Recirculating Storage Apparatus Temperature Control
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Solution Overview
Problem
Existing conveyor systems face challenges in efficiently matching continuous incoming product flow with intermittent outgoing flow, particularly in high-speed production lines, where temperature control and precise item handling are necessary while maintaining product order and reducing energy costs.
Innovation Solution
A recirculating storage apparatus with a closed-loop configuration, using vertically aligned shelves and actively controlled temperature airflow to manage retention time and temperature changes, ensuring efficient loading, unloading, and maintaining product sequence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a recirculating storage apparatus with closed-loop configuration is used to match continuous incoming flow with intermittent outgoing flow, then productivity is improved and energy costs are reduced, but device complexity increases
Solution Approach 1:
The storage apparatus is divided into multiple independently controllable zones along the recirculating conveyor loop. Each zone can be selectively heated or cooled based on product requirements, allowing continuous processing without requiring the entire system to operate at full capacity, thus reducing energy consumption while maintaining high productivity.
Solution Approach 2:
The system employs dynamically adjustable conveyor speeds and selectively controllable temperature zones that can adapt to varying production rates and product requirements. This dynamic control allows the apparatus to match continuous incoming flow with intermittent outgoing flow requirements, improving productivity while managing energy usage through on-demand heating/cooling rather than continuous operation.
2Manufacturing precision
If temperature controlled airflow is used to freeze or cook items during internal storage, then manufacturing precision is improved, but use of energy increases
Solution Approach 1:
Products are subjected to preliminary heating or cooling in designated zones before being transferred to the final processing zone. This preliminary action prepares the products for more efficient final processing, reducing the energy required for the main temperature transformation while maintaining precise temperature control throughout the process.
Solution Approach 2:
The system changes temperature parameters dynamically along the recirculating conveyor path, with different zones operating at different temperatures based on product requirements. This allows precise temperature control for specific processing needs while minimizing overall energy consumption by applying temperature control only where and when necessary, rather than uniformly throughout the entire system.
3Manufacturing precision
If vertically aligned shelves with closed-loop configuration are used, then manufacturing precision is improved for product handling, but device complexity increases
Solution Approach 1:
The vertically aligned shelf structure serves multiple functions: it provides organized product storage, enables precise vertical positioning for handling, facilitates efficient space utilization, and supports the recirculating conveyor mechanism. This multi-functionality achieves high manufacturing precision for product handling without proportionally increasing device complexity, as the same structural elements perform multiple roles.
Solution Approach 2:
The racking system employs nested or stacked shelf configurations where multiple levels of shelves are vertically aligned to maximize space utilization. This nesting arrangement provides precise handling positions while maintaining a compact overall structure, achieving manufacturing precision without excessive device complexity.
4Reliability
If recirculating carriers with vertical transfer means are used to maintain product order, then reliability is improved, but device complexity increases
Solution Approach 1:
The recirculating carrier system maintains continuous product flow through the storage apparatus while preserving product order. The vertical transfer means operate continuously or in seamless sequences to move products between levels without interruption or reordering, ensuring reliability of product sequence maintenance. This continuous operation avoids the need for complex repositioning mechanisms while maintaining product integrity.
Solution Approach 2:
The vertical transfer means act as intermediary mechanisms that smoothly transition products between different vertical levels of the recirculating carrier system. These intermediaries facilitate reliable product sequence maintenance by providing controlled, predictable transfer points that preserve product order without requiring complex coordination systems.
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 solution enables high-speed, continuous operation with precise temperature control, reducing energy costs and ensuring proper processing of products, while maintaining product order and facilitating integration with downstream automation.
Implementation Method 1
the apparatus uses a temperature controlled airflow for freezing or cooking items such as food products
Implementation Method 2
the apparatus uses a temperature controlled airflow for freezing or cooking items
Data Source
AI summary
A continuous storage apparatus holds carriers each having many vertical shelves to be continuously loaded and unloaded by pushers at adjacent positions. The conveyor order of arrival of items is maintained on departure. Shelves hold items to be frozen or cooked during storage by a forward or backward (countercurrent) flow of recirculating cold or hot air within the tunnels of the machine. Carrier motion is provided by lifting and lowering conveyor chains at both ends of the tunnels and by shunting the carriers, supported by wheels or skids on rails along the tunnels, when pushed by an actuator.