Modular Air Handler Racking for On-Demand Warehouse Airflow Control
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Solution Overview
Problem
Existing freezer warehouse systems face inefficiencies in heat transfer due to irregular spacer configurations, leading to obstructed airflow and inconsistent support, which affects the freezing and thawing of palletized products.
Innovation Solution
A modular air handler system is introduced, which can be installed in a racking assembly behind palletized products, allowing for controlled airflow through the use of enclosures with specific airflow apertures and a fan system that activates only when products are present, ensuring efficient heat transfer and reducing unnecessary energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If irregular spacer configurations are used to support palletized products, then product support is provided, but airflow is obstructed and heat transfer efficiency deteriorates
Solution Approach 1:
The spacer is divided into multiple discrete support elements (legs) spaced at intervals along the palletized product. This segmentation allows airflow to pass through the gaps between legs while still providing adequate structural support, resolving the contradiction between support strength and airflow efficiency
Solution Approach 2:
The spacer features localized support points rather than continuous contact. The support function is concentrated at specific locations (legs touching the product) while other areas remain open for airflow, creating different local properties for support versus airflow passage
2Temperature
If air handlers are continuously activated to maintain temperature, then temperature control is improved, but energy consumption increases
Solution Approach 1:
The air handler operates periodically rather than continuously, activating only when palletized product is detected in the rack and deactivating when the rack is empty or during off-peak periods. This periodic operation maintains necessary temperature control while significantly reducing overall energy consumption
Solution Approach 2:
The system uses sensors to automatically detect the presence of palletized product and triggers air handler activation accordingly. The system serves itself by monitoring its own state and making operational decisions, eliminating the need for continuous manual control or unnecessary operation
3Productivity
If modular air handler system is installed to improve airflow control, then heat transfer efficiency is improved, but device complexity increases
Solution Approach 1:
The air handling system is divided into multiple independent modular air handlers, each serving a specific rack or zone. This modular segmentation allows for localized airflow control and easier maintenance while managing overall system complexity through standardization of individual units
Solution Approach 2:
The modular air handlers are designed with universal features and standardized components that can be applied across different racks and locations. This universality reduces the variety of unique parts needed and simplifies installation and maintenance, offsetting the complexity introduced by having multiple units
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 modular air handler system enhances airflow and heat transfer efficiency by activating only when needed, maintaining consistent temperatures and reducing energy expenditure, thereby improving the freezing and thawing processes for palletized products.
Implementation Method 1
an air handler in fluid communication with the second airflow aperture of the enclosure, such that the air handler is operable to drive air through the palletized product assembly via the first airflow aperture
Implementation Method 2
Air handlers 8, e.g., chillers or heaters (FIG. 2) provided in the interior of warehouse 2 produce conditioned, e.g., cold or warmed air and maintain the temperature of ambient air within the warehouse space at a desired temperature
Data Source
AI summary
A modular air handler is adapted for installation in a racking assembly behind palletized product. The air handler operates to move air through the adjacent layers of palletized product upon placement of the palletized product in the adjacent space. The air handler can be deactivated in order to prevent unnecessary air flow when no palletized product is present in the adjacent space. A number of the modular air handlers may be provided for a racking assembly, such that individual pallet bays may be activated or deactivated as palletized product is deposited or withdrawn from the various pallet bays of the rack.