pressure transducers, temperature sensors, acoustic sensors, etc. In various embodiments, based on those inputs for example, controller 80 may be able to control compressor 12, condenser fan 15, water pump 62, water inlet valve 52, purge valve 56, hot gas valve 24, and/or thermal expansion device 18. Controller 80 may also be able to control display 104 on user control panel 102 (see FIG. 4). Display 104 may be able to display messages, including error or failure messages, as reported and/or indicated by controller 80 to display 104. Display 104 may be any type and/or of display including, but not limited to, an LCD screen, one or more LEDs, etc. without departing from the scope of the invention. In certain embodiments, ice maker 10 may include an alarm (not shown) which can provide an audible alert that controller 80 has detected a failure mode. Alarm may include, but is not limited to, a speaker, a buzzer, a chime, a bell, and/or some other device capable of making a human-audible and/or non-human-audible sound. In certain embodiments, the alarm of ice maker 10 may emit a non-human-audible sound which may be detected by a telephone, smartphone, tablet computer, portable computer, and/or any portable device for diagnosing the failure mode. Display 104 and/or alarm may permit a person to determine if ice maker 10 is working or if a failure mode has been detected. Accordingly, in various embodiments, ice maker 10 can indicate that a failure mode has been detected.

[0048] According to one or more embodiments of the invention, the I/O component can include a variety of suitable communication interfaces. For example, the I/O component can include wired connections, such as standard serial ports, parallel ports, universal serial bus (USB) ports, S-video ports, local area network (LAN) ports, and small computer system interface (SCSI) ports. Additionally, the I/O component may include, for example, wireless connections, such as infrared ports, optical ports, Bluetooth® wireless ports, wireless LAN ports, or the like. In certain embodiments, controller 80 may be connected to a network (not shown), which may be any form of interconnecting network including an intranet, such as a local or wide area network, or an extranet, such as the World Wide Web or the Internet. The network can be physically implemented on a wireless or wired network, on leased or dedicated lines, including a virtual private network (VPN).

[0049] By placing the water level sensor 90 outside of the sump 70, the sensor 90 is not located in the food zone. Due to such placement, water level sensor 90 may not be affected by the minerals or scale that the supply water can leave behind because water level sensor 90 does not come into contact with water. Additionally, because the water level sensor 90 does not come into contact with water it may not be affected by the electrical properties of water and can therefore be used to determine ice thickness for de-ionized supply water and supply water with a heavy mineral content. Also, in certain embodiments, the water level sensor 90 has no moving parts and therefore may not be susceptible to inconsistencies in its placement within ice maker 10 or changes over time as ice maker 10 ages.

[0050] Embodiments of this type of control and water level measurement system have additional advantages. First, as stated previously, a low-cost, high-reliability capacitive transducer may be used in ice maker 10. Second, in various embodiments, because water level sensor 90 detects the water level in sump 70 of ice maker 10, water level sensor 90 and controller 80 may be used to initiate the harvest cycle and may also control the water fill and purge functions. That is, when the sump 70 of ice maker 10 is filling, controller 80 can control the timing of the closing of water inlet valve 52 when the water level in sump 70 reaches the desired water level as sensed by water level sensor 90. Third, in certain embodiments, controller 80 can open purge valve 56 during the harvest cycle. Accordingly, when purging the mineral-concentrated water that remains in sump 70 when the harvest cycle begins, water level sensor 90 can provide an indication to controller 80 of when the desired amount of water has been purged from sump 70. Thus embodiments of the control and water level measurement system can replace both the ice thickness sensor and the sump water level sensors found in typical ice makers.

