U.S. patent application number 16/794431 was filed with the patent office on 2021-08-19 for sensor assembly including a multifunctional housing.
The applicant listed for this patent is Haier US Appliance Solutions, Inc.. Invention is credited to Kyle Edward Durham.
Application Number | 20210251464 16/794431 |
Document ID | / |
Family ID | 1000004666485 |
Filed Date | 2021-08-19 |
United States Patent
Application |
20210251464 |
Kind Code |
A1 |
Durham; Kyle Edward |
August 19, 2021 |
SENSOR ASSEMBLY INCLUDING A MULTIFUNCTIONAL HOUSING
Abstract
A dishwasher appliance includes a sump that collects wash fluid
and defines a mounting port for receiving a sensor assembly. The
sensor assembly includes an adapter that defines a plurality of
sensor ports for receiving different sensors, such as a pressure
sensor, a temperature sensor, and a turbidity sensor. The adapter
is translucent to facilitate turbidity sensing without introducing
leak points. In addition, the adapter defines an internal chamber
for receiving the wash fluid and an air chamber defined above the
internal chamber to prevent direct contact between the wash fluid
and the pressure sensor.
Inventors: |
Durham; Kyle Edward;
(Louisville, KY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Haier US Appliance Solutions, Inc. |
Wilmington |
DE |
US |
|
|
Family ID: |
1000004666485 |
Appl. No.: |
16/794431 |
Filed: |
February 19, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47L 2401/10 20130101;
A47L 15/4297 20130101; A47L 2401/14 20130101; A47L 2401/12
20130101; A47L 15/421 20130101; A47L 15/4287 20130101; A47L 15/4221
20130101 |
International
Class: |
A47L 15/42 20060101
A47L015/42 |
Claims
1. A dishwasher appliance comprising: a wash tub that defines a
wash chamber; a sump for collecting wash fluid, the sump defining a
mounting port; and a sensor assembly coupled to the mounting port,
the sensor assembly comprising: an adapter defining a mounting boss
for coupling to the mounting port, an internal chamber for
receiving the wash fluid, an air chamber defined above the internal
chamber, and a plurality of sensor ports; and a plurality of
sensors, each of the plurality of sensors being configured for
receipt within one of the plurality of sensor ports.
2. The dishwasher appliance of claim 1, wherein the plurality of
sensors comprises: a temperature sensor for measuring a temperature
of the wash fluid.
3. The dishwasher appliance of claim 2, wherein the adapter defines
a sleeve adjacent to the internal chamber for receiving the
temperature sensor.
4. The dishwasher appliance of claim 1, wherein the plurality of
sensors comprises: a turbidity sensor for measuring a turbidity of
the wash fluid.
5. The dishwasher appliance of claim 4, wherein the adapter defines
a first opposing wall and a second opposing wall that define a
trough within the internal chamber, and wherein the turbidity
sensor comprises: a turbidity lens that comprises a first
transmission arm positioned within the first opposing wall outside
of the trough and a second transmission arm positioned within the
second opposing wall outside of the trough.
6. The dishwasher appliance of claim 5, wherein the first opposing
wall and the second opposing wall are transparent to permit light
to pass from the first transmission arm to the second transmission
arm through the trough.
7. The dishwasher appliance of claim 1, wherein the adapter is
translucent.
8. The dishwasher appliance of claim 1, wherein the plurality of
sensors comprises: a pressure sensor for measuring a pressure of
the wash fluid, wherein the air chamber is positioned between the
internal chamber and the pressure sensor.
9. The dishwasher appliance of claim 8, wherein the pressure sensor
is positioned above the air chamber and is not in contact with the
wash fluid in the internal chamber.
10. The dishwasher appliance of claim 1, wherein the sensor
assembly further comprises: a primary seal positioned around the
mounting boss for creating a seal between the adapter and the
mounting port of the sump.
11. The dishwasher appliance of claim 1, wherein the adapter
defines one or more resilient snap-fit mechanisms for securing at
least one of the plurality of sensors.
12. The dishwasher appliance of claim 1, wherein the mounting port
is defined within a sidewall of the sump.
13. A sensor assembly for an appliance, the appliance comprising a
sump for collecting wash fluid, the sump defining a mounting port,
the sensor assembly comprising: an adapter defining a mounting boss
for coupling to the mounting port, an internal chamber for
receiving the wash fluid, an air chamber defined above the internal
chamber, and a plurality of sensor ports; and a plurality of
sensors, each of the plurality of sensors being configured for
receipt within one of the plurality of sensor ports.
