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 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.