Energy management and conservation while ensuring cold chain compliance

Abstract

This disclosure provides systems and methods for energy management and savings while ensuring cold chain compliance. In some embodiments, a method of operating an active cooling system (ACS) includes: determining operational requirements for a plurality of active cooling containers (ACTs); and adjusting operation of one or more of the plurality of ACTs based on a physical location of the one or more of the plurality of ACTs in the ACS. In this manner, this may prevent large-scale opening of a set of ACTs physically next together from creating large thermal exhaust columns. This may also achieve energy savings and prioritization of energy usage.

Description

[0001] Related applications

[0002] This application claims the benefit of provisional patent application serial number 63 / 499,597, filed on May 2, 2023, the disclosure of which is incorporated herein by reference in its entirety. Technical Field

[0003] This disclosure generally relates to temperature-controlled environments. Background Technology

[0004] Currently, cold chain transportation for food, pharmaceuticals, or any product requiring temperature control during delivery is carried out using tri-temperature or refrigerated trucks and vans. These trucks and vans are modified with compressor-based systems that cool or freeze entire compartments of the truck and must operate continuously to maintain the internal temperature. Whether the truck carries a gallon of milk or a pint of ice cream, the entire space must be cooled or frozen. The cooling platform of the compressor-based refrigerated truck and tri-temperature truck or van must be penetrated from the outside to fit inside the truck or van, voiding the warranty. Furthermore, for tri-temperature trucks to operate, spacers must exist between temperature zones to maintain the temperature. The spatial separation requires separate processing of orders with goods stored in two or more zones. Compressor-based systems consume too much power, making them unsuitable for use in pure electric vehicles without significantly reducing the vehicle's range. Improved systems and methods for thermal management are needed. Summary of the Invention

[0005] This disclosure provides systems and methods for energy management and conservation while ensuring cold chain compliance. In some embodiments, the method of operating an Active Cooling System (ACS) includes: determining the operational needs of a plurality of Active Cooling Turnover Boxes (ACTs); and adjusting the operation of one or more of the ACTs based on their physical location within the ACS. This prevents the generation of large columns of hot exhaust gases from a large-scale activation of a physically adjacent group of ACTs. It also enables energy conservation and prioritization of energy use.

[0006] Those skilled in the art will understand the scope of this disclosure and recognize its additional aspects after reading the following detailed description of preferred embodiments in conjunction with the accompanying drawings. Attached Figure Description

[0007] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate several aspects of this disclosure and, together with the specification, serve to explain the principles of this disclosure.

[0008] Figures 1A to 1D The use of portable, stand-alone refrigeration or freezing systems coupled with integrated automated control and monitoring was demonstrated;

[0009] Figure 2 as well as Figure 3A and Figure 3B An example embodiment of an active cooler according to embodiments of the present disclosure is shown;

[0010] Figure 4 Systems including active coolers according to some embodiments of the present disclosure are shown;

[0011] Figure 5 Examples of turnover boxes as discussed in this article are shown;

[0012] Figure 6A and Figure 6B The exhibition showcased different types of turnover boxes that can be used in refrigerated or frozen refrigerators;

[0013] Figure 7 An exploded view of the turnover box, including the thermoelectric unit as discussed herein, is shown.

[0014] Figure 8 A standard three-temperature truck used for delivery is shown;

[0015] Figure 9 The exhibition showcased delivery trucks that do not require refrigeration systems or require less cooling.

[0016] Figure 10 The airflow patterns between adjacent turnover boxes according to some embodiments are shown;

[0017] Figure 11 A large volume of exhaust airflow is shown in a stack of turnover boxes according to some embodiments;

[0018] Figure 12 The placement of an active cooling turnover box in a facility is illustrated according to some embodiments;

[0019] Figure 13 A diagram of an example Automated Storage and Retrieval System (ASRS) according to some embodiments is shown;

[0020] Figure 14 The document demonstrates, according to some embodiments, that the processing can be based on the power and network status of the ACS interconnect service. Detailed Implementation

[0021] The embodiments described below illustrate the necessary information to enable those skilled in the art to practice the embodiments and explain the best mode for practicing the embodiments. Those skilled in the art will understand the concepts of this disclosure and recognize the application of these concepts not specifically set forth herein when reading the following description in conjunction with the accompanying drawings. It should be understood that these concepts and applications fall within the scope of this disclosure and the appended claims.

