US20140069125A1 - Systems, methods, and apparatus for preventing condensation in refrigerated display cases - Google Patents
Systems, methods, and apparatus for preventing condensation in refrigerated display cases Download PDFInfo
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- US20140069125A1 US20140069125A1 US14/024,967 US201314024967A US2014069125A1 US 20140069125 A1 US20140069125 A1 US 20140069125A1 US 201314024967 A US201314024967 A US 201314024967A US 2014069125 A1 US2014069125 A1 US 2014069125A1
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- Prior art keywords
- heater circuit
- temperature
- level
- secondary heater
- sensor
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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
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- 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
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- 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
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- 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.
- FIG. 1A is a perspective view of a refrigerated display unit configured to include the dual-circuit anti-sweat heater control system, and a smart controller in accordance with one exemplary embodiment;
- FIG. 1B is a partial-perspective view of the door frame for one of the doors of the refrigerated display unit in accordance with one exemplary embodiment
- FIGS. 2A and 2B are schematic diagrams of the dual-circuit anti-sweat heater control system for use in the refrigerated display unit of FIG. 1A in accordance with one exemplary embodiment
- FIG. 3 is a schematic diagram of an alternative anti-sweat heater control system having a single or dual-circuit heating control system for use in the refrigerated display unit of FIG. 1A in accordance with an alternate exemplary embodiment;
- FIG. 4 is a flowchart of a method for providing anti-sweat heating control with the dual-circuit anti-sweat heater control system of FIGS. 2A-B in accordance with one exemplary embodiment
- FIG. 5 is a flowchart of another method for providing anti-sweat heating control with the dual-circuit anti-sweat heater control system of FIGS. 2A-B in accordance with another exemplary embodiment
- FIG. 6 is a flowchart of another method for providing anti-sweat heating control with the dual-circuit anti-sweat heater control system of FIGS. 2A-B in accordance with yet another exemplary embodiment
- FIG. 7 is a flowchart of a method for providing anti-sweat heating control with the anti-sweat heater control system of FIG. 3 in accordance with one exemplary embodiment
- FIG. 8 is a perspective view of another example refrigerated display unit configured to include the exemplary dual-circuit or single circuit anti-sweat heater control system and smart controller in accordance with one exemplary embodiment
- FIG. 9 is a perspective view of yet another refrigerated display unit configured to include the exemplary dual-circuit or single-circuit anti-sweat heater control system and smart controller in accordance with one exemplary embodiment.
- FIG. 10 is a flowchart of another method for providing anti-sweat heating control with the dual-circuit anti-sweat heater control system of FIGS. 2A-B or a single-circuit anti-seat heater control system in accordance with another exemplary embodiment.
- FIG. 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.
- FIG. 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 FIGS. 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 .
- 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 . While the exemplary embodiment of FIGS.
- 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 FIG. 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 FIG.
- the heater circuit 310 is disposed within a channel (e.g., the first 106 or second 107 channel) of the door frame 315 in a manner similar to that described with reference to FIG. 1B .
- the heater circuit 310 is substantially similar to the secondary heater circuit 110 of FIG. 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 FIG. 3 presents a single heater circuit 310 , alternatively, two heater circuits similar to that shown and described with reference to FIGS. 1 B and 2 A-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 .
- 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 .
- 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.
- 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 FIG. 3 .
- 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 FIGS. 1-2B or 1 A-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 FIGS. 1-2B or 1 A-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. For example 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 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 FIG. 10 below.
- the ambient humidity levels shown above in Table 1 can be substituted for the dewpoint temperature levels provided in FIGS. 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 .
- 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 FIG. 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.
- 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.
- 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 surface temperature reading from the sensor 120 can follow the percentages shown in Table 2 below.
- 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 FIG. 10 below.
- the temperature levels shown above in Table 2 can be substituted for the dewpoint temperature levels provided in FIGS. 5-8 to show example variations that can be provided in the voltage level of the secondary heater circuit of FIG. 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 FIGS. 1-2B or 1 A-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 FIGS. 1-2B or 1 A-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.
- the dewpoint temperature is calculated by the dewpoint sensor 120 .
- 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. For example 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 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 FIG. 10 below.
- the calculated dewpoint temperatures shown above in Table 3 can be substituted for the calculated dewpoint temperatures provided in FIGS. 5-8 to show example variations that can be provided in the voltage level of the secondary heater circuit of FIG. 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 FIGS. 1-2B or 1 A-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 FIGS. 1-2B or 1 A-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. 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 secondary heater circuit 110 When 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 FIG. 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 FIGS. 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 FIG. 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 FIG. 10 below.
- the ambient humidity levels shown above in Table 2 described above with reference to FIG. 4 can be substituted for the dewpoint temperature levels provided in FIGS. 5-8 to show example variations that can be provided in the voltage level of the secondary heater circuit of FIG. 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 FIG. 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 FIG. 4 or based on calculated dewpoint temperature as compared to a preset dewpoint temperature similar to that described in FIG. 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 FIGS. 1-2B or 1 A-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 FIGS. 1A-B employing the circuit system 300 of FIG. 3 or the system 200 of FIGS. 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 FIG. 5 .
- step 715 receives surface temperature readings from the one or multiple sensors 335 .
- step 750 receives the lowest surface temperature reading from the controller 335 .
- 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 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 FIG. 10 below.
- the temperature differences shown above in Table 4 can be substituted for the calculated dewpoint temperatures provided in FIGS. 5-8 to show example variations that can be provided in the voltage level of the heater circuit 310 of FIG. 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 .
- 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 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 .
- FIGS. 4-7 may be carried out or performed in any suitable order as desired in various alternative exemplary embodiments. Additionally, in certain exemplary embodiments, at least a portion of the steps may be carried out in parallel. Furthermore, in certain exemplary embodiments, one or more steps may be omitted.
- 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 FIGS. 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 FIGS. 4-7 .
- FIGS. 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 FIGS. 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 FIGS. 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.
- FIG. 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 FIG. 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 FIGS. 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 FIGS. 1-2B or 1 A-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 FIGS. 1-2B or 1 A-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.
- the dewpoint temperature is calculated by the dewpoint sensor 120 .
- 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 .
- 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 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. This includes systems where the full voltage level is 230 volts, 240 volts and/or 400 volts. Examples tables for each might look like that provided below in Tables 6-8.
- 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 .
- step 1055 a 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 .
- 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.
Abstract
Systems, methods, and apparatuses are provided for preventing condensation in refrigerated display cases. A display case can be provided with one or more heater circuits and one or more sensors communicably coupled thereto. The sensor can sense ambient humidity levels, ambient temperature levels, and surface temperature levels. In certain embodiments, dewpoint temperatures may be calculated based on the ambient humidity and temperature levels provided by the sensor. The sensed ambient humidity level, temperature level, surface temperature, or calculated dewpoint can be compared to preset trigger levels and at least one of the heater circuits can be activated if the preset trigger level is violated. Activation of the heater circuit can be for a predetermined amount or percentage of time or at a predetermined voltage level based on the sensed or calculated level or the amount the sensed or calculated level is over the preset trigger level.
Description
- This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 61/700,303, titled Systems, Methods, and Apparatus for Preventing Condensation in Display Cases, filed on Sep. 12, 2012, the entire contents of which are hereby incorporated herein by reference.
- 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.
- 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.
- For example, a door to a refrigerated display unit in a store may be opened frequently by customers. When this happens, the inside of the door, which may be, for example, at a temperature of −15 degrees Fahrenheit to 40 degrees Fahrenheit, is immediately exposed to the ambient air in the store, which is typically at a much higher temperature. Depending on the temperature and humidity levels of the ambient air, 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. Additionally, 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.
