Ice Bath Conductive Probe Monitoring to Prevent Pipe Freezing
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Solution Overview
Problem
Existing ice bath systems lack an effective means to monitor and control ice thickness around refrigeration coils and pipes, which can lead to freezing and damage, and require costly direct chilling systems for efficient cooling.
Innovation Solution
An ice bath system with at least three conductive probes positioned between the refrigeration coil and the pipe carrying the liquid to be cooled, where the first probe is closer to the coil and the second and third probes are equidistant from the coil and pipe, measuring conductance to determine ice thickness and purity, and controlling the refrigeration system to maintain optimal ice levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a refrigeration coil system is used to cool liquid, then cooling efficiency is improved, but ice buildup can freeze and damage the liquid-carrying pipes
Solution Approach 1:
The patent applies preliminary action by positioning conductive probes between the refrigeration coil and the liquid-carrying pipe before ice buildup occurs. These probes continuously monitor the gap distance and alert the system when ice is approaching the pipe, allowing preventive action to be taken before freezing damage can occur. This early detection mechanism resolves the contradiction by maintaining efficient cooling while preventing the harmful effect of pipe freezing.
Solution Approach 2:
The patent implements feedback through a monitoring system that uses conductive probes to continuously measure the distance between ice buildup and the liquid-carrying pipe. When the gap falls below a predetermined threshold, the system receives feedback and can adjust refrigeration operation to prevent pipe freezing. This closed-loop feedback mechanism allows the system to maintain optimal cooling efficiency while automatically preventing the harmful effect of pipe damage.
2Productivity
If ice buildup is increased to improve cooling capacity, then cooling performance is enhanced, but the risk of pipe blockage and freezing increases
Solution Approach 1:
The conductive probes provide preliminary warning before ice blockage occurs by monitoring the gap distance between ice buildup and the liquid-carrying pipe. This early detection allows the system to maintain high cooling capacity through controlled ice buildup while preventing the reliability issue of pipe blockage by taking preventive action at the alert threshold.
Solution Approach 2:
The monitoring system provides continuous feedback on ice proximity to the pipe, enabling the control system to adjust refrigeration operation to maintain optimal cooling capacity while preventing pipe blockage. The feedback mechanism ensures that high productivity is achieved without compromising system reliability.
3Temperature
If direct chilling system with internal coils is used, then cooling efficiency is improved, but manufacturing cost increases
Solution Approach 1:
The patent uses an intermediary monitoring system with conductive probes that detects ice buildup proximity to the liquid-carrying pipe in external refrigeration coil systems. This intermediary detection mechanism enables external coil systems to achieve cooling efficiency comparable to direct chilling systems by precisely controlling ice buildup, thereby reducing manufacturing cost while maintaining high cooling efficiency.
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
The system effectively monitors and controls ice thickness, preventing pipe freezing and ensuring efficient cooling by maintaining ice within defined limits, while also allowing for monitoring of water purity and reducing compressor cycles.
Implementation Method 1
The probes act together to measure conductance of the water. It is well known that the conductance of water changes in dependence upon whether the water is in the liquid or solid state and therefore by determining the conductance of water between the probes, it can be determined whether ice has reached the respective probes.
Implementation Method 2
a refrigeration coil for causing liquid in the container to turn to ice
Implementation Method 3
The liquid to be dispensed runs through the pipes within the bath of ice and so the liquid to be dispensed does not come into contact with the ice or water within the container. The ice formed in the container serves as a cooling reservoir so that, as heat is transferred from the liquid cooling pipe, the ice is melted, generally keeping the temperature of the ice bath constant.
Data Source
AI summary
An ice bath comprising a container, a refrigeration coil for causing liquid in the container to turn to ice, a pipe for carrying liquid to be cooled by the ice bath for dispense and a plurality of conductive probes for measuring ice thickness, wherein the conductive probes are provided between at least part of the refrigeration coil and the pipe for carrying liquid to be dispensed such that a first one of the conductive probes is provided closer to the refrigeration coil at least two other conductive probes, and thereby the at least two other conductive probes are provided closer to the piping than the first conductive probe, and wherein the second and third probes are equidistant from the refrigeration coil, the ice bath further comprising means for measuring the conductance between the first probe and the second probe, the first probe and the third probe, and the second probe and the third probe.