Active cold chain delivery box

Abstract

Discussed is an active cold chain delivery box (100) for real time temperature-based logic control for controlling the compressor speed automatically with minimal power consumption The active cold chain delivery box (100) includes a speed control unit (102) for a DC voltage compressor of a refrigerator system (128). The active cold chain delivery box (100) is completely independently powered and removable from the vehicle. The speed control unit (102) includes a first control unit (108) that receives inputs from an acquisition unit (112) and a second control unit (116) and processes data and transmits the controlled speed signal to a refrigeration system (128). Also, the speed control unit (102) is connected to the third control unit (120), that provides a speed signal for compressor of the refrigerator system (128).

Description

[0001] “ACTIVE COLD CHAIN DELIVERY BOX”

[0002] FIELD OF THE INVENTION:

[0003] The present invention relates to refrigeration system and more particularly to an active, vehicle-mountable cold chain delivery box integrated with a speed control unit for a refrigeration module and a variable speed DC compressor and an integrated loT-based control and telemetry unit for real-time environmental management.

[0004] BACKGROUND OF THE INVENTION:

[0005] A refrigerator prevents spoilage or damage to the stored items by maintaining required temperature within the storage section. A conventional refrigeration system includes an evaporator, a compressor, a condenser, a condenser fan and an expansion valve.

[0006] A traditional refrigeration system has compressors with a fixed speed, where the set temperature is maintained by operating the compressor at that fixed speed. The compressor continues running until the temperature inside the refrigerator approaches or drops below the set temperature or when the refrigerator is set to defrost mode. At this point, the compressor turns off. When the ambient temperature rises above the set point, the compressor starts running again. However, fixed speed compressors typically consume more power and lack features for a soft start or soft shut off that helps to reduce transient electrical loads. Further, traditional refrigeration system, especially in the transportation and delivery sector, use convective evaporators. These convective evaporators consume excess power as they require fans that are not needed in conductive evaporator systems. Fans put additional load on a battery powered system and reduce the usable volume inside the cabinet to maintain efficient airflow. Existing refrigerating systems include DC compressors and standard controllers to regulate compressor speed. However, in case of a variable speed compressor-based refrigerator, the speed control is manually operated.

[0007] The United Kingdom Patent No. GB2313436A to John William Beckett discloses a portable refrigerator for storing medicines including a coiled tube, a cylinder, evaporator and a condenser located externally of the storage compartment. However, the compressor is manually operated and does not provide auto temperature control.

[0008] The Chinese Patent No. CN204880924U to Yang Shi discloses a portable blood product refrigerator including casing, solar panels that are electrically connected by photovoltaic DC-to-AC converter and battery, compressor, condenser, expansion valve and evaporator. The portable blood products fridge has a battery that powers continuous refrigeration to refrigerating box. The battery enables the refrigerating box to maintain a consistently low temperature. However, the refrigerator disclosed in the said patent does not provide auto temperature control facility. The Japanese Patent Application No. JP2003279218A to Asano Yuichiro and others discloses an On-vehicle portable refrigerator. The said patent discloses a cooling cycle system that incorporates a small scroll compressor for compressive- circulating a refrigerant, that is integrated into a heat-insulated refrigerator case designed for storing refrigerated materials. However, the said patent does not provide facility to control the compressor speed.

[0009] Accordingly, there is a need for an active cold chain delivery box for autonomous temperature regulation, battery-aware compressor control, and buffered loT telemetry configured for real-time monitoring and decision-making during transport under constrained power environments.

[0010] SUMMARY OF THE INVENTION:

[0011] An active cold chain delivery box includes a speed control unit, and a third control unit for autonomous temperature regulation of a refrigeration system. The speed control unit is independently powered and removably attachable from the vehicle. The speed control unit is configured on the speed control unit includes a first control unit, a second control unit, an input unit, and a power unit to generate the speed signals and speed mode. The speed control unit is configured to generate the speed signals in first mode and second mode.

[0012] Further, the first control unit is configured on a speed control unit to generate the speed signals and speed mode. The speed control unit operates in first mode and second mode. Also, the first control unit includes a first controller, a timer module and a logic module to generate the speed signals and speed mode. The first controller receives, processing input data from an acquisition unit and a second control unit via an input unit. The timer module is configured on the first controller to control a timer for finding operating modes as a power mode or a normal mode of the speed control unit. The logic module is configured on the first controller to generate speed signals and status data, to operate the second control unit in Auto mode, Power mode, Normal Mode or Eco mode, and to transfers the data to a third control unit and an output unit. The third control unit receives the speed signal to regulate compressor of a refrigeration system for cooling the air. The second control unit receives the state data from the first control unit and wirelessly transmitting telemetry via MQTT or HTTPS. The power unit supplies power, transferers a battery charge signal from battery charge sensor to the first controller to control and generate the speed signals and modes. The refrigeration system includes an evaporator, a variable- speed DC compressor, a condenser, a condenser fan, and an expansion valve for cooling the air. The power unit includes a battery swapping accessibility for replacing a discharged battery with a charged battery quickly.

[0013] The first control unit receives inputs from an interface unit, and a sensor unit. The logic module operates in a manual mode or an automatic mode. The timer module limits the duration of Power Mode and switches to Normal Mode upon expiration. The timer module activates, and controls the timer and also monitors the power speed mode active duration for avoiding excessive power consumption.