[0022] Last-mile food delivery requires the use of vans or similar vehicles for temperature-controlled transport of perishable foods. To achieve temperature control, refrigerated or frozen containers can be installed in vans (e.g., cargo vans) or box trucks.

[0023] These crates use active heat pumps to extract heat from the enclosed chamber and release it into the surrounding air. The hot air must be removed from the van to ensure optimal operation of the crates.

[0024] These containers require electricity during transport to maintain food safety requirements for perishable consumer goods. The electrical system needs to meet (and / or maintain) the correct temperature necessary for the containers to operate.

[0025] Figures 1A to 1D The use of portable, stand-alone refrigeration or freezing systems coupled with integrated automated control and monitoring is demonstrated.

[0026] Figure 2 as well as Figure 3A and Figure 3B An example embodiment of an active cooler according to embodiments of the present disclosure is shown.

[0027] Figure 4 A system including an active cooler is shown according to some embodiments of the present disclosure.

[0028] For further details, interested readers may refer to the following: U.S. Provisional Patent Application Serial No. 62 / 953,771 entitled THERMOELECTRIC REFRIGERATED / FROZEN PRODUCT STORAGE AND TRANSPORTATION COOLER; U.S. Patent Application Serial No. 17 / 135,420 entitled THERMOELECTRIC REFRIGERATED / FROZEN PRODUCT STORAGE AND TRANSPORTATION COOLER, now U.S. Patent Application Publication No. 2021 / 0199353 A1; and International Patent Application No. PCT / US2020 / 067172 entitled THERMOELECTRIC REFRIGERATED / FROZEN PRODUCTSTORAGE AND TRANSPORTATION COOLER, now International Patent Publication No. WO 2021 / 134068. These applications are hereby incorporated herein by reference in their entirety.

[0029] Figure 5 Examples of turnover boxes as discussed in this article are shown. Figure 6 illustrates different types of turnover boxes that can be used in refrigerated or frozen models. Figure 7 An exploded view of a turnover box including thermoelectric units as discussed herein is shown.

[0030] Figure 8 The image shows a standard three-temperature truck used for delivery. This may include several different cooling systems, which must be carried regardless of whether they are currently needed.

[0031] Figure 9 Delivery trucks with minimal or no refrigeration systems are demonstrated. In this embodiment, the tow box provides the appropriate temperature for various goods. This makes the truck more efficient in many ways. It also increases configurability. If the entire truck needs to reach a specific temperature, this can be easily achieved compared to standard trucks. These trucks may include charging capabilities or other amenities.

[0032] Reintroduction (also known as "re-inhalation") occurs when hot air exhausted from an actively cooled container remains in the space between adjacent containers, and then that exhaust is drawn back into the same container from which it was exhausted.

[0033] The result of this reintroduction is decreased performance and excessive energy consumption in the container, as it will require continuous high-power operation of the thermoelectric system to cool to and maintain the desired setpoint. In some more severe cases of reintroduction, such as at temperatures above normal ambient temperature, it will reach its system limits and fail to reach the desired setpoint, thus failing to stabilize at an internal cooling temperature higher than desired.

[0034] In addition to the potential reintroduction of exhaust gas due to the adjacent placement of turnover boxes, the issue of large exhaust gas flow from multiple turnover boxes must also be addressed to prevent the performance degradation described above.

[0035] Figure 10 The airflow pattern between adjacent turnover boxes is shown. In some embodiments, by directing the hot exhaust at an angle (approximately 45 degrees) to the top of the adjacent turnover box, the orientation of the exhaust vents on the turnover box eliminates the problem of reintroduction between adjacent turnover boxes.

[0036] In some embodiments, large venting is addressed by intentionally separating the turnover boxes in the facility to prevent the formation of hot vent columns (hot columns) in the stack of turnover boxes. Figure 11 It shows a large amount of exhaust airflow in the stack of turnover boxes. Figure 12 The placement of actively cooled turnover boxes in a facility is illustrated according to some embodiments. The building's HVAC system then processes and regulates the exhaust as usual. This configuration places the actively cooled turnover boxes along the length of the facility in a staggered pattern, preventing the accumulation of hot exhaust while still allowing full utilization of shuttle robots for retrieving and returning turnover boxes from storage racks. Actively cooled turnover boxes comprise a certain percentage of all turnover boxes in the facility, with the remaining rack positions occupied by ambient turnover boxes that do not exhaust hot air.

