Quick freeze pallet racks with variable louvered doors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing blast freezing systems are inefficient due to airflow resistance and manual labor required for adjusting panels to accommodate varying pallet heights, leading to increased freezing time and resource wastage.
Innovation Solution
The implementation of automatically adjustable louvered doors in pallet rack systems that adapt to different pallet heights, enhancing airflow through the palletized goods while sealing empty spaces to prevent resource wastage, and incorporating flexible side seals to direct airflow effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual panel adjustment is used to accommodate varying pallet heights, then adaptability to different pallet sizes is improved, but labor intensity and operation complexity increase significantly
Solution Approach 1:
The louvered doors are designed to automatically adjust their opening degree based on the height of the palletized goods inserted into the rack. The mechanism detects the presence and height of the load, and the doors self-adjust to the appropriate opening position without requiring manual intervention, thereby eliminating labor-intensive panel adjustment while maintaining adaptability to various pallet heights
Solution Approach 2:
The louvered doors transition from a static fixed-position design to a dynamic adjustable design where the opening degree can change automatically. The doors are equipped with actuation mechanisms that enable them to move between different opening positions based on the detected pallet height, providing dynamic adaptability without manual operation
2Productivity
If airflow paths are designed to flow through palletized products, then freezing efficiency is improved, but airflow resistance increases due to drag through multiple consecutive pallets
Solution Approach 1:
The airflow path is segmented into multiple independent channels, each serving a specific pallet position. The louvered doors for each rack position can be independently controlled to optimize airflow distribution. This segmentation prevents airflow from having to pass through multiple consecutive pallets in series, reducing cumulative drag while maintaining effective freezing throughput
Solution Approach 2:
The airflow characteristics are optimized locally at each rack position rather than using a uniform airflow path through all pallets. Each louvered door assembly creates localized airflow patterns tailored to the specific pallet configuration at that position, ensuring adequate freezing efficiency while minimizing unnecessary airflow resistance and energy loss
3Ease of operation
If louvered doors remain open to accommodate palletized goods, then accessibility for loading is improved, but thermal loss increases when racks are not fully capacity
Solution Approach 1:
The louvered doors provide dynamic control over rack accessibility and thermal isolation. During loading operations, the doors can be opened to allow easy access for inserting palletized goods. After loading is complete, the doors automatically close to seal the rack position, preventing thermal loss when the rack is not being actively serviced or when operating at partial capacity
Solution Approach 2:
The system incorporates feedback mechanisms that detect whether a rack position is actively being loaded or is in a stationary state. Based on this feedback, the louvered doors automatically adjust their opening degree - remaining open during active loading operations for accessibility, and closing when loading is complete to minimize thermal loss and energy waste
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 improves thermal transfer efficiency, reduces the differential in temperature adjustment, decreases capital and utility costs, and eliminates the need for manual labor, allowing for efficient operation at any rack capacity.
Implementation Method 1
permit airflow through the panel at a variety of different height positions
Implementation Method 2
flexible side seals oriented substantially perpendicular to the frame are deformable upon introduction of airflow to press against the sides of the palletized product
Implementation Method 3
deformable upon introduction of airflow to press against the sides
Implementation Method 4
rack systems with airflow openings which are automatically adjusted to open to different heights corresponding to the different heights of various palletized goods placed in the rack for freezing, cooling, or other thermal adjustments through thermal transfer of airflow
Data Source
AI summary
Pallet racking systems are designed to quickly freeze items using thermal transfer by moving air through palletized products. Air is pulled through the palletized product to a negative air plenum behind the pallet rack. Back panels of the pallet racks provide variable-height airflow by use of louvers which are individually pressed open by the palletized product to accommodate differing product heights. The panels allow more efficient system operation with any number of rack positions filled.