[0051] In many embodiments, as illustrated in FIG. 3, ice maker 10 may be disposed inside of a cabinet 16 which may be mounted on top of an ice storage bin assembly 30 forming an ice maker assembly 200. Cabinet 16 may be closed by suitable fixed and removable panels to provide temperature integrity and compartmental access, as will be understood by those in the art. Ice storage bin assembly 30 includes an ice storage bin 31 having an ice hole 37 (see FIG. 4) through which ice produced by ice maker 10 falls. The ice is then stored in cavity 36 until retrieved. Ice storage bin 31 further includes an opening 38 which provides access to the cavity 36 and the ice stored therein. Cavity 36, ice hole 37 and opening 38 are formed by a left wall 33a, a right wall 33b, a front wall 34, a back wall 35 and a bottom wall (not shown). The walls of ice storage bin 31 may be thermally insulated with various insulating materials including, but not limited to, fiberglass insulation or open- or closed-cell foam comprised, for example, of polystyrene or polyurethane, etc. in order to retard the melting of the ice stored in ice storage bin 31. A door 40 can be opened to provide access to cavity 36.

[0052] Having described each of the individual components of embodiments of ice maker 10, the manner in which the components interact and operate may now be described. During operation of ice maker 10 in a cooling cycle, comprising a sensible cycle and a latent cycle, compressor 12 receives low-pressure, substantially gaseous refrigerant from evaporator assembly 20 through suction line 28, pressurizes the refrigerant, and discharges high-pressure, substantially gaseous refrigerant through discharge line 25 to condenser 14. In condenser 14, heat is removed from the refrigerant, causing the substantially gaseous refrigerant to condense into a substantially liquid refrigerant.

[0053] After exiting condenser 14, the high-pressure, substantially liquid refrigerant is routed through liquid line 27 to thermal expansion device 18, which reduces the pressure of the substantially liquid refrigerant for introduction into evaporator assembly 20. As the low-pressure expanded refrigerant is passed through tubing of evaporator assembly 20, the refrigerant absorbs heat from the tubes contained within evaporator assembly 20 and vaporizes as the refrigerant passes through the tubes. Low-pressure, substantially gaseous refrigerant is discharged from the outlet of evaporator assembly 20 through suction line 28, and is reintroduced into the inlet of compressor 12.

[0054] In certain embodiments, assuming that all of the components are working properly, at the start of the cooling cycle, water inlet valve 52 may be turned on to supply water to sump 70. After the desired level of water is supplied to sump 70, the water inlet valve 52 may be closed. Water pump 62 circulates the water from sump 70 to freeze plate 60 via water line 63 and distributor manifold or tube 66. Compressor 12 causes refrigerant to flow through the refrigeration system. The water that is supplied by water pump 62 then, during the sensible cooling cycle, begins to cool as it contacts freeze plate 60, returns to water sump 70 below freeze plate 60 and is recirculated by water pump 62 to freeze plate 60. Once the cooling cycle enters the latent cooling cycle, water flowing across freeze plate 60 starts forming ice cubes. After the ice cubes are formed, hot gas valve 24 is opened allowing warm, high-pressure gas from compressor 12 to flow through hot gas bypass line 23 to enter evaporator assembly 20, thereby harvesting the ice by warming freeze plate 60 to melt the formed ice to a degree such that the ice may be released from freeze plate 60 and falls through hole 37 (see FIG. 4) into ice storage bin 31 where the ice can be temporarily stored and later retrieved. Hot gas valve 24 is then closed and the cooling cycle can repeat.

[0055] To detect and protect against water leakage into or out of ice maker 10, controller 80 may monitor the water level (x) in sump 70 during the period in which the level of water in sump 70 is not expected to rise or fall. During the sensible cooling cycle, the water is cooled to the freezing point of the water. Stated otherwise, during the sensible cooling cycle the energy removed from the water contributes only to temperature change of the water and not to changing the state of the water from liquid to solid. During the latent cooling cycle, when the water begins reaching the freezing point, energy removed from the water begins to contribute to a change of state from liquid to solid.

