Method for real-time performance check of container system

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Solution Overview

Problem

Traditional pre-trip inspections of transport refrigeration units are time-consuming and costly, and may not detect component failures or wear until it's too late, risking cargo damage due to inadequate cooling or heating.

Innovation Solution

Implementing real-time performance checks of refrigeration unit components during normal operation, including idle modes, to monitor and test systems like cooling/heating, atmosphere control, ventilation, and sensors, using Fault Detection, Identification, and Handling (FDIH) to identify potential issues before they cause problems.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional pre-trip inspections are performed, then component failures can be detected, but the inspection process is time-consuming and costly

Engineering Contradiction:

Improvecomponent failure detectionVSAvoidinspection time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system performs preliminary testing of refrigeration components during idle periods before actual cargo transport begins. The controller executes diagnostic routines on compressors, fans, and heating elements during scheduled idle times, so that when transport starts, the system is already verified to be functioning properly, eliminating the need for time-consuming pre-trip inspections.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system transitions from periodic discrete inspections to continuous monitoring and testing. The controller continuously tracks power consumption of components and performs incremental diagnostic tests during idle periods, maintaining constant awareness of system health rather than relying on intermittent manual inspections, thereby detecting failures promptly without time loss.

Inventive Principle:

Principle #20Continuity of useful action

2Reliability

If traditional pre-trip inspections are performed, then component issues can be identified, but inspection costs increase

Engineering Contradiction:

Improvecomponent failure detectionVSAvoidinspection cost

Core Design Contradiction:

ReliabilityVSUse of energy by stationary object

Solution Approach 1:

The refrigeration system performs self-diagnosis through automated controller-executed tests during idle periods. The system monitors its own power consumption, tests component responses, and identifies failures autonomously without requiring external inspection personnel or manual intervention, thereby eliminating inspection labor costs while maintaining reliable failure detection.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system replaces manual mechanical inspection processes with automated electronic monitoring and diagnostic routines. The controller uses electrical measurements of power consumption and component response to detect failures, substituting human inspectors and manual testing equipment with automated electronic systems that reduce operational costs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If components are tested during normal operation, then the system can be monitored in real-time, but testing may interfere with normal climate control function

Engineering Contradiction:

Improvereal-time performance monitoringVSAvoidnormal operation continuity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The controller executes diagnostic tests periodically during scheduled idle periods rather than continuously during active transport. By timing tests to coincide with natural idle periods in the transport schedule, the system achieves real-time monitoring capability without interfering with normal climate control functions during cargo transport, as tests occur only when the system is already idle.

Inventive Principle:

Principle #19Periodic action

4Reliability

If comprehensive component testing is performed, then all systems can be verified, but the complexity of the testing system increases

Engineering Contradiction:

Improvecomplete system verificationVSAvoidtesting system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system extracts and monitors only the critical diagnostic parameter of power consumption for each component, rather than implementing complex multi-parameter testing equipment. By focusing on power consumption measurements during standardized test sequences, the system achieves comprehensive component verification using simple, built-in controller capabilities, avoiding added system complexity.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS10228188B2Method for real-time performance check of container system

Publication Date: 2019.03.12 MAERSK CONTAINER IND

AI summary

The invention relates to a method for real-time performance check of transport refrigeration units comprising the steps of:comparing via controller temperature sensors by pairs and determining from these comparisons by pairs if one or more temperature sensors are defective or in some extent deviates from expected temperature readings;at the same time measuring/monitoring the mass flow of cooling agent through a compressor and through an evaporator expansion valve Vexp which the controller by comparison determines if mass flow through the compressor do not deviate more than 25% from the mass flow through that evaporator expansion valve Vexp;if said deviation of mass flow through the compressor is more than 25% different from said mass flow through the expansion device Vexp, an error signal is provided.