- In an effort to reduce or eliminate these problems, it has become a common practice to employ heaters in door windows and door frames of refrigeration equipment. These devices, which will be referred to as refrigerated display units below, use small electrical heating elements to raise the temperature of the door glass or frame sufficiently above the dewpoint temperature so that condensation is reduced or eliminated. Door heaters are used in both refrigerators and freezers, and both types of units will be understood to be included in the term refrigerated display unit as it is used below. There is a significant energy cost associated with using such devices, however. It takes energy to power the heaters, and the heat generated by these heaters must be removed from the refrigerated volume by the refrigeration system. The costs involved with door heaters can be substantial.
- For a more complete understanding of the present disclosure and certain features thereof, reference is now made to the following description, in conjunction with the accompanying figures briefly described as follows:
-
FIG. 1A is a perspective view of a refrigerated display unit configured to include the dual-circuit anti-sweat heater control system, and a smart controller in accordance with one exemplary embodiment; -
FIG. 1B is a partial-perspective view of the door frame for one of the doors of the refrigerated display unit in accordance with one exemplary embodiment; -
FIGS. 2A and 2B are schematic diagrams of the dual-circuit anti-sweat heater control system for use in the refrigerated display unit ofFIG. 1A in accordance with one exemplary embodiment; -
FIG. 3 is a schematic diagram of an alternative anti-sweat heater control system having a single or dual-circuit heating control system for use in the refrigerated display unit ofFIG. 1A in accordance with an alternate exemplary embodiment; -
FIG. 4 is a flowchart of a method for providing anti-sweat heating control with the dual-circuit anti-sweat heater control system ofFIGS. 2A-B in accordance with one exemplary embodiment; -
FIG. 5 is a flowchart of another method for providing anti-sweat heating control with the dual-circuit anti-sweat heater control system ofFIGS. 2A-B in accordance with another exemplary embodiment; -
FIG. 6 is a flowchart of another method for providing anti-sweat heating control with the dual-circuit anti-sweat heater control system ofFIGS. 2A-B in accordance with yet another exemplary embodiment; -
FIG. 7 is a flowchart of a method for providing anti-sweat heating control with the anti-sweat heater control system ofFIG. 3 in accordance with one exemplary embodiment; -
FIG. 8 is a perspective view of another example refrigerated display unit configured to include the exemplary dual-circuit or single circuit anti-sweat heater control system and smart controller in accordance with one exemplary embodiment; -
FIG. 9 is a perspective view of yet another refrigerated display unit configured to include the exemplary dual-circuit or single-circuit anti-sweat heater control system and smart controller in accordance with one exemplary embodiment; and -
FIG. 10 is a flowchart of another method for providing anti-sweat heating control with the dual-circuit anti-sweat heater control system ofFIGS. 2A-B or a single-circuit anti-seat heater control system in accordance with another exemplary embodiment. - Exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which the exemplary embodiments are shown. The concepts disclosed and/or claimed herein may, however, be embodied in many different forms and should not be construed as limited to the exemplary embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of that which is disclosed to those or ordinary skill in the art. Like numbers refer to like, but not necessarily the same or identical, elements throughout.
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FIG. 1A is a perspective view of an exemplary refrigerateddisplay unit 100 configured to include a dual-circuit anti-sweat heater control system in accordance with one exemplary embodiment.FIG. 1B is a partial-perspective view of one of the door/window frames of the refrigerateddisplay unit 100 according to one exemplary embodiment. Referring now toFIGS. 1A and 1B , theexemplary display unit 100 can include acasing 101 which includesmultiple walls 105, such aback wall 111, anopposing front wall 115, two ormore side walls 120, a top wall orceiling 125, and a bottom wall orfloor 130. Thewalls 105 can define one or more cavities for storing products within theunit 100. Theunit 100 can also include one ormore cooling units 135 for cooling the cavity area. The front wall of thecasing 101 can include one or more openings that allow access to the products within the casing. - One or
more doors 102 can be pivotally or otherwise adjustably mounted to thecasing 101 to both cover and provide access to the openings. Eachdoor 102 can include anouter frame 140 that surrounds the perimeter of atransparent material 145, such as glass or plastic. Theouter frame 140 of thedoor 102 can be made of a metallic material, such as steel, aluminum, or any other material known to those of skill in the art. Eachdoor 102 can also include adoor handle 150 that can be coupled to or provided in theouter frame 140 or thetransparent material 145 of thedoor 102. Thedoor handle 150 can provide a means for rotatably opening thedoor 102 to access the contents within theunit 100. - A
casing door frame 103 is provided on thecasing 101 and disposed along the front wall for eachcorresponding door 102. Thedoor frame 103 generally has the same perimeter shape as thedoor 102 and is configured to contact at least a portion of thedoor 102 when thedoor 102 is in the closed position. For example, themetal frame 140 disposed along the outer periphery of thedoor 102 can contact thedoor frame 103 when thedoor 102 is in the closed position. In the example shown inFIG. 1A , thedoor frame 103 would have a generally rectangular shape to match the generally rectangular shape of thedoor 102 so that the metallicouter frame 140 of thedoor 102 can be mechanically, magnetically, and/or thermally coupled to thedoor frame 103. For example, heat can be transferred from thedoor frame 103 to the metallicouter frame 140 of the door by way of thermal conduction. - As best seen in
FIG. 1B , thedoor frame 103 can include a first channel 106 and a second channel 107 disposed along and within thedoor frame 103. The first channel 106 is sized and shaped to receive a primary heating device for a primary heater circuit. For example, 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 thedoor frame 103. In one exemplary embodiment, the primary heating device for the primary heater circuit is a small gauge heater wire. While the 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 thedoor frame 103. - The second channel 107 is sized and shaped to receive a secondary heating device for a secondary heater circuit. In certain exemplary embodiments, the primary and secondary heater circuits are electrically isolated or not electrically coupled to one another. In one exemplary embodiment, 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. Alternatively, 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 theunit 100 or a single first 106 and second 107 channel for theentire unit 100. -
FIGS. 2A and 2B are schematic diagrams of an exemplary dual-circuit anti-sweatheater control system 200 that can be incorporated into therefrigerated display unit 100 ofFIGS. 1A-1B . Now referring toFIGS. 1A-2B , the exemplary dual-circuit anti-sweatheater control system 200 includes aprimary heater circuit 105 and asecondary heater circuit 110. Theprimary heater circuit 105 and thesecondary heater circuit 110 can be disposed in or along thedoor frame 103 of theunit 100. For example, theprimary heater circuit 105 can have at least a portion that is disposed in the first channel 106 and thesecondary 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 aline conductor 205 and aneutral conduct 210. Theprimary heater circuit 105 has a top end and a bottom end and may be routed in aserpentine shape 130 to provide increased surface area contact along thedoor frame 103. In certain exemplary embodiments, at least a portion of theprimary heater circuit 105 is disposed in the first channel 106 and extends around the perimeter of eachdoor frame 103 or around portions of the perimeter of each door/window frame only where needed. As discussed above, in certain exemplary embodiments, theprimary heater circuit 105 includes a small gauge wire that emits heat through conduction to the surface of therespective door frame 103 and to the outer frame of thedoor 102 when thedoor 102 abuts thedoor frame 103 in the closed position. - The
secondary heater circuit 110 is electrically coupled to a source of power (not shown) by way of aline conductor 215 and aneutral conductor 220. In certain exemplary embodiments, the source of power for theprimary heater circuit 105 and thesecondary heater circuit 110 is the same. Alternatively, theprimary heater circuit 105 and thesecondary heater circuit 110 can have different sources of electrical power. In certain exemplary embodiments, at least a portion of thesecondary heater circuit 110 is disposed in the secondary channel 107 and extends around the perimeter of eachdoor frame 103. As discussed above, in certain exemplary embodiments, thesecondary 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 thedoor 102 when thedoor 102 abuts thedoor frame 103 in the closed position. - The