[0056] Thus, during the sensible cycle, the water level (x) in sump 70 should not be changing as ice is not yet forming. If the water level (x) in sump 70 is varying during the sensible cooling cycle, this could indicate the occurrence of a failure mode of various components of the refrigeration and water systems of ice maker 10. In a typical ice maker, the sensible cooling cycle may last about 3 minutes. However, the length of the sensible cooling cycle is highly dependent upon the temperature of the water supplied to ice maker 10 and the ambient conditions. Accordingly, warmer water supplied in warmer climates takes longer to cool to its freezing point. Thus, in certain conditions, the sensible cooling cycle may last about 15 minutes or longer. Thus any increase or decrease in the water level (x) in sump 70 that occurs during the sensible cooling cycle of each cooling cycle, beyond an acceptable range of water level (x) due to water turbulence or some other transient event, may be due to a leak. Accordingly, an unacceptable change of the water level in sump 70 may result in controller 80 shutting ice maker 10 off. Alternatively or additionally, display 104 and/or the alarm may indicate that such a failure mode has been detected. For example, the indication may be a message, an indicator light, and/or a sound specific to the detected failure mode. In yet another embodiment, controller 80 may, upon the detection of a leak, determine if the leak is within an acceptable range and may cause an indication to be displayed on display 104 and/or played on the alarm that a leak has been detected, but continue to operate to make ice.

[0057] In various embodiments, controller 80 may continue to monitor the water level (x) in sump 70 for a period of time after ice maker 10 has stopped operation as a result of a detected leak. If the water level (x) in sump 70 remains constant during this period of time, controller 80 may restart the cooling cycle of ice maker 10. In this manner, controller 80 may restart ice maker 10 if the sensed water level variation that caused the shutdown was due to a transient event (e.g., a splashing in sump 70 caused by a person or other external factor).

[0058] In a similar manner, various embodiments of ice maker 10 can determine the ability of ice maker 10 to refill sump 70 with water, thus indicating whether water inlet valve 52 is supplying the desired amount of water for making ice. Specifically, if during the refilling portion of the cooling cycle, which occurs after the ice has released from the freeze plate and the water pump has turned back ON, the water level (x) in sump 70 does not increase, then controller 80 can determine that the supply of water to ice maker 10 has failed. This failure mode could be the result of a failure of the water supply or a failure of water inlet valve 52. In certain embodiments, display 104 and/or the alarm may indicate that such a failure mode has been detected. For example, the indication may be a message, an indicator light, and/or a sound specific to the detected failure mode. Controller 80 may optionally shut off ice maker 10. Likewise, various embodiments of ice maker 10 can detect if water inlet valve 52 has failed in the OPEN position. This may be detected by controller 80 if the water level (x) in sump 70 continues to rise after controller 80 has attempted to CLOSE water inlet valve 52. In certain embodiments, display 104 and/or the alarm may indicate that such a failure mode has been detected. For example, the indication may be a message, an indicator light, and/or a sound specific to the detected failure mode. Controller 80 may optionally shut off ice maker 10.

[0059] In normal operating conditions, when water pump 62 is turned ON, the water level (x) in sump 70 will drop as water is removed from sump 70 by water pump 62 and moved through water line 63 and across freeze plate 60 of ice maker 10. Thus, by monitoring the water level (x) when water pump 62 is turned ON, it is possible to determine if water pump 62 is functioning properly. If the water level (x) does not drop during the several seconds following water pump 62 being turned on, then controller 80 may detect a failure mode of water pump 62 and can take the appropriate actions. In certain embodiments, display 104 and/or the alarm may indicate that such a failure mode has been detected. For example, the indication may be a message, an indicator light, and/or a sound specific to the detected failure mode. Controller 80 may optionally shut off ice maker 10.

[0060] Referring now to FIGS. 6A-6D, a method of operation of certain embodiments of ice maker 10 is described in detail. In FIG. 6A, at step 600 the method starts and at step 602, controller 80 turns ON compressor 12 and OPENS hot gas valve 24 to begin a harvest cycle. While controller 80 waits for a first period of time at step 603, compressor 12 remains ON and hot gas valve 24 remains OPEN so that any ice formed on freeze plate 60 can be harvested. In certain embodiments, for example, the first period of time may be from about 30 seconds to about 5 minutes (e.g., about 30 seconds, about 45 seconds, about 1 minute, about 1.5 minutes, about 2 minutes, about 2.5 minutes, about 3 minutes, about 3.5 minutes, about 4 minutes, about 4.5 minutes, about 5 minutes). After the first period of time has elapsed, the harvest cycle is complete.

