Turnover box power docking station system

Abstract

Systems and methods for a turnover box power docking station system are provided. In some embodiments, a method of operating a power docking station system includes: refraining from providing power to one or more electrical contacts of the power docking station system when there is no active cooling container on the power docking station system; determining that an active cooling turnover box exists on the power docking station system; and providing power to the one or more electrical contacts of the power docking station system in response to determining that the active cooling turnover box is present on the power docking station system. In some embodiments, this provides improved security for the electrical connection.

Description

[0001] Related applications

[0002] This application claims the benefit of provisional patent application serial number 63 / 507,504, filed on June 12, 2023, the disclosure of which is incorporated herein by reference in its entirety. Technical Field

[0003] This disclosure generally pertains 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 invention provides a system and method for a power docking station system for a turnover box. In some embodiments, a method of operating a power docking station system includes: avoiding supplying power to one or more electrical contacts of the power docking station system when an actively cooled turnover box is not present on the power docking station system; determining that an actively cooled turnover box (ACT) is present on the power docking station system; and supplying power to one or more electrical contacts of the power docking station system in response to determining that an ACT is present on the power docking station system. In some embodiments, this provides enhanced security for electrical connections.

[0006] ACT requires the application of electrical power when the container is stationary in its storage or picking location and the removal of electrical power when the container is moved for transport. In some embodiments, power may be applied or removed automatically and safely, potentially without direct manual operation. In some embodiments, one or more of these functions are provided by a power docking station system, which may be assembled within a single, compact mechanical housing.

[0007] 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

[0008] 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.

[0009] Figures 1A to 1D The use of portable, stand-alone refrigeration or freezing systems coupled with integrated automated control and monitoring was demonstrated;

[0010] 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;

[0011] Figure 4 Systems including active coolers according to some embodiments of the present disclosure are shown;

[0012] Figure 5 Examples of turnover boxes as discussed in this article are shown;

[0013] Figure 6A and Figure 6B The exhibition showcased different types of turnover boxes that can be used in refrigerated or frozen machines.

[0014] Figure 7 An exploded view of the turnover box, including the thermoelectric unit as discussed herein, is shown.

[0015] Figure 8 A standard three-temperature truck used for delivery is shown;

[0016] Figure 9 The exhibition showcased delivery trucks that do not require refrigeration systems or require less cooling.

[0017] Figure 10 An actively cooled turnover box, shown in two orientations according to some embodiments, is illustrated, with electrical contacts located on the bottom.

[0018] Figure 11 The vertical placement of an actively cooled turnover box onto a turnover box docking station, according to some embodiments, is illustrated; and

[0019] Figure 12 An overall view of a container docking station according to some embodiments is shown, with one contact shown in a raised position and another contact shown in a retracted position. Detailed Implementation

[0020] 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.

[0021] 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.

[0022] These crates use active heat pumps to extract heat from the enclosed chamber and release it into the surrounding air. Hot air should be removed from the crate to ensure optimal operation of the crates.

[0023] 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 for the containers to operate.

[0024] Figures 1A to 1D The use of portable, stand-alone refrigeration or freezing systems coupled with integrated automated control and monitoring is demonstrated.

[0025] 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.

[0026] Figure 4 A system including an active cooler is shown according to some embodiments of the present disclosure.

[0027] For further details, interested readers may refer to the following documents: 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 PRODUCT STORAGE AND TRANSPORTATION COOLER, now International Patent Publication No. WO 2021 / 134068. These applications are hereby incorporated herein by reference in their entirety.

[0028] 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.

[0029] 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.

[0030] 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.

[0031] This invention provides a system and method for a power docking station system for a turnover box. In some embodiments, a method of operating a power docking station system includes: avoiding supplying power to one or more electrical contacts of the power docking station system when an actively cooled turnover box is not present on the power docking station system; determining that an actively cooled turnover box (ACT) is present on the power docking station system; and supplying power to one or more electrical contacts of the power docking station system in response to determining that an ACT is present on the power docking station system. In some embodiments, this provides enhanced security for electrical connections.

[0032] ACT requires the application of electrical power when the container is stationary in its storage or picking location and the removal of electrical power when the container is moved for transport. Power should be applied and removed automatically and safely, without direct manual operation. These functions are provided by a power docking station system assembled within a single, compact mechanical housing.

[0033] In some embodiments, some of these assumptions apply. The embodiments described herein achieve some of these objectives.

[0034] This application requires that the operator not manually turn the power on or off. When the ACT is not present, the electrical contacts should not be energized to prevent accidental short circuits. The electrical contacts should only be energized after the ACT has been placed on the power dock to prevent arcing / sparking upon approach.

