Condensate Evaporator With Pivoting Pan Switch for Energy Savings
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Solution Overview
Problem
Existing condensate evaporators for large walk-in refrigerators consume excessive electrical energy as the resistance wire remains 'on' continuously, drawing power at either full or reduced rates, regardless of the condensate level, leading to inefficient energy usage.
Innovation Solution
A condensate evaporator design featuring a pivoting pan with a plunger-type push button switch and spring-loaded mechanism that only powers the heater when a predetermined weight of condensate is present, turning off once sufficient water has evaporated, allowing the pan to continue evaporation using residual heat for energy savings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a resistance wire heater is used continuously to evaporate condensate, then the condensate evaporation function is maintained, but electrical energy consumption increases excessively
Solution Approach 1:
The patent applies the dynamics principle by making the heater's operational state changeable rather than fixed. The heater transitions between ON and OFF states based on condensate presence, controlled by the plunger switch mechanism. This dynamic operation allows the system to consume energy only when necessary, resolving the contradiction between maintaining evaporation function and reducing energy consumption.
Solution Approach 2:
The patent implements self-service through the automatic control mechanism. The plunger switch automatically detects condensate presence and controls the heater accordingly without external intervention. The system serves itself by using the weight of condensate to trigger the switching mechanism, eliminating the need for complex external sensing devices and achieving both energy savings and reliable operation.
2Loss of energy
If a plunger type push button switch with spring-loaded mechanism is used to control heater power, then energy savings are achieved, but device complexity increases
Solution Approach 1:
The patent uses the plunger and spring mechanism as an intermediary between the condensate weight and the electrical switch. This mechanical intermediary translates the physical condition (condensate weight) into an electrical control signal, providing a simple and reliable way to control heater power while avoiding complex electronic sensing circuits.
Solution Approach 2:
The patent replaces complex electronic sensing and control systems with a simple mechanical plunger-spring switch mechanism. This mechanical substitution achieves the same control function with significantly reduced complexity, using only basic mechanical components that are easy to implement and maintain.
3Productivity
If the heater is kept on continuously at reduced power after water evaporation, then the evaporator remains ready to evaporate new condensate, but unnecessary electrical power is consumed
Solution Approach 1:
The patent implements periodic action by cycling the heater between ON and OFF states based on condensate presence. Instead of continuous operation at reduced power, the heater operates intermittently - fully ON when condensate is present and completely OFF when evaporated, achieving energy savings while maintaining productivity through rapid response to new condensate accumulation.
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 design significantly reduces electrical energy consumption by ensuring the heater is only active when substantial condensate is present and automatically turns off when evaporation is complete, utilizing residual heat for efficient evaporation, thus achieving substantial energy savings without complex sensing devices.
Implementation Method 1
The switch has a movably mounted plunger for movement between an extended position corresponding to a raised position of the end of the pan relative to the support surface and a retracted position corresponding to a lowered position of the end of the pan relative to the support surface. In this regard, the plunger is spring loaded by a spring that has a spring constant sufficient to support the pan with the two studs in a horizontal position on the support surface but insufficient to prevent the pan from pivoting about the two studs under the added weight of a predetermined amount of condensate in the pan.
Implementation Method 2
a heater pad on the pan for heating condensate in the cavity to a point of evaporation
Implementation Method 3
The studs are positioned to allow the pan to pivot on the surface about a horizontal axis passing through the studs towards one end of the pan under the weight of condensate in the cavity.
Data Source
AI summary
The condensate evaporator has a pan that is pivotally mounted on a fulcrum defined by two posts to depress the plunger of a switch as condensate collects in the pan. The switch and posts form a three point support for the pan on a flat surface. The switch is actuated by the pivoting of the pan to deliver power to a heater pad for heating the condensate.