CONDITIONING SYSTEMS AND METHODS FOR DOCKED CARGO CONTAINER

Description

CLAIM OF PRIORITY

This application claims priority to U.S. Provisional Patent Application Ser. No. 63/699,546, filed Sep. 26, 2024, which is hereby incorporated by reference herein in its entirety.

BACKGROUND

Cargo containers, including, for example, truck trailers commonly dock at a warehouse, distribution center, or other facility to load or unload the container/trailer. In certain climates, the environmental conditions inside the docked cargo containers can be disadvantageous to productivity and can place unwanted thermal stress on workers. For example, during winter in northern climates trailers entering a distribution center can be at or near the ambient outdoor air temperature, which can be very low. In such situations, trailers are commonly parked at open dock doors and allowed to warm before workers begin the loading and unloading process.

SUMMARY

The present inventors recognize, among other things, a need to rapidly condition cargo containers/trailers docked at a facility before loading and unloading or as loading and unloading commences to increase productivity and worker wellbeing at warehouses, distribution centers, and other facilities that receive and house various types of goods.

In an example, a system includes a door and an air conditioning system. The door is configured to move between a closed state in which the door covers an aperture sized and configured to receive a cargo container and opened state in which the aperture is uncovered. The air conditioning system includes a heat exchanger and a mount. The heat exchanger is configured to direct conditioned air into the cargo container. The mount is connected to the heat exchanger and configured to locate the heat exchanger adjacent the aperture in the opened state and in the closed state of the door without interfering with movement of the door.

In another example, a method includes positioning a heat exchanger adjacent an aperture, sensing the state of a door, and selectively actuating the heat exchanger. The aperture is covered by the door in a closed state and uncovered by the door in an opened state. The heat exchanger is positioned adjacent the aperture in the closed state and in the opened state of the door without interfering with movement of the door between states. The heat exchanger is selectively actuated to direct conditioned air into a cargo container received by the aperture based on the sensed state of the door.

In another example, an air conditioning system includes a heat exchanger and a mount connected to the heat exchanger. The mount is configured to locate the heat exchanger adjacent an aperture configured to receive a cargo container. The aperture is covered by a door in a closed state and uncovered by the door in an opened state. The mount positions the heat exchanger adjacent the aperture in the closed state and in the opened state of the door without interfering with movement of the door between states. The heat exchanger is configured to direct conditioned air into the cargo container.

This overview is intended to provide an overview of subject matter in the present application. It is not intended to provide an exclusive or exhaustive explanation of the invention. The detailed description is included to provide further information about the present application.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, which are not necessarily drawn to scale, like numerals may describe similar components in different views. Like numerals having different letter suffixes may represent different instances of similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present disclosure.

FIG. 1A is a perspective view depicting an example system in accordance with examples of this disclosure.

FIG. 1B is a side elevation view depicting the system of FIG. 1A.

FIG. 2 is a perspective view depicting an example conditioning system according to this disclosure.

And FIG. 3 is a flow chart of an example method in accordance with this disclosure.

DETAILED DESCRIPTION

FIG. 1A is a perspective view depicting example system 100 in accordance with examples of this disclosure. FIG. 1B is a side elevation view of system 100. In FIGS. 1A and 1B, example system 100 includes door 102, cargo container 104, air conditioning system 106, temperature sensor 108, door sensor 110, and controller 112. Door is movably connected to rails 114 adjacent aperture 116. Aperture 116 can be, for example, an aperture in a wall of a building like a warehouse. Aperture 116 is sized and configured to receive cargo container 104.

Door 102 is configured to move between closed and open states, for example by sliding or rolling on rails 114. In the closed state, door 102 covers aperture 116, which is sized and configured to receive cargo container 104. In the opened state, which is depicted in FIG. 1A, door 102 is moved upward along rails 108 to uncover aperture 116. Other examples according to this disclosure can include differently configured movable doors, including, e.g. a sectional door with curved rails that direct the door up and away from the aperture and cargo container, a roll-up door, side-hinged door, or tilt-up door.

Air conditioning system 106 includes heat exchanger 118 and mount 120. Heat exchanger 118 is configured to direct conditioned air into cargo container 104. Heat exchanger 118 can include a variety of different types of exchangers selected for the application and environmental conditions for which system 100 is employed. For example, heat exchanger 118 can include a variety of liquid-to-air heat exchangers or a variety of air-to-air heat exchangers. In an example, heat exchanger 118 is gas or electric heater, which draws in cool air, circulates the air through a heating element, and supplies heated air to a space, e.g. to the interior of cargo container 104.

Mount 120 is connected to heat exchanger 118 and configured to locate the heat exchanger adjacent aperture 116 in the opened state and in the closed state of door 102 without interfering with movement of the door along rails 114. In the example of FIGS. 1A and 1B, mount 120 is connected to each of the pair of rails 114. In another example, a heat exchanger mount in accordance with examples of this disclosure could be connected to a wall including aperture 116, e.g. a vertical wall in a warehouse or other type of building. Mount 120 and other mounts in accordance with examples of this disclosure can include a variety of structural elements, e.g. bars, plates, brackets, etc. that configure and size the mount to position adjacent aperture 116 in the opened state and in the closed state of door 102 without interfering with movement of the door.

System 100 also includes temperature sensor 108, door sensor 110, and controller 112. Temperature sensor 108 is configured to sense a temperature of air in cargo container 104. In the example of FIGS. 1A and 1B, temperature sensor 108 is located toward a bottom of aperture 116 and cargo container 104. Door sensor 110 is arranged and configured to sense the closed state and the open state of the door. In the example of FIGS. 1A and 1B, door sensor 110 is arranged on one of rails 114 toward the top of aperture 116 and cargo container 104. Controller 112 is communicatively connected to heat exchanger 118, temperature sensor 108, and door sensor 110.

Door sensor 110 can include a variety of types of sensors configured to sense the opened/closed state of door 104. For example, door sensor 110 can include a mechanical, electrical, or electro-mechanical switch configured to be actuated as the door moves along rails 114 between opened and closed states. Door sensor 110 could also include photoelectric, contact, or pressure sensors, among other types.

Controllers in accordance with examples of this disclosure, including controller 112 can be included in or separate from conditioning system 106. Examples according to this disclosure may include multiple controllers working in conjunction with each other to execute functions attributed to the controller(s).

Controller(s) included in examples according to this disclosure can be configured to communicate with one another and with other components of the system via various wired or wireless communications technologies and components using various public and/or proprietary standards and/or protocols. Examples of transport mediums and protocols for electronic communication between components of the work machine include Ethernet, Transmission Control Protocol/Internet Protocol (TCP/IP), IEEE 802.11 or Bluetooth, or other standard or proprietary transport mediums and communication protocols.

Controller 112 and other controllers in examples according to this disclosure can include software, hardware, and combinations of hardware and software configured to execute a number of functions attributed to the components in the disclosed examples. Such controllers in examples according to this disclosure can be an analog, digital, or combination analog and digital controller including a number of components. As examples, the controller(s) can include integrated circuit boards or ICB(s), printed circuit boards PCB(s), processor(s), data storage devices, switches, relays, etcetera. Examples of processors can include any one or more of a microprocessor, a controller, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field-programmable gate array (FPGA), or equivalent discrete or integrated logic circuitry.

Controller(s) in examples according to this disclosure, including controller 112 can include storage media to store and/or retrieve data or other information, for example, signals from sensors. Examples of non-volatile storage devices include magnetic hard discs, optical discs, floppy discs, flash memories, or forms of electrically programmable memories (EPROM) or electrically erasable and programmable (EEPROM) memories. Examples of volatile storage devices include random access memories (RAM), dynamic random access memories (DRAM), static random access memories (SRAM), and other forms of volatile storage devices. The data storage devices can be used to store program instructions for execution by processor(s) of, for example, the controller(s).

As described in more detail below, controller 112 is configured to actuate heat exchanger 118 to direct conditioned air into cargo container 104 based on at least one of the temperature of air in the cargo container sensed by temperature sensor 108 and the state of door 102 sensed by door sensor 110.

Example systems and methods in accordance with this disclosure, including system 100 can also include an outdoor air (OA) temperature sensor. The OA temperature sensor can be located anywhere that allows the sensor to measure temperature of the air outside the facility including aperture 116. The OA temperature sensor can be used by controller 112 to determine if any conditioning of the air in cargo container 104 is needed upon arrival of the cargo container at aperture 116.

FIG. 2 is a perspective view of example conditioning system 206 for use in systems in accordance with this disclosure, including system 100 of FIGS. 1A and 1B. Conditioning system 206 includes heat exchanger 218 and mount 220. Heat exchanger 218 includes housing 222, air inlet 224, air outlet 226, and heating element 228. Although not viewable in FIG. 2, heat exchanger 218 can include a fan arranged in housing 222. Mount 220 includes a pair of elongated bars 230 and brackets 232.

In examples, heating element 228 of heat exchanger 218 can include an electrically or gas-powered multi-stage heating element. The fan in housing 222 is configured to direct intake air into air inlet 224 and through multi-stage heating element 228, and direct conditioned air out of air outlet 226 into a cargo container, e.g. cargo container 104 in the example of FIGS. 1A and 1B.

Elongated bars 230 of mount 220 are each connected to housing 220 of heat exchanger 218. Each of elongated bars 230 are also connected to a pair of brackets 232. Brackets 232 are configured to be connected to a fixed structure to position heat exchanger 218 adjacent an aperture in an opened state and in a closed state of a door without interfering with movement of the door between states.

FIG. 3 is a flow chart of example method 300 in accordance with this disclosure. Method 300 includes positioning a heat exchanger adjacent an aperture (302), sensing the state of a door (304), and selectively actuating the heat exchanger (306). The aperture is covered by a door in a closed state and uncovered by the door in an opened state. The heat exchanger is positioned adjacent the aperture in the closed state and in the opened state of the door without interfering with movement of the door between states. The heat exchanger is selectively actuated to direct conditioned air into a cargo container received by the aperture based on the sensed state of the door. Example method 300 can also include sensing a temperature of air in the cargo container and selectively actuating the heat exchanger based on the sensed temperature of air in the cargo container. For example, method 300 can include selecting a speed of a fan and a heating stage of the multi-stage heating element of the heat exchanger based on the sensed temperature of air in the cargo container and actuating the fan at the selected speed and the multi-stage heating element at the selected heating stage.

In an example, power to heat exchanger 118/218 of conditioning system 106/206 is supplied and controller 112 places the heat exchanger in a standby mode. A vehicle towing cargo container 104 positions the cargo container at/in/over/adjacent to aperture 116. Upon arrival of cargo container 104, door 102 is in the closed state covering aperture 116. In response to input from an operator or controller 112, door 102 slides or rolls along rails 114 from the closed to the opened state, in which aperture 116 is uncovered. Door sensor 110 sends signal(s) to controller 112 indicating that door 102 is in the opened state and controller 112 actuates the fan in heat exchanger 118/218.

As noted above, example systems and methods in accordance with this disclosure can also include an OA temperature sensor, which can be employed by controller 112 in a start-up sequence of system 100. For example, after arrival of cargo container 104 and controller receiving signal(s) from door sensor 110 indicating door 102 is in the opened state, controller 112 can receive signal(s) from the OA temperature sensor indicative of a measured/sensed temperature of the outdoor air. In an example, controller 112 actuates heat exchanger 118/218 if the temperature of the outdoor air is below a threshold low temperature, in the case of heat exchanger heating. For example, controller 112 actuates the fan of heat exchanger 118/218 at a select speed and actuates heating element, e.g. 228 at a select heating stage based on the temperature of the outdoor air. In other examples according to this disclosure, a controller can actuate a heat exchanger if the temperature of the outdoor air is above a threshold high temperature to cause the heat exchanger to cool air in a cargo container.

In an example, heat exchanger 118/218 operates for a predetermined period of time and controller 112 receives and processes signal(s) from temperature sensor 108 indicative of the temperature of the air in cargo container 104. If the air temperature in cargo container 104 is below a set point temperature, controller 112 can increase the speed of the fan (if not at a maximum speed already) and can increment the heating stage of the heating element of heat exchanger 118/218 to the next stage (if not at a maximum speed already). If the air temperature in cargo container 104 is at or above the set point temperature, however, controller 112 can lower the speed of or turn off the fan and/or lower the heating stage of or turn off the heating element of the heat exchanger 118/218. In an example, work lights can be arranged in the area of aperture 116. In an example, upon the air temperature in cargo container 104 is at or above the set point temperature, however, controller 112 can turn on the work lights to indicate to operators that the temperature of cargo container 104 is appropriate for loading/unloading to commence.

Another example according to this disclosure may include partial or complete manual control of the conditioning system employed to rapidly condition the air in a cargo container. For example, instead of a controller initiating operation of the conditioning system automatically based on sensor or other input, a person could switch on and off the conditioning system with wall mounted or portable device, e.g., pendant, fob, or other portable device. For example, via the wall mounted or portable input device communicatively connected to the conditioning system, a user could turn on the fan, turn on the heater, and/or turn off the conditioning system.

The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments can be used, such as by one of ordinary skill in the art upon reviewing the above description.

The above detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the invention can be practiced. These embodiments are also referred to herein as “examples.” Such examples can include elements in addition to those shown or described. However, the present inventors also contemplate examples in which only those elements shown or described are provided. Moreover, the present inventors also contemplate examples using any combination or permutation of those elements shown or described (or one or more aspects thereof), either with respect to a particular example (or one or more aspects thereof), or with respect to other examples (or one or more aspects thereof) shown or described herein.

In the event of inconsistent usages between this document and any documents so incorporated by reference, the usage in this document controls. In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one, independent of any other instances or usages of “at least one” or “one or more.” In this document, the term “or” is used to refer to a nonexclusive or, such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated. In this document, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, composition, formulation, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.

The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments can be used, such as by one of ordinary skill in the art upon reviewing the above description. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments can be combined with each other in various combinations or permutations. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

Various aspects of the disclosure have been described. These and other aspects are within the scope of the following claims.