Automated blast cell loading and unloading
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Solution Overview
Problem
Blast freezing systems face challenges in automation due to extreme cold temperatures, leading to ice buildup and operational hindrances, resulting in manual loading and unloading of pallets, increased warehouse footprint, and reduced throughput.
Innovation Solution
The implementation of automated blast cell systems with side-loading doors, air flow guides, and control algorithms enables reliable automated loading and unloading, reduces the required warehouse space, and enhances throughput by optimizing air circulation and using autonomous cranes and robots to manage pallet movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated loading and unloading systems are implemented in blast cells, then productivity and throughput are improved, but the system becomes vulnerable to ice buildup and operational failures due to extreme cold temperatures
Solution Approach 1:
The system performs preliminary actions by pre-heating or protecting automated components before they are exposed to extreme cold temperatures. Loading and unloading operations are scheduled and prepared in advance to minimize exposure time to freezing conditions, and protective measures are put in place before ice buildup can occur.
Solution Approach 2:
The patent introduces intermediary elements such as heated enclosures, thermal barriers, or climate-controlled zones between the automated loading/unloading components and the extreme cold environment of the blast cell. These intermediaries protect the automation equipment from direct exposure to freezing temperatures while still enabling automated operations.
2Ease of operation
If manual loading and unloading with forklifts is used, then operational flexibility is maintained, but the warehouse footprint increases and safety risks arise from cross-traffic
Solution Approach 1:
The patent replaces manual forklift operations with automated loading and unloading systems such as robotic manipulators, automated guided vehicles, or mechanically integrated systems. This substitution eliminates the need for large maneuvering spaces and cross-traffic areas while maintaining operational flexibility through programmable control.
Solution Approach 2:
The system transitions from two-dimensional forklift maneuvering on the warehouse floor to three-dimensional automated operations, utilizing vertical space, robotic arms, or multi-level loading mechanisms. This dimensional change allows compact integration of loading/unloading functions without increasing horizontal footprint.
3Temperature
If extended blast freezing cycles are used to ensure thorough cooling, then cooling effectiveness is improved, but the time required for each pallet increases
Solution Approach 1:
The patent implements dynamic control of the blast freezing process, where airflow rate, temperature, and fan speed are continuously adjusted during the freezing cycle based on real-time monitoring of pallet temperature and environmental conditions. This dynamic optimization achieves thorough cooling more quickly than static extended cycles.
Solution Approach 2:
The system incorporates feedback mechanisms that monitor temperature distribution across pallets and adjust blasting parameters accordingly. Sensors detect when cooling objectives are met, and the system automatically terminates the cycle or adjusts parameters to prevent over-freezing, thereby reducing total cycle time while maintaining cooling effectiveness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution allows for efficient and safe automated operation of blast freezing systems, reducing cycle time, increasing throughput, and minimizing the footprint of blast cells, while ensuring consistent and efficient cooling of perishable goods.
Implementation Method 1
one or more fans that circulate air within the enclosure
Implementation Method 2
a cooling system (e.g., cooling coils, such as evaporators) that effectively transfers heat picked up from the pallets out of the enclosure
Implementation Method 3
air flow guides (e.g., vanes) on one or both sides of the flow path to evenly divide the volume of circulating air across each row of pallets
Data Source
AI summary
A system for blast-freezing items includes a plurality of cells arranged side-by-side, each cell including a housing with a bay space, a plenum, a front air passage, a rear air passage, and a fan. The fan is positioned in the plenum and configured to circulate air through the bay space. Each cell also includes a plurality of channels to separate pathways of air to segments of the bay space. The system also includes a plurality of crane rails extending between rows of cells and at least one crane capable of traveling along the plurality of crane rails to load or unload each of the plurality of cells.