[0061] At step 604, controller 80 via water level sensor 90 measures the water level (x) in sump 70 to determine whether the water level (x) is at or below the empty level. If the water level (x) is at or below the empty level, the water pump test at step 612 will not work so the method moves to step 606. At step 606, controller 80 turns ON water pump 62, turns ON condenser fan 15, and CLOSES hot gas valve 24, then moves to step 622 on FIG. 6B. If the water level (x) in sump 70 is above the empty level, then controller 80 turns ON water pump 62, turns ON condenser fan 15, and CLOSES hot gas valve 24 at step 608. Controller 80 then waits a second period of time at step 610 to give water pump 62 enough time to remove some water from sump 70. In certain embodiments, for example, the second period of time may be from about zero (0) seconds to about 15 seconds (e.g., about zero (0) seconds, about 5 seconds, about 10 seconds, about 15 seconds). In either case, whether the water level (x) in sump 70 is at the empty level or not, water pump 62 may be turned ON prior to hot gas valve 24 closing or water pump 62 may be turned ON and hot gas valve 24 may be CLOSED simultaneously. Thus water begins flowing over freeze plate 60 prior to and/or at the same time that the refrigeration system begins to cool freeze plate 60.

[0062] At step 612 controller 80 determines whether the water level (x) in sump 70 has decreased beyond a desired range. In certain embodiments, the desired range may be from about +/−1 percent of the measured water level (x) to about +/−25 percent of the measured water level (x). In one embodiment, for example, the desired range may be about +/−1 percent of the measured water level. In another embodiment, for example, the desired range may be about +/−5 percent of the measured water level (x). In yet another embodiment, for example, the desired range may be about +/−10 percent of the measured water level (x). In yet another embodiment, for example, the desired range may be about +/−15 percent of the measured water level (x). In yet another embodiment, for example, the desired range may be about +/−20 percent of the measured water level (x). In yet another embodiment, for example, the desired range may be about +/−25 percent of the measured water level (x). If the water level (x) did decrease beyond the desired range, indicating that water pump 62 is functioning, the method moves to step 622 on FIG. 6B. If the water level (x) did not decrease beyond the desired range then water pump 62 has most likely failed; accordingly, at step 614 controller 80 turns OFF all components of ice maker 10. At step 616, controller 80 waits for a third period of time. In certain embodiments, for example, the third period of time may be from about 10 seconds to about 1.5 minutes (e.g., about 10 seconds, about 20 seconds, about 30 seconds, about 40 seconds, about 50 seconds, about 1 minute, about 1.5 minutes).

[0063] After the third period of time has elapsed, controller 80 turns ON water pump 62 at step 618. Then at step 620, controller 80 again determines whether the water level (x) in sump 70 has beyond a desired range. If the water level (x) did not decrease beyond the desired range, the method returns to step 614 and controller 80 turns OFF all components. Optionally, controller 80 may be able to log, report and/or indicate that water pump 62 has failed. In certain embodiments, display 104 and/or the alarm may indicate that such a failure mode has been detected. For example, the indication may be a message, an indicator light, and/or a sound specific to the detected failure mode. By delaying for a period of time, controller 80 can wait for any turbulent and/or transient movement of water in sump 70 to cease and can check to ensure the proper operation of water pump 62. If at step 620 the water level (x) in sump 70 did decrease beyond the desired range, controller 80 turns ON compressor 12, turns ON condenser fan 15 at step 621 and proceeds to step 622 on FIG. 6B.

