Refrigerator fluid dispenser with dispensed volume calculation

A refrigerator and method utilize first and second sensors to determine a volume of fluid dispensed by a fluid dispenser that incorporates a fluid storage receptacle. The first sensor is disposed in upstream fluid communication with the fluid storage receptacle to generate a first signal representative of a volume of fluid entering the fluid storage receptacle and the second sensor is disposed downstream of the first sensor to generate a second signal representative of a volume of fluid exiting the fluid storage receptacle, and a controller determines the volume of fluid dispensed using the first and second signals output by the first and second sensors.

BACKGROUND

Many residential refrigerators include as a convenience feature an integrated dispenser for dispensing a fluid, e.g., water. In addition, some refrigerators incorporate a water tank or other fluid storage receptacle that may be fixed or removable, and positioned within a cooled compartment of the refrigerator to cool the contained water prior to dispensing or otherwise serving (e.g., in the case where the receptacle is removable). In addition, some refrigerators include flow sensors such as flow meters to measure the volume of water dispensed, generally to display to the user the amount of water being dispensed into a container. Further, in some designs the measurement of the amount of dispensed water can be used to enable a user to select a desired amount of water and have the dispenser automatically shut off when that desired amount has been reached. A need still exists, however, for a manner of accurately measuring the volume of dispensed water, particularly in applications where a dispenser incorporates fluid storage receptacle.

SUMMARY

The herein-described embodiments address these and other problems associated with the art by providing a refrigerator and method that utilize first and second sensors to determine a volume of fluid dispensed by a fluid dispenser that incorporates a fluid storage receptacle. The first sensor is disposed in upstream fluid communication with the fluid storage receptacle to generate a first signal representative of a volume of fluid entering the fluid storage receptacle and the second sensor is disposed downstream of the first sensor to generate a second signal representative of a volume of fluid exiting the fluid storage receptacle, and a controller determines the volume of fluid dispensed using the first and second signals output by the first and second sensors.

Therefore, consistent with one aspect of the invention, a refrigerator may include a housing including a freezer compartment and a fresh food compartment, one or more doors attached to the housing to provide access to the freezer and fresh food compartments, a water storage receptacle having an inlet and an outlet, a receptacle fill valve in upstream fluid communication with the inlet of the water storage receptacle to control a flow of water into the water storage receptacle, a dispensing valve in downstream fluid communication with the outlet of the water storage receptacle to control dispensing of water from the water storage receptacle, a flowmeter in upstream fluid communication with the inlet of the water storage receptacle to generate a first signal representative of a volume of water entering the water storage receptacle, a water level sensor positioned to generate a second signal representative of a level of water in the water storage receptacle, and a controller coupled to the dispensing valve, the flowmeter, and the water level sensor and configured to control the dispensing valve to dispense water from the water storage receptacle and to determine a volume of water dispensed through the dispensing valve using the first and second signals.

Consistent with another aspect of the invention, a refrigerator may include a housing defining at least one food compartment, at least one door attached to the housing, a fluid storage receptacle having an inlet and an outlet, a dispensing valve in downstream fluid communication with the outlet of the fluid storage receptacle to control dispensing of fluid from the fluid storage receptacle, a first sensor in upstream fluid communication with the inlet of the fluid storage receptacle to generate a first signal representative of a volume of fluid entering the fluid storage receptacle, a second sensor disposed downstream of the first sensor to generate a second signal representative of a volume of fluid exiting the outlet of the fluid storage receptacle, and a controller coupled to the dispensing valve, the first sensor, and the second sensor and configured to control the dispensing valve to dispense fluid from the fluid storage receptacle and to determine a volume of fluid dispensed through the dispensing valve using the first and second signals.

In some embodiments, the first sensor includes a flowmeter. Also, in some embodiments, the flowmeter is integrated with a receptacle fill valve in upstream fluid communication with the inlet of the fluid storage receptacle to control a flow of fluid into the fluid storage receptacle. Further, in some embodiments, the second sensor includes a fluid level sensor positioned to sense a level of fluid in the fluid storage receptacle. In some embodiments, the fluid level sensor includes an ultrasonic sensor positioned to detect a distance to a fluid surface in the fluid storage receptacle or a conductivity sensor disposed on a wall of the fluid storage container. In addition, some embodiments may also include a receptacle fill valve in upstream fluid communication with the inlet of the fluid storage receptacle to control a flow of fluid into the fluid storage receptacle.

