Ice Thickness Probe Assembly for Full Ice Build Detection
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Solution Overview
Problem
Conventional thermal storage systems lack an efficient method to monitor ice thickness on coil tubes, which is crucial for maintaining the vertical clearance gap and ensuring optimal heat transfer during the ice build-up phase, leading to potential inefficiencies and inaccuracies in determining full ice build.
Innovation Solution
An ice thickness probe assembly comprising a longitudinally-extending probe rod, an insulator casing, and a sleeve, along with a frame structure and reference probe, which allows for precise measurement and monitoring of ice thickness through electrical signal transmission, enabling accurate detection of full ice build and automatic shutdown of the glycol flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional ice thickness measuring devices are used, then ice thickness can be detected, but measurement precision and reliability are insufficient leading to inaccurate determination of full ice build
Solution Approach 1:
The probe is divided into multiple heating elements positioned at different depths along the probe rod, allowing segmented measurement of ice thickness at multiple locations simultaneously. This segmentation enables more precise and reliable detection of full ice build conditions.
Solution Approach 2:
The conventional mechanical or simple thermal sensing approach is replaced with an electrical heating and sensing system. The probe uses electrical heating elements to melt ice and measures the electrical properties (resistance, current) to determine ice thickness, providing more precise and reliable measurements.
2Productivity
If ice build-up is not properly monitored, then the system operates continuously, but the vertical clearance gap cannot be maintained leading to reduced heat transfer efficiency
Solution Approach 1:
The probe provides continuous feedback on ice thickness measurements to the control system. Based on this feedback, the system automatically adjusts or shuts off glycol flow to maintain optimal ice thickness and clearance gap, ensuring both productivity and heat transfer efficiency are maintained.
Solution Approach 2:
Manual or conventional mechanical monitoring methods are replaced with electrical sensing and automated control. The electrical probe system continuously monitors ice thickness and automatically controls the thermal storage process, optimizing both productivity and energy efficiency.
3Quantity of substance
If ice build-up continues without accurate monitoring, then more ice is produced, but over-ice build occurs causing system inefficiency and potential damage
Solution Approach 1:
The probe provides real-time feedback on ice thickness to prevent over-ice build. When the probe detects that ice has reached the desired thickness or is approaching harmful levels, the system automatically shuts off glycol flow, preventing both waste of energy and potential system damage from excessive ice accumulation.
Solution Approach 2:
The probe is designed to detect ice thickness before harmful over-ice build occurs. By taking preliminary action to shut off glycol flow when optimal ice thickness is reached, the system prevents the harmful effects of over-ice build before they can occur.
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 solution enables precise monitoring of ice thickness, ensuring the maintenance of the necessary clearance gap for efficient heat transfer and preventing over-ice build, thereby optimizing the thermal storage system's operation and energy usage.
Implementation Method 1
The probe includes a heating element positioned at its lower end
Implementation Method 2
The insulator casing is fabricated from an electrically-insulative material and is wrapped around, is in contact with and extends along the probe rod
Data Source
AI summary
An ice thickness probe includes a longitudinally-extending probe rod, an insulator casing and a sleeve. The probe rod is fabricated from an electrically-conductive material. The insulator casing is fabricated from an electrically-insulative material and is wrapped around, is in contact with and extends along the probe rod. The sleeve is fabricated from a stiff yet resilient material and is wrapped around, is in contact with and extends along the insulator casing. The insulator casing and the sleeve are concentrically disposed about the probe rod as viewed in cross-section. An ice thickness probe assembly includes a frame structure, a reference bar and at least one ice thickness probe. An ice thickness monitoring apparatus is used in a thermal storage coil having a tank containing water and a tube disposed in the water so that, when the thermal ice storage coil is energized, ice is produced and accumulates on the tube.