secondary heater circuit 110 can also be electrically and/or communicably coupled to asensor 120. Thesensor 120 can be disposed adjacent to or remote from thedoor frame 103. Further, thesensor 120 can be coupled to theunit 100 or positioned elsewhere, as long as it is electrically and/or communicably coupled to thesecondary heater circuit 110 or a controller controlling thesecondary heater circuit 110. Typically thesensor 120 will be placed in the same general area as theunit 100 where humidity is likely to be at the highest level. In one exemplary embodiment, thesensor 120 is coupled along the top of theunit 100 adjacent thedoor frame 103. Theexemplary sensor 120 can be a humidity sensor, a temperature sensor, or a dewpoint sensor. Alternatively, thesensor 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 thesecondary heater circuit 110. Thesensor 120 can include arelay 125 or switch that is electrically and/or communicably coupled to thesecondary heater circuit 110. In certain exemplary embodiments, when therelay 125 is open, power does not flow through thesecondary heater circuit 110 and thesecondary heater circuit 110 does not produce heat along thedoor frame 103. Alternatively, when therelay 125 is closed, power flows through thesecondary heater circuit 110 and thesecondary heater circuit 110 produces heat along thedoor frame 103. While the exemplary embodiment ofFIGS. 2A-B does not shown a sensor electrically coupled to theprimary heater circuit 105, in an alternative embodiment (not shown), thesensor 120 or another sensor is electrically and/or communicably coupled to theprimary 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 thesensor 120 of thesecondary heater circuit 110. -
FIG. 3 is schematic diagram of an alternative exemplary anti-sweatheater control system 300 that can be incorporated into therefrigerated display unit 100 ofFIG. 1A . Now referring toFIGS. 1A-B and 3, the exemplary anti-sweatheater control system 300 includes aheater circuit 310 disposed along or within thedoor frame 315, acontroller 330 electrically and/or communicably coupled to theheater circuit 310, and asensor 320 electrically and/or communicably coupled to theheater circuit 310 and/or thecontroller 330. In certain exemplary embodiments, thedoor frame 315 is the same or substantially similar to thedoor frame 103 ofFIG. 1A and theheater circuit 310 is disposed within a channel (e.g., the first 106 or second 107 channel) of thedoor frame 315 in a manner similar to that described with reference toFIG. 1B . In one exemplary embodiment, theheater circuit 310 is substantially similar to thesecondary heater circuit 110 ofFIG. 2A . Theheater circuit 310 can include a small gauge wire to emit heat along the surface of thedoor frame 315 and can include a line conductor and a neutral conductor electrically coupled to a source of power. While the exemplary embodiment ofFIG. 3 presents asingle heater circuit 310, alternatively, two heater circuits similar to that shown and described with reference to FIGS. 1B and 2A-B can be used. - The
exemplary door frame 315 further includes one ormore temperature sensors 335 coupled along an outer surface of thedoor frame 315 and electrically and/or communicably coupled to thecontroller 330 and/or theheater circuit 310. In certain exemplary embodiments, threetemperature sensors 335 are used and are disposed along different areas of the door/window frame 335. However, greater or fewer numbers oftemperature sensors 335, such as one or more temperature sensors, can be alternatively used. - The
exemplary system 300 also includes acontroller 330 electrically and/or communicably coupled to theheater circuit 310 and thetemperature sensors 335. The controller can be positioned adjacent to or remote from thedoor frame 315 and/or thesensor 320. Thecontroller 330 provides control signals for activating and deactivating theheater circuit 310. For example, thecontroller 330 can include arelay 325 or switch that activates and deactivates theheater circuit 310. In alternative embodiments where two heater circuits are used, each heater circuit can be electrically and/or communicably coupled to thecontroller 330 or only one can be electrically and/or communicably coupled to thecontroller 330. In this alternative exemplary embodiment, therelay 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 includestemperature sensor contacts 340 for electrically and/or communicably coupling thetemperatures sensors 335 to thecontroller 330. Theexemplary controller 330 can also include adata storage device 345. Thedata storage device 345 may be any suitable memory device, for example, caches, read only memory devices, and random access memory devices. Thedata storage device 345 can also store data, tables or executable instructions for use by thecontroller 330. Thedata storage device 345 can store data from thetemperature sensors 335 thesensor 320 as well as record the amount of time or how often theheater circuit 310 is activated. For example, thedata storage device 345 can record the dewpoint temperature from adewpoint sensor 320, the temperature readings from one or more of thetemperature sensors 335, and the length or percentage of time that theheater 310 has been activated. In embodiments using the dual heater circuit, such as those shown and described inFIGS. 2A-B , thedata 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. - In certain exemplary embodiments, the
controller 330 can also include a temperature display 350 that provides a visual indication of the temperature data received by thecontroller 330 from one or more of thetemperature sensors 340. In addition, the temperature display 350 can provide a visual indication of the dewpoint temperature or other information received by thecontroller 330 from thesensor 320. In certain exemplary embodiments, 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. In certain exemplary embodiments, the temperature display 350 and/or controller also includes an alarm. The alarm can be audible or visual. For example, 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 thetemperature sensors 335 are below the dewpoint temperature or remains below the dewpoint temperature for a predetermined or configurable amount of time. In certain exemplary embodiments, the predetermined amount of time can be anywhere between one second and two hundred minutes and can be pre-programmed in thecontroller 330 or programmable to an amount desired by a user at the controller. - The
exemplary controller 330 can also include aremote monitoring device 355. In certain exemplary embodiments, theremote monitoring device 355 is a wireless transmitter or transceiver or a Bluetooth transmitter for transmitting the data stored or received in thedata storage device 345 and orcontroller 330 wirelessly to a remote device for viewing the data by a user or another computer device. - The
system 300 also includes asensor 320 electrically and/or communicably coupled to thecontroller 330. Thesensor 320 can be coupled to theunit 100 or positioned elsewhere, as long as it is electrically and/or communicably coupled to thecontroller 330. In certain exemplary embodiments, thesensor 320 will be placed in the same general area as theunit 100 where humidity is likely to be at the highest level. In one exemplary embodiment, thesensor 320 is coupled along the top of theunit 100 adjacent thedoor frame 315. Theexemplary sensor 320 can be a humidity sensor, a temperature sensor, or a dewpoint sensor, as shown inFIG. 3 . Alternatively, thesensor 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 thecontroller 330. -
FIG. 4 is a flowchart of anexample method 400 for providing anti-sweat heating control with the dual circuit anti-sweat heater control system ofFIGS. 1-2B or 1A-B and 3, in accordance with one exemplary embodiment. Referring now toFIGS. 1-4 , theexemplary 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. In one exemplary embodiment, the heater control system is theunit 100 andsystem FIGS. 1-2B or 1A-B and 3. Instep 410, theprimary heater circuit 105 is operated at a constant power level. In one exemplary embodiment, the power level of theprimary heater circuit 105 is set to the lowest level that will output an amount of heat along the small gauge wire of thecircuit 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 instep 420 below. For example, if the ambient dewpoint temperature is normally 58 degrees Fahrenheit, the power level or the amount of power provided to theprimary 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. Theprimary 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. In one exemplary embodiment, the ambient humidity level is sensed by thesensor 120 and can be transmitted, for example, to the controller orrelay 125. In this exemplary embodiment, thesensor 120 is a humidity sensor or a combination sensor that include the ability to detect humidity levels. Instep 420, an inquiry is conducted to determine if the ambient humidity level is greater than a preset humidity level. For example, in situations where thesensor 120 or relay 125 make the determination, thesensor 120 orrelay 125 is set with a preset humidity level. When the humidity level, as sensed by thesensor 120, exceeds the preset humidity level, thesecondary heater circuit 110 will be activated for a preset amount or percentage of time. In one exemplary embodiment, the preset humidity level is fifty-five percent relative humidity. Alternatively, the preset humidity level could be set anywhere between 1-100 percent relative humidity. In an alternative embodiment, the information from thesensor 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. - If the ambient humidity level is less than, or less than or equal to, the preset humidity level, then the NO branch is followed back to step 415 to continue receiving ambient humidity level readings from the
