System and method for producing rolled ice cream
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Solution Overview
Problem
Existing systems for producing rolled ice cream require frequent compressor shutdowns and restarts, leading to brief bursts of hot gas that can negatively affect the consistency of the ice cream due to the need to maintain the plate within a specific temperature range, resulting in inconsistent product quality.
Innovation Solution
A system with a balance valve that allows refrigerant to bypass the outlet tube when the plate reaches a predetermined minimum operational temperature, enabling continuous compressor operation and preventing hot gas bursts upon restart, using a system controller to manage temperature settings and control the balance valve.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the compressor is shut down when the plate reaches minimum operational temperature, then energy consumption is reduced, but hot gas bursts occur upon restart that negatively affect ice cream consistency
Solution Approach 1:
A bypass valve is introduced as an intermediary component that allows refrigerant to take an alternative path around the plate cooling circuit. This mediator enables the compressor to continue operating while preventing hot gas from reaching the plate during restart phases, thus resolving the contradiction between energy savings and product consistency.
Solution Approach 2:
The refrigerant circulation path is segmented into two separate circuits: a main cooling circuit that cools the plate and a bypass circuit that allows refrigerant to circulate independently. This segmentation allows the system to maintain compressor operation while isolating the plate from harmful hot gas bursts during restart.
2Manufacturing precision
If the compressor operates continuously, then ice cream consistency is maintained, but energy consumption increases
Solution Approach 1:
The system dynamically adjusts refrigerant flow distribution between the cooling circuit and bypass circuit based on operational conditions. The bypass valve modulates its opening degree to control refrigerant flow, enabling continuous compressor operation with optimized energy consumption by redirecting excess refrigerant through the bypass path.
3Ease of operation
If the compressor is frequently turned on and off to maintain temperature range, then temperature control is simplified, but plate temperature stability deteriorates due to hot gas bursts
Solution Approach 1:
The bypass circuit enables continuous refrigerant circulation through the compressor without interruption, maintaining system pressure stability and eliminating temperature fluctuations caused by frequent compressor cycling. The useful action of refrigerant compression continues uninterrupted while the bypass prevents harmful effects on the plate.
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 maintains consistent ice cream quality by preventing temperature fluctuations, reducing the need for compressor shutdowns and minimizing the impact of hot gas bursts, ensuring a stable freezing process and improved product consistency.
Implementation Method 1
a compressor configured to provide compressed refrigerant
Implementation Method 2
a condenser coupled to the compressor. The condenser is configured to provide cooled refrigerant
Implementation Method 3
a balance valve, wherein the balance valve is configured to enable the refrigerant to bypass the outlet tube
Implementation Method 4
The system further comprises a balance valve, wherein the balance valve is configured to enable the refrigerant to bypass the outlet tube while the compressor and condenser are still operational when it is determined that the plate member has reached a predetermined minimum operational temperature
Data Source
AI summary
A system and method for producing rolled ice cream comprising a housing, a plate member located on a top surface of the housing, a compressor configured to provide compressed refrigerant, and a condenser coupled to the compressor. The condenser is configured to provide cooled refrigerant to a bottom surface of the plate member via an outlet tube. The system further comprises a balance valve, wherein the balance valve is configured to enable the refrigerant to bypass the outlet tube while the compressor and condenser are still operational when it is determined that the plate member has reached a predetermined minimum operational temperature.