In some embodiments, the controller is configured to determine the volume of fluid dispensed through the dispensing valve at least in part by determining a change in fluid level in the fluid storage receptacle using the second signal. In addition, in some embodiments, the controller is configured to determine the volume of fluid dispensed through the dispensing valve at least in part by determining a volume of fluid entering the fluid storage receptacle using the first signal. Moreover, in some embodiments, the controller is configured to determine the volume of fluid dispensed through the dispensing valve using the formula: VOUT=VIN+VΔLEVEL, where VOUT is the volume of fluid dispensed, VIN is the volume of fluid entering the fluid storage receptacle, and VΔLEVEL is the volume of fluid corresponding to the change in fluid level in the fluid storage receptacle.

In some embodiments, the controller is configured to accumulate the volume of fluid dispensed over a plurality of polling intervals when the dispensing valve is actuated to dispense fluid from the fluid storage receptacle. Moreover, in some embodiments, the fluid storage receptacle is vented. In some embodiments, the controller is further configured to cause the determined volume of water dispensed through the dispensing valve to be displayed on a display disposed on one of the housing and the at least one door. In addition, in some embodiments, the controller is further configured to control the dispensing valve to discontinue dispensing fluid when the determined volume of water dispensed through the dispensing valve reaches a predetermined volume.

In some embodiments, the controller is configured to set the predetermined volume in response to user input. In addition, some embodiments may further include a fluid dispensing control disposed on one of the housing and the at least one door, where the controller is configured to control the dispensing valve responsive to user input received by the fluid dispensing control.

Consistent with another aspect of the invention, a refrigerator may include a housing including a freezer compartment and a fresh food compartment, one or more doors attached to the housing to provide access to the freezer and fresh food compartments, a water storage receptacle having an inlet and an outlet, where the inlet is in fluid communication with a water supply, a dispensing valve in downstream fluid communication with the outlet of the water storage receptacle to control dispensing of water from the water storage receptacle, a water level sensor positioned to generate a signal representative of a level of water in the water storage receptacle, and a controller coupled to the dispensing valve and the water level sensor and configured to control the dispensing valve to dispense water from the water storage receptacle and to determine a volume of water dispensed through the dispensing valve based at least in part upon the signal representative of the level of water generated by the water level sensor.

Consistent with another aspect of the invention, a method of dispensing water in a refrigerator may include actuating a dispensing valve in downstream fluid communication with an outlet of a water storage receptacle to control dispensing of water from the water storage receptacle, with a first sensor in upstream fluid communication with an inlet of the water storage receptacle, generating a first signal representative of a volume of water entering the water storage receptacle, with a second sensor disposed downstream of the first sensor, generating a second signal representative of a volume of water exiting the outlet of the water storage receptacle, and with a controller, determining a volume of water dispensed through the dispensing valve using the first and second signals.

Also, in some embodiments, the first sensor includes a flowmeter and the second sensor includes a water level sensor positioned to sense a level of water in the water storage receptacle. Some embodiments may also include selectively actuating a receptacle fill valve in upstream fluid communication with the inlet of the water storage receptacle to control a flow of water into the water storage receptacle in response to determining from the second sensor that a water level in the water storage receptacle is below a fill threshold. In addition, in some embodiments, determining the volume of water dispensed through the dispensing valve includes determining a change in water level in the water storage receptacle using the second signal, determining a volume of water entering the water storage receptacle using the first signal, and determining the volume of water dispensed through the dispensing valve using the determined change in water level in the water storage receptacle and the determined volume of water entering the water storage receptacle.

Also, in some embodiments, determining the volume of water dispensed through the dispensing valve further includes accumulating the volume of water dispensed over a plurality of polling intervals when the dispensing valve is actuated to dispense water from the water storage receptacle. In addition, some embodiments may further include displaying the determined volume of water dispensed through the dispensing valve on a display disposed on one of a housing and a door of the refrigerator. Some embodiments may further include controlling the dispensing valve to discontinue dispensing fluid when the determined volume of water dispensed through the dispensing valve reaches a predetermined volume. Also, in some embodiments, determining the volume of water dispensed through the dispensing valve using the first and second signals includes determining the volume of water dispensed after a volume of water exceeding a capacity of the fluid storage receptacle has been dispensed.