14. The sensor assembly of claim 13, wherein the plurality of
sensors comprises: a temperature sensor for measuring a temperature
of the wash fluid.
15. The sensor assembly of claim 14, wherein the adapter defines a
sleeve adjacent to the internal chamber for receiving the
temperature sensor.
16. The sensor assembly of claim 13, wherein the plurality of
sensors comprises: a turbidity sensor for measuring a turbidity of
the wash fluid.
17. The sensor assembly of claim 16, wherein the adapter is
translucent.
18. The sensor assembly of claim 13, wherein the plurality of
sensors comprises: a pressure sensor for measuring a pressure of
the wash fluid, wherein the air chamber is positioned between the
internal chamber and the pressure sensor.
19. The sensor assembly of claim 18, wherein the pressure sensor is
positioned above the air chamber and is not in contact with the
wash fluid in the internal chamber.
20. The sensor assembly of claim 13, wherein the adapter defines
one or more resilient snap-fit mechanisms for securing at least one
of the plurality of sensors.
Description
FIELD OF THE INVENTION
[0001] The present disclosure relates generally to dishwasher
appliances, and more particularly to sensor assemblies including
adapter housings that receive multiple sensors within dishwasher
appliances.
BACKGROUND OF THE INVENTION
[0002] Dishwasher appliances generally include a tub that defines a
wash chamber. Rack assemblies can be mounted within the wash
chamber of the tub for receipt of articles for washing. Wash fluid
(e.g., various combinations of water and detergent along with
optional additives) may be introduced into the tub where it
collects in a sump space at the bottom of the wash chamber. During
wash and rinse cycles, a pump may be used to circulate wash fluid
to spray assemblies within the wash chamber that can apply or
direct wash fluid towards articles disposed within the rack
assemblies in order to clean such articles. During a drain cycle, a
drain pump may periodically discharge soiled wash fluid that
collects in the sump space and the process may be repeated.
[0003] As dishwashers become more advanced, sensors for various
purposes are used to control and monitor the status of the unit. As
such, each sensor typically adds cost, labor, and part count to the
dishwasher manufacturing process. In addition, each sensor must
typically be coupled to a port defined within the tub or sump of
the dishwasher, thus creating additional potential leak points.
[0004] Accordingly, a dishwasher appliance having improved features
for monitoring the appliance status and operating parameters during
an operating cycle would be desirable. More specifically, a
dishwasher appliance with an improved sensor assembly that is easy
to install, eliminates leak points, and facilitates efficient
process monitoring would be particularly beneficial.
BRIEF DESCRIPTION OF THE INVENTION
[0005] Aspects and advantages of the invention will be set forth in
part in the following description, or may be apparent from the
description, or may be learned through practice of the
invention.
[0006] In a first example embodiment, a dishwasher appliance is
provided including a wash tub that defines a wash chamber, a sump
for collecting wash fluid, the sump defining a mounting port, and a
sensor assembly coupled to the mounting port. The sensor assembly
includes an adapter defining a mounting boss for coupling to the
mounting port, an internal chamber for receiving the wash fluid, an
air chamber defined above the internal chamber, and a plurality of
sensor ports and a plurality of sensors, each of the plurality of
sensors being configured for receipt within one of the plurality of
sensor ports.
[0007] In a second example embodiment, a sensor assembly for an
appliance is provided. The appliance includes a sump for collecting
wash fluid, the sump defining a mounting port. The sensor assembly
includes an adapter defining a mounting boss for coupling to the
mounting port, an internal chamber for receiving the wash fluid, an
air chamber defined above the internal chamber, and a plurality of
sensor ports and a plurality of sensors, each of the plurality of
sensors being configured for receipt within one of the plurality of
sensor ports.
[0008] These and other features, aspects and advantages of the
present invention will become better understood with reference to
the following description and appended claims. The accompanying
drawings, which are incorporated in and constitute a part of this
specification, illustrate embodiments of the invention and,
together with the description, serve to explain the principles of
the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] A full and enabling disclosure of the present invention,
including the best mode thereof, directed to one of ordinary skill
in the art, is set forth in the specification, which makes
reference to the appended figures.
[0010] FIG. 1 provides a perspective view of an exemplary
embodiment of a dishwashing appliance of the present disclosure
with a door in a partially open position.