[0064] When the method continues on to FIG. 6B, compressor 12 is ON, condenser fan 15 is ON, hot gas valve 24 is CLOSED, and water pump 62 is ON. Accordingly, the refrigeration and water systems of ice maker 10 are operating and are beginning to cool any water that circulates over freeze plate 60. At step 622, controller 80 via water level sensor 90 measures the water level (x) in sump 70 to determine whether the water level (x) is above the ice making level. The ice making level may be the nominal level of water that is used to produce a desired thickness of ice. If the water level (x) is above the ice making level, controller 80 OPENS purge valve 56 to remove any excess water from sump 70 at step 624. If the water level (x) in sump 70 is at the ice making level, controller 80 CLOSES purge valve 56 at step 626. Then at step 628 controller 80 OPENS water inlet valve 52 to begin filling up sump 70 with water to be frozen into ice by ice maker 10.

[0065] At step 630, controller 80 via water level sensor 90 measures the water level (x) in sump 70 to determine whether the water level (x) in sump 70 is at the ice making level. If the water level (x) of sump 70 is at the ice making level, the method moves to step 646 on FIG. 6C. If the water level (x) in sump 70 is not at the ice making level, then at step 632 controller 80 may determine whether the water level (x) in sump 70 is increasing. If the water level (x) in sump 70 is not increasing, a failure mode of the water supply has likely occurred. This failure mode may be an insufficient amount of water has been supplied to sump 70. Accordingly, at step 636 controller 80 turns OFF compressor 12, turns OFF condenser fan 15, and CLOSES water inlet valve 52. At step 638, controller 80 waits for a fourth period of time. In certain embodiments, for example, the fourth period of time may be from about 10 seconds to about 1.5 minutes (e.g., about 10 seconds, about 20 seconds, about 30 seconds, about 40 seconds, about 50 seconds, about 1 minute, about 1.5 minutes).

[0066] After the fourth period of time has elapsed, controller 80 OPENS water inlet valve 52 at step 640. Then at step 642, controller 80 again determines whether the water level (x) in sump 70 is increasing. If the water level (x) is not increasing, the method returns to step 636 and controller 80 turns OFF compressor 12, turns OFF condenser fan 15, and CLOSES water inlet valve 52. Optionally, controller 80 may be able to log, report and/or indicate an “Insufficient Water” failure mode. In certain embodiments, display 104 and/or the alarm may indicate that such a failure mode has been detected. For example, the indication may be a message, an indicator light, and/or a sound specific to the detected failure mode. By delaying for a period of time, controller 80 can wait for any turbulent and/or transient movement of water in sump 70 to cease and can check to ensure that sump 70 has water. If at step 642 the water level (x) in sump 70 is increasing, controller 80 turns ON compressor 12 and turns ON condenser fan 15 at step 644 then proceeds to step 630 to check whether the water level (x) in sump 70 is at the ice making level. If the water level (x) in sump 70 is at the ice making level, the method moves to step 646 on FIG. 6C.

[0067] If back at step 632 the water level (x) in sump 70 is increasing, controller 80 may determine whether the sensible cooling cycle time has elapsed. By checking to see if the sensible cooling time has elapsed, controller 80 can determine if the flow rate of the water through water inlet valve 52 is insufficient and/or too slow. An insufficient and/or too slow water inlet flow rate may be caused by a variety of factors including, but not limited to, a loss of water pressure, an obstruction, a partially open purge valve 56, etc. Accordingly, ice maker 10 may not be able to properly make ice if sump 70 is still being filled to the ice making level after the sensible cooling cycle time has elapsed. Instead, it is desired that the water level (x) in sump 70 be at the ice making level prior to entering the latent cooling cycle. In certain embodiments, for example, the sensible cooling cycle time may be from about 1 minute to about 15 minutes (e.g., about 1 minute, about 1.5 minutes, about 2 minutes, about 2.5 minutes, about 3 minutes, about 3.5 minutes, about 4 minutes, about 4.5 minutes, about 5 minutes, about 5.5 minutes, about 6 minutes, about 6.5 minutes, about 7 minutes, about 7.5 minutes, about 8 minutes, about 8.5 minutes, about 9 minutes, about 9.5 minutes, about 10 minutes, about 10.5 minutes, about 11 minutes, about 11.5 minutes, about 12 minutes, about 12.5 minutes, about 13 minutes, about 13.5 minutes, about 14 minutes, about 14.5 minutes, about 15 minutes). If the sensible cooling cycle time has not yet elapsed, the method cycles back to step 630. If the sensible cooling cycle time has elapsed, the method cycles to step 636 as described above. Accordingly, step 632 and step 634 provide for detecting insufficient water. In certain embodiments, for example, controller 80 may skip step 632 and proceed from step 630 to step 634 without determining whether the water level (x) in sump 70 is increasing.