These and other advantages and features, which characterize the invention, are set forth in the claims annexed hereto and forming a further part hereof. However, for a better understanding of the invention, and of the advantages and objectives attained through its use, reference should be made to the Drawings, and to the accompanying descriptive matter, in which there is described example embodiments of the invention. This summary is merely provided to introduce a selection of concepts that are further described below in the detailed description, and is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

DETAILED DESCRIPTION

Embodiments consistent with the invention may utilize first and second sensors to determine a volume of fluid dispensed by a refrigerator fluid dispenser that incorporates a fluid storage receptacle. The first sensor, e.g., a flowmeter, may be disposed in upstream fluid communication with the fluid storage receptacle to generate a first signal representative of a volume of fluid entering the fluid storage receptacle. The second sensor, e.g., a fluid level sensor, may be disposed downstream of the first sensor to generate a second signal representative of a volume of fluid exiting the fluid storage receptacle. A controller may then determine the volume of fluid dispensed using the first and second signals output by the first and second sensors. Among other advantages that will become more apparently below, the use of multiple sensors enables an accurate determination of dispensed volume to be obtained even when the dispensed volume exceeds the capacity of the fluid storage receptacle.

Turning now to the Drawings, wherein like parts are denoted by like numbers throughout the several views, the embodiments discussed hereinafter will focus on an example implementation of the hereinafter-described techniques and apparatuses within a residential side-by-side refrigerator such as refrigerator10illustrated inFIGS. 1 and 2, such as the type that may be used in single-family or multi-family dwellings, or in other similar applications. However, it will be appreciated that the herein-described techniques and apparatuses may also be used in connection with other types of refrigerators in some embodiments. For example, the herein-described techniques may be used in commercial applications in some embodiments. Moreover, the herein-described techniques may be used in connection with various refrigerator configurations, e.g., within French door refrigerators, bottom freezer refrigerators, top freezer refrigerators, wine refrigerators and beverage centers, compact refrigerators, etc., so the embodiments are not limited to the side-by-side refrigerator implementation discussed further herein.

Refrigerator10as noted above is a side-by-side refrigerator, and as such includes a front-mounted door12and a cabinet or housing14that provides access to a freezer compartment13(FIG. 2) housed within cabinet or housing14. Similarly an adjacent pivotable door16may provide access to a fresh-food compartment (not shown) and when in the open position, food and beverage items may be inserted into and removed from the fresh-food compartment. Door12is generally provided with a hinge17along a side or top edge of housing14and is pivotable between a closed position illustrated inFIGS. 1 and 2and an open position (not shown). When door12is in an open position, food and beverage items may be inserted into and removed from freezer compartment13through door12or, alternatively, through an opening in door12. Control over refrigerator10by a user is generally managed through a control panel18, which can be disposed on a door such as door12. Control panel18can also be disposed within the freezer or fresh-food compartment in another embodiment, or in multiple doors, and can be utilized with a user interface19for the refrigerator10. It will be appreciated that in different refrigerator designs, control panel18may include various types of input and/or output devices, including various knobs, buttons, lights, switches, textual and/or graphical displays, touch screens, etc. through which a user may configure one or more settings, determine the status of a dispenser, start and/or stop a dispenser, set a flow rate and/or fill amount, etc.

As shown inFIGS. 1-2, refrigerator10may include a water dispenser20, which in some embodiments may be a quick fill dispenser capable of dispensing water at a faster rate than provided through a residential water supply coupled to the refrigerator. Referring toFIG. 2, dispenser20may include at least one fluid storage receptacle, e.g., a water storage receptacle30, positioned in the refrigerator. Water storage receptacle30quickly feeds one or more downstream outlets40, as opposed to a more typical water dispenser that uses water pressure to dispense water and/or allows water to flow through a water filter60at a restricted flow rate associated with the water filter. Water storage receptacle30may be in a variety of locations and configurations within the refrigerator10. More specifically, in some embodiments, the water storage receptacle30may be positioned in housing14, or as illustrated via dashed lines at30′ inFIG. 2, in a door such as door12. In some embodiments, the dispensed water exiting water storage receptacle30is in fluid communication with one or more downstream outlets40, which may include at least one dispensing valve42that is positioned downstream of and/or at a lower elevation than at least a portion of water storage receptacle30to control a variety of flow rates and/or volumes of dispensed water. In some embodiments, dispensing valve42may be a variable valve to allow for varying flow rates, while in other embodiments, dispensing valve42may simply be an on-off valve. The water flow rate from water storage receptacle30and/or outlet40may be pumped, gravity dispensed, and/or pressurized, etc. to quickly dispense water from the refrigerator10. A variety of flow rates may be used in some embodiments, as desired by the user. For example, in some embodiments the water flow rate may be in the range of about 1 gallon per minute to about 2 gallons per minute. Moreover, the flow rates may be adjustable as noted above.

