Cooling Tunnel Conveyor Layout for Variable Cooling Times
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cooling tunnels face inefficiencies in handling objects with varying target cooling times, leading to either over-cooling of objects with shorter times or under-cooling of those with longer times, which affects throughput and product quality.
Innovation Solution
A cooling tunnel design featuring a circulating conveyor system with a first and second section, along with a return section, allows for flexible routing and control of objects based on their target cooling times, enabling objects to be introduced in any order and cooled accordingly, without compromising throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If objects with different target cooling times are cooled in a continuous cooling tunnel following strict target cooling times, then objects with shorter target cooling times are cooled for longer than necessary, but this reduces the throughput of the cooling tunnel
Solution Approach 1:
The patent implements dynamic control of the conveying device, allowing it to adjust speed and timing for different objects. The control device monitors target cooling times and dynamically adjusts the conveying speed to match each object's specific cooling requirements, enabling precise cooling time control without reducing overall throughput.
Solution Approach 2:
The cooling tunnel divides the conveying path into multiple sections with independently controllable conveying speeds. This segmentation allows different sections to operate at different speeds based on the cooling requirements of objects in each section, enabling precise control of cooling times for individual objects while maintaining high throughput.
2Productivity
If higher priority is given to throughput in continuous cooling tunnels, then some objects or batches will inevitably be cooled too briefly, but this has a negative effect on product quality
Solution Approach 1:
The system dynamically adjusts conveying speed based on real-time monitoring of object positions and target cooling times. When an object approaches its target cooling time, the conveying speed is automatically reduced to ensure precise cooling completion, preventing under-cooling while maintaining high throughput for other objects.
Solution Approach 2:
The control device receives feedback on object positions and cooling progress, automatically adjusting conveying speeds to ensure each object receives the precise cooling time required. This feedback mechanism prevents under-cooling of any object while maintaining overall high throughput.
3Reliability
If objects are rotated by 180 degrees using a turntable to enable simultaneous supply of cooling air from opposite sides, then cooling effectiveness is improved, but the structural complexity increases
Solution Approach 1:
The patent removes the turntable component from the system and instead uses a linear conveying path with cooling air supply devices positioned on both sides. This extraction of the rotational mechanism eliminates the associated structural complexity while maintaining cooling effectiveness through alternative means.
Solution Approach 2:
Instead of rotating objects to expose both sides to cooling air, the patent inverts the approach by keeping objects in a linear path and positioning cooling air supply devices on both sides of the conveying path. This alternative configuration achieves the same cooling effectiveness without requiring object rotation.
4Reliability
If alternating supply of cooling air from opposite sides is implemented, then cooling effectiveness is improved, but the structural complexity increases
Solution Approach 1:
The patent eliminates the complex alternating supply mechanism by implementing simultaneous cooling air supply from both sides through independently controllable cooling air supply devices. This extraction of the alternating mechanism reduces structural complexity while maintaining cooling effectiveness.
Solution Approach 2:
The cooling air supply devices are designed with multi-functionality, capable of operating independently on each side and being controlled individually. This universal design allows the system to achieve cooling effectiveness without requiring complex alternating mechanisms, as each side can function independently.
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 ensures high throughput while maintaining precise control over cooling times, avoiding the bottlenecks and inefficiencies associated with previous technologies, and allows for efficient use of cooling medium and energy.
Implementation Method 1
a large number of successive treatment positions (21.1 to 21.8) within the treatment room (20) for loading the objects (10) to be cooled with a cooling medium, in particular cooling air
Data Source
Figure 1a~2
Figure 3A~3B
Figure 4
AI summary
A cooling tunnel comprises an insertion gate (23) for inserting articles to be cooled which are preferably stacked on pallets, an exit gate (24) for exiting articles, a plurality of subsequent treatment positions (21.1 to 21.x) for impinging the articles to be cooled with a cooling medium, especially cooling air, and a conveying device (30) for transporting the articles to be cooled from the insertion gate (23) to the exit gate (24), the conveying device (30) leading through the individual treatment positions (21.1 to 21.x). The conveying device (30) comprises a first section (31) which runs through a plurality of treatment positions and which extends from the insertion gate (23) to a position of return (33), a second section (32) which runs through a plurality of treatment positions and which extends from the point of return (33) to the exit gate (24), and a return section (34) which is arranged upstream of the exit gate (24) and which connects an exit-side region of the second section (32) to an insertion-side region of the first section (31) to optionally exit articles or continue cooling them. The cooling tunnel according to the invention allows a high throughput at variable set cooling times and while maintaining the same in a narrow tolerance range. The invention also relates to a method for operating a cooling tunnel or a pallet cooling system.