[0068] When the method continues on to FIG. 6C, compressor 12 is ON, condenser fan 15 is ON, hot gas valve 24 is CLOSED, and water pump 62 is ON. Accordingly, the refrigeration and water systems of ice maker 10 are operating and are beginning to cool any water that circulates over freeze plate 60. At step 646, because the water level (x) in sump is at the ice making level (step 630 on FIG. 6B), controller 80 CLOSES water inlet valve 52. At step 648, controller 80 via water level sensor 90 measures the water level (x) in sump 70 to determine whether the water level (x) is varying beyond an acceptable range of the ice making level. In certain embodiments, the acceptable range may be from about +/−1 percent of the ice making level to about +/−25 percent of the ice making level. In one embodiment, for example, the acceptable range may be about +/−1 percent of the ice making level. In another embodiment, for example, the acceptable range may be about +/−5 percent of the ice making level. In yet another embodiment, for example, the acceptable range may be about +/−10 percent of the ice making level. In yet another embodiment, for example, the acceptable range may be about +/−15 percent of the ice making level. In yet another embodiment, for example, the acceptable range may be about +/−20 percent of the ice making level. In yet another embodiment, for example, the acceptable range may be about +/−25 percent of the ice making level. At this time during the sensible cooling cycle, the water that is supplied by water pump 62 cools as it contacts freeze plate 60, returns to water sump 70 below freeze plate 60 and is recirculated by water pump 62 to freeze plate 60. During sensible cooling, the water level (x) in sump 70 should not be decreasing as the water is only decreasing in temperature but is not yet freezing into ice on freeze plate 60.

[0069] Accordingly, if the water level (x) is varying from the ice making level beyond an acceptable range, there may be a leak in sump 70, and/or water inlet valve 24 or purge valve 52 may be leaking. At step 650 controller 80 turns OFF all components of the refrigeration and water systems of ice maker 10. Optionally, controller 80 may be able to log, report and/or indicate a leak failure mode. In certain embodiments, display 104 and/or the alarm may indicate that such a failure mode has been detected. For example, the indication may be a message, an indicator light, and/or a sound specific to the detected failure mode. At step 652, controller 80 waits for a fifth period of time. In certain embodiments, for example, the fifth period of time may be from about 1 minute to about 7 minutes (e.g., about 1 minute, about 1.5 minutes, about 2 minutes, about 2.5 minutes, about 3 minutes, about 3.5 minutes, about 4 minutes, about 4.5 minutes, about 5 minutes, about 5.5 minutes, about 6 minutes, about 6.5 minutes). After the fifth period of time has elapsed, the method moves to step 600 on FIG. 6A.

[0070] If at step 648 controller 80 determines that the water level (x) is not varying beyond an acceptable range, controller 80 checks during step 654 whether the sensible cooling cycle time has elapsed. Sensible cooling cycle time may be from about 1 minute to about 15 minutes (e.g., about 1 minute, about 1.5 minutes, about 2 minutes, about 2.5 minutes, about 3 minutes, about 3.5 minutes, about 4 minutes, about 4.5 minutes, about 5 minutes, about 5.5 minutes, about 6 minutes, about 6.5 minutes, about 7 minutes, about 7.5 minutes, about 8 minutes, about 8.5 minutes, about 9 minutes, about 9.5 minutes, about 10 minutes, about 10.5 minutes, about 11 minutes, about 11.5 minutes, about 12 minutes, about 12.5 minutes, about 13 minutes, about 13.5 minutes, about 14 minutes, about 14.5 minutes, about 15 minutes). If the sensible cooling cycle time has not yet elapsed, the method cycles back to step 648. After the sensible cooling cycle time has elapsed, the ice maker enters the latent cooling cycle. During the latent cooling cycle, water that collects in freeze plate 60 starts forming ice and the water level (x) in sump 70 begins to decrease. Accordingly, the water level (x) in sump 70 will continue to drop as the thickness of ice forming in freeze plate 60 increases.