[0011] FIG. 2 provides a side, cross sectional view of the
exemplary dishwashing appliance of FIG. 1.
[0012] FIG. 3 provides a perspective view of a sump assembly of the
exemplary dishwashing appliance of FIG. 1 according to an example
embodiment of the present subject matter.
[0013] FIG. 4 provides a cross sectional view of the exemplary sump
assembly of FIG. 3 including a sensor assembly in accordance with
an exemplary embodiment of the present subject matter.
[0014] FIG. 5 provides an exploded view of the exemplary sensor
assembly of FIG. 4 according to an exemplary embodiment.
[0015] FIG. 6 provides a perspective view of the exemplary sensor
assembly of FIG. 4 according to an exemplary embodiment.
[0016] FIG. 7 provides a cross sectional view of the exemplary
sensor assembly of FIG. 4 according to an exemplary embodiment.
[0017] FIG. 8 provides another cross sectional view of the
exemplary sensor assembly of FIG. 4 according to an exemplary
embodiment.
[0018] FIG. 9 provides a close-up, cross sectional view of the
exemplary sensor assembly of FIG. 4 according to an exemplary
embodiment.
[0019] FIG. 10 provides another cross sectional view of the
exemplary sensor assembly of FIG. 4 according to an exemplary
embodiment.
[0020] FIG. 11 provides another cross sectional view of the
exemplary sensor assembly of FIG. 4 according to an exemplary
embodiment.
[0021] Repeat use of reference characters in the present
specification and drawings is intended to represent the same or
analogous features or elements of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0022] Reference now will be made in detail to embodiments of the
invention, one or more examples of which are illustrated in the
drawings. Each example is provided by way of explanation of the
invention, not limitation of the invention. In fact, it will be
apparent to those skilled in the art that various modifications and
variations can be made in the present invention without departing
from the scope or spirit of the invention. For instance, features
illustrated or described as part of one embodiment can be used with
another embodiment to yield a still further embodiment. Thus, it is
intended that the present invention covers such modifications and
variations as come within the scope of the appended claims and
their equivalents.
[0023] As used herein, the term "article" may refer to, but need
not be limited to dishes, pots, pans, silverware, and other cooking
utensils and items that can be cleaned in a dishwashing appliance.
The term "wash cycle" is intended to refer to one or more periods
of time during which a dishwashing appliance operates while
containing the articles to be washed and uses a detergent and
water, preferably with agitation, to e.g., remove soil particles
including food and other undesirable elements from the articles.
The term "rinse cycle" is intended to refer to one or more periods
of time during which the dishwashing appliance operates to remove
residual soil, detergents, and other undesirable elements that were
retained by the articles after completion of the wash cycle. The
term "drain cycle" is intended to refer to one or more periods of
time during which the dishwashing appliance operates to discharge
soiled water from the dishwashing appliance. The term "wash fluid"
refers to a liquid used for washing and/or rinsing the articles and
is typically made up of water that may include other additives such
as detergent or other treatments. Furthermore, as used herein,
terms of approximation, such as "approximately," "substantially,"
or "about," refer to being within a ten percent margin of
error.
[0024] FIGS. 1 and 2 depict an exemplary domestic dishwasher or
dishwashing appliance 100 that may be configured in accordance with
aspects of the present disclosure. For the particular embodiment of
FIGS. 1 and 2, the dishwasher 100 includes a cabinet 102 (FIG. 2)
having a tub 104 therein that defines a wash chamber 106. As shown
in FIG. 2, tub 104 extends between a top 107 and a bottom 108 along
a vertical direction V, between a pair of side walls 110 along a
lateral direction L, and between a front side 111 and a rear side
112 along a transverse direction T. Each of the vertical direction
V, lateral direction L, and transverse direction T are mutually
perpendicular to one another.
[0025] The tub 104 includes a front opening 114 and a door 116
hinged at its bottom for movement between a normally closed
vertical position (shown in FIG. 2), wherein the wash chamber 106
is sealed shut for washing operation, and a horizontal open
position for loading and unloading of articles from the dishwasher
100. According to exemplary embodiments, dishwasher 100 further
includes a door closure mechanism or assembly 118 that is used to
lock and unlock door 116 for accessing and sealing wash chamber
106.