[0014] The logic module operates in an automatic mode, to determine speed based on the comparison between a set temperature (Ts), an actual cabinet temperature (Ta), a timer, and user-defined thresholds (x, y). The logic module activates the eco mode to generate minimum speed based on Ta, Ts and Timer values.

[0015] The second control unit provides wireless transmission of system telemetry, that includes temperature, battery state, compressor state, and door sensor activity sensed by the sensor unit. The second control unit includes IOT controller to control the transmission of input signal from the input unit. The second control unit transmits telemetry data by MQTT or HTTPS protocol with JSON encoding and TLS encryption.The third control unit being configured for regulating the speed of the compressor according to speed command from the first control unit.

[0016] Further the power unit includes a primary power input, a swappable battery, and a switching mechanism for fail-safe automatic source selection, the power unit includes a battery swapping accessibility to replace a discharged battery with a charged battery quickly. Also, the power unit includes a switching mechanism for prioritize wall power and switches default to battery mode during power loss without controller intervention.

[0017] The speed control unit includes a memory buffer for storing sensor data with timestamps during network outages and retransmitting the said data upon reconnection of network. The first control unit receives the door open / close events with individual timestamps and stores the five most recent events for transmits upon network reconnection.

[0018] The active cold chain delivery box is detachably mountable on a mounting plate to position on the two-wheeler, three-wheeler, or four-wheeler. The active cold chain delivery box is position able on the four-wheeler, that includes a condenser unit mountable on the exterior and an indoor evaporator unit mountable to the interior wall of the box. The speed control unit continuously monitors the battery signal in real time and controls the speed of the compressor based on battery charge signal from the power unit to operate in power saving mode. The third control unit being configured for regulating the speed of the compressor according to speed command from the first control unit. The sensor unit including a temperature sensor, current sensor, door position sensor.

[0019] A method for generating compressor speed and in the active cold chain delivery box initially receives a set temperature (Ts) via from user. Next the first control unit measures actual internal cabinet temperature (Ta) and battery state-of- charge (SOC) via sensors. Next timer module controls the timer. Further, the logic module generates the power mode, Normal mode, Eco speed mode. Also, the second control unit transmits real-time telemetry data via a wireless connection. Further the first control unit stores sensor and event packets with timestamps in a local buffer during communication outage, and retransmits data in First in First Out order upon connectivity restoration.

[0020] The active cold chain delivery box facilitates auto mode, in that mode realtime temperature-based logic control changes the compressor speed automatically. The active cold chain delivery box provides easy installation of the system in the vehicle. The active cold chain delivery box facilitates cloud interface to control the parameters. The active cold chain delivery box is user friendly, economical, avoids excessive power consumption and has facility of text-based fault message display and transmission to cloud. BRIEF DESCRIPTION OF DRAWINGS:

[0021] The objectives and advantages of the present invention will become apparent from the following description read in accordance with the accompanying drawings wherein,

[0022] FIG. 1 shows a schematic of an active cold chain delivery box in accordance with a preferred embodiment of the present invention;

[0023] FIG. 2 shows a high-level schematic of the active cold chain delivery box of FIG. 1;

[0024] FIG. 3 shows a step wise execution for speed control of the compressor of the active cold chain delivery box of FIG. 1 ;

[0025] FIG. 4 shows a flow diagram of speed mode selection by a first control unit of the active cold chain delivery box of FIG. 1 ;

[0026] FIG. 5 shows a switching mechanism in first embodiment in accordance with the present invention;

[0027] FIG. 6A, FIG. 6B and FIG. 6C shows a second embodiment in accordance with the present invention;

[0028] FIG 7A, FIG. 7B shows the battery mounting in accordance with the second embodiment of the present invention as shown in FIG. 6A;

[0029] FIG. 8 shows a third embodiment in accordance with the present invention; FIG. 9 shows a fourth embodiment in accordance with the present invention;

[0030] FIG. 10 shows step wise execution to control speed of the compressor in fifth embodiment in accordance with the present invention; and

[0031] FIG. 11 shows graphical representation of compressor cycling, event detection, and operation continuity across environmental disruptions according to the present invention.

[0032] DESCRIPTION OF THE INVENTION:

[0033] References in the specification to "one embodiment" or "an embodiment" means that a particular feature, structure, characteristic, or function described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.

[0034] References in the specification to “preferred embodiment” means that a particular feature, structure, characteristic, or function described in detail thereby omitting known constructions and functions for clear description of the present invention.

[0035] The foregoing description of specific embodiments of the present invention has been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed and obviously many modifications and variations are possible in light of the above teaching. In general aspect, the present invention discloses an active cold chain delivery box that is integrated with a speed control unit for real time parameterbased logic control for changing the compressor speed. The active chain delivery box includes the speed control unit that controls the speed of the compressor to achieve precise temperature control while minimizing power consumption and utilizing real time cloud base input monitoring.

[0036] The device of the present invention is vehicle mountable. In one embodiment of the present invention, the active cold chain delivery box is compact, portable and positioned on a small vehicle like a two-wheeler.

[0037] In second embodiment of the present invention, the active cold chain delivery box has larger size, high storage capacity and large cooling capacity mounted on a vehicle, for example, a three-wheeler, four-wheeler.

[0038] Now Referring to FIG. 1, an active cold chain delivery box (100) in a preferred embodiment of the present invention is described. The active cold chain delivery box (100) includes a speed control unit (102) connected to a refrigeration system (128). The active cold chain delivery box (100) includes a speed control unit (102) for a DC voltage compressor of a refrigerator system (128) that is completely independently powered and is removable from the vehicle. The speed control unit (102) receives inputs from the user, processes the inputs and transmits the controlled speed signal to the refrigeration system (128).