In addition, in some embodiments, a second dispenser15may also be provided in refrigerator10, e.g., for dispensing ice produced by an icemaker within door12or housing14. In some embodiments, second dispenser15may also be capable of dispensing water, e.g., to provide water for drinking glasses/cups at a lower flow rate than provided by dispenser20. In other embodiments, separate ice and water dispensers may be provided in addition to quick fill dispenser20, while in other embodiments, no ice dispenser may be provided. In still other embodiments, dispenser20may be capable of both quick fill and standard rate water dispensing, whereby no separate standard rate water dispenser may be used.

Moreover, it will be appreciated that the techniques discussed hereinafter may be used in connection with other types of fluid dispensers, including standard flow rate water dispensers, coffee dispensers, beverage dispensers, hot water dispensers, quick fill dispensers for non-water fluids, etc., so the invention is not limited to use with the quick fill water dispenser discussed herein.

As mentioned above, water storage receptacle30, or portions thereof, may be located within refrigerator10in a variety of locations. In some embodiments, a water storage receptacle, or portions thereof, may be positioned in a door, e.g., as represented at30′ inFIG. 2. In such embodiments, a water supply line may be routed, for example, from housing14into door12, e.g., adjacent door hinge17. In some embodiments, a hose connection (not shown) may be used between door12and housing14to allow the one or more doors12to be removable.

Alternatively, as illustrated inFIG. 2, water storage receptacle30may be positioned in refrigerator housing14, e.g., proximate a top of housing14. In the illustrated embodiment, quick fill dispenser20may include an outlet hose43extending from an outlet54of water storage receptacle30through hinge17to a dispenser exit or outlet40of door12. Dispenser20may also, in some embodiments, include a pump56in fluid communication with water storage receptacle30and outlet40. It should be understood that other methods may be used to dispense water from water storage receptacle30(e.g. pressure and/or gravity). Moreover, in some embodiments, a bladder or conduit may be used for water storage receptacle in the housing14.

In some embodiments, dispenser20may also include a hot/cold plate46to heat and/or cool the water storage receptacle's water within. If used, hot/cold plate46may be positioned adjacent water storage receptacle30to allow a user to set the temperature of the water therein. The temperature may also be displayed on control panel18in some embodiments. User interface19may also allow the user to select the desired temperature of the water within water storage receptacle30.

In addition, in some embodiments, outlet40of dispenser20may include one or more couplings44to releasably secure one or more downstream attachments2. As shown inFIGS. 1-2, dispensing valve42and/or outlet40may include a coupling44(e.g. hose quick connector and/or garden hose thread feature) to allow an additional downstream attachment2(e.g. second hose, extension, or accessory). In some embodiments, attachment2may be added as an extension to increase the distance the dispensed water may be discharged from refrigerator10to a container or dispensing target area. For example, attachment2may be used to fill a pot or container on an adjacent range1as shown inFIG. 1, a coffee maker on the kitchen counter, a large pitcher, a coffee carafe, etc.

In addition, in various embodiments, dispenser20may include one or more sensors48to monitor characteristics of the water in the water storage receptacle30(e.g. tank32). Characteristics of the water may include, but are not limited to, status (e.g. full, empty, refill, ready to dispense, etc.), temperature, water level or volume, duration to fill, flow rate, etc. Sensor48may include electronic and/or mechanical devices used to monitor dispenser20and/or water therein, such as but not limited to a float, laser eye, water level switch, ultrasonic sensor, conductivity sensor, weight sensor (e.g. load cell), flow sensor (e.g. flowmeter), optical sensor, temperature sensor (e.g. infrared sensor, wired or wireless contact sensor), timer, wired or wireless sensors, etc. In various embodiments, a light or fill gage19bor other indicators may be used in user interface19to highlight the feature and communicate when dispenser20is available.

In some embodiments, for example, the one or more sensors48may include a water level sensor positioned and suitable for sensing a height or elevation of water in water storage receptacle30, such a sensor may use a float, a conductivity, capacitive or resistive sensor mounted to a wall of water storage receptacle30, an ultrasonic sensor positioned above the receptacle to detect a distance to the water surface, or other sensor designs suitable for sensing a level of water in the receptacle. Then, based upon a known geometry of the receptacle, a current volume of water in the receptacle may be determined. The water level sensor may generate a signal that is communicated to a controller to enable the controller to determine a water level in the receptacle, as well as to determine a change in water level, and thus volume, over time.

