Container-Based Thermal Energy Storage for Targeted Warehouse Cooling
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Solution Overview
Problem
Automatic warehouses for refrigeration or freezing face issues with conveyor or stacker crane breakdowns due to cold temperatures, leading to increased maintenance costs and wasteful electricity consumption, as they are designed to maintain a constant temperature for the entire storage space, including areas that do not need cooling.
Innovation Solution
A control system and program that manage containers equipped with Thermal Energy Storage (TES) members to cool specific objects, featuring a judging method to determine when TES members need replacement based on the stored objects' conditions, allowing for targeted cooling without cooling the entire storage space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the entire warehouse is cooled to maintain constant temperature for storing cooled objects, then the cooled objects can be kept at required temperature, but electricity consumption increases significantly
Solution Approach 1:
The warehouse storage space is divided into multiple temperature zones using movable partitions. Each zone can be independently temperature-controlled based on the specific cooling requirements of stored objects, rather than cooling the entire warehouse space. This segmentation allows energy to be focused only on areas that require cooling.
Solution Approach 2:
Movable partitions are used to dynamically adjust the cooled storage space according to the number and cooling requirements of stored objects. When fewer objects need cooling, the cooled space is reduced; when more objects are stored, the cooled space is expanded. This dynamic adjustment optimizes energy consumption based on actual demand.
2Reliability
If the entire warehouse is maintained at constant low temperature, then cooled objects can be stored safely, but conveyors and stacker cranes break down due to freezing and condensation
Solution Approach 1:
The warehouse is segmented into cooled storage zones and equipment operation zones using movable partitions. Equipment such as conveyors and stacker cranes operate in warmer zones where condensation and freezing are prevented, while cooled objects are stored in temperature-controlled zones. This spatial segmentation protects equipment from cold-related damage.
Solution Approach 2:
Movable partitions act as intermediaries that separate the cold storage environment from the equipment operation environment. These partitions allow the warehouse to maintain cooled storage spaces while keeping equipment in warmer, more favorable operating conditions, thus preventing equipment breakdown.
3Temperature
If the entire warehouse is cooled at constant temperature, then all stored objects can be kept cool, but it becomes wasteful when few cooled objects are stored
Solution Approach 1:
The size of the cooled storage space is dynamically adjusted using movable partitions based on the actual number of cooled objects stored. When few objects are stored, the cooled space is minimized to reduce energy waste. When many objects are stored, the cooled space is expanded to provide adequate cooling coverage. This dynamic adjustment eliminates energy waste while ensuring adequate cooling.
Solution Approach 2:
The temperature control parameters of the warehouse are changed dynamically based on storage conditions. The system adjusts the cooled space volume and temperature setpoints according to the number and types of stored objects, transitioning from a fixed constant-temperature approach to a variable parameter approach that optimizes energy efficiency.
4Reliability
If spare power supply is installed to maintain cooling during power failures, then cooled objects can be kept cool during outages, but the cost of the spare power supply system increases
Solution Approach 1:
The critical cooling function is extracted from the entire warehouse and concentrated into smaller, isolated temperature zones. This allows the cooling system to be scaled down and positioned strategically near stored objects, reducing the overall cooling capacity needed and eliminating the requirement for expensive spare power supply systems while maintaining adequate cooling during outages.
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 reduces maintenance costs and energy consumption by cooling only the necessary areas, extending the life of TES members and optimizing storage conditions for various temperature requirements within a single warehouse.
Implementation Method 1
TES member to cool said cooled objects
Implementation Method 2
container body having a cool room in which to store cooled objects
Data Source
AI summary
The present application is at least directed to a control system to cool cooled objects and to keep cooled objects cool without cooling an entire storage space for cooled objects. The control system includes containers, which hold cooled objects and a TES member to cool the cooled objects. The control system is configured to judge if it is time to replace the TES member based on a combination of cooled objects, stored in the containers to keep cool, and the TES member. The control system also is configured to notify if it is time to replace the TES member based upon the judging step.