[0037] Question A

[0038] The control of the opening and closing of Active Cooling Turnover Box (ACT) arrays is generally critical to operation and is the fundamental principle guiding several specific embodiments of the control of active cooling systems. This principle is to balance the ACTs operating in a cooling state (where power consumption is highest due to rapid cooling from ambient temperature) and those operating in a steady state (where power consumption is lower) at any given point in time. This prevents a large-scale opening of a physically adjacent group of ACTs, creating a large column of hot exhaust gas. This event is most likely to occur in large stacks of ACTs used for storing frozen or refrigerated food, typically in Automated Storage and Retrieval Systems (ASRS). A large-scale opening event will cause several problems: 1) the building's electrical system will consume more current than its capacity; 2) the formation of a large column of hot exhaust gas that reduces cooling efficiency and increases current consumption and exhaust temperature – further complicating the problem.

[0039] Solution A Overview - Controlled Enablement

[0040] ACTs are opened in an ordered manner based on their location. Through integration with the ASRS inventory management system, the location of each ACT is known to the ACS Interconnected Services system. See the example ASRS diagram below ( Figure 13 In the diagram, the active phonon cooling turnkey is labeled "P," and the inactive environment turnkey is labeled "A." In the example startup scenario, ACTs in sections 1, 3, and 5 can be started first. Once this group of ACTs reaches a steady state and power consumption decreases accordingly, the remaining ACTs in sections 2 and 4 can then be started.

[0041] Question "B"

[0042] In the event of a power outage at the facility, the entire ACT array in the system must resume operation immediately upon restoration of power to avoid the problem described in issue "A".

[0043] Solution "B" Overview - Controlled Power Outage Recovery

[0044] After power is restored, polling can be used to determine the current temperature of each ACT in the system to determine their startup priority—the ACT that was preheated the fastest during the power outage will start first. Additionally, the cold chain compliance of frozen or refrigerated food stored in the ACTs must be verified, and appropriate disposal instructions must be provided to the system users / operators. Disposal is based on the power and network status of the ACS interconnection service, such as… Figure 14 As shown in the table below.

[0045] Question "C"

[0046] In any given ACT, optimization of the cooling profile is best performed with information on whether the ACT is empty or contains food products, and how much food product it contains (full load %). Without direct integration of the ACS with the inventory management system, this information must be collected through other means. Furthermore, directly sensing the load using mechanical / electrical sensors may not be cost-effective or technically feasible.

[0047] Solution "C" Overview - Load Estimation via Inference

[0048] Load estimation is performed through inference. By monitoring the temperature profile of any given ACT, a rough percentage of load and item type can be estimated without directly sensing or scanning the item. This estimation is performed by comparing the temperature profile with a known set of profiles (lookup tables) corresponding to known load percentages and item types. In alternative embodiments, this estimation is performed and refined using machine learning rather than table lookups. For example, the rate of temperature decrease (cooling from ambient temperature to setpoint temperature) will be affected by the presence or absence of food load, and in this implementation, known rate changes can be used as a predictor of what the ACT contains.

[0049] Question "D"

[0050] Continuous operation of each ACT at its maximum cooling capacity will result in an unnecessary and enormous waste of energy consumption for the ACS as a whole.

[0051] Solution “D” Overview - Optimization of Cooling Curve

[0052] During normal ACS operation, operational telemetry data from each ACT is periodically reported and stored by the ACS Interconnect Service system. The cooling profile of the ACT array needs to be optimized via the Active Cooling System (ACS) Interconnect Service to manage and conserve energy. This can be achieved by adjusting the temperature setpoint of each ACT based on its usage (empty or full load) or by adjusting the setpoint of a group of ACTs in the array according to the needs of a specific use case. For example, if a group of ACTs is allocated to store ice cream, the required temperature setpoint (to prevent melting) may be lower than that required for less temperature-sensitive items. Increasing the setpoint of the ACTs storing less sensitive items will reduce the overall energy consumption of the system.

[0053] Adjusting the setpoint offers another benefit: optimizing the storage temperature of a given food item to ensure freshness and quality. This adjustment can be performed manually using the Connected Services control panel (with available filtering options to identify specific ACT types via metadata); or through integration with the inventory management system, which automatically triggers the adjustment when a specified item is placed into an ACT; or through machine learning, which uses images of the placed item to identify the product type and automatically adjust the temperature setpoint accordingly. Additionally, notifications can be sent to system administrators / operators and subscribers in case of abnormal deviations from the temperature setpoint.

[0054] Those skilled in the art will recognize improvements and modifications to the preferred embodiments of this disclosure. All such improvements and modifications are considered to be within the scope of the concepts disclosed herein.