[0035] Before removing the ACT, the electrical contacts should be de-energized to prevent arcing / sparking upon removal. The electrical contacts should allow the ACT to be placed from multiple directions while ensuring correct polarity in each orientation.

[0036] As the ACT slides past the electrical contacts on its way to its final seating position, these contacts should not damage or degrade the ACT. The docking station components need to be protected against water ingress.

[0037] The docking station assembly should be able to be installed in various mechanical applications. The height of the internal PCB assembly is adjustable to change the proximity detection sensitivity of the ACT.

[0038] Figure 10 An actively cooled turnover box shown in two orientations is illustrated, with electrical contacts located on the bottom. According to some embodiments, the correct polarity is maintained in either orientation. Figure 11 The vertical placement of an actively cooled turnover box onto a turnover box docking station is shown according to some embodiments. Figure 12 An overall view of a container docking station according to some embodiments is shown, with one contact shown in a raised position and another contact shown in a retracted position.

[0039] In some embodiments, when the ACT is placed on a docking station, the docking station provides DC power to actively cool the container. Electrical contacts on the docking station abut against contacts on the bottom of the ACT. Magnetic attraction is used to pull the docking station contacts to the container contacts. As the steel plate behind the container contacts moves far enough away from the docking station contacts, gravity causes the docking station contacts to detach from the container. Safety circuitry in the container docking station includes proximity sensors to distinguish the ACT from any other object, and timing circuitry to delay power application for various safety reasons.

[0040] When placing the turnover box on the dock:

[0041] A proximity sensor on the dock identifies the ACT within placement range. This initiates a delayed power application. Multiple embodiments of the proximity sensor are possible, including reed switches / magnets, microswitches, Hall effect sensors, optical switches / readers, or near-field communication (NFC) technology. Inactive totes or other objects will not have the presence to trigger this activation, ensuring activation only occurs when an actively cooled tote is placed. The height of the internal PCB assembly housing the sensor is adjustable to change the proximity detection sensitivity of the ACT. Additionally, a sensor / timer scheme prevents power application during "pass-by" periods in a double-depth rack configuration, where the rear tote briefly "passes" past the front contact position on its way to its rear location.

[0042] 1. The two contacts (+ / -) of the dock rise to mate with the turnover box.

[0043] 2. Power is applied to the mating contacts.

[0044] When removing the turnover box from the dock:

[0045] 1. The turnover box slides along the contacts or extends the contacts to maintain power supply to the turnover box.

[0046] 2. The turnover box moves out of the activation range of the proximity sensor, and the power supply is disconnected from the contacts.

[0047] 3. When the magnetic connection with the container contacts is disconnected, the container docking station contacts are magnetically pulled down or dropped (e.g., due to gravity) into the docking station shell.

[0048] Actuation of dock station contacts:

[0049] The copper contacts on the dock are positioned above the magnet, so they abut against the steel plate behind the conductive contacts of the crate. The magnet provides a strong mating force between the contacts, thus keeping the contact resistance low. For this purpose, spring actuation is not chosen; in this embodiment, the dock contacts would push against the crate body, damaging it and depositing plastic residue on the dock contacts.

[0050] In some embodiments, the docking station contacts have a 10 mm travel and a 5 mm effective vertical range. The additional travel allows for electrical disconnection when the docking station contacts are engaged.

[0051] Preventing contacts from getting stuck at the raised position helps maintain low mating contact resistance. Measures include:

[0052] In some embodiments, when the steel plate in the turnover box contact assembly is no longer present, the contacts retract magnetically toward the ferromagnetic rod.

[0053] The wiring and selection of conductors (using multiple strands with flexible insulation or no insulation) help prevent the connector from lifting the contacts or pressing them against the guide post.

[0054] In some embodiments, the contacts and surrounding structure are designed to prevent material buildup beneath the contacts and subsequent damage from foreign objects. To prevent damage from water ingress, internal channels are provided to guide any collected water to designated drain holes.

[0055] In some embodiments, the electrical contacts in the docking station consist of a plastic plug with an internal magnet covered by a conductive strip. The contact plug straddles a guide post that allows vertical movement while limiting movement in any other direction with minimal friction.

[0056] The guide posts that limit the contact plugs are located on a tray mounted within the dock housing. In addition to locating the guide posts, the tray also positions a safety control panel. Features on the tray allow for vertical adjustment of the safety control panel. The safety control panel contains a proximity sensor. The height of this proximity sensor relative to the position of the container above the dock defines the sensor's operable area. Height control of the control panel within the tray allows for calibration of the proximity sensor's operation. This calibration is necessary to ensure power is shut off when the dock contacts separate from the container contacts. Ensuring power is shut off when contacts engage or disengage reduces the risk of arcing or sparking when the container is powered on and off.

[0057] 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 a power docking station system, the method comprising: When there is no active cooling storage box on the power docking station system, avoid supplying power to one or more electrical contacts of the power docking station system; It was determined that an active cooling transfer box existed on the power docking station system; as well as In response to determining the presence of an active cooling hopper on the power docking station system, power is supplied to the one or more electrical contacts of the power docking station system.

2. The method according to claim 1, wherein determining the presence of an active cooling transfer box on the power dock system comprises: It was determined that the proximity sensor had detected the presence of an active cooling turnover box on the power dock system.

3. The method according to any one of claims 1 to 2, wherein the one or more electrical contacts of the power docking station system abut against one or more contacts on the bottom of the active cooling turnover box.

4. The method according to any one of claims 1 to 3, wherein the magnetic attraction forces the one or more electrical contacts of the power docking station system to the one or more contacts on the bottom of the active cooling turnover box.

5. The method according to any one of claims 1 to 4, further comprising: When the active cooling container is removed, the one or more electrical contacts of the power dock system detach from the one or more contacts on the bottom of the active cooling container faster than when the active cooling container is removed.

6. The method according to any one of claims 1 to 5, further comprising: When an item is detected on the power docking station system, it is determined whether the item is an actively cooled turnover box.

7. The method of claim 6, further comprising: When it is determined that the item is an actively cooled turnover box, power is supplied to the one or more electrical contacts of the power docking station system; as well as When it is determined that the item is not an actively cooled storage container, power should be avoided being supplied to the one or more electrical contacts of the power docking station system.

8. The method according to any one of claims 6 to 7, further comprising: Upon determining that the item is an actively cooled turnover box, delayed power is applied to one or more electrical contacts of the power docking station system.

9. The method according to any one of claims 1 to 8, further comprising: When the active cooling container is on the power docking station system, the one or more electrical contacts of the power docking station system rise to the one or more contacts on the bottom of the active cooling container.

10. The method according to any one of claims 2 to 9, wherein the proximity sensor comprises one of the group consisting of: reed switches / magnets, microswitches, Hall effect sensors, optical switches / readers, and near field communication (NFC) technology.

11. A power docking station system, comprising: One or more electrical contacts; as well as Controller; The controller is configured to: When there is no actively cooled storage box on the power docking station system, avoid supplying power to the one or more electrical contacts; It was determined that an active cooling transfer box existed on the power docking station system; and In response to determining the presence of an active cooling turntable on the power docking station system, power is supplied to the one or more electrical contacts.

12. The power docking station system of claim 11, wherein the power docking station system further includes a proximity sensor; and the controller is configured to determine the presence of an active cooling turnover box on the power docking station system, including being configured to: determine that the proximity sensor has detected the presence of an active cooling turnover box on the power docking station system.

13. The power docking station system according to any one of claims 11 to 12, wherein the one or more electrical contacts of the power docking station system abut against one or more contacts on the bottom of the active cooling turnover box.

14. The power docking station system according to any one of claims 11 to 13, wherein the magnetic attraction force draws the one or more electrical contacts of the power docking station system to the one or more contacts on the bottom of the active cooling turnover box.

15. The power docking station system according to any one of claims 11 to 14, wherein: When the active cooling container is removed, the one or more electrical contacts of the power dock system detach from the one or more contacts on the bottom of the active cooling container faster than when the active cooling container is removed.

16. The power docking station system according to any one of claims 11 to 15, wherein the controller is further configured to: When an item is detected on the power docking station system, it is determined whether the item is an actively cooled turnover box.

17. The power docking station system of claim 16, wherein the controller is further configured to: Upon determining that the item is an actively cooled storage container, power is supplied to the one or more electrical contacts of the power docking station system; and When it is determined that the item is not an actively cooled storage container, power should be avoided being supplied to the one or more electrical contacts of the power docking station system.

18. The power docking station system according to any one of claims 16 to 17, wherein the controller is further configured to: Upon determining that the item is an actively cooled turnover box, delayed power is applied to one or more electrical contacts of the power docking station system.

19. The power docking station system according to any one of claims 11 to 18, wherein: When the active cooling container is on the power docking station system, the one or more electrical contacts of the power docking station system rise to the one or more contacts on the bottom of the active cooling container.

20. The power docking station system according to any one of claims 12 to 19, wherein the proximity sensor comprises one of the group consisting of: reed switches / magnets, microswitches, Hall effect sensors, optical switches / readers, and near field communication (NFC) technology.

Images