Ambient-Sensed Generator Control for Refrigerated Transport
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Solution Overview
Problem
Current refrigeration systems for transporting frozen goods consume excessive fuel and incur high operational and maintenance costs due to continuous generator operation, even when ambient temperatures match or exceed the required box temperature, leading to inefficiency and risk of goods perishing if the compressor fails.
Innovation Solution
A generator start/stop controller utilizing an ambient temperature sensor and microprocessor logic to regulate generator operation, automatically turning the generator off when ambient temperature equals or exceeds the required box temperature, and restarting it only when necessary to maintain the required temperature, eliminating the need for an in-box temperature sensor and reducing fuel consumption and environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the generator operates continuously to power the refrigeration system, then the frozen goods are reliably kept at the required temperature, but fuel consumption increases significantly and operational costs rise
Solution Approach 1:
The generator operation is made dynamic rather than static. The control system continuously monitors ambient temperature and automatically adjusts generator operation status (on/off) based on real-time conditions. This dynamic control allows the system to optimize fuel consumption while maintaining temperature reliability when needed.
Solution Approach 2:
The system implements feedback control by using the ambient temperature sensor to provide continuous information to the control system. The control system processes this feedback and automatically adjusts generator operation accordingly, creating a closed-loop control that balances reliability and fuel efficiency.
2Stability of the object's composition
If the generator operates continuously to power the circulating fans, then air circulation is maintained throughout the container, but fuel consumption increases and the fans counterproductively raise the in-box temperature
Solution Approach 1:
The circulating fan operation is made dynamic based on ambient temperature conditions. The control system automatically adjusts fan operation status (on/off) according to real-time ambient temperature readings, eliminating continuous operation and reducing fuel consumption when ambient temperature equals or exceeds the required box temperature.
Solution Approach 2:
The system uses feedback from the ambient temperature sensor to control fan operation. The control system receives continuous temperature information and automatically adjusts fan operation, creating a responsive control mechanism that eliminates unnecessary energy consumption.
3Temperature
If the generator operates in cold ambient conditions where ambient temperature equals or below the required in-box temperature, then the refrigeration system maintains proper temperature, but the generator running time and associated costs are wasted
Solution Approach 1:
The system performs preliminary assessment of ambient temperature conditions before determining generator operation necessity. By monitoring ambient temperature in advance and comparing it to the required box temperature, the control system can proactively prevent unnecessary generator startup or shutdown, eliminating wasted energy in cold conditions.
Solution Approach 2:
The control system uses real-time feedback from the ambient temperature sensor to make intelligent decisions about generator operation. When feedback indicates ambient temperature is at or below the required temperature, the system automatically shuts down the generator, preventing energy waste while maintaining temperature reliability when needed.
4Duration of action of moving object
If the generator is equipped with a large fuel tank to sustain long trips, then the generator can operate continuously without refueling, but the overall fuel consumption and operational costs remain excessively high
Solution Approach 1:
The generator operation is converted from continuous to periodic based on ambient temperature conditions. The control system enables the generator to operate only during periods when ambient temperature exceeds the required box temperature, creating a periodic operation pattern that significantly reduces total fuel consumption while maintaining adequate operation duration when needed.
Solution Approach 2:
The system uses continuous feedback from the ambient temperature sensor to dynamically adjust generator operation duration. This feedback mechanism ensures the generator operates for the precise duration needed to maintain temperature reliability, eliminating prolonged operation in cold conditions and optimizing the balance between duration and fuel consumption.
Data Source
AI summary
A method and apparatus is disclosed for starting and stopping a generator set that supplies power to a refrigeration system. An ambient temperature sensor is used rather than an in-box sensor in addition to a programmed microprocessor to regulate the operation of the generator. Unnecessary use of the generator is, thereby, limited which contributes to cost, energy and equipment savings and a cleaner environment while ensuring the required in-box temperature is maintained and the quality of perishable goods are not compromised.