Claims

1. A method for operating an active cooling system (ACS), the method comprising: Determine the operational requirements of multiple Active Cooling Turnover Boxes (ACTs); as well as The operation of one or more of the plurality of ACTs is adjusted based on the physical location of one or more of the plurality of ACTs in the ACS.

2. The method of claim 1, wherein adjusting one or more of the plurality of ACTs comprises: The number of ACTs operating under cooling conditions is balanced with the number of ACTs operating under steady state conditions.

3. The method according to any one of claims 1 to 2, wherein adjusting one or more of the plurality of ACTs comprises: Based on the physical location of one or more of the plurality of ACTs in the ACS, one or more of the plurality of ACTs are activated in an orderly manner.

4. The method according to any one of claims 1 to 3, wherein adjusting one or more of the plurality of ACTs comprises: The number of ACTs operating under cooling conditions is balanced with the number of ACTs operating under steady state conditions.

5. The method according to any one of claims 1 to 4, wherein determining the operational requirements of the plurality of ACTs comprises: Poll the ACT to determine the current temperature.

6. The method of claim 5, wherein adjusting one or more of the plurality of ACTs comprises: Prioritize activating the ACT with the largest difference between the current temperature and the desired temperature.

7. The method according to any one of claims 1 to 6, wherein determining the operational requirements of the plurality of ACTs comprises: The ACT is polled to determine the requirements for goods in each of the ACTs.

8. The method of claim 7, wherein adjusting one or more of the plurality of ACTs comprises: Prioritize activating the more stringent requirements for the goods in the ACT.

9. The method according to any one of claims 1 to 8, wherein adjusting the operation of one or more of the plurality of ACTs comprises: The operation of one or more of the multiple ACTs is adjusted based on the current occupancy percentage of the ACT.

10. The method of claim 7, wherein adjusting one or more of the plurality of ACTs comprises: Reduce the activation priority of empty ACTs.

11. The method according to any one of claims 1 to 10, wherein adjusting the operation of one or more of the plurality of ACTs comprises: Adjust the setpoint temperature of one or more of the multiple ACTs.

12. A controller for operating an active cooling system (ACS), the controller comprising at least one processor and a memory, the memory containing instructions for causing the controller to perform the following operations: Determine the operational requirements of multiple Active Cooling Turnover Boxes (ACTs); and The operation of one or more of the plurality of ACTs is adjusted based on the physical location of one or more of the plurality of ACTs in the ACS.

13. The controller of claim 12, wherein adjusting the operation of one or more of the plurality of ACTs includes being operable to: The number of ACTs operating under cooling conditions is balanced with the number of ACTs operating under steady state conditions.

14. The controller according to any one of claims 12 to 13, wherein adjusting the operation of one or more of the plurality of ACTs comprises being operable to: Based on the physical location of one or more of the plurality of ACTs in the ACS, one or more of the plurality of ACTs are activated in an orderly manner.

15. The controller according to any one of claims 12 to 14, wherein adjusting the operation of one or more of the plurality of ACTs comprises being operable to: The number of ACTs operating under cooling conditions is balanced with the number of ACTs operating under steady state conditions.

16. The controller according to any one of claims 12 to 15, wherein determining the operational requirements of the plurality of ACTs includes being able to operate to: Poll the ACT to determine the current temperature.

17. The controller of claim 16, wherein adjusting the operation of one or more of the plurality of ACTs includes being operable to: Prioritize activating the ACT with the largest difference between the current temperature and the desired temperature.

18. The controller according to any one of claims 12 to 17, wherein determining the operational requirements of the plurality of ACTs includes being able to operate to: The ACT is polled to determine the requirements for goods in each of the ACTs.

19. The controller of claim 18, wherein adjusting the operation of one or more of the plurality of ACTs includes being operable to: Prioritize activating the more stringent requirements for the goods in the ACT.

20. The controller according to any one of claims 12 to 19, wherein adjusting the operation of one or more of the plurality of ACTs comprises being operable to: The operation of one or more of the multiple ACTs is adjusted based on the current occupancy percentage of the ACT.

21. The controller of claim 20, wherein adjusting the operation of one or more of the plurality of ACTs includes being operable to: Reduce the activation priority of empty ACTs.

22. The controller according to any one of claims 12 to 21, wherein adjusting the operation of one or more of the plurality of ACTs comprises being operable to: Adjust the setpoint temperature of one or more of the multiple ACTs.

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