Thermal Container Spray Control for Standby Energy Reduction

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Solution Overview

Problem

Thermal container treatment devices, such as coolers, heaters, and pasteurizers, face high electrical and thermal energy consumption during standby and normal operations due to continuous dispensing of treatment medium, which is inefficient and delays readiness for immediate use.

Innovation Solution

A thermal container treatment device with a control system that operates pumps at reduced power during standby mode and switches to rated power for normal operation, utilizing temperature sensors and bypasses to manage treatment medium flow, reducing energy consumption and ensuring rapid readiness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the pump operates at rated power during standby mode to maintain treatment medium flow, then the device is ready for immediate use, but electrical and thermal energy consumption increases

Engineering Contradiction:

Improvereadiness for immediate useVSAvoidelectrical and thermal energy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The pump operates dynamically with two distinct modes: rated power during normal operation and reduced power during standby mode. This dynamic operation allows the system to adapt power consumption to actual operational needs while maintaining readiness through periodic operation at reduced power.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The pump operates periodically at reduced power during standby mode rather than continuously at rated power. This periodic operation maintains treatment medium flow and temperature sufficient for quick transition to full operation while significantly reducing energy consumption during idle periods.

Inventive Principle:

Principle #19Periodic action

2Ease of operation

If the pump operates continuously at rated power, then treatment medium is always dispensable via spray device, but thermal energy consumption increases due to continuous atomization

Engineering Contradiction:

Improvetreatment medium dispensabilityVSAvoidthermal energy consumption

Core Design Contradiction:

Ease of operationVSLoss of energy

Solution Approach 1:

The pump operates at partial power (reduced rated power) during standby mode, providing just enough treatment medium flow to maintain dispensability without excessive atomization. This partial action satisfies the minimum requirement for operational readiness while avoiding the energy waste of full-power continuous operation.

Inventive Principle:

Principle #16Partial or excessive action

3Use of energy by moving object

If the pump is switched off during standby mode, then energy consumption is minimized, but the device requires delay before immediate use

Engineering Contradiction:

Improveelectrical and thermal energy consumptionVSAvoiddelay before immediate use

Core Design Contradiction:

Use of energy by moving objectVSLoss of time

Solution Approach 1:

The pump performs preliminary operation at reduced power during standby mode, maintaining treatment medium flow and temperature in advance. This preliminary action ensures that when full operation is required, the system can transition immediately without delay for warming or priming, while still achieving energy savings compared to continuous rated power operation.

Inventive Principle:

Principle #10Preliminary action

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

Reduces thermal and electrical energy consumption by minimizing treatment medium atomization and ensures quick transition to operational readiness by optimizing pump power usage and temperature control.

Implementation Method 1

a pump (7) is provided in the pipe connection (6)

Methodology Applied

Scientific EffectPumping: Pump

Implementation Method 2

atomization of the treatment medium during application via the spraying device is prevented

Methodology Applied

Scientific EffectAtomization:

Implementation Method 3

A temperature sensor (8) for measuring the temperature of the treatment medium (5) is provided in the basin (4)

Methodology Applied

Scientific EffectTemperature sensing:

Implementation Method 4

A control device (9) is provided which is designed not to operate the pump (7) or to operate the pump (7) at a reduced rated power during standby operation

Methodology Applied

Scientific EffectPower control:

Data Source

PatentEP4649968A1Thermal container treatment device and method for operating the thermal container treatment device

Publication Date: 2025.11.19 KRONES AG

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AI summary

The invention relates to a thermal container treatment device comprising a conveying device (45) for containers (44), a treatment zone (1, 15, 17, 32-43) with a spray device (2, 17, 18, 58-69) for applying treatment medium to the container (44), a basin (4, 19, 20, 46-57) for collecting and supplying treatment medium, and a pipe connection (6, 21, 22) between the basin and the spray device, wherein a pump (7, 23, 24) is provided in the pipe connection. A temperature sensor (8, 25, 26, 84) is provided in the basin below a fill level of the treatment medium.The thermal tank treatment device comprises a control device (9) configured to operate the pump at rated power for dispensing treatment medium via the spray device during normal operation in the treatment zone, and to either not operate the pump or operate it at a reduced rated power during standby operation in the treatment zone, without treatment medium being dispensable via the spray device. The invention further relates to a method for controlling the thermal tank treatment device.