Milk-flow Control Unit for Dynamic Pump Speed and Cooling Capacity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing milk cooling systems face challenges in efficiently managing the unstable milk flow and varying animal production rates, leading to inefficient energy use and temperature control between the balance tank and storage tank.
Innovation Solution
A control unit that generates control signals based on temperature and level-indicating signals to manage the milk pump speed and cooling system capacity, independently of milk flow sensors, optimizing pump operation and energy usage by adjusting speed and cooling capacity according to milk level and temperature thresholds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the milk pump operates continuously to handle unstable milk flow, then the milk flow rate is maintained, but energy consumption increases
Solution Approach 1:
The milk pump operates dynamically by adjusting its speed based on real-time milk level feedback from the balance tank. The control unit modulates pump operation between active and inactive states, or between different speeds, to match the actual milk flow requirements rather than running continuously, thereby reducing energy consumption while maintaining productivity.
Solution Approach 2:
The system uses a feedback mechanism where a level-indicating signal from a sensor in the balance tank continuously monitors the milk level. This signal is fed back to the control unit, which adjusts the milk pump operation accordingly - activating the pump when the level is high and deactivating or reducing speed when the level is low, optimizing energy usage based on actual conditions.
2Temperature
If the cooling system operates at full capacity to maintain low milk temperature, then temperature control is ensured, but energy efficiency decreases
Solution Approach 1:
The cooling system operates dynamically with variable capacity rather than at full power continuously. The control unit adjusts the cooling capacity based on the actual milk flow rate and temperature requirements, reducing cooling intensity when less milk needs cooling and maintaining full capacity only when necessary, thus improving energy efficiency while ensuring temperature control.
Solution Approach 2:
The cooling system applies partial action by providing cooling capacity proportional to the actual need. Instead of always operating at full capacity, the system applies just enough cooling to maintain the required temperature, avoiding excessive energy consumption while still ensuring temperature control is met.
3Productivity
If the milk pump speed is increased to handle high milk flow, then throughput is improved, but energy consumption increases
Solution Approach 1:
The milk pump operates at variable speeds rather than at a fixed high speed. The control unit dynamically adjusts the pump speed based on the milk level in the balance tank and the actual throughput requirements, using higher speeds only when needed to maximize productivity while reducing speeds or stopping when lower throughput is sufficient, thereby optimizing the energy-to-productivity ratio.
4Speed
If the cooling system capacity is increased to cool milk faster, then cooling speed is improved, but energy efficiency decreases
Solution Approach 1:
The cooling system capacity is dynamically adjusted based on the actual milk flow rate and temperature differential required. The control unit increases cooling capacity and speed only when the milk flow and temperature conditions warrant rapid cooling, and reduces capacity when the milk flow is low or the temperature is already close to the target, thereby improving energy efficiency while maintaining cooling speed when needed.
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 enables efficient milk temperature control and energy savings by minimizing unnecessary pump and cooling system operation, preventing tank overflow or emptying, and maintaining acceptable temperatures while maximizing throughput and energy efficiency.
Implementation Method 1
a first heat exchanger incorporates the first evaporator and a second heat exchanger incorporates the second evaporator
Implementation Method 2
heat is withdrawn from the product or the medium by the first evaporator cooling the product or the medium
Implementation Method 3
the product or an intermediate heat transfer medium is cooled in at least two first stages
Implementation Method 4
a first evaporator and a second evaporator separate from the first evaporator, wherein a first heat exchanger incorporates the first evaporator
Implementation Method 5
During the first stage, heat is withdrawn from the product or the medium by the first evaporator cooling the product or the medium to an intermediate temperature
Data Source
AI summary
A control unit, computer-implemented method, and computer program for controlling a milk transport and cooling apparatus where a flow of milk is controlled from a balance tank to a storage tank, based on a temperature-indicating signal measuring a temperature of the flow of milk before entering the storage tank, and a level-indicating signal reflecting a milk level in the balance tank in relation to low- and high-threshold levels respectively, such that the control unit generates a first control signal controlling the speed of the milk pump based on the temperature-indicating signal when the level-indicating signal is within low- and high-threshold levels respectively, and can also generate a second control signal controlling a capacity of a chiller based on the temperature-indicating signal with respect to an uninterrupted time period.