Water storage receptacle30may also include an inlet50and an outlet54. Inlet50may be coupled to an upstream supply line52, and in some embodiments, supply line52may be coupled to a water supply62through a filter60, a sensor64and a receptacle fill valve66. Filter60may be disposed in various locations in refrigerator10, and in many instances is oriented in a location that enables the filter to be replaced by a user periodically. Sensor64is in upstream fluid communication with inlet50of water storage receptacle30to sense a volume of water entering water storage receptacle30and generate therefrom a signal representative of this volume, which may in turn be communicated to a controller to enable the controller to determine a flow rate through the supply line, and thus a volume of water entering the receptacle. In some embodiments, sensor64may be a flowmeter, although other sensors suitable for measuring a volume or flow of water into a receptacle may be used in the alternative.

Receptacle fill valve66is also in upstream fluid communication with inlet50of water storage receptacle30to regulate or control the flow of water into the receptacle. In some embodiments, valve66may be controlled by a controller, e.g., in response to a water level sensed by sensor48, while in other embodiments, valve66may be controlled independently of a controller, e.g., based upon a microswitch coupled to a float that is triggered when the water level falls below a predetermined water level.

It will be appreciated that a water level sensor or other sensor may additionally be used to determine a volume of water exiting outlet54of water storage receptacle30. Such a sensor may be downstream of sensor66, and moreover, may be disposed within water storage receptacle30in some embodiments (as would be the case with some water level sensors such as conductivity sensors), positioned proximate to or within water storage receptacle30to detect a surface of the water in some embodiments (as would be the case with some water level sensors such as ultrasonic sensors), disposed downstream of or within outlet54in other embodiments (as would be the case with a flowmeter), or in other suitable positions to generate a signal from which the volume of water exiting the receptacle can be determined.

In some embodiments, dispenser outlet40may be configured to adjust the flow rate (e.g. gravity flow rate) of water exiting water storage receptacle30, and may include a hose or conduit43, laminar flow device45, and/or dispensing valve42to allow water to flow out of dispenser20. The size of hose43may be adjusted to increase/decrease the water flow rate (e.g. similar to the water output of a kitchen faucet). Laminar flow device45, if used, may be a variety of devices to control the water flow characteristics (e.g. an aerator). Dispensing valve42may be connected to the end of hose43to control water flow from water storage receptacle30, and in some embodiments the flow rate from valve42may be adjusted (e.g. decreased and/or increased) depending on the desired amount of water to be dispensed therethrough. The duration of supplying water (e.g. gravity and/or pumped) from dispenser20may be manually and/or automatically started and/or ended by the refrigerator10. The user may manually start and/or end the supplying of water, e.g., based upon a trigger and/or micro switch coupled to a paddle or button on door12. In other embodiments dispensing (e.g. gravity, pump, and/or pressure) may be automated. For example, water may be dispensed and automatically ended upon a predetermined duration or volume being dispensed, e.g., as determined using the various techniques discussed in greater detail below. Moreover, in various embodiments, a time algorithm may be used to dispense a set amount of water before stopping. Valve42may also be electronically activated in some embodiments. Further, in some embodiments, valve42or user interface19may be child-resistant (e.g. push and turn) or have a lockout feature (e.g. button/switch) to reduce the likelihood of an unauthorized user (e.g. a child) from opening the valve and/or any undesired dispensing activity.

As noted above, a variety of water storage receptacles30may be positioned in a variety of positions within the refrigerator10. In some embodiments, the water storage receptacle30may be a tank32, conduit, and/or bladder, and in some embodiments, tank32may be blow-molded plastic or injection molded. If a bladder is used, the bladder may be rubber or other suitable materials that may collapse and/or expand based upon the volume of fluid contained within. If a conduit is used, the conduit may be a coiled hose, pipe, or cylinder structure. In some embodiments, a vent34may also be used in fluid commination with water storage receptacle30. For example, vent34may be positioned at the top of tank32, vented into one or more of the refrigerator compartments, vented within one or more doors, or vented to the exterior of the refrigerator, etc. Moreover, in some embodiments, vent34may include a backflow preventer to reduce or prevent water from escaping.

