Vertical-Loop Freezer Cabinet for Single-Operator Continuous Loading
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Solution Overview
Problem
Existing freezer cabinets require large installation areas and significant operational effort, especially when designed for continuous freezing operations, as they often need two operators for loading and unloading and have a large footprint.
Innovation Solution
The freezer cabinet design features loading and unloading openings on the same side, allowing for a single operator to manage continuous operations, with baskets circulating vertically behind these openings for efficient loading and unloading. The baskets are open at the top and front, enabling automatic removal using an extraction rake, and the system includes a folding mechanism to minimize cold loss and facilitate easy cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If freezer cabinets are designed as belt freezers or spiral freezers for continuous freezing operations, then continuous freezing capability is improved, but installation area (footprint) increases significantly
Solution Approach 1:
The patent transitions from horizontal belt/spiral conveyor designs to a vertical loop configuration. Baskets circulate in vertical loops within the housing, with loading and unloading openings positioned at different vertical levels. This dimensional change from horizontal to vertical space utilization dramatically reduces the horizontal footprint while maintaining continuous freezing capability.
Solution Approach 2:
The continuous conveyor system is segmented into discrete baskets that circulate independently in vertical loops. Each basket can be individually loaded and unloaded, allowing for modular operation. The circulation path is divided into multiple vertical loops with intermediate transfer points, enabling continuous operation while reducing the overall installation area compared to a single long horizontal belt.
2Productivity
If belt freezers are designed with separate loading and unloading openings at opposite ends, then continuous loading and unloading is enabled, but two operators are required increasing operational effort
Solution Approach 1:
The patent merges the loading and unloading operations into a single operational station by positioning both openings on the same side of the housing. Baskets circulate to this single station where loading and unloading occur in sequence, allowing one operator to manage both functions. This consolidates what were previously separated opposite-end operations into a unified side-mounted interface.
Solution Approach 2:
Baskets are pre-positioned in the vertical circulation loop so that when a basket reaches the loading/unloading station, it is already in the correct position and orientation for efficient operation. The continuous circulation ensures that the next basket is always approaching the station, allowing the operator to maintain continuous workflow without waiting for basket positioning.
3Ease of operation
If loading and unloading openings are positioned on the same side, then a single operator is sufficient reducing operational effort, but continuous loading and unloading becomes more complex
Solution Approach 1:
The patent resolves the complexity issue by utilizing vertical space for basket circulation loops. Instead of complex horizontal mechanisms to position baskets for side-mounted loading/unloading, the system uses simple vertical gravity-assisted circulation. Baskets move up and down in loops, naturally positioning themselves at the loading/unloading station on the same side without requiring complex positioning mechanisms.
Solution Approach 2:
The vertical circulation loop acts as an intermediary mechanism that simplifies the loading and unloading process. Rather than directly complex mechanisms at the opening, the system uses the circulating basket loop as a mediator to bring products to the loading/unloading point in a controlled, sequential manner, reducing operational complexity despite the single-sided configuration.
4Ease of operation
If baskets are open at the top and front for easy loading and unloading, then ease of operation is improved, but cold loss increases
Solution Approach 1:
The patent employs flexible foil curtains (thin films) to seal the open top and front of the baskets. These foil curtains can be easily opened during loading and unloading operations to provide access, then closed to minimize cold air loss. The flexible nature of the foil allows it to conform to the basket opening while providing effective thermal insulation when closed, balancing ease of operation with energy conservation.
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 design achieves continuous freezing with reduced operational effort and space requirements, ensuring efficient loading and unloading while maintaining hygiene and minimizing cold loss through automated and partially automated processes.
Implementation Method 1
the evaporator 22 required for refrigeration is located over a large area
Implementation Method 2
with which frozen goods such. B. Meat should get a deep-frozen outer layer as quickly as possible
Data Source
Figure 1
Figure 2
Figure 3
AI summary
For continuous loading and unloading of a freezer (1) with only one operator loading and unloading (3.4) are arranged in the front door and can by designing the baskets (2a, b) from spaced, rear-connected prongs with help be emptied automatically by a removal rake. For cleaning, the entire inner workings are moved out of the housing (5) of the freezer cabinet on a slide (7).