Blast Cell Crane Automation for Side-Loading Freezer Systems
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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 issues, which hinder the use of automated components and require manual loading and unloading by forklifts, increasing warehouse footprint and reducing efficiency.
Innovation Solution
The implementation of blast cells with side-loading doors, air flow guides, and autonomous cranes, along with control algorithms, enables reliable automated loading and unloading, reduces the footprint, and enhances throughput by optimizing air circulation and scheduling of freezing cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual loading and unloading by forklifts is used, then the blast cell can be operated, but the warehouse footprint increases and operational efficiency decreases
Solution Approach 1:
The patent replaces manual forklift operations with an automated robotic system that uses a robotic arm to load and unload pallets from the blast cell. This mechanical substitution eliminates the need for human operators and forklifts, enabling automation while reducing the space required for maneuvering equipment.
Solution Approach 2:
The patent introduces vertical stacking of pallets within the blast cell, utilizing the vertical dimension to increase storage capacity without expanding the horizontal footprint. Multiple pallets are stacked on top of each other, allowing the automated system to service pallets at different heights while maintaining a compact warehouse layout.
2Reliability
If extended blast freezing cycles are run to ensure target temperature, then cooling effectiveness is achieved, but productivity decreases
Solution Approach 1:
The patent divides the blast cell into multiple independent zones or sections, each capable of holding and cooling pallets simultaneously. This segmentation allows different batches of pallets to be processed in parallel, increasing overall throughput while maintaining reliable temperature control in each zone. The system can load new pallets into one zone while another zone completes its freezing cycle.
Solution Approach 2:
The automated robotic system enables continuous operation by immediately loading new pallets as soon as existing pallets complete their freezing cycle. This eliminates idle time and maintains continuous useful action in the blast freezing process, increasing productivity without compromising temperature control reliability.
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 safe, efficient, and automated operation of blast freezing systems, reducing the need for manual labor, minimizing ice buildup, and increasing the efficiency and consistency of the freezing process while optimizing space and resource use.
Implementation Method 1
one or more fans that circulate air within the enclosure and 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 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.