[0039] Accordingly, the speed control unit (102) of the active cold chain delivery box (100) includes a power unit (104), an input unit (105), an output unit (107), and a first control unit (108). The speed control unit (102) further includes an acquisition unit (112), a second control unit (116), a display unit (124) and a communication unit (126).

[0040] In accordance with the present invention, the acquisition unit (112) receives parameters from a user (106) (not shown in FIG. 1), and parameters from a sensor (110) (not shown in FIG. 1). The acquisition unit (112) establishes communication between a user (106) and the first control unit (108) through an input unit (105). The acquisition unit (112) is connected to the first control unit (108) to transmit the received parameters. The first control unit (108) includes a processor that generates a speed signal.

[0041] The first control unit (108) receives input from the acquisition unit (112) for deciding speed signal as per respective selected mode and set temperature. The second control unit (116) is for example, an IOT controller. The second control unit (116) transmits the input signal received from the input unit (105). The first control unit (108) processes the data received from the input unit (105). The first control unit (108) transmits the controlled and processed real time parameters like temperature, time, mode, etc. to the display unit (124) through the output unit (107).

[0042] Also, the first control unit (108) is further connected to the third control unit (120), that provides a speed signal for the compressor of a refrigerator system (128) through the communication unit (126). The communication unit (126) is for example, a wired or wireless communication. The communication unit (126) receives and transfers data between the refrigerator system (128) and the first control unit (108) via the third control unit (120). In a preferred embodiment of the present invention, the power unit (104) powers the first control unit (108). The power unit (104) also includes a battery (not shown in the FIG. 1) and a converter unit (not shown in the FIG. 1). The third control unit (120) is powered directly from the DC voltage source.

[0043] Now referring to FIG. 2, a high-level schematic of the active cold chain delivery box (100) is discussed herein. The active cold chain delivery box (100) includes the speed control unit (102), the third control unit (120) and the refrigerator system (128).

[0044] The speed control unit (102) includes a power unit (104), an input unit (105), an output unit (107), and a first control unit (108). The speed control unit (102) further includes an acquisition unit (112), a second control unit (116), a display unit (124) and a communication unit (126).

[0045] The power unit (104) includes a first converter (209), a second converter (210) a third converter (211) and a battery (212). A first converted 209) is for example, 3.8 V DC converter, a second converter (210) is for example, 5V DC converter and a third converter is for example, a 3.3 V DC converter. The power unit (104) provides DC voltage from the respective converter to speed control unit (102).

[0046] The acquisition unit (112) includes a sensor unit (204), an interface unit (208). The acquisition unit (112) transfers input data to the input unit (105). The sensor unit (204) includes a first sensor, a second sensor and the like. The first sensor is for example, a temperature sensor. The first sensor is positioned in a cabinet of the refrigeration system to sense the actual temperature ‘Ta’ of inner cabinet. The second sensor senses ambient temperature. The third sensor is positioned on the cabinet door to sense whether the door is in the ‘open’ or ‘closed’ position.

[0047] The interface unit (208) is for example, keypad, mobile, tab, on / off switch, the computer and the like. The user interface facilitates user to provide inputs such as time, speed, set point temperature, power on / off, mode of operation, etc. through the interface unit 208.

[0048] The first control unit (108) includes a first controlled 213), a timer module (214), a logic module (215), and a memory (217) (not shown in FIG. 2). The first controller (213) is configured to generate speed command according to the inputs. The first controller (213) is, for example, a microprocessor. The first controller (213) processes the data to find the ‘speed command” according to inputs received from the input unit (105) and the refrigerator system (128).

[0049] The timer module (214) is configured on the first controller (213) to set or reset a timer. The timer decides the Power mode or Normal Mode of the system (102). The logic module (215) is configured on the first controller (213), determines the compressor speed mode based on temperature difference (Ts - Ta), elapsed timer status, and user-defined control thresholds (x, y). The logic module (215) determines three operational modes as Power mode, Normal mode and Eco mode. In Power Mode the compressor runs at full speed to quickly reach target Ts. In Normal Mode the compressor speed is moderate to maintain Ts. In Eco Mode if Ta < Ts, the compressor is reduced or compressor speed is zero. The second control unit (116) includes a second controller (not shown in FIG.2). The second controller is for example, an IOT controller. The second control unit (116) receives operational data from the first control unit (108), that aggregates inputs from all loT sensors. The second control unit (116) is configured to handle telemetry logic, including buffering and wireless transmission via MQTT or HTTPS.

[0050] The refrigerator system (128) includes an outer cabinet and an inner cabinet. The outer cabinet is fully welded sheet metal cabinet with front opening double door design. The inner and outer cabinets have a gap between them for insulation. The rest of the body has an angle frame at the bottom but no other support frame and is completely designed out of metal sheet that helps to reduce the weight of the refrigerator assembly. The inner cabinet is fully welded on one side with open metal sheet body wrapped around with evaporator tubing. The evaporator (216) provides conductive cooling. The inner cabinet has a step to allow placement of refrigeration components in the rear.

