Additive Manufacturing of a Frost-Detection Resistive Sensor for Optimizing Demand Defrost in Refrigeration Systems
This article presents the development of a resistive frost-detection sensor fabricated using Fused Filament Fabrication (FFF) with a conductive filament. This sensor was designed to enhance demand-defrost control in industrial refrigeration systems. Frost accumulation on evaporator surfaces blocks a...
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| Format: | Article |
| Language: | English |
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MDPI AG
2024-12-01
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| Series: | Sensors |
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| Online Access: | https://www.mdpi.com/1424-8220/24/24/8193 |
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| author | Martim Lima de Aguiar Pedro Dinis Gaspar Pedro Dinho da Silva |
| author_facet | Martim Lima de Aguiar Pedro Dinis Gaspar Pedro Dinho da Silva |
| author_sort | Martim Lima de Aguiar |
| collection | DOAJ |
| description | This article presents the development of a resistive frost-detection sensor fabricated using Fused Filament Fabrication (FFF) with a conductive filament. This sensor was designed to enhance demand-defrost control in industrial refrigeration systems. Frost accumulation on evaporator surfaces blocks airflow and creates a thermal insulating barrier that reduces heat exchange efficiency, increasing energy consumption and operational costs. Traditional timed defrosting control methods can mitigate these effects but often lead to inefficiencies due to their inability to align with actual frost accumulation, which can vary according to system and environmental conditions. Frost-detection sensors aim to solve this problem by acting as a tool to support defrosting control. A series of tests were conducted to evaluate the sensor’s performance in detecting frost under controlled conditions on a heat exchanger (HX). The sensor reliably detected frost in all cases, demonstrating its effectiveness in real-time frost detection. The sensor measurements were validated by comparison with results obtained through a computer vision method, confirming its reliability. It was also found that the sensor can detect temperature changes. This advancement in sensor technology highlights the potential of additive manufacturing to provide cost-effective, customizable, replicable, and compact sensor designs, contributing to improved system performance and energy efficiency in refrigeration systems. |
| format | Article |
| id | doaj-art-ea46382010ea47b2a189fe5b641fc58d |
| institution | OA Journals |
| issn | 1424-8220 |
| language | English |
| publishDate | 2024-12-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Sensors |
| spelling | doaj-art-ea46382010ea47b2a189fe5b641fc58d2025-08-20T02:01:19ZengMDPI AGSensors1424-82202024-12-012424819310.3390/s24248193Additive Manufacturing of a Frost-Detection Resistive Sensor for Optimizing Demand Defrost in Refrigeration SystemsMartim Lima de Aguiar0Pedro Dinis Gaspar1Pedro Dinho da Silva2Department of Electromechanical Engineering, University of Beira Interior, Rua Marquês d’Ávila e Bolama, 6201-001 Covilhã, PortugalDepartment of Electromechanical Engineering, University of Beira Interior, Rua Marquês d’Ávila e Bolama, 6201-001 Covilhã, PortugalDepartment of Electromechanical Engineering, University of Beira Interior, Rua Marquês d’Ávila e Bolama, 6201-001 Covilhã, PortugalThis article presents the development of a resistive frost-detection sensor fabricated using Fused Filament Fabrication (FFF) with a conductive filament. This sensor was designed to enhance demand-defrost control in industrial refrigeration systems. Frost accumulation on evaporator surfaces blocks airflow and creates a thermal insulating barrier that reduces heat exchange efficiency, increasing energy consumption and operational costs. Traditional timed defrosting control methods can mitigate these effects but often lead to inefficiencies due to their inability to align with actual frost accumulation, which can vary according to system and environmental conditions. Frost-detection sensors aim to solve this problem by acting as a tool to support defrosting control. A series of tests were conducted to evaluate the sensor’s performance in detecting frost under controlled conditions on a heat exchanger (HX). The sensor reliably detected frost in all cases, demonstrating its effectiveness in real-time frost detection. The sensor measurements were validated by comparison with results obtained through a computer vision method, confirming its reliability. It was also found that the sensor can detect temperature changes. This advancement in sensor technology highlights the potential of additive manufacturing to provide cost-effective, customizable, replicable, and compact sensor designs, contributing to improved system performance and energy efficiency in refrigeration systems.https://www.mdpi.com/1424-8220/24/24/8193additive manufacturingresistive sensorfused filament fabricationfrost detectiondemand defrostingheat exchanger |
| spellingShingle | Martim Lima de Aguiar Pedro Dinis Gaspar Pedro Dinho da Silva Additive Manufacturing of a Frost-Detection Resistive Sensor for Optimizing Demand Defrost in Refrigeration Systems Sensors additive manufacturing resistive sensor fused filament fabrication frost detection demand defrosting heat exchanger |
| title | Additive Manufacturing of a Frost-Detection Resistive Sensor for Optimizing Demand Defrost in Refrigeration Systems |
| title_full | Additive Manufacturing of a Frost-Detection Resistive Sensor for Optimizing Demand Defrost in Refrigeration Systems |
| title_fullStr | Additive Manufacturing of a Frost-Detection Resistive Sensor for Optimizing Demand Defrost in Refrigeration Systems |
| title_full_unstemmed | Additive Manufacturing of a Frost-Detection Resistive Sensor for Optimizing Demand Defrost in Refrigeration Systems |
| title_short | Additive Manufacturing of a Frost-Detection Resistive Sensor for Optimizing Demand Defrost in Refrigeration Systems |
| title_sort | additive manufacturing of a frost detection resistive sensor for optimizing demand defrost in refrigeration systems |
| topic | additive manufacturing resistive sensor fused filament fabrication frost detection demand defrosting heat exchanger |
| url | https://www.mdpi.com/1424-8220/24/24/8193 |
| work_keys_str_mv | AT martimlimadeaguiar additivemanufacturingofafrostdetectionresistivesensorforoptimizingdemanddefrostinrefrigerationsystems AT pedrodinisgaspar additivemanufacturingofafrostdetectionresistivesensorforoptimizingdemanddefrostinrefrigerationsystems AT pedrodinhodasilva additivemanufacturingofafrostdetectionresistivesensorforoptimizingdemanddefrostinrefrigerationsystems |