As shown inFIG. 3, refrigerator10may also include a controller70that may be interfaced with various components, including a cooling or refrigeration system76, an ice and water system78(which may include, among additional ice making and dispensing components, the various components discussed above with respect to dispenser20ofFIGS. 1-2), one or more user controls80for receiving user input (e.g., various combinations of switches, knobs, buttons, sliders, touchscreens or touch-sensitive displays, microphones or audio input devices, image capture devices, etc., including but not limited to control panel18and user interface19), and one or more user displays82(including various indicators, graphical displays, textual displays, speakers, etc.), as well as various additional components suitable for use in a refrigerator, e.g., interior and/or exterior lighting84, among others. User controls and/or user displays80,82may be disposed, for example, on one or more control panels disposed in the interior and/or on doors and/or other external surfaces of the refrigerator. Further, in some embodiments audio feedback may be provided to a user via one or more speakers, and in some embodiments, user input may be received via a spoken or gesture-based interface. Additional user controls may also be provided elsewhere on refrigerator10, e.g., within the fresh food and/or freezer compartments. In addition, refrigerator10may be controllable remotely, e.g., via a smartphone, tablet, personal digital assistant or other networked computing device, e.g., using a web interface or a dedicated app.

Controller70may also be interfaced with various sensors86located to sense environmental conditions inside of and/or external to refrigerator10, e.g., one or more temperature sensors, humidity sensors, etc. Such sensors may be internal or external to refrigerator10, and may be coupled wirelessly to controller70in some embodiments. Sensors86may also include additional types of sensors such as door switches, switches that sense when a portion of an ice dispenser has been removed, and other status sensors, as will become more apparent below.

In some embodiments, controller70may also be coupled to one or more network interfaces88, e.g., for interfacing with external devices via wired and/or wireless networks such as Ethernet, Wi-Fi, Bluetooth, NFC, cellular and other suitable networks, collectively represented inFIG. 2at90. Network90may incorporate in some embodiments a home automation network, and various communication protocols may be supported, including various types of home automation communication protocols. In other embodiments, other wireless protocols, e.g., Wi-Fi or Bluetooth, may be used.

In some embodiments, refrigerator10may be interfaced with one or more user devices92over network90, e.g., computers, tablets, smart phones, wearable devices, etc., and through which refrigerator10may be controlled and/or refrigerator10may provide user feedback.

In some embodiments, controller70may operate under the control of an operating system and may execute or otherwise rely upon various computer software applications, components, programs, objects, modules, data structures, etc. In addition, controller70may also incorporate hardware logic to implement some or all of the functionality disclosed herein. Further, in some embodiments, the sequences of operations performed by controller70to implement the embodiments disclosed herein may be implemented using program code including one or more instructions that are resident at various times in various memory and storage devices, and that, when read and executed by one or more hardware-based processors, perform the operations embodying desired functionality. Moreover, in some embodiments, such program code may be distributed as a program product in a variety of forms, and that the invention applies equally regardless of the particular type of computer readable media used to actually carry out the distribution, including, for example, non-transitory computer readable storage media. In addition, it will be appreciated that the various operations described herein may be combined, split, reordered, reversed, varied, omitted, parallelized and/or supplemented with other techniques known in the art, and therefore, the invention is not limited to the particular sequences of operations described herein.

Numerous variations and modifications to the refrigerator illustrated inFIGS. 1-3will be apparent to one of ordinary skill in the art, as will become apparent from the description below. Therefore, the invention is not limited to the specific implementations discussed herein.

Refrigerator Fluid Dispenser with Dispensed Volume Calculation

Now turning toFIG. 4, this figure shows more generically a fluid dispensing system100suitable for use in a refrigerator such as refrigerator10ofFIGS. 1-3, and incorporating dispensed volume calculation as described herein. Dispensing system100includes a fluid storage receptacle102having an inlet and an outlet, with the inlet coupled to a fluid supply104through a receptacle fill valve106in upstream fluid communication with the inlet of receptacle102to control a flow of fluid into the fluid storage receptacle and a flowmeter108in upstream fluid communication with the inlet of receptacle102to generate a signal representative of a volume of fluid entering receptacle102. In some embodiments, valve106and flowmeter108may be separate components, while in other embodiments, and as illustrated by box110, these components may be integrated with one another in the same housing.

A fluid level sensor112, e.g., a conductivity sensor mounted on a wall of receptacle102, an ultrasonic sensor positioned to sense a water surface within receptacle102, or another suitable sensor, may be downstream of flowmeter108and positioned to generate a signal representative of a level of fluid in the receptacle, which as will be discussed in greater detail below, may also be used to represent a volume of fluid exiting the outlet of the fluid storage receptacle during dispensing. In addition, a dispensing valve114may be in downstream fluid communication with the outlet of fluid storage receptacle102to control dispensing of fluid from the fluid storage receptacle to a dispenser outlet116.