[0051] The refrigerator system (128) includes an evaporator (216), a compressor (220), a condenser (224), a condenser fan (228), and an expansion valve( 232). The evaporator (216) wraps around an inner cabinet of the refrigerator system (128). The double circuit or single circuit wraps around the evaporator (216) of a predefined design length. The evaporator circuit is wrapped in a helical form around the inner cabinet. The evaporator (216) receives heat from the system that is to be cooled. The compressor (220) is a DC variable speed compressor. The condenser fan (228), for example, is a cooling fan to cool the condenser (224). The expansion valve (232) for example, is a non-electronic type.

[0052] The third control unit (120) includes a third controller (not shown in FIG. 2). The third control unit (120) is configured to control the speed of the compressor ( 220) according to speed command from the first control unit (108).

[0053] The speed control unit (102) transfers data to and from the refrigerator system (128) through the communication unit (126). The communication unit (126), for example, is wired communication or wireless communication. The wired communication, for example, is UART (Universal Asynchronous Receiver / Transmitter) and the wireless communication is for example, by Bluetooth, or alike.

[0054] Now referring to FIG. 3 the step wise execution of speed control unit (102) in accordance with the present invention is described hereinafter. Initially, in a step (304) the user activates speed control unit (102) to control the speed of the refrigeration system (128). In a mode selection step (308), the user selects the operating mode of the system. The user enters operating mode of the speed control unit (102) through the interface unit (208). The user (106) controls the speed of the compressor manually. The system (102) operates in two modes, that is a first mode (312-F) and a second mode (312-S).

[0055] Next in a first mode activation step (312-F), the system (102) operates in the first mode. The “first mode” is manual mode of the speed control. Next, in a data acquisition step (316-F) the user enters the preset speed value and temperature set values through the interface unit (208). Next in a speed transfer step (320-F) the first control unit (108) sends speed signal to the third control unit (120). Next in a speed control step (324-F), the third control unit (120) controls the speed of the compressor (220).

[0056] Further in a second mode activation step (312-S), the speed control unit (102) operates in the second mode. The “second mode” is “automatic mode of the speed control. Next in a data acquisition step (316-s) the first control unit (108) receives the preset speed value and temperature set values, the set temperature ‘Ts’ and the actual temperature ‘Ta’ x and y via the interface unit (208) and the sensor unit (204). Next in a timer reset step (320-s) the timer module (214) configured on the first control unit (108) resets the timer (214). Next in a step of speed generation (324- S), the logic module (215) configured on the first control unit (108) generates the speed mode as a “Power mode”, a “normal mode” and a “eco mode” and a “zero speed signal”. In a power mode, the logic module (215) generates maximum speed based on Ta, Ts and Timer values. In a normal mode, the logic module (215) generates normal speed based on Ta, Ts and Timer values. In an eco-mode, the logic module (215) generates minimum speed based on Ta, Ts and Timer values. In a normal mode, the logic module (215) generates normal speed based on Ta, Ts and Timer values. The compressor speed commands are generated based on the selected mode.

[0057] Next, in a timer status step (328-s), the third control unit (120) checks the timer status signal. Next in a speed transfer step (332-8) the first control unit (108) sends speed signal to the third control unit (120) through the communication unit (126) and continues the step (316-S). Next in a speed control step (336-S), the third control unit (120) controls the speed of the compressor (220). Also, first control unit (108) transfers the current status, mode, temperature, sensor signals to the output unit (107) for the user.

[0058] Now referring to Fig. 1, FIG. 2, FIG, 3 and FIG. 4A FIG. 4B, the operation cycle of the speed control unit (102) is discussed. The speed control unit (102) operates in two modes, that is a first mode and a second mode. In the first mode of the speed control unit (102), the user enters operated mode of the speed control unit (102) through the interface unit (208). In the first mode, the user (106) controls the speed of the compressor manually.

[0059] The user (106) enters the preset speed value and temperature set values through the interface unit (208). To achieve higher speed value, the power consumption is more, however, the time to achieve the predefined set temperature reduces with higher speed. The first control unit (108) sends speed signal to the third control unit (120). Accordingly, the third control unit (120) controls the speed of the compressor (220).

[0060] According to preferred embodiment of the present invention, the second mode of the system (10)2 is discussed. The second mode is automatic mode of the speed control unit (102). In the second mode of the speed control unit (102), the user (106) enters the set temperature values Ts, first set temperature Tsthrough the interface unit (208). Also, the sensor unit (204) continuously monitors the actual temperature of internal cabinet and transfers to the first control unit (108). Also, the sensor unit (204) monitors door position of the cabinet of the compressor (220). In the second mode of the speed control unit (102), the speed of the compressor is controlled automatically based on the set temperature ‘Ts’ and the actual temperature ‘Ta’.

[0061] Now Referring to FIG. 4, the step wise execution of the second mode of the speed control unit (102) is discussed. In second mode, the speed of the compressor is controlled automatically based on the set temperature ‘Ts’ and the actual temperature ‘Ta’.

[0062] Accordingly, in an initial step (404), the system receives user inputs as set temperature values Ts, actual temperature Ta, ‘x’ value and ‘y’ value through the interface unit (208). The 'x' parameter is a user-defined offset threshold in °C for activating Power Mode (e.g., x = 3 °C), while 'y' is a smaller offset for entering Eco Mode (e.g., y = 0.5°C). These values are adjustable and stored in non-volatile memory. In a next step (408), operating mode of the speed control unit (102) is selected and the timer (214) is reset.