[0071] At step 656 controller 80 via water level sensor 90 measures the water level (x) in sump 70 to determine whether the water level (x) in sump 70 has reached the desired harvest level. The desired harvest level may correspond to a desired ice thickness. Thus when controller 80 via water level sensor 90 measures that the water level (x) in sump 70 is at the harvest level, the desired thickness of ice in freeze plate 60 has been reached and the harvest cycle can begin. The method thus moves to step 660 on FIG. 6D. If the water level (x) in sump 70 has not reached the harvest level, controller 80 checks during step 658 whether the maximum freeze time has elapsed. In certain embodiments, for example, the maximum freeze time may be from about 30 minutes to about 1.5 hours (e.g., about 30 minutes, about 45 minutes, about 1 hour, about 1.25 hours, about 1.5 hours). In various embodiments, the maximum freeze time may be about 1 hour. If the maximum freeze time has elapsed, the method moves to step 660 on FIG. 6D. Accordingly, in certain embodiments, even if the desired harvest level is not reached, indicating that the desired ice thickness is not reached, ice maker 10 can still harvest the ice after a maximum freeze time has been reached. If the maximum freeze time has not yet elapsed, the method will cycle back to step 656.

[0072] When the method continues on to FIG. 6D, compressor 12 is ON, condenser fan 15 is ON, hot gas valve 24 is CLOSED, and water pump 62 is ON. At step 660 controller 80 turns OFF condenser fan 15, OPENS hot gas valve 24, and OPENS purge valve 56. Opening hot gas valve 24 allows warm, high-pressure gas from compressor 12 to flow through hot gas bypass line 23 to enter evaporator assembly 20. Ice is thereby harvested by warming freeze plate 60 to melt the formed ice to a degree such that the ice may be released from freeze plate 60 and falls through a hole 37 (see FIG. 4) into ice storage bin assembly 30. At step 662, controller 80 via water level sensor 90 measures the water level (x) in sump 70 to determine whether the water level (x) in sump 70 is decreasing. If the water level (x) in sump 70 is not decreasing, there may be a purge valve 52 failure and controller 80 may be able to optionally log, report and/or indicate a purge valve 52 failure mode. In certain embodiments, display 104 and/or the alarm may indicate that such a failure mode has been detected. For example, the indication may be a message, an indicator light, and/or a sound specific to the detected failure mode. The method then proceeds to step 665.

[0073] If the water level (x) is decreasing, then at step 665, controller 80 via water level sensor 90 measures the water level (x) in sump 70 to determine whether the water level (x) in sump 70 has reached the desired empty level. If the water level (x) in sump 70 has reached the empty level, controller 80 turns OFF water pump 62 and CLOSES purge valve 56 at step 668. The method then continues to step 670. However, if at step 665, the water level (x) in sump 70 has not reached the empty level, controller 80 checks during step 670 whether harvest sensor 58 is OPEN. If harvest sensor 58 is OPEN, the method proceeds to step 672 where controller 80 keeps or turns ON water pump 62 and CLOSES purge valve 56. At step 674, controller 80 waits for a sixth period of time, keeping water pump 62 ON. In certain embodiments, for example, the sixth period of time may be from about zero (0) seconds to about 15 seconds (e.g., about zero (0) seconds, about 5 seconds, about 10 seconds, about 15 seconds). Then after the sixth period of time has elapsed, controller 80 turns ON condenser fan 14 and CLOSES hot gas valve 24 at step 676. Accordingly, any water in sump 70 may, in certain embodiments, be circulated over freeze plate 60 prior to the refrigeration system cooling evaporator assembly 20 and freeze plate 60. The method then returns to step 622 on FIG. 6B to start another cooling cycle to make another batch of ice.

