Modular heat transfer system
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Solution Overview
Problem
Existing freezer warehouse systems face inefficiencies in controlling and maintaining the temperature of palletized products, as they often require unnecessary airflow through empty bays, leading to energy wastage and suboptimal temperature control.
Innovation Solution
A modular heat transfer system comprising air handler assemblies and a control system that activate airflow only when palletized products are present, using sensors to manage airflow through each bay independently, ensuring precise temperature control and minimizing energy usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If airflow is continuously maintained through all bays in the warehouse, then temperature control is maintained, but energy consumption increases unnecessarily when bays are empty
Solution Approach 1:
The warehouse storage system is divided into multiple independent bays, each equipped with its own airflow control. This segmentation allows individual bays to be controlled separately, enabling airflow to be activated only in bays containing palletized products, thereby reducing overall energy consumption while maintaining temperature control where needed.
Solution Approach 2:
The airflow system transitions from a static continuous operation to a dynamic on-demand operation. Sensors detect the presence of palletized products in each bay and dynamically activate or deactivate airflow accordingly, optimizing energy usage based on real-time conditions while ensuring temperature control is applied only when necessary.
2Use of energy by moving object
If airflow is activated only when products are present, then energy consumption is reduced, but temperature control precision may be compromised
Solution Approach 1:
Temperature sensors and product presence sensors provide continuous feedback to the control system. This feedback mechanism ensures that airflow is activated not only when products are present but also when temperature deviations occur, maintaining precise temperature control while avoiding unnecessary energy consumption during stable conditions.
Solution Approach 2:
The system adjusts airflow parameters (activation, intensity, duration) based on detected conditions such as product presence, temperature deviations, and bay occupancy. These parameter changes enable precise temperature control to be maintained only when and where needed, optimizing the balance between energy efficiency and control precision.
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 system efficiently manages temperature by activating airflow only when needed, reducing energy consumption and ensuring consistent temperature control across palletized products, thereby optimizing the freezing or thawing process.
Implementation Method 1
airflow through at least one of the plurality of bays
Implementation Method 2
temperature sensor configured and positioned to sense a temperature of the palletized product assembly
Data Source
AI summary
A system and method controls a heat transfer system for palletized product. A controller and an array of sensors cooperate to control chillers and fans to efficiently change the temperature of product within the cases, while collecting and providing data regarding the efficacy and overall spatial profile of the freezing or other temperature-control operation. These data can be used to provide user feedback, optimize the temperature-control process, and ensure a desired performance of the system.