[0063] In next step (412), the first control unit (108) compares the actual temperature ‘Ta’ and set temperature ‘Ts’. If actual temperature ‘Ta’ is less than or equal to the set temperature ‘Ts’, the first control unit (108) generates zero speed command in step (312-b) step. Additionally, the first control unit (108 ) sends zero speed signal to the third control unit (120). Accordingly, the third control unit (120) controls the speed of the compressor (220).

[0064] Next, in step (412-a), if the actual temperature ‘Ta’ is greater than temperature value ‘Ts +x’, then the first control unit (108) further compares ‘Ta’ and ‘Ts +y’ in step (412-bl). In step (412-bl), the first control unit (108) compares the actual temperature value Ta and second set temperature ‘Ts +y’. If actual temperature ‘Ta’ is less than ‘Ts +y’, the first control unit (108) generates eco speed signal as in step (412-bl2) and transfers to the third control unit (120) through the communication unit (126) and follows the step (412). The first control unit (108) transfers Eco mode with minimum speed to the third control unit (120) through the communication unit () and follows the step (312).

[0065] Also, in step (412-bl), if actual temperature ‘Ta’ is larger than ‘Ts+y’ and additionally power timer as in step (412-al2) is on, the first control unit (108) generates normal signal as in step (412-bl 1) and further compares Ta and “Ts +y’ in step (412-bl).

[0066] Next, in step (412-a), the actual temperature ‘Ta’is larger than the ‘Ts+X’, the first control unit (108) checks the timer status as set or reset in the step (412-al). In the step (412-al), if the timer (214) is reset the timer is set in the step (412-al 1) and in step (412-al2) check for timer over status. If the timer is not over in the step (412-al2), then maximum speed in the power mode is set in the step (412-al4). Next actual temperature is compared with ‘Ts+X’ in step (412-a).

[0067] Further, in step (412-al), if the timer (214) is not reset, then follows step (412-al2). In the step (412-al2), if the timer (214) is over, then in step (412-a3), the timer (214) is reset and follows step (412-bl 1). Advantageously, the timer (214) ensures that the power speed mode is not active for longer than a predefined time to avoid excessive power consumption.

[0068] Now referring to FIG. 5 a first embodiment in accordance with the present invention is described, that includes a switching mechanism (500) in the power unit (104). The switching mechanism (500) facilitates automatically prioritization of a primary DC power source (512), over the secondary backup source (212). The primary DC power source (512), is for example, a wall adapter for power source. The secondary backup source (212), is for example a battery 48V DC. The switching mechanism (504) includes a relay (508) as a switching device.

[0069] The relay (508) is, for example a Single-Pole Double-Throw (SPDT) relay, that is energized by the wall power supply (512). The Normally Open (NO) terminal of the relay (508), that couples to the wall adapter output of the power supply (512) to the switching mechanism. The Normally Closed (NC) terminal of the relay (508), that couples to the battery (212) to the switching mechanism. The common terminal of the relay (508) provides the power signal to the load or the power input (104) of the speed control unit (102).

[0070] In the power on state of power supply (512), the relay (508) connects the wall adapter to the load. In the wall off state of the power supply (512), the relay de-energizes automatically, and respectively switches the load over to battery (212) power via the NC contact of the relay (508).

[0071] The switching mechanism (504) provides a firmware-independent automatic switching, prevents back-feed between the said two power sources (512) and (212) and enables transparent failover without user intervention. The switching mechanism (500) circuit is mechanically fail-safe. In case of relay coil failure or power loss, the system (102) defaults to battery operation.

[0072] Now referring to FIG. 6A, FIG. 6B and FIG. 6C a second embodiment in context of the present invention, the active cold chain delivery box (600), that is light weight in construction and position able on the two-wheeler is described herein. The active cold chain delivery box (600) is removably assemblable by unbolting a plurality of mounting screws from the bottom side (604), when required. The active cold chain delivery box (600) is detachably mountable on a mounting plate (608) from the bottom side (604). Further, the mounting plate (608) includes features multiple securing provision holes, that align with the chassis mounting points of various two-wheeler makes and models. The mounting plate (608) includes a first plurality of mounting provision (612) and a second plurality of mounting provision (616). The bottom surface (604) includes a plurality of footmount locations and a plurality of mounting points to position and lock the evaporator (216) and condenser (224) into a single unibody structure of active cold chain delivery box (600), ensures that the entire assembly remains rigidly secured in place. Also, the active cold chain delivery box (600) is detachably mounted on a vehicle-compatible base mounting plate (608) that includes a matrix of mounting holes for universal fitment. The dual-layer mounting includes initial mounting to the base plate, followed by mounting on to the vehicle chassis. The mounting feature further facilitates passive vibration damping via a foot-mount points. An alignment guides to position the condenser and evaporator in a rigid unibody structure. The mounting dimensions (e.g., 560 x 515 mm) conform to typical twowheeler frame tolerances.

[0073] Now Referring to FIG. 7A and FIG. 7B shows the power unit mounting facility in the second embodiment (600) in accordance with the present invention is described. FIG. 7A shows a removal position of the battery (112) from the power unit (104). Fig. 7B shows a position of battery swapping while mounting in the power unit (104). In second embodiment (600) of the present invention, the active cold chain delivery box provides a battery swap feature for easy accessibility, that is easy swapping of the battery to save operational time by replacing a discharged battery with a charged one within minutes. The power unit (104) incorporates a tool-less battery swapping mechanism (700) designed for field operability. The battery swapping mechanism (700) includes a locking groove-and-channel structure (704), a spring-loaded push button (708) to eject the battery pack, a charging connector (716) with keyed alignment to prevent reverse insertion. This design enables safe, rapid battery replacement within 30 seconds, reducing downtime during route-based cold chain operations.