[0026] As best illustrated in FIG. 2, tub side walls 110
accommodate a plurality of rack assemblies. More specifically,
guide rails 120 may be mounted to side walls 110 for supporting a
lower rack assembly 122, a middle rack assembly 124, and an upper
rack assembly 126. As illustrated, upper rack assembly 126 is
positioned at a top portion of wash chamber 106 above middle rack
assembly 124, which is positioned above lower rack assembly 122
along the vertical direction V. Each rack assembly 122, 124, 126 is
adapted for movement between an extended loading position (not
shown) in which the rack is substantially positioned outside the
wash chamber 106, and a retracted position (shown in FIGS. 1 and 2)
in which the rack is located inside the wash chamber 106. This is
facilitated, for example, by rollers 128 mounted onto rack
assemblies 122, 124, 126, respectively. Although a guide rails 120
and rollers 128 are illustrated herein as facilitating movement of
the respective rack assemblies 122, 124, 126, it should be
appreciated that any suitable sliding mechanism or member may be
used according to alternative embodiments.
[0027] Some or all of the rack assemblies 122, 124, 126 are
fabricated into lattice structures including a plurality of wires
or elongated members 130 (for clarity of illustration, not all
elongated members making up rack assemblies 122, 124, 126 are shown
in FIG. 2). In this regard, rack assemblies 122, 124, 126 are
generally configured for supporting articles within wash chamber
106 while allowing a flow of wash fluid to reach and impinge on
those articles, e.g., during a cleaning or rinsing cycle. According
to another exemplary embodiment, a silverware basket (not shown)
may be removably attached to a rack assembly, e.g., lower rack
assembly 122, for placement of silverware, utensils, and the like,
that are otherwise too small to be accommodated by rack 122.
[0028] Dishwasher 100 further includes a plurality of spray
assemblies for urging a flow of water or wash fluid onto the
articles placed within wash chamber 106. More specifically, as
illustrated in FIG. 2, dishwasher 100 includes a lower spray arm
assembly 134 disposed in a lower region 136 of wash chamber 106 and
above a sump 138 so as to rotate in relatively close proximity to
lower rack assembly 122. Similarly, a mid-level spray arm assembly
140 is located in an upper region of wash chamber 106 and may be
located below and in close proximity to middle rack assembly 124.
In this regard, mid-level spray arm assembly 140 may generally be
configured for urging a flow of wash fluid up through middle rack
assembly 124 and upper rack assembly 126. Additionally, an upper
spray assembly 142 may be located above upper rack assembly 126
along the vertical direction V. In this manner, upper spray
assembly 142 may be configured for urging and/or cascading a flow
of wash fluid downward over rack assemblies 122, 124, and 126. As
further illustrated in FIG. 2, upper rack assembly 126 may further
define an integral spray manifold 144, which is generally
configured for urging a flow of wash fluid substantially upward
along the vertical direction V through upper rack assembly 126.
[0029] Dishwasher 100 may further include a water supply valve 146
positioned between an external water supply 148 and a circulation
pump (such as pump 152 described below) to selectively allow water
to flow from the external water supply 148 into circulation pump
152. Additionally or alternatively, water supply valve 146 can be
positioned between the external water supply 148 and sump 138 to
selectively allow water to flow from the external water supply 148
into sump 138. Water supply valve 146 can be selectively controlled
to open and allow the flow of water into dishwasher 100 and can be
selectively controlled to cease the flow of water into dishwasher
100.
[0030] The various spray assemblies, manifolds, and water supplies
described herein may be part of a fluid distribution system or
fluid circulation assembly 150 for circulating water and wash fluid
in the tub 104. More specifically, fluid circulation assembly 150
includes a pump 152 for circulating water and wash fluid (e.g.,
detergent, water, and/or rinse aid) in the tub 104. Pump 152 may be
located within sump 138 or within a machinery compartment located
below sump 138 of tub 104, as generally recognized in the art.
Fluid circulation assembly 150 may include one or more fluid
conduits or circulation piping for directing water and/or wash
fluid from pump 152 to the various spray assemblies and manifolds,
e.g., during wash and/or rinse cycles. For example, as illustrated
in FIG. 2, a primary supply conduit 154 may extend from pump 152,
along rear 112 of tub 104 along the vertical direction V to supply
wash fluid throughout wash chamber 106.
[0031] As illustrated, primary supply conduit 154 is used to supply
wash fluid to one or more spray assemblies, e.g., to mid-level
spray arm assembly 140 and upper spray assembly 142. However, it
should be appreciated that according to alternative embodiments,
any other suitable plumbing configuration may be used to supply
wash fluid throughout the various spray manifolds and assemblies
described herein. For example, according to another exemplary
embodiment, primary supply conduit 154 could be used to provide
wash fluid to mid-level spray arm assembly 140 and a dedicated
secondary supply conduit (not shown) could be utilized to provide
wash fluid to upper spray assembly 142. Other plumbing
configurations may be used for providing wash fluid to the various
spray devices and manifolds at any location within dishwasher
appliance 100.
[0032] Each spray arm assembly 134, 140, 142, integral spray
manifold 144, or other spray device may include an arrangement of
discharge ports or orifices for directing wash fluid received from
pump 152 onto dishes or other articles located in wash chamber 106.
The arrangement of the discharge ports, also referred to as jets,
apertures, or orifices, may provide a rotational force by virtue of
wash fluid flowing through the discharge ports. Alternatively,
spray arm assemblies 134, 140, 142 may be motor-driven, or may
operate using any other suitable drive mechanism. Spray manifolds
and assemblies may also be stationary. The resultant movement of
the spray arm assemblies 134, 140, 142 and the spray from fixed
manifolds provides coverage of dishes and other dishwasher contents
with a washing spray. Other configurations of spray assemblies may
be used as well. For example, dishwasher 100 may have additional
spray assemblies for cleaning silverware, for scouring casserole
dishes, for spraying pots and pans, for cleaning bottles, etc. One
skilled in the art will appreciate that the embodiments discussed
herein are used for the purpose of explanation only, and are not
limitations of the present subject matter.
[0033] In operation, pump 152 draws wash fluid in from sump 138 and
pumps it to a diverter assembly 156, e.g., which is positioned
within sump 138 of dishwasher appliance. Diverter assembly 156 may
include a diverter disk (not shown) disposed within a diverter
chamber 158 for selectively distributing the wash fluid to the
spray arm assemblies 134, 140, 142 and/or other spray manifolds or
devices. For example, the diverter disk may have a plurality of
apertures that are configured to align with one or more outlet
ports (not shown) at the top of diverter chamber 158. In this
manner, the diverter disk may be selectively rotated to provide
wash fluid to the desired spray device.
[0034] According to an exemplary embodiment, diverter assembly 156
is configured for selectively distributing the flow of wash fluid
from pump 152 to various fluid supply conduits, only some of which
are illustrated in FIG. 2 for clarity. More specifically, diverter
assembly 156 may include four outlet ports (not shown) for
supplying wash fluid to a first conduit for rotating lower spray
arm assembly 134, a second conduit for rotating mid-level spray arm
assembly 140, a third conduit for spraying upper spray assembly
142, and a fourth conduit for spraying an auxiliary rack such as
the silverware rack.
[0035] The dishwasher 100 is further equipped with a controller 160
to regulate operation of the dishwasher 100. The controller 160 may
include one or more memory devices and one or more microprocessors,
such as general or special purpose microprocessors operable to
execute programming instructions or micro-control code associated
with a cleaning cycle. The memory may represent random access
memory such as DRAM, or read only memory such as ROM or FLASH. In
one embodiment, the processor executes programming instructions
stored in memory. The memory may be a separate component from the
processor or may be included onboard within the processor.
Alternatively, controller 160 may be constructed without using a
microprocessor, e.g., using a combination of discrete analog and/or
digital logic circuitry (such as switches, amplifiers, integrators,
comparators, flip-flops, AND gates, and the like) to perform
control functionality instead of relying upon software.
[0036] The controller 160 may be positioned in a variety of
locations throughout dishwasher 100. In the illustrated embodiment,
the controller 160 may be located within a control panel area 162
of door 116 as shown in FIGS. 1 and 2. In such an embodiment,
input/output ("I/O") signals may be routed between the control
system and various operational components of dishwasher 100 along
wiring harnesses that may be routed through the bottom of door 116.
Typically, the controller 160 includes a user interface
panel/controls 164 through which a user may select various
operational features and modes and monitor progress of the
dishwasher 100. In one embodiment, the user interface 164 may
represent a general purpose I/O ("GPIO") device or functional
block. In one embodiment, the user interface 164 may include input
components, such as one or more of a variety of electrical,
mechanical or electro-mechanical input devices including rotary
dials, push buttons, and touch pads. The user interface 164 may
include a display component, such as a digital or analog display
device designed to provide operational feedback to a user. The user
interface 164 may be in communication with the controller 160 via
one or more signal lines or shared communication busses.
[0037] It should be appreciated that the invention is not limited
to any particular style, model, or configuration of dishwasher 100.
The exemplary embodiment depicted in FIGS. 1 and 2 is for
illustrative purposes only. For example, different locations may be
provided for user interface 164, different configurations may be
provided for rack assemblies 122, 124, 126, different spray arm
assemblies 134, 140, 142 and spray manifold configurations may be
used, and other differences may be applied while remaining within
the scope of the present subject matter.
[0038] Referring now generally to FIGS. 3 and 4, sump 138 of
dishwasher appliance 100 may include a drain basin 170 coupled to a
bottom wall 172 of tub 104 by a cylindrical sidewall 174. During
operation of dishwasher appliance 100, wash fluid 176 (see FIG. 4)
is directed toward sump 138 where it falls into drain basin 170 and
is collected and contained by cylindrical sidewall 174. As shown,
circulation pump 152 may be fluidly coupled to sump 138, e.g.,
through a port defined within cylindrical sidewall 174 such that
circulation pump 152 may draw wash fluid 176 from sump 138 for
circulation within dishwasher appliance 100. In addition, as shown
for example in FIG. 2, a drain conduit 178 may be fluidly coupled
to drain basin 170 and a drain pump 180 may be fluidly coupled to
drain conduit 178 for selectively discharging wash fluid 176 from
washing machine appliance, e.g., to an external drain 182.
[0039] Notably, it is frequently desirable to monitor wash fluid
176 during operation of dishwasher appliance 100. For example,
dishwasher appliance 100 may use turbidity sensors to monitor the
contaminant level or soil level of wash fluid 176, e.g., in order
to determine the cleanliness of the dishes or to know when the wash
fluid should be refreshed. In addition, for example, it is
frequently desirable to monitor the temperature of wash fluid 176
and make appropriate corrections for optimal cleaning action.
Furthermore, pressure sensors are frequently used to detect the
water level within sump 138, e.g., to ensure effective washing
action without overfilling sump 138.
[0040] As explained above, conventional dishwasher appliances
include separate sensors that are attached or operably coupled to
sump 138 at different locations, e.g., via different ports. During
assembly, an operator must separately install each sensor into its
own dedicated port, increasing the number of dishwasher parts and
the complexity of assembly. Moreover, each of the ports defined
within the sump of conventional dishwasher appliances results in
additional potential leak points, thereby resulting in more service
calls, leaks, or operability issues.
[0041] Referring now generally to FIGS. 3 through 11, a sensor
assembly 200 will be described according to exemplary embodiments
of the present subject matter. Sensor assembly 200 is generally
configured for receiving a plurality of sensors in a single module
that may be installed at a single mounting port defined on sump
138. In this manner, the number of potential leak points may be
reduced, dishwasher assembly may be simplified, and the overall
performance and reliability of dishwasher appliance 100 may be
improved. Although sensor assembly 200 is described herein as being
used in dishwasher appliance 100, it should be appreciated that
sensor assembly 200 may be used in any other suitable application
while remaining within the scope of the present subject matter. For
example, aspects of the present subject matter may be used in other
appliances, such as washing machine appliances, or in any other
appliance where it is desirable to monitor a fluid.
[0042] According to the illustrated embodiment, sensor assembly 200
is generally configured for receiving a pressure sensor 202, a
turbidity sensor 204, and a temperature sensor 206. It should be
appreciated that according to alternative embodiments, sensor
assembly 200 may include additional sensors, different types of
sensors, different mounting configurations, etc. Each of these
sensors 202-206 will be described generally below. However, it
should be appreciated that certain details of construction or
operation of each of these sensors 202-206 may be omitted in the
drawings or associated description for brevity.
[0043] According to the illustrated embodiment, sump 138 defines a
mounting port 210 (see FIGS. 3 and 4) that is generally configured
for receiving sensor assembly 200 as described herein. In this
regard, mounting port 210 may be any suitable boss, connector, or
coupling feature that can securely join sensor assembly 200 and
sump 138. For example, mounting port 210 is illustrated as a boss
that is defined in cylindrical sidewall 174 and includes a chamber
inlet 212 positioned proximate the bottom of sump 138, e.g., near
drain basin 170. Chamber inlet 212 generally provides fluid
communication between sump 138 and sensor assembly 200, e.g., to
facilitate process monitoring. It should be appreciated that the
size, position, and configuration of mounting port 210 may vary
while remaining within the scope of the present subject matter.
[0044] Referring now specifically to FIGS. 5 through 11, sensor
assembly 200 includes a housing or adapter 220 that defines a
mounting boss 222 for coupling with mounting port 210. In this
regard, mounting boss 222 may include complimentary features to
mounting port 210 such that adapter 220 may be quickly installed
into mounting port 210. In addition, sensor assembly 200 may
include a primary seal 224 that is positioned around mounting boss
222 for creating a fluid tight seal between adapter 220 and
mounting port 210. Although primary seal 224 is illustrated as an
O-ring, it should be appreciated that any suitable fluid seal may
be used according to alternative embodiments.
[0045] Adapter 220 further defines a plurality of sensor ports 226
that are generally configured for receiving one or more sensors of
sensor assembly 200, e.g., such as pressure sensor 202, turbidity
sensor 204, and/or temperature sensor 206. In this regard, sensor
ports 226 may be any suitable boss, connector, or coupling
mechanism that is suitable for joining a sensor with adapter 220.
Notably, sensor assembly may further have feature for simplifying
installation of such sensors as well as joining of adapter 220 and
mounting port 210. For example, adapter 220 may define one or more
resilient snap-fit mechanisms 228 for securing at least one of the
plurality of sensors 202-206 to adapter 220. In addition, sensors
202-206 may include complimentary features for simplifying the
installation of such sensors onto adapter 220.
[0046] Pressure sensor 202 may generally be configured for
continuously or periodically measuring a level of water or wash
fluid within dishwasher 100. Specifically, pressure sensor 202 may
be operably coupled to sump 138 for measuring a pressure of wash
fluid 176 that collects within sump 138 to facilitate wash fluid
level detection. In general, pressure sensor 202 may be any sensor
suitable for determining a water level within sump 138 based on
pressure readings. For example, pressure sensor 202 may be a
piezoelectric pressure sensor and thus may include an elastically
deformable plate or diaphragm (not shown) and a piezoresistor
mounted on the elastically deformable plate. However, it should be
appreciated that according to alternative embodiments, pressure
sensor 202 may be any type of pressure sensor that is fluidly
coupled to sump 138 in any other suitable manner for obtaining sump
pressures to facilitate water level detection.
[0047] Notably, adapter 220 may define features that facilitate
improved pressure measurement and detection while reducing the
likelihood of degradation or failure of pressure sensor 202. In
this regard, one of the plurality of sensor ports 226 defined by
adapter 220 may be a pressure port 230 to which pressure sensor 202
may be coupled. Adapter 220 may further define an internal chamber
232 that is fluidly coupled with sump 138 through chamber inlet
212. In this manner, wash fluid 176 from within sump 138 floods
internal chamber 232 (as shown for example in FIG. 4) to facilitate
pressure detection. In addition, adapter 220 defines a separate air
chamber 234 that is positioned above internal chamber 232 along the
vertical direction V and is designed to remain free of wash fluid
176 during operation of dishwasher appliance 100. According to the
illustrated embodiment, pressure sensor 202 is mounted at the very
top of adapter 220, e.g., above air chamber 234 such that air
chamber 234 acts as an air gap between pressure sensor 202 and wash
fluid 176 within internal chamber 232. Thus, according to exemplary
embodiments, pressure sensor 202 never contacts wash fluid 176.
This may be important, for example, to prevent contact of wash
fluid 176 with pressure sensor 202, which may build up dirt, grime,
or contamination over time, thereby affecting measurement
accuracy.
[0048] Pressure sensor 202 may further include a pressure seal 236
that creates a fluid seal or airtight seal between pressure sensor
202 and adapter 220. Pressure sensor 202 will generally operate by
measuring a pressure of air within air chamber 234 and using the
measured chamber pressure to estimate the water level in sump 138.
For example, when the water level within sump 138 falls below
chamber inlet 212, the pressure within air chamber 234 normalizes
to ambient or atmospheric pressure, and thus reads a zero pressure.
However, when wash fluid 176 is present in sump 138 and rises above
chamber inlet 212, the wash fluid 176 fills internal chamber 232
and causes the air pressure within air chamber 234 to become
positive and increase proportionally with the water level. Although
sump 138 is described herein as containing wash fluid, it should be
appreciated that aspects of the present subject matter may be used
for detecting the level of any other suitable liquid in any other
appliance.
[0049] Adapter 220 may further include a turbidity port 240 that is
generally configured for receiving the turbidity sensor 204 and/or
the temperature sensor 206. In this regard, according to the
illustrated embodiment, turbidity sensor 204 and temperature sensor
206 are mounted in a single module that may be installed onto
turbidity port 240. According to alternative embodiments, turbidity
sensor 204 and temperature sensor 206 may be separate sensors
mounted to separate, dedicated sensor ports 226 defined by adapter
220. As illustrated, an end cap 242 may be configured for receiving
turbidity sensor 204, temperature sensor 206, and operating
electronics. End cap 242 may further define snap-fit mechanisms for
clipping onto adapter 220 and securing turbidity sensor 204 and
temperature sensor 206 in place.
[0050] As described herein, "temperature sensor" may refer to any
suitable type of temperature sensor. For example, the temperature
sensors may be thermocouples, thermistors (e.g., such as negative
temperature coefficient or "NTC" thermistors), or resistance
temperature detectors. In addition, temperature sensor 206 may be
mounted at any suitable location and in any suitable manner for
obtaining a desired temperature or wash fluid 176, either directly
or indirectly. For example, referring briefly to FIG. 9, adapter
220 may define a sleeve 244 that is adjacent to internal chamber
232 and is configured for receiving temperature sensor 206. Sleeve
244 may be a pocket that is fluidly isolated from wash fluid 176
within internal chamber 232 while remaining in thermal
communication with wash fluid 176. According to an exemplary
embodiment, sleeve 244 may be filled with a thermally conductive
grease or potting material for ensuring good thermal contact
between temperature sensor 206 and wash fluid 176.
[0051] As mentioned above, turbidity sensor 204 may be mounted
within or joined to adapter 220 via turbidity port 240. As best
shown in FIGS. 10 and 11, turbidity sensor 204 generally includes
an emitter 248 for emitting a beam of light 250 (see FIG. 10) that
is passed through wash fluid 176 and a receiver 252 for receiving
the beam of light 250. In this manner, the turbidity of wash fluid
176 may be estimated based on the distortion of the beam of light
250. According to the illustrated embodiment, turbidity sensor 204
further includes a turbidity lens 254 that includes a first
transmission arm 256 positioned over emitter 248 and a second
transmission arm 258 positioned over receiver 252. Each of first
transmission arm 256 and second transmission arm 258 are configured
for turning the beam of light 250 by 90.degree.. Thus, a gap is
defined between the distal ends of the first transmission arm 256
and second transmission arm 258 through which the beam of light 250
is transmitted. By providing wash fluid 176 within that gap, the
turbidity of the wash fluid 176 may be determined.
[0052] As illustrated, adapter 220 defines a first opposing wall
260 and a second opposing wall 262 that define a trough 264 within
internal chamber 232. Wash fluid 176 may flow into the trough 264
to facilitate turbidity sensing. Notably, first transmission arm
256 and second transmission arm 258 may be positioned adjacent to
or within opposing walls 260, 262. According to such an embodiment,
opposing walls 260, 262 may define a transparent or translucent
window through which the beam of light 250 may pass. According to
the illustrated embodiment, adapter 220 is formed entirely from a
translucent material such that the beam of light 250 may pass
therethrough.
[0053] Although turbidity sensor 204 is illustrated herein as
including a turbidity lens 254 for turning the beam of light 250
through a translucent portion of adapter 220 for sensing turbidity,
it should be appreciated that this is only one exemplary
embodiment. Any other suitable type or configuration of turbidity
sensor may be used while remaining within the scope of the present
subject matter. For example, according to alternative embodiment,
lens 254 may be omitted altogether and emitter 248 and receiver 252
may be positioned for transmitting the beam of light 250 directly
across the gap or through the wash fluid in any other suitable
manner. Other sensor configurations are possible and within the
scope of the present subject matter.
[0054] This written description uses examples to disclose the
invention, including the best mode, and also to enable any person
skilled in the art to practice the invention, including making and
using any devices or systems and performing any incorporated
methods. The patentable scope of the invention is defined by the
claims, and may include other examples that occur to those skilled
in the art. Such other examples are intended to be within the scope
of the claims if they include structural elements that do not
differ from the literal language of the claims, or if they include
equivalent structural elements with insubstantial differences from
the literal language of the claims.
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