[0074] However, if at step 670, harvest sensor 58 is CLOSED, controller 80 may check during step 678 whether the maximum harvest time has elapsed. In certain embodiments, for example, the maximum harvest time may be from about 1 minute to about 5 minutes (e.g., about 1 minute, about 1.5 minutes, about 2 minutes, about 2.5 minutes, about 3 minutes, about 3.5 minutes, about 4 minutes, about 4.5 minutes, about 5 minutes). In various embodiments, for example, the maximum harvest time may be about 3.5 minutes. If the maximum freeze time has elapsed, the method proceeds to step 672 as described above.

[0075] Referring to FIG. 7, the present invention may also be used to detect an amount of scale 96 built up near the upper portion of the sump 70. During the ice making phase, the amount of water in the sump 70 will transition from an initial water level 92 to lower levels (represented by falling water level 94). As the water level falls, the capacitive sensor 90 may detect the scale 96 and the controller 80 may interpret this level as requiring a cleaning cycle. For example, using a capacitive sensor 90 formed from a series of capacitors extending over the length of the sensor 90, the sensor would gather the capacitance reading from each of the individual capacitors. The microcontroller within the sensor 90 may be programmed to recognize a situation where the capacitors near the top of the sump 70 are reading a steady capacitance (signaling a steady amount of water in the sump), while the capacitors near the middle or lower region of the sump 70 are reading a falling capacitance (indicating a falling water level). In this situation, the microcontroller may detect an error condition signaling scale and take alternative steps. For example, the microcontroller may ignore the upper capacitor readings and only utilize the readings from the lower capacitors as a fail-safe mechanism. Alternatively, the microcontroller may send a signal to the controller 80, which may alert the user to check the icemaker, run a cleaning cycle, or otherwise attend to the scale condition.

[0076] Upon detecting a predetermine amount of scale, the controller 80 may then initiate a cleaning cycle in a number of ways. For example, the controller 80 could automatically halt the ice making and harvesting phases and initiate a cleaning cycle to remove the scale. The controller 80 could continue to operate the ice maker normally and then initiate the cleaning cycle at a later point in time, such as after the ice bin was sufficiently full or during some predetermined shut-down time. Alternatively, the controller could place the ice maker into a default, safe mode of operation using previously determined cycle times pre-programmed into the controller 80, and then resume normal operation after completion of a cleaning cycle. The controller 80 could also push a notification to an operator such that the operator would manually initiate a cleaning cycle. This notification could be some form of alarm or indication displayed on an external display or sent to the operator via, for example, a push notification to a mobile device via WiFi or cellular communication techniques. If necessary, the controller 80 could instruct or direct that multiple cleaning cycles be performed in succession, or suggest to the operate the use of higher concentrations of descaling chemicals, if the scale was not removed after the first cleaning or until the amount of measured scale falls below a predetermined threshold. The controller 80 may also automatically adapt the frequency of the cleaning cycle based on the rate of scale measured between cleaning cycles.

[0077] While various steps are described herein in one order, it will be understood that other embodiments of the method can be carried out in any order and/or without all of the described steps without departing from the scope of the invention.

[0078] Thus, there have been shown and described novel methods and apparatuses of an ice maker having a controller adapted to measure the water level in a sump and to detect various failure modes, which overcome many of the problems of the prior art set forth above. The use of a capacitive water level sensor provides many benefits, including consistent, repeatable accuracy, whose measurement is not affected by temperature (within the ratings of the device). It will be apparent, however, to those familiar in the art, that many changes, variations, modifications, and other uses and applications for the subject devices and methods are possible. All such changes, variations, modifications, and other uses and applications that do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow.