Virtual Door Sensing From Climate Control Data Under Vibration

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Solution Overview

Problem

Physical door sensors for transport units are prone to mechanical failures and reduced sensitivity due to vibrations, leading to inaccurate door event detection and increased energy consumption and cargo spoilage.

Innovation Solution

A virtual door sensor system that utilizes machine learning algorithms to analyze transport climate control system data, predicting door events without mechanical inputs, thereby enhancing accuracy and reducing maintenance needs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If physical door sensors with mechanical or magnetic components are used, then door event detection is provided, but the sensors become faulty or less sensitive due to mechanical failures or vibration during transport

Engineering Contradiction:

Improvedoor event detection accuracyVSAvoidmechanical failures and vibration

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces physical mechanical or magnetic door sensors with a virtual door sensor that uses machine learning algorithms to analyze climate control system data. This substitution eliminates moving mechanical parts that are susceptible to vibration and mechanical failure, thereby resolving the contradiction between providing door event detection and avoiding mechanical failures during transport.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces climate control system operating data as an intermediary to detect door events indirectly. Instead of directly sensing door position with mechanical components, the system analyzes changes in climate data (temperature, humidity, air quality) that occur when doors are opened or closed. This intermediary approach avoids the harmful effects of vibration and mechanical failure while still providing accurate door event detection.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If physical door sensors are used, then door status is monitored, but energy consumption increases and cargo spoilage risk increases due to inaccurate detection

Engineering Contradiction:

Improvedoor event detection accuracyVSAvoidenergy consumption

Core Design Contradiction:

Measurement precisionVSLoss of energy

Solution Approach 1:

The virtual door sensor system replaces inaccurate physical sensors that lead to energy waste. By using machine learning to analyze existing climate control data, the system achieves more precise door event detection without requiring additional energy-consuming hardware, thereby resolving the contradiction between measurement precision and energy loss.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system uses the climate control system's own operating data to detect door events, eliminating the need for separate physical door sensors. This self-service approach leverages existing system resources to improve detection accuracy without increasing energy consumption, as the same sensors and processors are used for both climate control and door event detection.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS20250381820A1Virtual door sensor for transport unit

Publication Date: 2025.12.18 THERMO KING CORP

AI summary

A method of providing a virtual door sensor for a transport unit is disclosed. The method includes monitoring operation of a transport climate control system for a climate controlled space to obtain transport climate control system operating data; transforming the transport climate control system operating data into door event model inputs; predicting a door event based on the obtained door event model inputs; and transmitting a notification according to the predicted door event.