humidity sensor 120. On the other hand, if the ambient humidity level is greater than or greater than or equal to the preset humidity level, then the YES branch is followed to step 425, whererelay 125 closes and power is supplied to thesecondary heater circuit 110 for a predetermined amount or percentage of time. In one exemplary embodiment, the controller can send a signal to close therelay 125 based on the determination made instep 420. In one exemplary embodiment, the amount or percentage of time that thesecondary heater circuit 110 is activated is dependent on the current humidity level reading from the sensor. For example, if the preset limit is fifty-five percent relative humidity and the reading from thesensor 120 is fifty-six percent relative humidity, thesecondary 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. As the ambient humidity level increases further above the preset humidity level, the percentage of time that thesecondary heater circuit 110 is on is increased. For example the percentage of time that thesecondary heater circuit 110 is on based on the ambient humidity level reading from thesensor 120 can follow the percentages shown in Table 1 below. -
TABLE 1 Percentage of Time Ambient Humidity Level 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. As an additional option, in addition to or in the alternative to operating thesecondary heater circuit 110 as described above, the operation of theprimary heater circuit 105 can be adjusted such that theprimary 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. In another alternative embodiment, once activated, thesecondary heater circuit 110 remains ON constantly until thehumidity sensor 120 receives an subsequent ambient humidity reading that is less than or less than or equal to the preset humidity level. - In yet another alternative exemplary embodiment, instead of varying the amount of time the secondary heater circuit is activated based on the ambient 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
FIG. 10 below. For purposes of example, the ambient humidity levels shown above in Table 1 can be substituted for the dewpoint temperature levels provided inFIGS. 5-8 to show example variations that can be provided in the voltage level of the secondary heater circuit based on differing electrical systems. - In
step 430, subsequent ambient humidity level readings can be received by the circuit and/or the controller from thehumidity sensor 120. Instep 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 withstep 420 above, the determination can be made by thesensor 120, therelay 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 thesensor 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. Instep 440, therelay 125 opens and thesecondary heater circuit 110 is deactivated. In one exemplary embodiment, the controller can send a signal to open therelay 125 based on the determination made instep 435. In addition, optionally, if adjustments to the operation of theprimary heater circuit 105 were made in a manner similar to that described instep 425, theprimary 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 thehumidity sensor 120. - While the exemplary embodiment of
FIG. 4 has been described with reference to a humidity sensor and humidity levels, in an alternative embodiment, the method ofFIG. 4 could be modified to activate and deactivate thesecondary heater circuit 110 based on surface temperature readings from atemperature sensor 120 positioned along an outer surface of thedoor 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 thesecondary 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 therelay 125 closes and power is supplied to thesecondary heater circuit 110 for a predetermined amount or percentage of time in a manner substantially similar to those described above for the humidity sensor. In one exemplary embodiment, the amount or percentage of time that thesecondary heater circuit 110 is activated is dependent on the amount that the surface temperature reading received from thesensor 120 is above the present temperature limit. For example, if the preset temperature limit is 58 degrees Fahrenheit and the surface temperature reading from thesensor 120 is 59 degrees Fahrenheit, thesecondary 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 thesecondary heater circuit 110 is on is increased. For example the percentage of time that thesecondary heater circuit 110 is on based on the surface temperature reading from thesensor 120 can follow the percentages shown in Table 2 below. -
TABLE 2 Percentage of Time Degrees Fahrenheit Secondary Heater Circuit is On 0-58 0% 59 40% 60 55% 61 70% 62 85% 63 and above 100% - Table 2, provided above, 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. As an additional option, in addition to or in the alternative to operating thesecondary heater circuit 110 as described above, the operation of theprimary heater circuit 105 can be adjusted such that theprimary 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. In another alternative embodiment, once activated, thesecondary heater circuit 110 remains ON constantly until thesurface temperature sensor 120 receives a subsequent ambient temperature reading that is less than, or less than or equal to, the preset temperature limit. - In yet another alternative exemplary embodiment, instead of varying the amount of time the secondary heater circuit is activated based on the surface temperature level, 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
FIG. 10 below. For purposes of example, the temperature levels shown above in Table 2 can be substituted for the dewpoint temperature levels provided inFIGS. 5-8 to show example variations that can be provided in the voltage level of the secondary heater circuit ofFIG. 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 ofFIGS. 1-2B or 1A-B and 3, in accordance with one exemplary embodiment. Now referring toFIGS. 1-3 and 5, theexemplary 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. In one exemplary embodiment, the heater control system is theunit 100 andsystem FIGS. 1-2B or 1A-B and 3. Instep 510, theprimary heater circuit 105 is operated at a constant power level. In one exemplary embodiment, the power level of theprimary heater circuit 105 is set to the lowest amount that will output a level of heat along the small gauge wire of thecircuit 105 to prevent condensation along thedoor frame 103 and the outer frame of thedoor 102 during normal conditions, such as those levels that are less than or less than or equal to the preset levels discussed instep 530 below. For example, if the ambient dewpoint temperature is normally 58 degrees Fahrenheit, the power level or the amount of power provided to theprimary heater circuit 105 will be adjusted to maintain the temperature along thedoor frame 103 and the outer frame of thedoor 102 at a level above 58 degrees Fahrenheit. Theprimary 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. In one exemplary embodiment, the ambient humidity level is sensed by thesensor 120 and can be transmitted, for example, to the controller orrelay 125. In this exemplary embodiment, thesensor 120 is a dewpoint sensor that is capable of sensing both ambient humidity and temperature levels. An ambient temperature level is received from thesensor 120 at, for example, the controller, instep 520. While the exemplary embodiment describes both the ambient temperature and humidity levels being sensed by asingle 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. Instep 525, 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 thedewpoint sensor 120. In an alternative embodiment, the dewpoint temperature is calculated by the controller. - In
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 thesensor 120 or relay 125 make the determination, thesensor 120 and/orrelay 125, is set with a preset dewpoint temperature. When the dewpoint temperature, as calculated by thesensor 120, exceeds the preset dewpoint temperature, thesecondary 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 thesensor 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. - If the calculated dewpoint temperature is less than, or less 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. On the other hand, if the calculated dewpoint temperature is greater than or greater than or equal to the preset dewpoint temperature, the YES branch is followed to step 535, whererelay 125 closes and power is supplied to thesecondary heater circuit 110 for a predetermined amount or percentage of time. In one exemplary embodiment, the controller can send a signal to close therelay 125 based on the determination made instep 530. In one exemplary embodiment, the amount or percentage of time that thesecondary heater circuit 110 is activated is dependent on the calculated dewpoint temperature from thesensor 120. For example, if the preset dewpoint temperature is 58 degrees Fahrenheit and the calculated dewpoint temperature is 59 degrees Fahrenheit, thesecondary 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. As the calculated dewpoint temperature increases further above the preset dewpoint temperature, the percentage of time that thesecondary heater circuit 110 is on is increased. For example the percentage of time that thesecondary heater circuit 110 is on based on the calculated dewpoint temperature can follow the percentages shown in Table 3 below. -
TABLE 3 Calculated Percentage of Time Secondary Dewpoint Temp. (° F.) Heater Circuit is On 0-58 0% 59 40% 60 55% 61 70% 62 85% 63 and above 100% - Table 3, provided above, 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. As an additional option, in addition to or in the alternative to operating thesecondary heater circuit 110 as described above, the operation of theprimary heater circuit 105 can be adjusted such that theprimary 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. In another alternative embodiment, once activated, thesecondary 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. - In yet another alternative exemplary embodiment, instead of varying the amount of time the secondary heater circuit is activated based on the calculated 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
FIG. 10 below. For purposes of example, the calculated dewpoint temperatures shown above in Table 3 can be substituted for the calculated dewpoint temperatures provided inFIGS. 5-8 to show example variations that can be provided in the voltage level of the secondary heater circuit ofFIG. 5 based on differing electrical systems. - In
