Self-Adjusting Cryogenic Food Freezer Using Real-Time Sensing
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Solution Overview
Problem
Cryogenic food freezing systems require trained personnel to adjust freezing conditions, leading to inefficient operation and unnecessary cryogenic substance waste due to changing production rates and facility conditions, as operators often fail to make immediate adjustments due to labor intensity and lack of awareness of variable changes along the processing line.
Innovation Solution
A self-adjusting cryogenic food freezing system that senses physical characteristics of the food product in real time, using a laser scanner and infrared temperature sensors to automatically control heat transfer and conveyor speed, ensuring efficient freezing by continuously adapting to changing conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual operation by trained personnel is used to adjust freezing conditions, then the system can be controlled, but the operation becomes labor-intensive and delays adjustment response to changing conditions
Solution Approach 1:
The system uses sensors to automatically detect changes in production rates and facility conditions, and the controller autonomously adjusts freezing parameters without requiring operator intervention. The system serves itself by continuously monitoring and self-correcting based on sensed data.
Solution Approach 2:
Sensors continuously monitor physical characteristics of the food product and system conditions, feeding this information back to the controller which automatically adjusts freezing conditions. This closed-loop feedback system eliminates the delay between condition changes and operational responses.
2Adaptability or versatility
If operators are deployed to monitor and adjust freezing conditions, then the system can adapt to changes, but labor costs and operational complexity increase
Solution Approach 1:
The patent replaces the mechanical system of manual monitoring and adjustment with an automated sensing and control system. Sensors detect physical characteristics and the controller processes this data to automatically adjust freezing parameters, substituting human operators with electronic measurement and control systems.
Solution Approach 2:
The system performs self-monitoring and self-adjustment through integrated sensors and controllers that automatically respond to changing conditions without external human intervention, thereby reducing operational complexity while maintaining adaptability.
3Ease of manufacture
If freezing conditions are not continuously adjusted, then the system operates simpler, but cryogenic substance is wasted and freezing efficiency decreases
Solution Approach 1:
The system dynamically changes freezing parameters based on real-time sensed data about production rates and food product characteristics. The controller adjusts cryogenic substance delivery rates, conveyor speeds, and other parameters to match actual freezing needs, preventing waste while maintaining efficiency.
Solution Approach 2:
The freezing system transitions from static, fixed conditions to dynamic, continuously adjustable parameters. Sensors and controllers enable real-time modification of freezing conditions to match changing production rates and product requirements, optimizing cryogenic substance usage.
4Ease of operation
If manual adjustment of freezing conditions is performed, then some control is achieved, but operators are not aware of variable changes along the processing line
Solution Approach 1:
Multiple sensors positioned along the processing line continuously monitor physical characteristics of the food product and system conditions, providing comprehensive feedback to the controller. This distributed sensing network eliminates information loss by capturing data from all critical locations along the processing line.
Solution Approach 2:
The system replaces human operators' limited awareness with electronic sensors that continuously monitor and detect variable changes throughout the entire processing line. The sensing system provides complete information about product characteristics and conditions at all locations without human intervention.
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 achieves efficient freezing and reduced manual labor by automatically adjusting freezing conditions, optimizing heat transfer and cryogenic substance usage, leading to improved processing efficiency and uniformity.
Implementation Method 1
a laser scanner disposed at an inlet of the housing for scanning a cross-sectional area of the food product entering the cryogenic freezer
Implementation Method 2
a pair of infrared (IR) temperature sensors, wherein a first IR sensor is disposed downstream of the laser scanner and upstream of an inlet to said internal chamber, and a second IR sensor is disposed downstream of an outlet of said internal chamber
Implementation Method 3
providing a cryogenic substance to the food product for heat transfer at said food product
Implementation Method 4
providing a cryogenic substance to the food product for heat transfer at said food product
Data Source
AI summary
A method for freezing a food product in a cryogenic freezer includes sensing at least one physical characteristic of the food product in real time, providing a cryogenic substance to the food product for heat transfer at said food product, automatically self-adjusting the heat transfer at the food product responsive to the sensing the at least one physical characteristic, and continuously self-adjusting the heat transfer for bringing the food product to a select temperature. A related freezer apparatus is also provided.