[0074] Now referring to FIG. 8, a third embodiment of the active cold chain delivery box (800) in accordance with the present invention is described herein. The active cold chain delivery box (800) is position able in the threewheeler. The active cold chain delivery box (800) is a single weather-sealed enclosure, that includes the compressor (220), a condenser (224), battery pack (212), and the speed control unit (102). The speed control unit (102) is positioned in a compact cabin-mounted unit, connected back to the main enclosure via a pre-wired harness.

[0075] Now referring to FIG. 9, an embodiment of the active cold chain delivery box (900) in accordance with the present invention is described. The active cold chain delivery box (900) is position able in a four-wheeler. Further, according to fourth embodiment of the present invention, the refrigeration system (128) for four- wheel vehicles includes two standalone modules an outdoor condenser unit (224) mountable on the exterior of any generic insulated delivery box (900) and an indoor evaporator unit (216) securely mountable to the interior wall of the box (900). The speed control unit (102) provides centralizing control via the user interface (208) and the battery (212) provides power management. The speed control unit (102) is accessible from the driver’s cabin of the four-wheeler. The communication unit (126) includes multi-core wiring harnesses for transmission / receival of power signal, speed signal data, temperature sensor signal, and door-sensor signals to and from the speed control unit (102) and the refrigerator system (128). The communication unit (126) also electronically couples the condenser (224) and evaporator (216). The system (102) also enables and ensures safe, accessible operation from within the driver’ s cabin of the four-wheeler. The fourth embodiment facilitates conversion of any insulated passive storage box into a active cold chain delivery box, that is independently powered by a battery and does not rely on engine power.

[0076] Now referring to FIG. 10 a step wise execution to control speed of the compressor in a power saving mode of the fifth embodiment (1000) in accordance with the present invention is described. According to power saving mode of fifth embodiment of the present invention, the speed control unit (102) continuously monitors the battery signal and controls the speed of the compressor based on battery charge signal from the power unit (104). The first control unit (108) processes the data received from the input unit (105) and battery (212) for deciding speed signal as per respective selected mode and set temperature, that reduces power consumption to enhance battery life. Initially in a step (1005), the speed control unit (102) activates the power saving mode. The user selects and activates automatic second operating mode of the speed control unit (102) via the interface unit (208). Next in a step of data acquisition (1010), the first control unit (108) receives the preset values via the interface unit (208) and sensor signals from the sensor unit (204). Thee first control unit (108) receives input from the acquisition unit (112) and a battery charge signal from a current sensor of the sensor unit (204). Next in a step of battery status signal generation (1015), the logic module (215) generates signals indicating battery state of charge (SOC) by comparing the battery charge to the battery predefined standards stored in the memory. Next in a step of speed mode generation (1020), the logic module (215) generates “eco mode” of speed. In an Eco mode, the logic module (215) generates minimum speed. In eco mode reduced compressor speed, reduces power consumption to increase operation time before battery runs out. For the SOC greater than 15%, the logic module (215) activates the “normal mode” of the speed. The logic module (215) generates normal speed based on Ta, Ts and x and y values. Next in a speed transfer step (1025) the first control unit (108) sends speed signal to the third control unit (120) through the communication unit (126) and continues the step (1005). Next, in a speed control step (1030), the third control unit (120) controls the speed of the compressor 220.

[0077] A sixth embodiment of telemetry and buffering System for remote monitoring of the active cold chain delivery box (1100) Of the present invention is described herein. A step wise execution to display the current status on the display device by telemetric monitoring of the sixth embodiment (1100) in accordance with the present invention is described. According the sixth embodiment of the present invention, the system (102) continuously monitors the sensor inputs, like GPS data, compressor door sensor data, battery sensor data status.

[0078] Further the speed control unit (102) buffers data to transmit to cloud database via telemetry. The telemetry subsystem enables continuous remote monitoring of system parameters such as an internal temperature (Ta), a door sensor status (open / close), a compressor status, a battery state-of-charge (SOC), and GPS location.

[0079] The parameter data is structured into JSON-formatted packets and transmitted to a cloud platform via MQTT or HTTPS protocol. For a network outage or cloud server unavailability situation, the telemetry controller appends outgoing data packets to a circular memory buffer in non-volatile storage.

[0080] Each packet is stored with original timestamp (RTC-based). Buffered packets are re-transmitted in FIFO order once network connectivity is restored. Additionally, according to sixth embodiment of the present invention, irrespective of network conditions, the speed control unit (102) transmits a distinct “door sensor data” packet. The door sensor data packet includes the data respective to previous last five open or close events of door. Each door sensor data packet has its original timestamp, that enables compliance validation for pharmaceuticals, vaccines, or perishable goods that require temperature consistency verification.

[0081] Door event data packet feature provides an accurate chronology of door activity even when real time reporting is interrupted due to loss of network connectivity or for the door open / close event occurance in between telemetry intervals The step wise execution of buffer transmission mode of the speed control unit (102) of the sixth embodiment of the present invention is described.

[0082] Initially, in a step of data logging the primary input data, like battery health status (SOH, SOC), GPS location, were sent to cloud database. Next in a step of data packet publishing, if due to network outage or server unavailability, the primary packet data was not available to the user, the data is saved to the buffer memory of the system (102). In next step of data transferring, in situation irrespective of network conditions, the system (102) transfers a “door sensor” data packet to the first control unit (108). The door sensor data packet includes the data respective to previous last five open or close events of door. Each door sensor data packet has its original timestamp. In a next step buffered packet retransmission, follows the door-event packet, and transmits the oldest unsent entry from the memory buffer, preservs its original capture timestamp.

[0083] In next step of publication confirmation of data, if data publication on display is successful, the buffer pointer clears the sent data packets and that entry remains queued for a subsequent retry.

[0084] EXAMPLES:

[0085] Example 1: Performance validation of the active cold chain delivery box in accordance with the present invention.

[0086] Referring to FIG. 6A, FIG. 6B, FIG. 6C, FIG. 7A, FIG. 7B, and Table 1A the active cold chain delivery box is described using specific exemplary details. Referring to FIG. 6A, the active cold chain delivery box is detachably mounted on the two-wheeler. The telemetry data during last- mile deliveries tested on 31stJanuary 2025.

[0087] Referring to FIG. 6C. FIG. 7A, FIG. 7B, the mounting plate (608) has provided battery-swap access and supports an enclosed control box with the system (102), both fastened directly to the plate. The plate (608) included multiple securing holes that align with the chassis mounting points of various two-wheeler makes and models. The active cold chain delivery box enclosure itself includes dedicated foot-mount locations and plate- fixing points that lock the evaporator and condenser into a single unibody structure, ensured that the entire assembly remains rigidly secured in place. Further, the user accessed the system (102) via the interface unit (208), for example a mobile or laptop. The user has entered the predefined values x, y, timer in the system. User has activated the cold chain box in the second mode.

[0088] The specifications of the active cold chain delivery box in context of the present invention are prescribed in the table 1 as follows.

[0089] Table 1A: Specifications

[0090] Table 2: The Compressor Cycling Test @ -21°C

[0091] In the second mode of the system (102), the second control unit (116) has communicated with IOT devices, like sensor or thermostats, and provided input data as temperature, compressor status, battery charge status level and GPS location of the user to the input unit (105). The second control unit (116) has received the data like temperature, compressor status, battery charge level, and door events from the first control unit (108), and transmitted data telemetry to cloud-based platforms. Initially, the first control unit (108) was operated in ‘normal mode’. The speed of the compressor is normal. Referring to Table 2 the speed control unit (102) represents dynamic speed control based on set temperature, compressor speed. The speed of the compressor (220) was 3485 RPM, for the reduced current 15A close to cut-off temperature at -21 °C, thereby results indicated reduced power consumption 720 W of power unit (104). The current drop from 26A to 15A at shutdown supported overload protection

[0092] Table 3: Energy optimization by the first control unit in eco mode and power mode

[0093] Referring to Table 3 the logic module (215) switches mode according to (x, y) cutoff thresholds, that are cutoff at -5°C, restarted at +3.2°C.

[0094] Now Referring to FIG. 11, Exemplary Telemetry data during Last- Mile Deliveries of the active chain delivery box on day 31 / 01 / 2025 is described herein. Point ‘A’ represents the active chain delivery box was switched off due to operation for a duration, Cutoff at -5°C, restart at +3.2°C indicated threshold control of the active chain delivery box. Point ‘B’ represents precooling loading period of the active chain delivery box had temperature -1°C to -50 °C. Point ‘D1represents the active chain delivery box loaded in the vehicle had temperature -40°C. Point ‘E’ represents a first delivery of goods from the delivery box, the said first delivery the door was kept for 3-4 mins door status was ‘Open’ at ambient temperature 20 °C. Point ‘F’ represents a second delivery of goods from the delivery box, due to the said second delivery the door status was ‘Open’ at ambient temperature 25 °C. Point ‘H’ represents a third delivery, ‘Open’ door status shown ambient temperature 27°C. The point ‘E’, ‘F’ and ‘H’ represents the Door open events were aligned with temp rise proved door-triggered telemetry. Further point ‘G’ represents fail safe logic due to a battery swapping feature of the present invention. The battery swap continuity supported fail-safe logic of the present invention

[0095] In the context of the present invention, FIG. 11 shows that the compressor was resumed post load event with time-based control. Also, the Door open events aligned with temp rise proved door-triggered telemetry. Further, the battery swap continuity supported fail-safe logic of the present invention. Further Continuous telemetry indicated real-time cloud integration.

[0096] Advantageously, the active cold chain delivery box (100) is light weight in construction and portable for last mile delivery vehicles. The active cold chain delivery box (100) provides a refrigerator that is completely independently powered and is removable from the cargo vehicle. The active cold chain delivery box (100) includes conductive evaporators, that increase the usable volume inside the cabinet and has data logging / IOT capabilities. The active cold chain delivery box (100) facilitates the manual mode, user input-based method of controlling the compressor speed through power modes.

[0097] The active cold chain delivery box (100) facilitates auto mode, in that mode real-time temperature-based logic control changes the compressor speed automatically. The active cold chain delivery box (100) provides easy installation of the system in the vehicle. The active cold chain delivery box (100) facilitates cloud interface to control the parameters. The active cold chain delivery box (100) is user friendly, economical, avoids excessive power consumption and has facility of textbased fault message display and transmission to cloud.

[0098] The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, to thereby enable others, skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated.

[0099] It is understood that various omission and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the scope of the present invention.

