EP2895808B1 - Methods for preventing condensation in refrigerated display cases - Google Patents

Methods for preventing condensation in refrigerated display cases Download PDF

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Publication number
EP2895808B1
EP2895808B1 EP13773452.1A EP13773452A EP2895808B1 EP 2895808 B1 EP2895808 B1 EP 2895808B1 EP 13773452 A EP13773452 A EP 13773452A EP 2895808 B1 EP2895808 B1 EP 2895808B1
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EP
European Patent Office
Prior art keywords
heater circuit
secondary heater
temperature
level
sensor
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Not-in-force
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EP13773452.1A
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German (de)
English (en)
French (fr)
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EP2895808A1 (en
Inventor
Chandrashekhara S. CHIKKAKALBALU
Ajay IYENGAR
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Heatcraft Refrigeration Products LLC
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Heatcraft Refrigeration Products LLC
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Publication of EP2895808A1 publication Critical patent/EP2895808A1/en
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    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47F—SPECIAL FURNITURE, FITTINGS, OR ACCESSORIES FOR SHOPS, STOREHOUSES, BARS, RESTAURANTS OR THE LIKE; PAYING COUNTERS
    • A47F3/00—Show cases or show cabinets
    • A47F3/04—Show cases or show cabinets air-conditioned, refrigerated
    • A47F3/0404—Cases or cabinets of the closed type
    • A47F3/0408—Cases or cabinets of the closed type with forced air circulation
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25D—REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
    • F25D21/00—Defrosting; Preventing frosting; Removing condensed or defrost water
    • F25D21/06—Removing frost
    • F25D21/08—Removing frost by electric heating
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25D—REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
    • F25D21/00—Defrosting; Preventing frosting; Removing condensed or defrost water
    • F25D21/04—Preventing the formation of frost or condensate
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25D—REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
    • F25D2400/00—General features of, or devices for refrigerators, cold rooms, ice-boxes, or for cooling or freezing apparatus not covered by any other subclass
    • F25D2400/02—Refrigerators including a heater

Definitions

  • the present disclosure relates generally to the field of heater systems for refrigerated display units and more particularly to systems, methods, and apparatus for a dual circuit anti-sweat heater control system.
  • refrigerated display units Retail and other establishments that store and sell refrigerated items frequently must be concerned with condensation problems. It is a common practice in commercial refrigerators and freezers, referred to below as refrigerated display units, to utilize a glass display door/window with a large transparent window in it to provide easy access for a customer while allowing the customer to also see what is inside the refrigerated display unit. Frequently, the window makes up the majority of the door panel. Under adverse environmental conditions, condensation on the door/window frames of the unit and window panes and outer frame of the door can be a problem.
  • a door to a refrigerated display unit in a store may be opened frequently by customers.
  • the inside of the door which may be, for example, at a temperature of -15 degrees Fahrenheit to 40 degrees Fahrenheit
  • the ambient air in the store which is typically at a much higher temperature.
  • condensation may form on the cold outside surfaces of the door. If the humidity is relatively high, heavy condensation may form almost immediately, which can completely obscure the view through the door/window glass. This obviously is detrimental to the purpose of the window, which is to provide a clear view inside the cooler to better promote the products stored therein.
  • the condensation may be heavy enough to cause the door/window to drip when opened or condensation on the door frame to drip down the front of the display unit. This is a particular problem in retail stores where it can create a slip hazard.
  • WO 2010/059854 A1 discloses an anti-sweat heater system.
  • the present invention provides a method for controlling a heating system as recited in claims 1, 8 and 12.
  • Figure 1A is a perspective view of an exemplary refrigerated display unit 100 configured to include a dual-circuit anti-sweat heater control system in accordance with one exemplary embodiment.
  • Figure 1B is a partial-perspective view of one of the door/window frames of the refrigerated display unit 100 according to one exemplary embodiment.
  • the exemplary display unit 100 can include a casing 101 which includes multiple walls 105, such a back wall 111, an opposing front wall 115, two or more side walls 120, a top wall or ceiling 125, and a bottom wall or floor 130.
  • the walls 105 can define one or more cavities for storing products within the unit 100.
  • the unit 100 can also include one or more cooling units 135 for cooling the cavity area.
  • the front wall of the casing 101 can include one or more openings that allow access to the products within the casing.
  • Each door 102 can be pivotally or otherwise adjustably mounted to the casing 101 to both cover and provide access to the openings.
  • Each door 102 can include an outer frame 140 that surrounds the perimeter of a transparent material 145, such as glass or plastic.
  • the outer frame 140 of the door 102 can be made of a metallic material, such as steel, aluminum, or any other material known to those of skill in the art.
  • Each door 102 can also include a door handle 150 that can be coupled to or provided in the outer frame 140 or the transparent material 145 of the door 102.
  • the door handle 150 can provide a means for rotatably opening the door 102 to access the contents within the unit 100.
  • a casing door frame 103 is provided on the casing 101 and disposed along the front wall for each corresponding door 102.
  • the door frame 103 generally has the same perimeter shape as the door 102 and is configured to contact at least a portion of the door 102 when the door 102 is in the closed position.
  • the metal frame 140 disposed along the outer periphery of the door 102 can contact the door frame 103 when the door 102 is in the closed position.
  • the door frame 103 would have a generally rectangular shape to match the generally rectangular shape of the door 102 so that the metallic outer frame 140 of the door 102 can be mechanically, magnetically, and/or thermally coupled to the door frame 103.
  • heat can be transferred from the door frame 103 to the metallic outer frame 140 of the door by way of thermal conduction.
  • the door frame 103 can include a first channel 106 and a second channel 107 disposed along and within the door frame 103.
  • the first channel 106 is sized and shaped to receive a primary heating device for a primary heater circuit.
  • the channels 106, 107 can have a depth such that, when heating device is disposed therein, the top or outward facing portion of the heating device will be flush with the surface of the remainder of the door frame 103.
  • the primary heating device for the primary heater circuit is a small gauge heater wire.
  • first channel 106 is shown as being generally straight, in alternative embodiments, the first channel 106, and the primary heating device for the primary heater circuit disposed therein, can have a serpentine or other pattern to provide a greater amount of surface area contact for the primary heater circuit along the door frame 103.
  • the second channel 107 is sized and shaped to receive a secondary heating device for a secondary heater circuit.
  • the primary and secondary heater circuits are electrically isolated or not electrically coupled to one another.
  • the secondary heating device for the secondary heater circuit is a small gauge heater wire. While the second channel 107 is shown as being generally straight along each edge of the door/window frame (such as around each opening) (to create a generally rectangular shape for the channel 107), in alternative embodiments, the second channel 107, and the secondary heating device for the secondary heater circuit disposed therein, can have a serpentine or other pattern to provide a greater amount of surface area contact for the secondary heater circuit along the door/window frame.
  • the secondary heater circuit can be routed and positioned anywhere additional heat is needed in a refrigerated display unit to limit or prevent condensation build-up. While the example discussed above shows just one first channel 106 and second channel 107, it is understood that the unit 100 can have a first 106 and second 107 channel about each opening, about a group of openings in the unit 100 or a single first 106 and second 107 channel for the entire unit 100.
  • FIGS 2A and 2B are schematic diagrams of an exemplary dual-circuit anti-sweat heater control system 200 that can be incorporated into the refrigerated display unit 100 of Figures 1A-1B .
  • the exemplary dual-circuit anti-sweat heater control system 200 includes a primary heater circuit 105 and a secondary heater circuit 110.
  • the primary heater circuit 105 and the secondary heater circuit 110 can be disposed in or along the door frame 103 of the unit 100.
  • the primary heater circuit 105 can have at least a portion that is disposed in the first channel 106 and the secondary heater circuit 110 can have a least a portion that is disposed in the secondary channel 107.
  • the primary heater circuit 105 is electrically coupled to a source of power (not shown) by way of a line conductor 205 and a neutral conduct 210.
  • the primary heater circuit 105 has a top end and a bottom end and may be routed in a serpentine shape 130 to provide increased surface area contact along the door frame 103.
  • at least a portion of the primary heater circuit 105 is disposed in the first channel 106 and extends around the perimeter of each door frame 103 or around portions of the perimeter of each door/window frame only where needed.
  • the primary heater circuit 105 includes a small gauge wire that emits heat through conduction to the surface of the respective door frame 103 and to the outer frame of the door 102 when the door 102 abuts the door frame 103 in the closed position.
  • the secondary heater circuit 110 is electrically coupled to a source of power (not shown) by way of a line conductor 215 and a neutral conductor 220.
  • a source of power (not shown) by way of a line conductor 215 and a neutral conductor 220.
  • the source of power for the primary heater circuit 105 and the secondary heater circuit 110 is the same.
  • the primary heater circuit 105 and the secondary heater circuit 110 can have different sources of electrical power.
  • at least a portion of the secondary heater circuit 110 is disposed in the secondary channel 107 and extends around the perimeter of each door frame 103.
  • the secondary heater circuit 110 includes a small gauge wire that emits heat through conduction to the surface of the respective door/window frame 103 and to the outer frame of the door 102 when the door 102 abuts the door frame 103 in the closed position.
  • the secondary heater circuit 110 can also be electrically and/or communicably coupled to a sensor 120.
  • the sensor 120 can be disposed adjacent to or remote from the door frame 103. Further, the sensor 120 can be coupled to the unit 100 or positioned elsewhere, as long as it is electrically and/or communicably coupled to the secondary heater circuit 110 or a controller controlling the secondary heater circuit 110. Typically the sensor 120 will be placed in the same general area as the unit 100 where humidity is likely to be at the highest level. In one exemplary embodiment, the sensor 120 is coupled along the top of the unit 100 adjacent the door frame 103.
  • the exemplary sensor 120 can be a humidity sensor, a temperature sensor, or a dewpoint sensor.
  • the sensor 120 represents more than one sensor (including any one of or combination of the sensor types previously stated) that is electrically and/or communicably coupled to the secondary heater circuit 110.
  • the sensor 120 can include a relay 125 or switch that is electrically and/or communicably coupled to the secondary heater circuit 110.
  • the relay 125 when the relay 125 is open, power does not flow through the secondary heater circuit 110 and the secondary heater circuit 110 does not produce heat along the door frame 103.
  • the relay 125 when the relay 125 is closed, power flows through the secondary heater circuit 110 and the secondary heater circuit 110 produces heat along the door frame 103.
  • the exemplary embodiment of Figures 2A-B does not shown a sensor electrically coupled to the primary heater circuit 105, in an alternative embodiment (not shown), the sensor 120 or another sensor is electrically and/or communicably coupled to the primary heater circuit 105.
  • This other sensor can be a humidity sensor, a temperature sensor, a dewpoint sensor or any combination thereof, similar to that described for the sensor 120 of the secondary heater circuit 110.
  • FIG 3 is schematic diagram of an alternative exemplary anti-sweat heater control system 300 that can be incorporated into the refrigerated display unit 100 of Figure 1A .
  • the exemplary anti-sweat heater control system 300 includes a heater circuit 310 disposed along or within the door frame 315, a controller 330 electrically and/or communicably coupled to the heater circuit 310, and a sensor 320 electrically and/or communicably coupled to the heater circuit 310 and/or the controller 330.
  • the door frame 315 is the same or substantially similar to the door frame 103 of Figure 1A and the heater circuit 310 is disposed within a channel ( e .
  • the heater circuit 310 is substantially similar to the secondary heater circuit 110 of Figure 2A .
  • the heater circuit 310 can include a small gauge wire to emit heat along the surface of the door frame 315 and can include a line conductor and a neutral conductor electrically coupled to a source of power. While the exemplary embodiment of Figure 3 presents a single heater circuit 310, alternatively, two heater circuits similar to that shown and described with reference to Figures 1B and 2A-B can be used.
  • the exemplary door frame 315 further includes one or more temperature sensors 335 coupled along an outer surface of the door frame 315 and electrically and/or communicably coupled to the controller 330 and/or the heater circuit 310.
  • one or more temperature sensors 335 coupled along an outer surface of the door frame 315 and electrically and/or communicably coupled to the controller 330 and/or the heater circuit 310.
  • three temperature sensors 335 are used and are disposed along different areas of the door/window frame 335.
  • greater or fewer numbers of temperature sensors 335 such as one or more temperature sensors, can be alternatively used.
  • the exemplary system 300 also includes a controller 330 electrically and/or communicably coupled to the heater circuit 310 and the temperature sensors 335.
  • the controller can be positioned adjacent to or remote from the door frame 315 and/or the sensor 320.
  • the controller 330 provides control signals for activating and deactivating the heater circuit 310.
  • the controller 330 can include a relay 325 or switch that activates and deactivates the heater circuit 310.
  • each heater circuit can be electrically and/or communicably coupled to the controller 330 or only one can be electrically and/or communicably coupled to the controller 330.
  • the relay 325 can be, for example, a double pole relay capable of operating both heater circuits, such that one pole is normally closed and one is normally open.
  • the controller 330 also includes temperature sensor contacts 340 for electrically and/or communicably coupling the temperatures sensors 335 to the controller 330.
  • the exemplary controller 330 can also include a data storage device 345.
  • the data storage device 345 may be any suitable memory device, for example, caches, read only memory devices, and random access memory devices.
  • the data storage device 345 can also store data, tables or executable instructions for use by the controller 330.
  • the data storage device 345 can store data from the temperature sensors 335 the sensor 320 as well as record the amount of time or how often the heater circuit 310 is activated.
  • the data storage device 345 can record the dewpoint temperature from a dewpoint sensor 320, the temperature readings from one or more of the temperature sensors 335, and the length or percentage of time that the heater 310 has been activated.
  • the data storage device 345 may record on-time information individually for each heater circuit as well as the amount of power or the heater level for each heater circuit.
  • the controller 330 can also include a temperature display 350 that provides a visual indication of the temperature data received by the controller 330 from one or more of the temperature sensors 340.
  • the temperature display 350 can provide a visual indication of the dewpoint temperature or other information received by the controller 330 from the sensor 320.
  • the temperature display 350 is a light emitting diode (LED) display and liquid crystal (LCD) display, an analog display, or any other display known to those of ordinary skill in the art.
  • the temperature display 350 and/or controller also includes an alarm. The alarm can be audible or visual.
  • the alarm can emit a sound via a speaker (not shown) or a blinking light or both when the temperature reading from one or more of the temperature sensors 335 are below the dewpoint temperature or remains below the dewpoint temperature for a predetermined or configurable amount of time.
  • the predetermined amount of time can be anywhere between one second and two hundred minutes and can be pre-programmed in the controller 330 or programmable to an amount desired by a user at the controller.
  • the exemplary controller 330 can also include a remote monitoring device 355.
  • the remote monitoring device 355 is a wireless transmitter or transceiver or a Bluetooth transmitter for transmitting the data stored or received in the data storage device 345 and or controller 330 wirelessly to a remote device for viewing the data by a user or another computer device.
  • the system 300 also includes a sensor 320 electrically and/or communicably coupled to the controller 330.
  • the sensor 320 can be coupled to the unit 100 or positioned elsewhere, as long as it is electrically and/or communicably coupled to the controller 330. In certain exemplary embodiments, the sensor 320 will be placed in the same general area as the unit 100 where humidity is likely to be at the highest level. In one exemplary embodiment, the sensor 320 is coupled along the top of the unit 100 adjacent the door frame 315.
  • the exemplary sensor 320 can be a humidity sensor, a temperature sensor, or a dewpoint sensor, as shown in Figure 3 . Alternatively, the sensor 320 represents more than one sensor (including any one of or combination of the sensor types previously stated) that are electrically and/or communicably coupled to the controller 330.
  • FIG 4 is a flowchart of an example method 400 for providing anti-sweat heating control with the dual circuit anti-sweat heater control system of Figures 1-2B or 1A-B and 3 , in accordance with one exemplary embodiment.
  • the exemplary method 400 begins at the START step and proceeds to step 405 where a heater control system for a display case door/window is provided.
  • the heater control system is the unit 100 and system 200 or 300 described in Figures 1-2B or 1A-B and 3 .
  • the primary heater circuit 105 is operated at a constant power level.
  • the power level of the primary heater circuit 105 is set to the lowest level that will output an amount of heat along the small gauge wire of the circuit 105 to prevent condensation along the door/window frame and the outer frame of the door/window during normal conditions, such as those levels that are less than or less than or equal to the preset levels discussed in step 420 below.
  • the ambient dewpoint temperature is normally 58 degrees Fahrenheit
  • the power level or the amount of power provided to the primary heater circuit 105 will be adjusted to maintain the temperature along the door/window frame and the outer frame of the door/window at a level above 58 degrees Fahrenheit.
  • the primary heater circuit 105 is not typically intended to be sufficient when ambient conditions dramatically differ from the normal level.
  • the ambient humidity level is received in step 415.
  • the ambient humidity level is sensed by the sensor 120 and can be transmitted, for example, to the controller or relay 125.
  • the sensor 120 is a humidity sensor or a combination sensor that include the ability to detect humidity levels.
  • an inquiry is conducted to determine if the ambient humidity level is greater than a preset humidity level. For example, in situations where the sensor 120 or relay 125 make the determination, the sensor 120 or relay 125 is set with a preset humidity level. When the humidity level, as sensed by the sensor 120, exceeds the preset humidity level, the secondary heater circuit 110 will be activated for a preset amount or percentage of time.
  • the preset humidity level is fifty-five percent relative humidity.
  • the preset humidity level could be set anywhere between 1-100 percent relative humidity.
  • the information from the sensor 120 can be sent to a controller (such as a controller having the same features and functionality as that described with regards to controller 330) which determines if the ambient humidity level is greater than the preset humidity level. While the exemplary embodiment describes determining if the ambient humidity is greater than a preset humidity level, alternatively the system can determine if the ambient humidity is greater than or equal to the preset humidity level.
  • the NO branch is followed back to step 415 to continue receiving ambient humidity level readings from the humidity sensor 120.
  • the YES branch is followed to step 425, where relay 125 closes and power is supplied to the secondary heater circuit 110 for a predetermined amount or percentage of time.
  • the controller can send a signal to close the relay 125 based on the determination made in step 420.
  • the amount or percentage of time that the secondary heater circuit 110 is activated is dependent on the current humidity level reading from the sensor.
  • the secondary heater circuit 110 is operated for forty percent of the time going forward, such as by being on for two minutes and then off for three minutes, or any other combination thereof to satisfy the percentage of time setting.
  • the percentage of time that the secondary heater circuit 110 is on is increased.
  • the percentage of time that the secondary heater circuit 110 is on based on the ambient humidity level reading from the sensor 120 can follow the percentages shown in Table 1 below. TABLE 1 Ambient Humidity Level Percentage of Time Secondary Heater Circuit is On 0-55% 0% 56% 40% 57% 55% 58% 70% 59% 85% 60-100% 100%
  • Table 1 shown above is only one example of a preset humidity limit, the ambient humidity levels and the amount that the secondary heater circuit is operated based on the ambient humidity levels and the preset humidity limit. While the exemplary embodiment shown above provides for a linear increase in the percentage of time that the secondary heater 110 is on, the increase could be non-linear in alternative exemplary embodiments. Further, the increase in percentage levels of on time could be spread out over a greater amount of relative humidity such that further step increases in percentage on time are realized. In addition, the present humidity level for initial activation could be set at a level that is greater than or less than the fifty-five percent humidity level provided for in the exemplary embodiment.
  • the operation of the primary heater circuit 105 can be adjusted such that the primary heater circuit 105 can be turned on for the preset amount of time, instead of being on all the time, depending on the humidity level. This optional arrangement would provide additional energy savings if needed or desired.
  • the secondary heater circuit 110 once activated, the secondary heater circuit 110 remains ON constantly until the humidity sensor 120 receives an subsequent ambient humidity reading that is less than or less than or equal to the preset humidity level.
  • the voltage level supplied to the secondary heater circuit can be varied based on the ambient humidity level in a manner substantially similar to that described in Figure 10 below.
  • the ambient humidity levels shown above in Table 1 can be substituted for the dewpoint temperature levels provided in Figures 5-8 to show example variations that can be provided in the voltage level of the secondary heater circuit based on differing electrical systems.
  • step 430 subsequent ambient humidity level readings can be received by the circuit and/or the controller from the humidity sensor 120.
  • step 435 an inquiry is conducted to determine if the subsequent humidity level is greater than or greater than or equal to the preset humidity level. As with step 420 above, the determination can be made by the sensor 120, the relay 125 or the controller (not shown). If the subsequent humidity level is greater than or greater than or equal to the preset humidity level, the YES branch is followed back to step 430 to continue receiving subsequent humidity level readings from the sensor 120. Alternatively, if the subsequent ambient humidity level reading is less than or less than or equal to the preset humidity level, the NO branch is followed to step 440. In step 440, the relay 125 opens and the secondary heater circuit 110 is deactivated.
  • the controller can send a signal to open the relay 125 based on the determination made in step 435.
  • the primary heater circuit 105 can be adjusted to once again operate in its original operational state (e.g., operating constantly at a constant power level). The process then returns to step 415 to receive the next ambient humidity level reading from the humidity sensor 120.
  • the method of Figure 4 could be modified to activate and deactivate the secondary heater circuit 110 based on surface temperature readings from a temperature sensor 120 positioned along an outer surface of the door frame 103 or other surface being monitored and heated as compared to a preset temperature. For example, if the surface temperature reading is less than, or less than or equal to, the preset temperature the secondary heater circuit 110 is not activated. On the other hand, if the surface temperature reading is greater than, or greater than or equal to, the preset temperature, then the relay 125 closes and power is supplied to the secondary heater circuit 110 for a predetermined amount or percentage of time in a manner substantially similar to those described above for the humidity sensor.
  • the amount or percentage of time that the secondary heater circuit 110 is activated is dependent on the amount that the surface temperature reading received from the sensor 120 is above the present temperature limit. For example, if the preset temperature limit is 58 degrees Fahrenheit and the surface temperature reading from the sensor 120 is 59 degrees Fahrenheit, the secondary heater circuit 110 is operated for forty percent of the time, such as by being on for two minutes and then off for three minutes, or any other combination thereof to satisfy the percentage on setting. As the surface temperature increases further above the preset temperature limit, the percentage of time that the secondary heater circuit 110 is on is increased. For example the percentage of time that the secondary heater circuit 110 is on based on the surface temperature reading from the sensor 120 can follow the percentages shown in Table 2 below. TABLE 2 Degrees Fahrenheit Percentage of Time Secondary Heater Circuit is On 0-58 0% 59 40% 60 55% 61 70% 62 85% 63 and above 100%
  • Table 2 is only one example of the set-up for preset temperature limit, the actual surface temperature levels and the amount that the secondary heater circuit is operated based on the surface temperature and the preset temperature limit. While the exemplary embodiment shown above in Table 2 provides for a linear increase in the percentage of time that the secondary heater circuit 110 is on, the increase could be non-linear in alternative exemplary embodiments. Further, the increase in percentage levels of on time could be spread out over a greater amount of surface temperatures such that additional step increases in percentage on time are realized. In addition, the preset temperature for initial activation could be set at a level that is greater than or less than the 59 degrees Fahrenheit provided for in the exemplary embodiment.
  • the operation of the primary heater circuit 105 can be adjusted such that the primary heater circuit 105 can be turned on for the preset amount of time, instead of being on all of the time, depending on the sensed surface temperature. This optional arrangement would provide additional energy savings if needed or desired.
  • the secondary heater circuit 110 once activated, the secondary heater circuit 110 remains ON constantly until the surface temperature sensor 120 receives a subsequent ambient temperature reading that is less than, or less than or equal to, the preset temperature limit.
  • the voltage level supplied to the secondary heater circuit can be varied based on the surface temperature level in a manner substantially similar to that described in Figure 10 below.
  • the temperature levels shown above in Table 2 can be substituted for the dewpoint temperature levels provided in Figures 5-8 to show example variations that can be provided in the voltage level of the secondary heater circuit of Figure 4 based on differing electrical systems.
  • FIG. 5 is a flowchart of another method for providing anti-sweat heating control with the dual-circuit anti-sweat heater control system of Figures 1-2B or 1A-B and 3 , in accordance with one exemplary embodiment.
  • the exemplary method 500 begins at the START step and proceeds to step 505 where a heater control system for a display case door/window is provided.
  • the heater control system is the unit 100 and system 200 or 300 described in Figures 1-2B or 1A-B and 3 .
  • the primary heater circuit 105 is operated at a constant power level.
  • the power level of the primary heater circuit 105 is set to the lowest amount that will output a level of heat along the small gauge wire of the circuit 105 to prevent condensation along the door frame 103 and the outer frame of the door 102 during normal conditions, such as those levels that are less than or less than or equal to the preset levels discussed in step 530 below.
  • the ambient dewpoint temperature is normally 58 degrees Fahrenheit
  • the power level or the amount of power provided to the primary heater circuit 105 will be adjusted to maintain the temperature along the door frame 103 and the outer frame of the door 102 at a level above 58 degrees Fahrenheit.
  • the primary heater circuit 105 is not typically intended to be sufficient when ambient conditions dramatically differ from the normal level.
  • the ambient humidity level is received in step 515.
  • the ambient humidity level is sensed by the sensor 120 and can be transmitted, for example, to the controller or relay 125.
  • the sensor 120 is a dewpoint sensor that is capable of sensing both ambient humidity and temperature levels.
  • An ambient temperature level is received from the sensor 120 at, for example, the controller, in step 520. While the exemplary embodiment describes both the ambient temperature and humidity levels being sensed by a single sensor 120, alternatively two separate sensors may be used, one for temperature and one for humidity and the dewpoint temperature can be determined either by one of those two sensors or by a controller (not shown) electrically and/or communicably coupled to the sensor(s) 120.
  • the dewpoint temperature is calculated based on the received ambient humidity level and the received ambient temperature. In one exemplary embodiment, the dewpoint temperature is calculated by the dewpoint sensor 120. In an alternative embodiment, the dewpoint temperature is calculated by the controller.
  • step 525 an inquiry is conducted to determine if the calculated dewpoint temperature is greater than, or greater than or equal to, the preset dewpoint temperature. For example, in situations where the sensor 120 or relay 125 make the determination, the sensor 120 and/or relay 125, is set with a preset dewpoint temperature. When the dewpoint temperature, as calculated by the sensor 120, exceeds the preset dewpoint temperature, the secondary heater circuit 110 will be activated for a preset amount or percentage of time. In one exemplary embodiment, the preset dewpoint temperature is 58 degrees Fahrenheit. Alternatively, the preset dewpoint temperature could be set anywhere between 40-80 degrees Fahrenheit. In an alternative embodiment, the information from the sensor 120 can be sent to a controller which determines if the calculated dewpoint temperature is greater than, or greater than or equal to, the preset dewpoint temperature.
  • the NO branch is followed back to step 515 to continue receiving ambient humidity and temperature level readings from the dewpoint sensor 120.
  • the YES branch is followed to step 535, where relay 125 closes and power is supplied to the secondary heater circuit 110 for a predetermined amount or percentage of time.
  • the controller can send a signal to close the relay 125 based on the determination made in step 530.
  • the amount or percentage of time that the secondary heater circuit 110 is activated is dependent on the calculated dewpoint temperature from the sensor 120.
  • the secondary heater circuit 110 is operated for forty percent of the time going forward, such as by being on for two minutes and then off for three minutes, or any other combination thereof to satisfy the percentage of time setting.
  • the percentage of time that the secondary heater circuit 110 is on is increased.
  • the percentage of time that the secondary heater circuit 110 is on based on the calculated dewpoint temperature can follow the percentages shown in Table 3 below. TABLE 3 Calculated Dewpoint Temp. (°F) Percentage of Time Secondary Heater Circuit is On 0-58 0% 59 40% 60 55% 61 70% 62 85% 63 and above 100%
  • Table 3 is only one example of a preset dewpoint temperature limit, the calculated dewpoint temperature levels and the amount that the secondary heater circuit 110 is operated based on the calculated dewpoint temperature and the preset dewpoint temperature limit. While the exemplary embodiment shown above provides for a linear increase in the percentage of time that the secondary heater is on, the increase could be non-linear in alternative exemplary embodiments. Further, the increase in percentage levels of on time could be spread out over a greater amount of dewpoint temperatures such that further step increases in percentage on time are realized. In addition, the dewpoint temperature for initial activation could be set at a level that is greater than or less than 58 degrees Fahrenheit provided for in the exemplary embodiment.
  • the operation of the primary heater circuit 105 can be adjusted such that the primary heater circuit 105 can be turned on for the preset amount of time, instead of being on all of the time, depending on the dewpoint temperature. This optional arrangement would provide additional energy savings if needed or desired.
  • the secondary heater circuit 110 once activated, the secondary heater circuit 110 remains ON constantly until the calculated dewpoint temperature subsequently determined is less than, or less than or equal to, the preset dewpoint temperature.
  • the voltage level supplied to the secondary heater circuit can be varied based on the calculated dewpoint temperature in a manner substantially similar to that described in Figure 10 below.
  • the calculated dewpoint temperatures shown above in Table 3 can be substituted for the calculated dewpoint temperatures provided in Figures 5-8 to show example variations that can be provided in the voltage level of the secondary heater circuit of Figure 5 based on differing electrical systems.
  • step 540 subsequent ambient humidity level and temperature readings are received at the dewpoint sensor 120 and subsequent ambient dewpoint temperatures are calculated, for example either at the sensor 120 or the controller (not shown).
  • step 545 an inquiry is conducted to determine if the subsequent dewpoint temperature is greater than, or greater than or equal to, the preset dewpoint temperature. As with step 530 above, the determination can be made by the sensor 120, the relay 125 or a controller (not shown). If the subsequent dewpoint temperature is greater than, or greater than or equal to, the preset dewpoint temperature, the YES branch is followed back to step 540 to continue receiving subsequent humidity level and temperature readings from the sensor 120 and calculating subsequent dewpoint temperatures.
  • step 550 the relay 125 opens and the secondary heater circuit 110 is deactivated.
  • the controller can send a signal to open the relay 125 based on the determination made in step 545.
  • the primary heater circuit 105 can be adjusted to once again operate in its original operational state (e.g., operating constantly at a constant power level). The process then returns to step 515 to receive the next ambient humidity level reading from the sensor 120.
  • FIG. 6 is a flowchart of another method for providing anti-sweat heating control with the dual-circuit anti-sweat heater control system of Figures 1-2B or 1A-B and 3 , in accordance with one exemplary embodiment.
  • the exemplary method 600 begins at the START step and proceeds to step 605 where a heater control system for a display case door/window is provided.
  • the heater control system is the unit 100 and system 200 or 300 described in Figures 1-2B or 1A-B and 3 .
  • the primary heater circuit 105 is operated at a constant power level.
  • the power level of the primary heater circuit 105 is set to the lowest amount that will output a level of heat along the small gauge wire of the circuit 105 to prevent condensation along the door frame 103 and the outer frame of the door 102 during normal conditions, such as those levels that are less than or less than or equal to the present levels discussed in step 620 below.
  • the ambient dewpoint temperature is normally 58 degrees Fahrenheit
  • the power level or the amount of power provided to the primary heater circuit 105 will be adjusted to maintain the temperature along the door frame 103 and the outer frame of the door 102 at a level above 58 degrees Fahrenheit.
  • the primary heater circuit 105 is not typically intended to be sufficient when ambient conditions dramatically differ from the normal level or variations in conditions from time-to-time.
  • the ambient humidity level is received in step 615.
  • the ambient humidity level is sensed by the sensor 120 and can be transmitted to, for example, a controller or relay 125.
  • the sensor 120 is a humidity sensor.
  • an inquiry is conducted to determine if the ambient humidity level is greater than, or greater than or equal to, a preset humidity level.
  • a preset humidity level For example, in situations where the sensor 120 or relay 125 make the determination, the sensor 120 or relay 125 can be set with a preset humidity level.
  • the humidity level as sensed by the sensor 120, exceeds or equals (depending upon how it is set up) the preset humidity level, the secondary heater circuit 110 will be activated for a preset amount or percentage of time similar to that described in Figure 4 .
  • the information from the sensor 120 can be sent to a controller (not shown) which determines if the ambient humidity level is greater than, or great than or equal to, the preset humidity level.
  • step 625 an inquiry is conduct to determine if the ambient humidity level is less than, or less than or equal to a second preset humidity level.
  • a second preset humidity level There may be situations where the ambient humidity level, temperature, or calculated dewpoint temperature are so low that it is not even necessary to operate the primary heater circuit 105 because the risk of condensation is small or non-existent.
  • the second preset humidity level is 0-30% relative humidity.
  • the second preset humidity level could be anywhere between 0-40% relative humidity.
  • the determination can be made by the sensor 120, the relay 125, or a controller (not shown).
  • step 610 If the ambient humidity level is not less than, or less than or equal to, the second present humidity level, the NO branch is followed back to step 610 to continue operation of the primary heater circuit 105 at the constant power level. On the other hand, if the ambient humidity level is less than, or less than or equal to, the second preset humidity level, the YES branch is followed to step 630, where the primary heater circuit 105 is deactivated. While not shown in Figures 2A-B , a relay could also be electrically coupled between the sensor 120 and the primary heater circuit 105 or between a different sensor and the primary heater circuit 105 to activate and deactivate the primary heater circuit 105. The process then returns to step 615 to continue to receive ambient humidity level readings.
  • step 620 if the ambient humidity level is greater than, or greater than or equal to, the present humidity level, the YES branch is followed to step 635, where relay 125 closes and power is supplied to the secondary heater circuit 110 for a predetermined amount or percentage of time similar to the manner and options described in Figure 4 above.
  • the operation of the primary heater circuit 105 can be adjusted such that the primary heater circuit 105 can be turned on for the preset amount of time, instead of being on all of the time, depending on the humidity level. This optional arrangement would provide additional energy savings if needed or desired.
  • the voltage level supplied to the secondary heater circuit can be varied based on the ambient humidity level in a manner substantially similar to that described in Figure 10 below.
  • the ambient humidity levels shown above in Table 2 described above with reference to Figure 4 can be substituted for the dewpoint temperature levels provided in Figures 5-8 to show example variations that can be provided in the voltage level of the secondary heater circuit of Figure 6 based on differing electrical systems.
  • the controller can send a signal to close the relay 125 based on the determination made in step 620.
  • step 640 subsequent ambient humidity level readings are received by the humidity sensor 120.
  • step 645 an inquiry is conducted to determine if the subsequent humidity level is greater than, or greater than or equal to, the preset humidity level. As with step 620 above, the determination can be made by the sensor 120, the relay 125, or a controller (not shown). If the subsequent humidity level is greater than, or greater than or equal to, the preset humidity level, the YES branch is followed back to step 640 to continue receiving subsequent humidity level readings at the sensor 120.
  • step 650 the relay 125 opens and the secondary heater circuit 110 is deactivated.
  • the controller can send a signal to open the relay 125 based on the determination made in step 645.
  • the primary heater circuit 105 can be adjusted to once again operate in its original operational state (e.g., operating constantly at a constant power level). The process then returns to step 615 to receive the next ambient humidity level reading at the humidity sensor 120.
  • the method of Figure 6 could be modified to activate and deactivate the primary 105 and secondary 110 heater circuits based on ambient temperature readings from a temperature sensor 120 as compared to a preset temperature similar to that described in Figure 4 or based on calculated dewpoint temperature as compared to a preset dewpoint temperature similar to that described in Figure 5 .
  • the second preset temperature could be between 0-40 degrees Fahrenheit, while the second preset dewpoint temperature could be between 32-50 degrees Fahrenheit.
  • FIG. 7 is a flowchart of another method for providing anti-sweat heating control with the dual-circuit anti-sweat heater control system of Figures 1-2B or 1A-B and 3 , in accordance with one exemplary embodiment.
  • the exemplary method 700 begins at the START step and proceeds to step 705 where a heater control system for a display case door/window is provided.
  • the heater control system is the unit 100 described in Figures 1A-B employing the circuit system 300 of Figure 3 or the system 200 of Figures 2A-B .
  • the primary heater circuit 105 is operated at a constant power level.
  • Step 710 is optional and is employed if there are two heating circuits in the system.
  • the power level of the primary heater circuit 105 is set to the lowest amount that will output a level of heat along the small gauge wire of the circuit 105 to prevent condensation along the door frame 103 and the outer frame of the door 102 during normal conditions. For example, if the ambient dewpoint temperature is normally 58 degrees Fahrenheit, the power level or the amount of power provided to the primary heater circuit 105 will be adjusted to maintain the temperature along the door frame 103 and the outer frame of the door 102 at a level above 58 degrees Fahrenheit.
  • the primary heater circuit 105 is not typically intended to be sufficient when ambient conditions dramatically differ from the normal level or variations in conditions from time-to-time.
  • each temperature sensor 335 transmits the sensed temperature readings to the controller 330 via one or more temperature sensor contacts 340.
  • three separate temperature sensors are positioned along an outer surface of the door frame 103. Alternatively greater or fewer numbers of temperature sensors may be used in step 715.
  • the controller 330 evaluates the readings from the multiple temperature sensors 335 and determines the lowest received surface temperature reading received in that iteration from the temperature sensors 335.
  • the ambient humidity level is received at the controller 330 in step 725 from the sensor 320.
  • the sensor 320 is a dewpoint sensor.
  • An ambient temperature level is received by the controller 330 from the sensor 320 in step 730. While the exemplary embodiment describes both the ambient temperature and humidity levels being sensed by a single sensor 320, alternatively two separate sensors may be used, one for temperature and one for humidity and the dewpoint temperature can be determined either by one of those two sensors or by the controller 330.
  • the dewpoint temperature is calculated based on the received ambient humidity level and the received ambient temperature. In one exemplary embodiment, the dewpoint temperature is calculated by the dewpoint sensor 320 and transmitted to the controller 330. Alternatively, the dewpoint temperature is calculated by the controller 330. In step 740, the controller 330 compares the lowest surface temperature reading to the calculated dewpoint temperature.
  • step 745 an inquiry is conducted to determine if the lowest surface temperature reading is less than, or less than or equal to, the calculated dewpoint temperature. For example, when the lowest surface temperature reading is less than, or less than or equal to the calculated dewpoint temperature, the heater circuit 310 will be activated for a preset amount or percentage of time similar to that described in Figure 5 .
  • step 715 If the lowest surface temperature reading is greater than, or greater than or equal to, the calculated dewpoint temperature, the NO branch is followed back to step 715 to continue receiving surface temperature readings from the one or multiple sensors 335. On the other hand, if the lowest surface temperature reading is less than, or less than or equal to, the calculated dewpoint temperature, the YES branch is followed to step 750, where relay 325 closes and power is supplied to the heater circuit 310 for a predetermined amount or percentage of time. In one exemplary embodiment, the controller can send a signal to close the relay 125 based on the determination made in step 745.
  • the amount or percentage of time that the heater circuit 310 is activated is dependent on the amount of difference between the lowest surface temperature reading from the sensors 335 and the calculated dewpoint temperature.
  • the percentage of time that the heater circuit 310 is on can be similar to that shown in Table 4 below. TABLE 4 Difference Between Temperature Sensor and Calculated Dewpoint Temperature (in °F) Percentage of Time Secondary Heater Circuit is On 0 0% 1 40% 2 55% 3 70% 4 85% 5 and above 100%
  • Table 4 is only one example. While the exemplary embodiment shown above provides for a linear increase in the percentage of time that the heater circuit 310 is on, the increase could be non-linear in alternative exemplary embodiments. Further, the increase in percentage levels of on time could be spread out over a greater amount of differences between the surface temperature sensor(s) 335 and the calculated dewpoint temperature such that further step increases in percentage on time are realized. In addition, the initial difference for initial activation of the heater circuit 310 could be set at a level that is greater than or less than 1 degree Fahrenheit of difference provided for in the exemplary embodiment.
  • the operation of the primary heater circuit 105 can be adjusted such that the primary heater circuit 105 can be turned on for the preset amount of time, instead of being on all of the time, depending on the dewpoint temperature. This optional arrangement would provide additional energy savings if needed or desired.
  • the heater circuit 310 once activated, the heater circuit 310 remains ON constantly until the difference is subsequently determined is less than, or less than or equal to, one.
  • the voltage level supplied to the heater circuit 310 can be varied based on the temperature difference in a manner substantially similar to that described in Figure 10 below.
  • the temperature differences shown above in Table 4 can be substituted for the calculated dewpoint temperatures provided in Figures 5-8 to show example variations that can be provided in the voltage level of the heater circuit 310 of Figure 7 based on differing electrical systems.
  • Subsequent surface temperature readings are received from the sensors 335 and transmitted to the controller 330 in step 755.
  • the controller 330 determines the lowest surface temperature of the subsequently received surface temperature readings.
  • the controller 330 calculates a subsequent dewpoint temperature based on subsequent humidity and temperature readings received from the sensor 320 and transmitted to the controller 330.
  • the controller 330 compares the subsequent lowest surface temperature reading to the subsequent dewpoint temperature in step 770.
  • step 775 an inquiry is conducted to determine if the lowest subsequent surface temperature reading is less than, or less than or equal to, the subsequent dewpoint temperature. If so, the YES branch is followed back up to step 755 to continue receiving subsequent surface temperature readings from the temperature sensors 335.
  • step 780 where the controller 330 transmits a signal to open the relay 325 and deactivate the heater circuit 310.
  • the primary heater circuit 105 can be adjusted to once again operate in its original operational state (e.g., operating constantly at a constant power level). The process then continues to step 715 to continue receiving surface temperature readings from the one or more temperature sensors 335.
  • the surface temperatures, the calculated dewpoints and the time (either by percentage, total amount) that the circuit 310 is activated can be recorded and stored in the data storage device 345.
  • information that is currently being received by the controller 300 and/or data stored in the data storage device 345 can be wirelessly or wire transmitted to another device, such as another computer by way of the remote monitoring device 355.
  • the exemplary embodiments described herein provide the technical effects of creating a system, method, and apparatus that provides real-time, single or dual-circuit anti-sweat control for refrigerated display cases.
  • Various block and/or flow diagrams of systems, methods, apparatus, and/or computer program products according to exemplary embodiments are described above. It will be understood that one or more elements of the schematic diagrams or steps in the flowcharts can be implemented by computer-executable program instructions. Likewise, some elements of the schematic diagrams and steps of the flowchart diagrams may not necessarily need to be performed in the order presented, or may not necessarily need to be performed at all, according to certain alternative embodiments.
  • These computer-executable program instructions may be loaded onto a special purpose computer or other particular machine, a processor, or other programmable data processing apparatus, such as the controller, to produce a particular machine, such that the instructions that execute on the computer, processor, or other programmable data processing apparatus create means for implementing one or more functions specified in the flowcharts.
  • These computer program instructions may also be stored in a computer-readable memory, such as the data storage device 345 on or communicably coupled to the controller, that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means that implement one or more functions specified in the flow diagram block or blocks.
  • embodiments of the invention may provide for a computer program product, comprising a computer usable medium having a computer readable program code or program instructions embodied therein, said computer readable program code adapted to be executed to implement one or more functions specified in the flowcharts of Figures 4-7 .
  • the computer program instructions may also be loaded onto a computer or other programmable data processing apparatus, such as the controller, to cause a series of operational elements or steps to be performed on the computer or other programmable apparatus to produce a computer-implemented process such that the instructions that execute on the computer or other programmable apparatus provide elements or steps for implementing the functions specified in the steps of Figures 4-7 .
  • Figures 8 and 9 are perspective view of two additional example refrigerated display units configured to include the dual-circuit or single circuit anti-sweat heater control system 200, 300 and/or a smart controller system 200, 300 and capable of controlling condensation using the exemplary methods described in Figures 4-7 in accordance with one exemplary embodiment.
  • the exemplary refrigerated display unit 800 can include a casing 815 which includes multiple side walls 820 and a bottom wall or floor (not shown).
  • the exemplary display unit 800 can have an opening 825 along the top defined by the side walls 820 for providing access into the casing or cavity 830 of the unit 800. Further, the side walls 820 and the bottom wall can define one or more cavities 830 for storing products within the unit 800 for access through the top opening 825.
  • the unit 800 can also include one or more cooling units (not shown) for cooling the cavity area 830.
  • the side walls 820 can include one or more transparent panels 835.
  • One or more of the transparent panels 835 can also include or be attached to a metallic frame 805, 810.
  • the metallic frame 805, 810 can be made of a metallic material, such as steel or aluminum.
  • the metallic frame 805, 810 itself, or an area about the transparent material, such as glass or transparent plastic can include a primary heater circuit and/or a secondary heater circuit as shown and described in Figures 2A-B and 3 to transfer heat or to heat up the metallic frame 805, 810 or transparent side walls 835 to limit or prevent condensation by way of thermal conduction.
  • Figure 9 presents another refrigerated display unit 900 or a portion of the display unit that can be used in conjunction with the unit 800 of Figure 8 in accordance with one exemplary embodiment.
  • the exemplary unit 900 can include a casing which includes multiple side walls 915 and a bottom wall or floor 910.
  • the exemplary display unit 900 can have an opening 920 along the top defined by the side walls for providing access into the casing or cavity of the unit 900. Further, the side walls and the bottom wall can define one or more cavities for storing products within the unit 900 for access through the top opening 920.
  • the unit 900 can also include one or more cooling units 925 for cooling the cavity area and a metallic area 905 disposed near the cooling unit and providing or acting as part of one of the side walls or the top of one of the side walls.
  • This large metallic area 905 can be a source of condensation if not properly controlled.
  • the metallic area 905 can include a primary heater circuit and/or a secondary heater circuit as shown and described in Figures 2A-B and 3 to transfer heat or to heat up the metallic area 905 to limit or prevent condensation by way of thermal conduction.
  • FIG 10 is a flowchart of another method for providing anti-sweat heating control with the dual-circuit anti-sweat heater control system of Figures 1-2B or 1A-B and 3 , or through the use of a single-circuit anti-sweat heater control system in accordance with one exemplary embodiment.
  • the exemplary method 1000 begins at the START step and proceeds to step 1005 where a heater control system for a display case door/window is provided.
  • the heater control system is the unit 100 and system 200 or 300 described in Figures 1-2B or 1A-B and 3 .
  • the primary heater circuit 105 if a dual heater circuit system is being employed, is operated at a constant power level.
  • the power level of the primary heater circuit 105 is set to the lowest amount that will output a level of heat along the small gauge wire of the circuit 105 to prevent condensation along the door frame 103 and the outer frame of the door 102 during normal conditions, such as those levels that are less than or less than or equal to the preset levels discussed in step 1030 below.
  • the ambient dewpoint temperature is normally 58 degrees Fahrenheit
  • the power level or the amount of power provided to the primary heater circuit 105 will be adjusted to maintain the temperature along the door frame 103 and the outer frame of the door 102 at a level above 58 degrees Fahrenheit.
  • the primary heater circuit 105 is not typically intended to be sufficient when ambient conditions dramatically differ from the normal level.
  • the ambient humidity level is received in step 1015.
  • the ambient humidity level is sensed by the sensor 120 and can be transmitted, for example, to the controller or relay 125.
  • the sensor 120 is a dewpoint sensor that is capable of sensing both ambient humidity and temperature levels.
  • An ambient temperature level is received from the sensor 120 at, for example, the controller, in step 1020. While the exemplary embodiment describes both the ambient temperature and humidity levels being sensed by a single sensor 120, alternatively two separate sensors may be used, one for temperature and one for humidity and the dewpoint temperature can be determined either by one of those two sensors or by a controller (not shown) electrically and/or communicably coupled to the sensor(s) 120.
  • the dewpoint temperature is calculated based on the received ambient humidity level and the received ambient temperature. In one exemplary embodiment, the dewpoint temperature is calculated by the dewpoint sensor 120. In an alternative embodiment, the dewpoint temperature is calculated by the controller.
  • step 1030 an inquiry is conducted to determine if the calculated dewpoint temperature is greater than, or greater than or equal to, the preset dewpoint temperature.
  • the sensor 120 and/or relay 125 is set with a preset dewpoint temperature.
  • the secondary heater circuit 110 will be activated at one of a set of preset stepped voltage levels, which can be at a series of steps below the full voltage level for the circuit.
  • the preset dewpoint temperature is 58 degrees Fahrenheit.
  • the preset dewpoint temperature could be set anywhere between 40-80 degrees Fahrenheit.
  • the information from the sensor 120 can be sent to a controller which determines if the calculated dewpoint temperature is greater than, or greater than or equal to, the preset dewpoint temperature.
  • step 1015 receives ambient humidity and temperature level readings from the dewpoint, or other, sensor 120.
  • step 1040 determines whether the voltage level setting for the secondary heater is above the preset dewpoint temperature. For example, the system, (i.e.
  • the relay or controller can be set up with a series or preset stepped voltage levels that would be applied/supplied to the secondary heater circuit 110 (or the primary heater circuit in a single heater circuit arrangement) based on the calculated dewpoint temperature.
  • the determination as to the amount of voltage supplied to or driving the secondary heater circuit 110 is dependent on the calculated dewpoint temperature from the sensor 120. For example, if the preset dewpoint temperature is 58 degrees Fahrenheit and the calculated dewpoint temperature is 59 degrees Fahrenheit, the controller can determine that the secondary heater circuit 110 is to be supplied with 50 Volts of electricity.
  • the controller may determine, based on preset values or percentages, to increase the voltage level to be supplied to the secondary heater circuit 110. For example the controller's determination as to the voltage level to be supplied to the secondary heater circuit 110 based on the calculated dewpoint temperature can follow the voltage levels shown in Table 5 below. TABLE 5 Calculated Dewpoint Temp. (°F) Percentage of Time Secondary Heater Circuit is On 0-58 0 Volts 59 50 Volts 60 70 Volts 61 95 Volts 62 105 Volts 63 and above 120 Volts
  • Table 5 is only one example of a preset dewpoint temperature limit, the calculated dewpoint temperature levels and the voltage levels provided to the secondary heater circuit 110 based on the calculated dewpoint temperature and the preset dewpoint temperature limit. While the exemplary embodiment shown above provides for a generally linear increase in the amount of voltage provided to drive the secondary heater circuit, the increase could be non-linear in alternative exemplary embodiments. Further, the increase in voltage levels could be spread out over a greater amount of dewpoint temperatures such that further step increases in voltage levels are realized. In addition, the dewpoint temperature for initial activation could be set at a level that is greater than or less than 58 degrees Fahrenheit provided for in the exemplary embodiment.
  • the exemplary table presented above is based on an electrical system where 120 volts is the full voltage level
  • the exemplary system and method can be modified to work with other types of electrical systems as well, where full voltage level is other than 120 volts.
  • the operation of the primary heater circuit 105 can be adjusted such that the voltage level of the primary heater circuit 105 can be adjusted, instead of being on at full voltage level all of the time, depending on the dewpoint temperature.
  • This optional arrangement would provide additional energy savings if needed or desired.
  • the secondary heater circuit 110 (or the primary heater circuit in a single heater circuit embodiment) is supplied with the amount of voltage corresponding with the preset voltage level setting based on the calculated dewpoint temperature or the amount that the calculated dewpoint temperature is above the preset dewpoint temperature.
  • relay 125 closes and power is supplied to the secondary heater circuit 110 at one of a set of preset stepped voltage levels, like those shown in Table 5.
  • the controller can send a signal to close the relay 125 and provide the secondary heater circuit with the amount of voltage corresponding to the preset voltage level setting based on the determination made in step 1040.
  • the secondary heater circuit 110 once activated, the secondary heater circuit 110 remains ON constantly at the particular preset voltage level until the calculated dewpoint temperature subsequently determined is less than, or less than or equal to, the preset dewpoint temperature or the calculated dewpoint temperature changes to one that is greater than or greater than or equal to the preset dewpoint temperature but is different than that of the current calculated dewpoint temperature.
  • step 1050 subsequent ambient humidity level readings are received at the sensor 120. Subsequent ambient temperature level readings are received at the sensor 120 in step 1055.
  • step 1060 a subsequent dewpoint temperature is calculated, for example either at the sensor 120 or the controller (not shown), based on the subsequent ambient humidity and temperature level readings received in steps 1050 and 1055, in a manner substantially the same as that discussed with regard to step 1025.
  • step 1065 an inquiry is conducted to determine if the subsequent calculated dewpoint temperature is greater than, or greater than or equal to, the preset dewpoint temperature. As with step 1030 above, the determination can be made by the sensor 120, the relay 125 or a controller (not shown).
  • step 1040 determines the amount of voltage to provide to the secondary heater circuit and to continue receiving subsequent humidity level and temperature readings from the sensor 120 and calculating subsequent dewpoint temperatures.
  • step 1070 the relay 125 opens and the secondary heater circuit 110 is deactivated.
  • the controller can send a signal to open the relay 125 based on the determination made in step 1065.
  • the primary heater circuit 105 can be adjusted to once again operate in its original operational state (e.g., operating constantly at a constant full voltage level or could alternatively remain at the reduced voltage level). The process then returns to step 1015 to receive the next ambient humidity level reading from the sensor 120.
  • blocks of the block diagrams and steps of the flow diagrams, and combinations of blocks in the block diagrams and steps of the flow diagrams, respectively, may be implemented by execution of computer-executable program instructions.
  • some blocks of the block diagrams and steps of the flow diagrams may not necessarily need to be performed in the order presented, or may not necessarily need to be performed at all, according to some embodiments.
  • additional components and/or operations beyond those depicted in blocks of the block and/or steps of the flow diagrams may be present in certain embodiments.
  • blocks of the block diagrams and steps of the flow diagrams support combinations of means for performing the specified functions, combinations of elements or steps for performing the specified functions and program instruction means for performing the specified functions. It will also be understood that each block of the block diagrams and step of the flow diagrams, and combinations of blocks in the block diagrams and steps of the flow diagrams, may be implemented by controllers or special-purpose, hardware-based computer systems that perform the specified functions, elements or steps, or combinations of special-purpose hardware and computer instructions.
  • Computer-executable program instructions may be loaded onto a controller or other special-purpose computer or other particular machine, a processor, or other programmable data processing apparatus to produce a particular machine, such that execution of the instructions on the computer, processor, or other programmable data processing apparatus causes one or more functions or steps specified in the flow diagrams to be performed.
  • These computer program instructions may also be stored in a computer-readable storage medium (CRSM) that upon execution may direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable storage medium implement one or more functions or steps specified in the flow diagrams.
  • the computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational elements or steps to be performed on the computer or other programmable apparatus to produce a computer-implemented process.
  • CRSM computer-readable communication media
  • CRCM computer-readable instructions, program modules, or other data transmitted within a data signal, such as a carrier wave, or other transmission.
  • CRSM does not include CRCM.

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AU2013315540A1 (en) 2015-04-02
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US20140069125A1 (en) 2014-03-13
EP2895808A1 (en) 2015-07-22
WO2014043308A1 (en) 2014-03-20

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