Each of valves106,114and sensors108,112is additionally coupled to a controller118to enable the controller to control dispensing valve114to dispense fluid from fluid storage receptacle102, to control fill valve106to fill receptacle102, and to determine a volume of fluid dispensed through dispensing valve114using signals generated by sensors108,112.

In the illustrated embodiment, controller118may in particular determine a volume of fluid dispensed through dispensing valve114using a combination of signals output by flowmeter108and fluid level sensor112, using the signal output by flowmeter108to determine or calculate a volume of fluid entering the fluid storage receptacle and using the signal output by fluid level sensor112to determine or calculate a change in fluid level in the fluid storage receptacle. In some embodiments, for example, volumes are primarily determined using fluid level sensor112, with flowmeter108used to compensate or adjust the volumes determined using the fluid level sensor to account for the flow of additional fluid into the receptacle through receptacle fill valve106during dispensing. As such, in the event that dispensing is occurring when receptacle fill valve106is closed, the determined volume is based on the change in fluid level in the receptacle.

In particular, in some embodiments, the volume of fluid dispensed through dispensing valve114may be determined using the formula:
VOUT=VIN+VΔLEVEL
where VOUTis the volume of fluid dispensed, VINis the volume of fluid entering the fluid storage receptacle, and VΔLEVELis the volume of fluid corresponding to the change in fluid level in the fluid storage receptacle. The volume of fluid corresponding to the change in fluid level may be based, for example, on a known geometry of the fluid storage receptacle, whereby the volume of fluid retained within the receptacle may be based upon the dimensions of the receptacle at different elevations. The volume may also be based upon empirically-determined volumes for different elevations in some embodiments. In some embodiments, for example, a lookup table may be used to store a volume corresponding to each of a plurality of levels such that a volume corresponding to a particular level sensed by fluid level sensor112may be retrieved from the lookup table, such that a volume corresponding to the change in fluid level may be determined by determining a difference between the volumes corresponding to a current fluid level and a previous fluid level.

The volume dispensed may be calculated over intervals during which the dispensing valve is open, and may be accumulated over a plurality of polling intervals while the dispensing valve is actuated. The accumulated volume may then be displayed to a user (e.g., via a door-mounted display, via a smartphone display, etc.) and/or used to control when the dispensing valve is deactivated and dispensing is discontinued, e.g., when dispensing a predetermined or controlled volume (e.g., as may be selected by a user via a door-mounted user control or via a smartphone control).

FIGS. 5-7, for example, are flowcharts illustrating several routines that may be executed by a controller, e.g., controller118of dispensing system100, to determine and utilize a determined volume of dispensed fluid.FIG. 5, for example, illustrates an example implementation of a fill valve control routine120, which may be used to control fill valve106to maintain a desired level of fluid in fluid storage receptacle102. During each of a plurality of polling intervals (block122), routine120may determine a fluid level in receptacle102using fluid level sensor112(block124). Block126may determine if the fluid level is at or below a minimum level set for the receptacle, and if so, pass control to block128to open fill valve106, thereby introducing fluid into receptacle102from fluid supply104. Control then returns to block122to wait for the next polling interval.

Returning to block126, if the fluid level is not below the minimum level, block130next determines if the fluid level is at or above a maximum level set for the receptacle, indicating that the receptacle is full. If so, control passes to block132to close the fill valve, returning control to block122to wait for the next polling interval. And returning to block130, if the fluid level is not above the maximum level, control returns directly to block122. As such, routine120maintains the level of fluid within receptacle102between the minimum and maximum levels.

FIG. 6next illustrates an example implementation of a manual dispense routine140, which may be used to manually dispense fluid from dispensing system100, e.g., in response to activation of the dispenser via selection of a button, paddle, or other user control (block142). First, in block144, dispensing valve114is opened and a dispensed volume variable is set to zero. Block146then initiates a loop to continuously dispense fluid and accumulate a total dispensed volume using the dispensed volume variable and over a plurality of polling intervals. For each interval, block148determines a fluid level change from the last interval using the signal output by fluid level sensor112, e.g., by comparing a current fluid level sensed by sensor112with a fluid level sensed during the prior interval. Next, in block150a fill volume since the last interval is determined using the signal output by flowmeter108, e.g., based upon a current flow rate multiplied by the length of the polling interval. Block152then determines a volume of fluid dispensed over the interval by summing together the fill volume since the last interval and a change in volume determined based upon the change in fluid level over the interval, and then adds the determined volume to the dispensed volume variable, thereby accumulating the determined volumes calculated for each interval. Block154next displays the current dispensed volume (e.g., on user interface19, or on a smartphone display).

Block156next determines if the dispenser has been deactivated (e.g., by a user discontinuing depression of a button or a paddle), and if not, returns control to block146to wait for the next polling interval. If so, however, block156passes control to block158to close the dispensing valve, and routine140is complete.

FIG. 7next illustrates an example implementation of a measured dispense routine160, which may be used to dispense fluid a predetermined amount of fluid from dispensing system100, e.g., in response to user selection of a predetermined amount in combination with activation of the dispenser via selection of a button, paddle, or other user control (block162). Blocks164-174operate in a similar manner to blocks144-154of routine140. First, in block164, dispensing valve114is opened and a dispensed volume variable is set to zero. Block166then initiates a loop to continuously dispense fluid and accumulate a total dispensed volume using the dispensed volume variable and over a plurality of polling intervals. For each interval, block168determines a fluid level change from the last interval using the signal output by fluid level sensor112, e.g., by comparing a current fluid level sensed by sensor112with a fluid level sensed during the prior interval. Next, in block170a fill volume since the last interval is determined using the signal output by flowmeter108, e.g., based upon a current flow rate multiplied by the length of the polling interval. Block172then determines a volume of fluid dispensed over the interval by summing together the fill volume since the last interval and a change in volume determined based upon the change in fluid level over the interval, and then adds the determined volume to the dispensed volume variable, thereby accumulating the determined volumes calculated for each interval. Block174next displays the current dispensed volume (e.g., on user interface19, or on a smartphone display).

Block176next determines if the dispensed volume equals (or exceeds) the predetermined volume for the measured fill, and if not, passes control to block178to determine if the dispenser has been prematurely deactivated (e.g., by a user discontinuing depression of a button or a paddle). If not, block178returns control to block166to wait for the next polling interval. If, however, either the predetermined volume has been reached, or the dispenser has be prematurely deactivated, control passes to block180to close the dispensing valve, and routine160is complete.

It will be appreciated that whenever the level of fluid in receptacle102is above the minimum level that activates the fill valve as discussed above in connection with routine120ofFIG. 5, the fill volume determined in block150of routine140and in block170of routine160will generally be zero, as no fluid will be flowing through flowmeter108. Thus, the calculation of the volume dispensed over the interval in each of blocks152and172of routines140and160will equal the volume based upon the change in fluid level as sensed by fluid level sensor108. It is only when the level of fluid in the receptacle drops below the minimum level and fill valve106is activated that the fill volume sensed by flowmeter108is incorporated into the dispensed volume calculation, and as such, the fill volume serves as an adjustment factor for the fluid level sensor to account for the fact that the fluid entering the receptacle causes the level in the receptacle to drop less than would occur if fill valve106was closed.

By doing so, and particularly with regard to dispensing fluids in connection with vented fluid storage receptacles, controller118need not base calculations on a closed loop system whereby the volume of fluid entering the receptacle equals the volume of fluid exiting the receptacle. Separate determinations may instead be made of the volume of fluid entering and exiting the receptacle and combined to determine the volume of fluid dispensed by the dispenser. As such, particularly in situations where the total volume of fluid dispensed exceeds the capacity of the fluid storage receptacle, an accurate determination of volume of dispensed fluid may be dispensed even as additional fluid is being introduced into the receptacle during dispensing.

Various modifications may be made to the illustrated embodiments without departing from the spirit and scope of the invention. For example, in some embodiments a flowmeter or other sensor for determining the volume of water entering a receptacle may be omitted, and volume calculations may be performed solely using a water level sensor disposed within the water storage receptacle. Other modifications will be apparent to those of ordinary skill having the benefit of the instant disclosure.

It is to be understood that the embodiments are not limited in its application to the details of construction and the arrangement of components set forth in the description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Unless limited otherwise, the terms “connected,” “coupled,” “in communication with,” and “mounted,” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. In addition, the terms “connected” and “coupled” and variations thereof are not restricted to physical or mechanical connections or couplings.

The foregoing description of several embodiments of the invention has been presented for purposes of illustration. It is not intended to be exhaustive or to limit the invention to the precise steps and/or forms disclosed, and obviously many modifications and variations are possible in light of the above teaching.