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 management.
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 detect product presence and adjust airflow accordingly, thereby optimizing temperature control and reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If airflow is continuously maintained through all bays in the freezer warehouse, then temperature stability is improved, but energy consumption increases due to unnecessary airflow through empty bays
Solution Approach 1:
The system dynamically adjusts airflow based on real-time detection of pallet presence using sensors. When a pallet is detected in a bay, the air handler activates to provide cooling airflow; when no pallet is present, the air handler remains inactive. This dynamic operation maintains temperature stability where needed while eliminating energy waste in empty bays.
Solution Approach 2:
The system uses sensors to automatically detect the presence or absence of pallets and triggers the air handler activation accordingly. The detection and control mechanisms operate autonomously without manual intervention, allowing the system to self-regulate airflow based on actual cooling needs in each bay.
2Use of energy by moving object
If modular air handler assemblies are selectively activated only when pallets are present, then energy consumption is reduced, but temperature control reliability may be compromised
Solution Approach 1:
The system incorporates sensors that continuously monitor pallet presence and provide feedback signals to the control mechanism. This feedback loop ensures that air handlers are activated precisely when pallets are detected and deactivated when they are removed, maintaining reliable temperature control only in bays with actual product requiring cooling.
Solution Approach 2:
The sensors detect pallet presence in advance, triggering the air handler activation before any temperature instability can occur. This preliminary action ensures that cooling is already in place when product is introduced, preventing temperature fluctuations and maintaining reliability.
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 efficiently manages temperature by ensuring airflow only where needed, reducing energy expenditure and enhancing the spatial profile of temperature control operations, providing user feedback and optimizing performance.
Implementation Method 1
an air handler positioned and configured to drive an airflow through at least one of the plurality of bays
Implementation Method 2
a 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.