Claims

CLAIMS:

1. An active cold chain delivery box (100) comprising: a speed control unit (102), the speed control unit (102) being configured for generating the speed signals in first mode and second mode, being independently powered and removably attachable from the vehicle, including a first control unit (108); the first control unit (108) being configured on a speed control unit (102) for generating the speed signals and speed mode, including a first controller (213), being configured for receiving, processing input data from an acquisition unit (112), and a second control unit (116) via an input unit (105), a timer module (214), the timer module (214) being configured on the first controller (213) for controlling a timer for finding a power mode or a normal mode operating mode of the speed control unit (102), and a logic module (215), the logic module (215) being configured on the first controller (213) for generating speed signals and status data, to operate the second control unit (102) in Auto mode, Power mode, Normal Mode or Eco mode, and transferring to a third control unit (120) and an output unit (107); a third control unit (120) being configured for receiving the speed signal for regulating compressor (220) of a refrigeration system (128) for cooling the air;a second control unit (116) being configured for receiving state data from the first control unit and wirelessly transmitting telemetry using MQTT or HTTPS; and a power unit (104) being configured for supplying power, transferring a battery charge signal from battery charge sensor to the first controller (213) for controlling and generating the speed signals and modes.

2. The active cold chain delivery box (100) as claimed in claim 1, wherein the refrigeration system (128) including an evaporator (216), a variable-speed DC compressor (220), a condenser (224), a condenser fan (228), and an expansion valve (232) for cooling the air.

3. The active cold chain delivery box (100) as claimed in claim 1, wherein the first control unit (108) receiving inputs from an interface unit (208), and a sensor unit (204).

4. The active cold chain delivery box (100) as claimed in claim 1, wherein the logic module (215) operating in a manual mode or an automatic mode.

5. The active cold chain delivery box (100) as claimed in claim 1, wherein the timer module (215) for limiting the duration of Power Mode and switching to Normal Mode upon expiration.

6. The active cold chain delivery box (100) as claimed in claim 1, wherein the logic module (215) operating in an automatic mode, for determining speed based on the comparison between a set temperature (Ts), an actual cabinet temperature (Ta), a timer, and user-defined thresholds (x, y).

7. The active cold chain delivery box (100) as claimed in claim 1, wherein a second control unit (116) being configured for wireless transmission of system telemetry including temperature, battery state, compressor state, and door sensor activity.

8. The active cold chain delivery box (100) as claimed in claim 1, wherein the power unit (104) including a primary power input, a swappable battery, and a switching mechanism (508) for fail-safe automatic source selection.

9. The active cold chain delivery box (100) as claimed in claim 1, wherein the speed control unit (102) including a memory buffer for storing sensor data with timestamps during network outages and retransmitting the said data upon reconnection of network.

10. The active cold chain delivery box (100) as claimed in claim 1, wherein the power unit (104) including a battery swapping accessibility for replacing a discharged battery with a charged battery quickly.

11. The active cold chain delivery box (100) as claimed in claim 1, wherein the power unit (104) including switching mechanism for prioritize wall power and default to battery mode during power loss without microcontroller intervention.

12. The active cold chain delivery box (100) as claimed in claim 1, wherein the first control unit (108) receiving the door open / close events with individual timestamps and storing the five most recent events for transmitting upon network reconnection.

13. The active cold chain delivery box (100) as claimed in claim 1 being position able on the four-wheeler including a condenser unit (224) mountable on theexterior and an indoor evaporator unit (216) mountable to the interior wall of the box (900).

14. The active cold chain delivery box (100) as claimed in claim 1 wherein the logic module (215) activating the eco mode for generating minimum speed based on Ta, Ts and Timer values.

15. The active cold chain delivery box (100) as claimed in claim 1, the speed control unit (102) continuously monitoring the battery signal in real time and controlling the speed of the compressor based on battery charge signal from the power unit (104) for operating in power saving mode.

16. The active cold chain delivery box (100) as claimed in claim 1, wherein a second control unit (116) including IOT controller for controlling the transmission of input signal from the input unit (105).

17. The active cold chain delivery box (100) as claimed in claim 1, wherein the third control unit (120) being configured for controlling the speed of the compressor (220) according to speed command from the first control unit (108).

18. The active cold chain delivery box (100) as claimed in claim 1, wherein the timer module (214) being configured for activating, controlling the timer and monitoring the power speed mode active duration for avoiding excessive power consumption.

19. The active cold chain delivery box (100) as claimed in claim 1, being detachably mountable on a mounting plate (608) for positioning on the two-wheeler, three- wheeler, or four-wheeler.

20. The active cold chain delivery box (100) as claimed in claim 1, wherein the second control unit transmitting telemetry data by MQTT or HTTPS protocol with JSON encoding and TLS encryption.

21. The active cold chain delivery box (100) as claimed in claim 1, wherein sensor unit (204) including a temperature sensor, current sensor, door position sensor.

22. A method for generating compressor speed and energy efficiency in the active cold chain delivery box (100), the methodcomprising: a) receiving a set temperature (Ts) via from user; b) measuring actual internal cabinet temperature (Ta) and battery state-of-charge (SOC) via sensors; c) controlling the timer-by-timer module; d) generating the power mode, Normal mode, Eco speed mode by logic module; e) transmitting real-time telemetry data via a wireless connection; f) storing sensor and event packets with timestamps in a local buffer during communication outage, and g) retransmitting data in First in First Out order upon connectivity restoration.

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