step 540, subsequent ambient humidity level and temperature readings are received at thedewpoint sensor 120 and subsequent ambient dewpoint temperatures are calculated, for example either at thesensor 120 or the controller (not shown). Instep 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 withstep 530 above, the determination can be made by thesensor 120, therelay 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 thesensor 120 and calculating subsequent dewpoint temperatures. Alternatively, if the subsequent ambient dewpoint temperature calculation is less than or less than or equal to the preset dewpoint temperature, the NO branch is followed to step 550. Instep 550, therelay 125 opens and thesecondary heater circuit 110 is deactivated. In one exemplary embodiment, the controller can send a signal to open therelay 125 based on the determination made instep 545. In addition, optionally, if adjustments to the operation of theprimary heater circuit 105 were made in a manner similar to that described instep 535, theprimary 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 thesensor 120. -
FIG. 6 is a flowchart of another method for providing anti-sweat heating control with the dual-circuit anti-sweat heater control system ofFIGS. 1-2B or 1A-B and 3, in accordance with one exemplary embodiment. Now referring toFIGS. 1-2B and 6 or 1A-B, 3 and 6, theexemplary 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. In one exemplary embodiment, the heater control system is theunit 100 andsystem FIGS. 1-2B or 1A-B and 3. Instep 610, theprimary heater circuit 105 is operated at a constant power level. In one exemplary embodiment, the power level of theprimary heater circuit 105 is set to the lowest amount that will output a level of heat along the small gauge wire of thecircuit 105 to prevent condensation along thedoor frame 103 and the outer frame of thedoor 102 during normal conditions, such as those levels that are less than or less than or equal to the present levels discussed instep 620 below. For example, if the ambient dewpoint temperature is normally 58 degrees Fahrenheit, the power level or the amount of power provided to theprimary heater circuit 105 will be adjusted to maintain the temperature along thedoor frame 103 and the outer frame of thedoor 102 at a level above 58 degrees Fahrenheit. Theprimary 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. In one exemplary embodiment, the ambient humidity level is sensed by thesensor 120 and can be transmitted to, for example, a controller orrelay 125. In this exemplary embodiment, thesensor 120 is a humidity sensor. Instep 620, an inquiry is conducted to determine if the ambient humidity level is greater than, or greater than or equal to, a preset humidity level. For example, in situations where thesensor 120 or relay 125 make the determination, thesensor 120 or relay 125 can be set with a preset humidity level. When the humidity level, as sensed by thesensor 120, exceeds or equals (depending upon how it is set up) the preset humidity level, thesecondary heater circuit 110 will be activated for a preset amount or percentage of time similar to that described inFIG. 4 . In an alternative embodiment, the information from thesensor 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. - If the ambient humidity level is less than, or less than or equal to, the preset humidity level, the NO branch is followed to step 625. In
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. 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 theprimary heater circuit 105 because the risk of condensation is small or non-existent. In one exemplary, the second preset humidity level is 0-30% relative humidity. Alternatively, the second preset humidity level could be anywhere between 0-40% relative humidity. As withstep 620, the determination can be made by thesensor 120, therelay 125, or a controller (not shown). 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 theprimary 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 theprimary heater circuit 105 is deactivated. While not shown inFIGS. 2A-B , a relay could also be electrically coupled between thesensor 120 and theprimary heater circuit 105 or between a different sensor and theprimary heater circuit 105 to activate and deactivate theprimary heater circuit 105. The process then returns to step 615 to continue to receive ambient humidity level readings. - Returning to 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 thesecondary heater circuit 110 for a predetermined amount or percentage of time similar to the manner and options described inFIG. 4 above. As an additional option, in addition to or in the alternative to operating thesecondary heater circuit 110 as described above, the operation of theprimary heater circuit 105 can be adjusted such that theprimary 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. In an alternative exemplary embodiment, instead of varying the amount of time thesecondary heater circuit 110 is activated based on the ambient 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 inFIG. 10 below. For purposes of example, the ambient humidity levels shown above in Table 2 described above with reference toFIG. 4 can be substituted for the dewpoint temperature levels provided inFIGS. 5-8 to show example variations that can be provided in the voltage level of the secondary heater circuit ofFIG. 6 based on differing electrical systems. - In one exemplary embodiment, the controller can send a signal to close the
relay 125 based on the determination made instep 620. Instep 640, subsequent ambient humidity level readings are received by thehumidity sensor 120. Instep 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 withstep 620 above, the determination can be made by thesensor 120, therelay 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 thesensor 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 650. Instep 650, therelay 125 opens and thesecondary heater circuit 110 is deactivated. In one exemplary embodiment, the controller can send a signal to open therelay 125 based on the determination made instep 645. In addition, optionally, if adjustments to the operation of theprimary heater circuit 105 were made in a manner similar to that described instep 635, theprimary 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 thehumidity sensor 120. - While the exemplary embodiment of
FIG. 6 has been described with reference to a humidity sensor and humidity levels, in an alternative embodiment, the method ofFIG. 6 could be modified to activate and deactivate the primary 105 and secondary 110 heater circuits based on ambient temperature readings from atemperature sensor 120 as compared to a preset temperature similar to that described inFIG. 4 or based on calculated dewpoint temperature as compared to a preset dewpoint temperature similar to that described inFIG. 5 . In one exemplary embodiment, 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 ofFIGS. 1-2B or 1A-B and 3, in accordance with one exemplary embodiment. Now referring toFIGS. 1-2B and 7 or 1A-B, 3, and 7, theexemplary 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. In one exemplary embodiment, the heater control system is theunit 100 described inFIGS. 1A-B employing thecircuit system 300 ofFIG. 3 or thesystem 200 ofFIGS. 2A-B . Instep 710, theprimary 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. In one exemplary embodiment, the power level of theprimary heater circuit 105 is set to the lowest amount that will output a level of heat along the small gauge wire of thecircuit 105 to prevent condensation along thedoor frame 103 and the outer frame of thedoor 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 theprimary heater circuit 105 will be adjusted to maintain the temperature along thedoor frame 103 and the outer frame of thedoor 102 at a level above 58 degrees Fahrenheit. Theprimary 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. - Surface temperature readings are received from one or
multiple temperature sensors 335 and transmitted to thecontroller 330 instep 715. In one exemplary embodiment, eachtemperature sensor 335 transmits the sensed temperature readings to thecontroller 330 via one or moretemperature sensor contacts 340. In one exemplary embodiment, three separate temperature sensors are positioned along an outer surface of thedoor frame 103. Alternatively greater or fewer numbers of temperature sensors may be used instep 715. Instep 720, thecontroller 330 evaluates the readings from themultiple temperature sensors 335 and determines the lowest received surface temperature reading received in that iteration from thetemperature sensors 335. - The ambient humidity level is received at the
controller 330 instep 725 from thesensor 320. In this exemplary embodiment, thesensor 320 is a dewpoint sensor. An ambient temperature level is received by thecontroller 330 from thesensor 320 instep 730. While the exemplary embodiment describes both the ambient temperature and humidity levels being sensed by asingle 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 thecontroller 330. Instep 735, 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 thedewpoint sensor 320 and transmitted to thecontroller 330. Alternatively, the dewpoint temperature is calculated by thecontroller 330. Instep 740, thecontroller 330 compares the lowest surface temperature reading to the calculated dewpoint temperature. - In
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, theheater circuit 310 will be activated for a preset amount or percentage of time similar to that described inFIG. 5 . - 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, whererelay 325 closes and power is supplied to theheater circuit 310 for a predetermined amount or percentage of time. In one exemplary embodiment, the controller can send a signal to close therelay 125 based on the determination made instep 745. In one exemplary embodiment, the amount or percentage of time that theheater circuit 310 is activated is dependent on the amount of difference between the lowest surface temperature reading from thesensors 335 and the calculated dewpoint temperature. For example the percentage of time that theheater circuit 310 is on can be similar to that shown in Table 4 below. -
TABLE 4 Difference Between Temperature Percentage of Sensor and Calculated Dewpoint Time Secondary Temperature (in ° F.) Heater Circuit is On 0 0% 1 40% 2 55% 3 70% 4 85% 5 and above 100% - Table 4, provided above, 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 theheater 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. As an additional option, in addition to or in the alternative to operating thesecondary heater circuit 110 as described above, the operation of theprimary heater circuit 105 can be adjusted such that theprimary 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. In another alternative embodiment, once activated, theheater circuit 310 remains ON constantly until the difference is subsequently determined is less than, or less than or equal to, one. - In yet another alternative exemplary embodiment, instead of varying the amount of time the
heater circuit 310 is activated based on the temperature difference, the voltage level supplied to theheater circuit 310 can be varied based on the temperature difference in a manner substantially similar to that described inFIG. 10 below. For purposes of example, the temperature differences shown above in Table 4 can be substituted for the calculated dewpoint temperatures provided inFIGS. 5-8 to show example variations that can be provided in the voltage level of theheater circuit 310 ofFIG. 7 based on differing electrical systems. - Subsequent surface temperature readings are received from the
sensors 335 and transmitted to thecontroller 330 instep 755. Instep 760, thecontroller 330 determines the lowest surface temperature of the subsequently received surface temperature readings. Instep 765, thecontroller 330 calculates a subsequent dewpoint temperature based on subsequent humidity and temperature readings received from thesensor 320 and transmitted to thecontroller 330. Thecontroller 330 compares the subsequent lowest surface temperature reading to the subsequent dewpoint temperature instep 770. Instep 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 thetemperature sensors 335. Otherwise, the NO branch is followed to step 780, where thecontroller 330 transmits a signal to open therelay 325 and deactivate theheater circuit 310. In addition, optionally, if adjustments to the operation of theprimary heater circuit 105 were made in a manner similar to that described instep 750, theprimary 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 ormore temperature sensors 335. - During any of the steps provided in
FIG. 7 , the surface temperatures, the calculated dewpoints and the time (either by percentage, total amount) that thecircuit 310 is activated can be recorded and stored in thedata storage device 345. In addition, while thecontroller 330 is operating, information that is currently being received by thecontroller 300 and/or data stored in thedata storage device 345 can be wirelessly or wire transmitted to another device, such as another computer by way of theremote monitoring device 355. - The methods shown and described in
FIGS. 4-7 may be carried out or performed in any suitable order as desired in various alternative exemplary embodiments. Additionally, in certain exemplary embodiments, at least a portion of the steps may be carried out in parallel. Furthermore, in certain exemplary embodiments, one or more steps may be omitted. - Accordingly, 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. As an example, 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 ofFIGS. 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 ofFIGS. 4-7 . -
FIGS. 8 and 9 are perspective view of two additional example refrigerated display units configured to include the dual-circuit or single circuit anti-sweatheater control system smart controller system FIGS. 4-7 in accordance with one exemplary embodiment. Referring now toFIG. 8 , the exemplary refrigerated display unit 800 can include acasing 815 which includesmultiple 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 theside walls 820 for providing access into the casing orcavity 830 of the unit 800. Further, theside walls 820 and the bottom wall can define one ormore 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 thecavity area 830. - The
side walls 820 can include one or moretransparent panels 835. One or more of thetransparent 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 inFIGS. 2A-B and 3 to transfer heat or to heat up the metallic frame 805, 810 ortransparent side walls 835 to limit or prevent condensation by way of thermal conduction. - Similarly,
FIG. 9 presents anotherrefrigerated display unit 900 or a portion of the display unit that can be used in conjunction with the unit 800 ofFIG. 8 in accordance with one exemplary embodiment. Referring now toFIG. 9 , theexemplary unit 900 can include a casing which includesmultiple side walls 915 and a bottom wall orfloor 910. Theexemplary display unit 900 can have anopening 920 along the top defined by the side walls for providing access into the casing or cavity of theunit 900. Further, the side walls and the bottom wall can define one or more cavities for storing products within theunit 900 for access through thetop opening 920. Theunit 900 can also include one ormore cooling units 925 for cooling the cavity area and ametallic 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 largemetallic area 905 can be a source of condensation if not properly controlled. Themetallic area 905 can include a primary heater circuit and/or a secondary heater circuit as shown and described inFIGS. 2A-B and 3 to transfer heat or to heat up themetallic 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 ofFIGS. 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. Now referring toFIGS. 1-3 and 10, theexemplary 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. In one exemplary embodiment, the heater control system is theunit 100 andsystem FIGS. 1-2B or 1A-B and 3. Instep 1010, theprimary heater circuit 105, if a dual heater circuit system is being employed, is operated at a constant power level. In one exemplary embodiment, the power level of theprimary heater circuit 105 is set to the lowest amount that will output a level of heat along the small gauge wire of thecircuit 105 to prevent condensation along thedoor frame 103 and the outer frame of thedoor 102 during normal conditions, such as those levels that are less than or less than or equal to the preset levels discussed instep 1030 below. For example, if the ambient dewpoint temperature is normally 58 degrees Fahrenheit, the power level or the amount of power provided to theprimary heater circuit 105 will be adjusted to maintain the temperature along thedoor frame 103 and the outer frame of thedoor 102 at a level above 58 degrees Fahrenheit. Theprimary 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. In one exemplary embodiment, the ambient humidity level is sensed by thesensor 120 and can be transmitted, for example, to the controller orrelay 125. In this exemplary embodiment, thesensor 120 is a dewpoint sensor that is capable of sensing both ambient humidity and temperature levels. An ambient temperature level is received from thesensor 120 at, for example, the controller, instep 1020. While the exemplary embodiment describes both the ambient temperature and humidity levels being sensed by asingle 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. Instep 1025, 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 thedewpoint sensor 120. In an alternative embodiment, the dewpoint temperature is calculated by the controller. - In
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. For example, in situations where thesensor 120 or relay 125 make the determination, thesensor 120 and/orrelay 125, is set with a preset dewpoint temperature. When the dewpoint temperature, as calculated by thesensor 120, exceeds the preset dewpoint temperature, thesecondary 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. 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 thesensor 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. - If the calculated dewpoint temperature is less than, or less than or equal to, the preset dewpoint temperature, the NO branch is followed back to step 1015 to continue receiving ambient humidity and temperature level readings from the dewpoint, or other,
sensor 120. On the other hand, if the calculated dewpoint temperature is greater than or greater than or equal to the preset dewpoint temperature, the YES branch is followed to step 1040, where a determination is made as to the voltage level setting for the secondary heater based at least upon the amount that the dewpoint temperature 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. In one exemplary embodiment, the determination as to the amount of voltage supplied to or driving thesecondary heater circuit 110 is dependent on the calculated dewpoint temperature from thesensor 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 thesecondary heater circuit 110 is to be supplied with 50 Volts of electricity. As the calculated dewpoint temperature increases further above the preset dewpoint temperature, the controller may determine, based on preset values or percentages, to increase the voltage level to be supplied to thesecondary heater circuit 110. For example the controller's determination as to the voltage level to be supplied to thesecondary heater circuit 110 based on the calculated dewpoint temperature can follow the voltage levels shown in Table 5 below. -
TABLE 5 Calculated Dewpoint Percentage of Time Secondary Temp. (° F.) 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, provided above, 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. Furthermore, while 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. This includes systems where the full voltage level is 230 volts, 240 volts and/or 400 volts. Examples tables for each might look like that provided below in Tables 6-8. -
-
TABLE 6 Calculated Percentage of Time Dewpoint Temp. (° F.) Secondary Heater Circuit is On 0-58 0 Volts 59 110 Volts 60 140 Volts 61 170 Volts 62 200 Volts 63 and above 230 Volts -
-
TABLE 7 Calculated Percentage of Time Dewpoint Temp. (° F.) Secondary Heater Circuit is On 0-58 0 Volts 59 120 Volts 60 150 Volts 61 180 Volts 62 210 Volts 63 and above 240 Volts -
-
TABLE 8 Calculated Percentage of Time Dewpoint Temp. (° F.) Secondary Heater Circuit is On 0-58 0 Volts 59 200 Volts 60 250 Volts 61 300 Volts 62 350 Volts 63 and above 400 Volts - As an additional option, in addition to or in the alternative to operating the
secondary heater circuit 110 as described above, the operation of theprimary heater circuit 105 can be adjusted such that the voltage level of theprimary 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. Instep 1045, 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. For example,relay 125 closes and power is supplied to thesecondary heater circuit 110 at one of a set of preset stepped voltage levels, like those shown in Table 5. In one exemplary embodiment, the controller can send a signal to close therelay 125 and provide the secondary heater circuit with the amount of voltage corresponding to the preset voltage level setting based on the determination made instep 1040. In the exemplary embodiment provided above, once activated, thesecondary 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. - In
step 1050, subsequent ambient humidity level readings are received at thesensor 120. Subsequent ambient temperature level readings are received at thesensor 120 instep 1055. Instep 1060, a subsequent dewpoint temperature is calculated, for example either at thesensor 120 or the controller (not shown), based on the subsequent ambient humidity and temperature level readings received insteps step 1025. Instep 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 withstep 1030 above, the determination can be made by thesensor 120, therelay 125 or a controller (not shown). If the subsequent calculated dewpoint temperature is greater than, or greater than or equal to, the preset dewpoint temperature, the YES branch is followed back to step 1040 to continue determining the amount of voltage to provide to the secondary heater circuit and to continue receiving subsequent humidity level and temperature readings from thesensor 120 and calculating subsequent dewpoint temperatures. Alternatively, if the subsequent calculated dewpoint temperature is less than or less than or equal to the preset dewpoint temperature, the NO branch is followed to step 1070. Instep 1070, therelay 125 opens and thesecondary heater circuit 110 is deactivated. In one exemplary embodiment, the controller can send a signal to open therelay 125 based on the determination made instep 1065. In addition, optionally, if adjustments to the operation of theprimary heater circuit 105 were made in a manner similar to that described instep 1045, theprimary 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 thesensor 120. - Although example embodiments of the disclosure have been described, one of ordinary skill in the art will recognize that numerous other modifications and alternative embodiments are within the scope of the disclosure. For example, any of the functionality and/or processing capabilities described with respect to a particular device or component may be performed by any other device or component. Furthermore, while various example implementations and architectures have been described in accordance with example embodiments of the disclosure, one of ordinary skill in the art will appreciate that numerous other modifications to the example implementations and architectures described herein are also within the scope of this disclosure. Certain aspects of the disclosure are described above with reference to block and flow diagrams of systems, methods, apparatuses, and/or computer program products according to example embodiments. It will be understood that one or more 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. Likewise, 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. Further, 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.
- Accordingly, 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.
- Additional types of CRSM that may be present in any of the devices described herein may include, but are not limited to, programmable random access memory (PRAM), SRAM, DRAM, RAM, ROM, electrically erasable programmable read-only memory (EEPROM), flash memory or other memory technology, compact disc read-only memory (CD-ROM), digital versatile disc (DVD) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the information and which can be accessed. Combinations of any of the above are also included within the scope of CRSM. Alternatively, computer-readable communication media (CRCM) may include computer-readable instructions, program modules, or other data transmitted within a data signal, such as a carrier wave, or other transmission. However, as used herein, CRSM does not include CRCM.
- Although example embodiments have been described in language specific to structural features and/or methodological acts, it is to be understood that the disclosure is not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as illustrative forms of implementing the example embodiments. Conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain example embodiments could include, while other example embodiments do not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements, and/or steps are included or are to be performed in any particular embodiment.
Claims (21)
1. A method for controlling a heating system in a refrigerated display case comprising the steps of:
providing a refrigerated display case comprising a secondary heater circuit and a sensor communicably coupled to the secondary heater circuit;
receiving an ambient humidity level from the sensor;
determining if the ambient humidity level is greater than a preset humidity level; and
activating the secondary heater circuit based on the determination that the ambient humidity level is greater than the preset humidity level.
2. The method of claim 1 , further comprising the steps of:
providing a primary heater circuit for the refrigerated display case; and
operating the primary heater circuit at a constant power level.
3. The method of claim 2 , wherein the refrigerated display case comprises:
a plurality of walls defining at least one cavity;
an aperture disposed though a first of the plurality of the walls to provide access to the cavity; and
a door comprising a door frame along the first wall and disposed about at least a portion of the aperture,
wherein at least a portion of the primary heater circuit and the secondary heater circuit are disposed within the door frame.
4. The method of claim 2 , wherein the refrigerated display case comprises:
a plurality of side walls, and a floor coupled to one or more of the side walls;
said side walls and floor defining a cavity within the display case, wherein at least one of the side walls include a portion that is at least partially transparent and wherein at least one other of the side walls includes a top portion comprising a metallic panel;
said side walls defining an opening along a top of the side walls to access the cavity from an area above the side walls;
wherein the at least one of the side walls comprises a metallic panel and wherein the primary heater circuit and the secondary heater circuit are in thermal communication with at least a portion of the metallic panel, said primary heater circuit being electrically isolated from said secondary heater circuit.
5. The method of claim 1 , wherein activating the secondary heater circuit comprises activating the secondary heater circuit for a predetermined amount of time, wherein the predetermined amount of time the secondary heater circuit is activated is based on the ambient humidity level.
6. The method of claim 5 , wherein the predetermined amount of time the secondary heater circuit is activated increases as the ambient humidity level from the sensor increases.
7. The method of claim 1 , further comprises the steps of:
determining, based on the received ambient humidity level, a first voltage level setting for the secondary heater circuit, wherein the first voltage level setting is less than a full voltage level; and
wherein activating the secondary heater circuit comprises activating the secondary heater circuit at the first voltage level based on the determination that the ambient humidity level is greater than the preset humidity level.
8. The method of claim 7 , wherein the full voltage level is selected from the group consisting of 120 volts, 230 volts, 240 volts, and 400 volts.
9. A method for controlling a heating system in a refrigerated display case comprising the steps of:
providing a refrigerated display case comprising:
a primary heater circuit;
a secondary heater circuit; and
a sensor communicably coupled to the secondary heater circuit;
operating the primary heater circuit at a constant power level;
receiving an ambient temperature level from the sensor;
determining if the ambient temperature level is greater than a preset temperature level; and
activating the secondary heater circuit based on the determination that the ambient temperature level is greater than the preset temperature level.
10. The method of claim 9 , wherein activating the secondary heater circuit comprises activating the secondary heater circuit for a predetermined amount of time, wherein the predetermined amount of time the secondary heater circuit is activated is based on the ambient temperature level.
11. The method of claim 10 , wherein the predetermined amount of time the secondary heater circuit is activated increases as the ambient humidity level from the sensor increases.
12. The method of claim 9 , further comprises the steps of:
determining, based on the received ambient temperature level, a first voltage level setting for the secondary heater circuit, wherein the first voltage level setting is less than a full voltage level; and
wherein activating the secondary heater circuit comprises activating the secondary heater circuit at the first voltage level based on the determination that the ambient temperature level is greater than the preset temperature level.
13. A method for controlling a heating system in a refrigerated display case comprising the steps of:
providing a refrigerated display case comprising:
a primary heater circuit;
a secondary heater circuit; and
a dewpoint sensor communicably coupled to the secondary heater circuit and disposed outside of the display case;
operating the primary heater circuit at a constant power level;
receiving an ambient humidity level from the dewpoint sensor;
receiving an ambient temperature from the dewpoint sensor;
calculating a dewpoint temperature;
determining if the calculated dewpoint temperature is greater than a preset dewpoint temperature; and
activating the secondary heater circuit based on the determination that the calculated dewpoint temperature is greater than the preset dewpoint temperature.
14. The method of claim 13 , wherein activating the secondary heater circuit comprises activating the secondary heater circuit for a predetermined amount of time, wherein the predetermined amount of time the secondary heater circuit is activated is based on the calculated dewpoint temperature.
15. The method of claim 14 , wherein the predetermined amount of time the secondary heater circuit is activated increases as the calculated dewpoint temperature increases.
16. The method of claim 13 , further comprises the steps of:
determining, based on the calculated dewpoint temperature, a first voltage level setting for the secondary heater circuit, wherein the first voltage level setting is less than a full voltage level; and
wherein activating the secondary heater circuit comprises activating the secondary heater circuit at the first voltage level based on the determination that the calculated dewpoint temperature is greater than the preset dewpoint temperature.
17. A method for controlling a heating system in a refrigerated display case comprising the steps of:
providing a refrigerated display case comprising:
a display case comprising a plurality of walls defining at least one cavity;
an aperture disposed though a first of the plurality of the walls to provide access to the cavity from an exterior of the display case;
a door frame along the first wall and disposed about at least a portion of the aperture;
at least one temperature sensor disposed along an outer exposed surface of the door frame;
a heater circuit disposed within the door frame; and
a dewpoint sensor communicably coupled to the heater circuit;
receiving at least one surface temperature reading from the at least one temperature sensor;
sensing an ambient temperature at the dewpoint sensor;
sensing an ambient relative humidity at the dewpoint sensor;
calculating a dewpoint temperature based on the sensed ambient temperature and sensed ambient relative humidity;
determining if the surface temperature reading is less than the calculated dewpoint temperature; and
activating the heater circuit based on the determination that the surface temperature reading is less than the calculated dewpoint temperature.
18. The method of claim 17 , wherein the step of receiving at least one surface temperature reading comprises receiving a plurality of surface temperature readings from a plurality of temperature sensors disposed along the outer exposed surface of the door frame, the method further comprising:
determining a lowest surface temperature reading from the received plurality of surface temperature readings;
determining if the lowest surface temperature reading is less than the calculated dewpoint temperature; and
activating the heater circuit based on the determination that the lowest surface temperature reading is less than the calculated dewpoint temperature.
19. The method of claim 17 , wherein the refrigerated display case further comprises a data storage device communicably coupled to a controller and the at least one temperature sensor, the data storage device configured to store control information for the heater circuit, the control information capable of being used to generate a chart of operational parameters for the heater circuit to educate the customer on the effect of humidity on energy consumption by the heater circuit.
20. The method of claim 17 , wherein the refrigerated display unit further comprises an alarm communicably coupled to a controller controlling the heater circuit, wherein the controller evaluates the energy consumed by the heater circuit and initiates the alarm if the energy consumed by the heater circuit is greater than a predetermined level.
21. The method of claim 17 , wherein the refrigerated display unit further comprises an alarm communicably coupled to a controller controlling the heater circuit, wherein the controller evaluates the received surface temperature reading to determine if the surface temperature remains below the calculated dewpoint temperature for a predetermined amount of time after activating the heater circuit and wherein the controller initiates the alarm based on a positive determination that the surface temperature remains below the calculated dewpoint temperature for a predetermined amount of time after activating the heater circuit.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US14/024,967 US20140069125A1 (en) | 2012-09-12 | 2013-09-12 | Systems, methods, and apparatus for preventing condensation in refrigerated display cases |
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US201261700303P | 2012-09-12 | 2012-09-12 | |
US14/024,967 US20140069125A1 (en) | 2012-09-12 | 2013-09-12 | Systems, methods, and apparatus for preventing condensation in refrigerated display cases |
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US20140069125A1 true US20140069125A1 (en) | 2014-03-13 |
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US14/024,967 Abandoned US20140069125A1 (en) | 2012-09-12 | 2013-09-12 | Systems, methods, and apparatus for preventing condensation in refrigerated display cases |
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US (1) | US20140069125A1 (en) |
EP (1) | EP2895808B1 (en) |
AU (1) | AU2013315540A1 (en) |
CA (1) | CA2884093A1 (en) |
MX (1) | MX2015003024A (en) |
WO (1) | WO2014043308A1 (en) |
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US20150285551A1 (en) * | 2014-04-04 | 2015-10-08 | Hussmann Corporation | Merchandiser including frame heaters |
US20180224150A1 (en) * | 2017-02-08 | 2018-08-09 | Walmart Apollo, Llc | System for monitoring an open container |
US20200156441A1 (en) * | 2018-11-16 | 2020-05-21 | Ford Global Technologies, Llc | Vehicle defogging and demisting system |
US11116333B2 (en) | 2019-05-07 | 2021-09-14 | Carrier Corporation | Refrigerated display cabinet including microchannel heat exchangers |
CN114576900A (en) * | 2022-03-22 | 2022-06-03 | 海信(山东)冰箱有限公司 | Refrigerator and anti-condensation control method for turnover beam of refrigerator |
US11559147B2 (en) | 2019-05-07 | 2023-01-24 | Carrier Corporation | Refrigerated display cabinet utilizing a radial cross flow fan |
KR102605443B1 (en) * | 2023-05-03 | 2023-11-23 | (주)에코알앤에스 | Showcase to increase energy efficiency through automatic temperature control |
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CN110942711B (en) * | 2018-09-21 | 2021-07-23 | 合肥海尔电冰箱有限公司 | Display device for displaying refrigerator and display method thereof |
DE102020111671A1 (en) | 2020-02-21 | 2021-08-26 | Liebherr-Hausgeräte Lienz Gmbh | Sales refrigerator with frame heating |
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US11116333B2 (en) | 2019-05-07 | 2021-09-14 | Carrier Corporation | Refrigerated display cabinet including microchannel heat exchangers |
US11559147B2 (en) | 2019-05-07 | 2023-01-24 | Carrier Corporation | Refrigerated display cabinet utilizing a radial cross flow fan |
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Also Published As
Publication number | Publication date |
---|---|
EP2895808B1 (en) | 2017-06-14 |
WO2014043308A1 (en) | 2014-03-20 |
CA2884093A1 (en) | 2014-03-20 |
MX2015003024A (en) | 2015-06-10 |
AU2013315540A1 (en) | 2015-04-02 |
EP2895808A1 (en) | 2015-07-22 |
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Legal Events
Date | Code | Title | Description |
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AS | Assignment |
Owner name: HEATCRAFT REFRIGERATION PRODUCTS LLC, TEXAS Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:CHIKKAKALBALU, CHANDRASHEKHARA S.;IYENGAR, AJAY;REEL/FRAME:031192/0813 Effective date: 20130911 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |