Modular heater assembly with interchangeable auxiliary sensing contacts

Abstract

A heater system is provided, comprising: a plurality of heaters; a controller for supplying power to the plurality of heaters; a plurality of sets of auxiliary wires extending from the plurality of heaters; and a wire harness for connecting the plurality of sets of auxiliary wires to the controller. Each set of auxiliary wires includes three wires, two of the three wires being made of different materials and being joined to form a thermocouple junction, such that each of the plurality of heaters is operable to function as both a heater and a temperature sensor.

Description

Technical Field

[0001] This disclosure relates to resistance heaters and temperature sensing devices such as thermocouples. Background Technology

[0002] The statements in this section provide only background information relevant to this disclosure and may not constitute prior art.

[0003] Resistance heaters are used in a variety of applications to provide heat to a target and / or the environment. One type of resistance heater known in the art is a cylindrical heater, which typically consists of a resistance wire heating element wound around a ceramic core. A typical ceramic core defines two longitudinal holes in which power / terminal pins are arranged. A first end of the resistance wire is electrically connected to one power pin, while the other end is electrically connected to the other power pin. The assembly is then inserted into a tubular metal sheath of a larger diameter having an open end and a closed end, or both open ends, thereby creating an annular space between the sheath and the resistance wire / core assembly. An insulating material, such as magnesium oxide (MgO), is injected into the open end of the sheath to fill the annular space between the resistance wire and the inner surface of the sheath.

[0004] For example, the open end of the sheath is sealed using a potting compound and / or discrete sealing components. Then, the entire assembly is compacted or compressed, such as by forging or other suitable processes, to reduce the diameter of the sheath, thereby compacting and compressing the MgO and at least partially crushing the ceramic core so that the core collapses around the pins, thus ensuring good electrical contact and heat transfer. The compacted MgO provides a relatively good heat transfer path between the heating element and the sheath, and it also electrically insulates the sheath from the heating element.

[0005] To determine the appropriate operating temperature for the heater, discrete temperature sensors, such as thermocouples, are placed on or near the heater. Adding discrete temperature sensors to the heater and its environment can be expensive and increases the complexity of the entire heating system. Summary of the Invention

[0006] This section provides a general overview of this disclosure, rather than a full disclosure of its entire scope or all its features.

[0007] In one embodiment, a heater system is provided, comprising: a plurality of heaters; a controller for supplying power to the plurality of heaters; a plurality of auxiliary lines extending from the plurality of heaters; and a wiring harness for connecting the plurality of auxiliary lines to the controller. Each set of auxiliary lines includes three wires, two of which are made of different materials and are connected to form a thermocouple junction, such that each of the plurality of heaters is operable as both a heater and a temperature sensor.

[0008] Among other features, at least one of the three wires is made of a first conductive material, and the remaining wires are made of a second conductive material. The first conductive material is a copper-nickel alloy, and the second conductive material is a nickel-chromium alloy. Multiple sets of auxiliary wires include a temperature sensing wire, an auxiliary power supply wire, and an auxiliary power return wire, wherein the temperature sensing wire is connected to one of the auxiliary power supply wire and the auxiliary power return wire to form a thermocouple junction. The thermocouple junction is also connected to the end of the resistance heating element of each heater. The wiring harness also includes a main power supply wire and a main power return wire directly connected to the controller, wherein one of the main power supply wire and the main power return wire is made of the same material as the temperature sensing wire.

[0009] Among other features, the heater system also includes multiple connectors that are directly connected to multiple sets of auxiliary lines. The wiring harness also includes a main power supply line and a main power return line, wherein the main power supply line and the main power return line are selectively connected to the same connector to lay one of the heaters as an independent heater, or the main power supply line and the main power return line are selectively connected to different connectors, such that at least some of the heaters are connected in series.

[0010] In another embodiment, a power control system for controlling at least one heater is provided, comprising: a controller; a main power supply line and a main power return line directly connected to the controller; a first line and a second line connecting the at least one heater to the main power supply line and the main power return line. The main power supply line is connected to the first line and is made of a first conductive material. The main power return line is connected to the second line and is made of a second conductive material different from the first conductive material.

[0011] Among other features, the first conductive material is a copper-nickel alloy, and the second conductive material is a nickel-chromium alloy. The power control system also includes at least one connector for connecting the main power supply line and the main power return line to at least one heater.

[0012] Among other features, the power control system also includes a wiring harness comprising multiple main power supply lines corresponding to multiple heaters, multiple main power return lines, and multiple connectors. The wiring harness connects the controller to the multiple heaters, allowing the heaters to be connected in series or as independent heaters. The wiring harness also includes multiple connecting wires for connecting multiple connectors, allowing the multiple heaters to be connected in series in different sequences.

[0013] In another embodiment, a modular heater unit is provided, comprising a heater and a set of three wires extending from the heater. Two of the three wires are made of different materials and are connected to form a thermocouple junction.

[0014] Among other features, at least three wires include a temperature sensing wire made of a first conductive material, an auxiliary power supply wire made of a second conductive material different from the first conductive material, and an auxiliary power return wire. The temperature sensing wire is connected to one of the auxiliary power supply wire and the auxiliary power return wire. The first conductive material is a copper-nickel alloy, and the second conductive material is a nickel-chromium alloy. The heater includes a resistance heating element, and a thermocouple junction is connected to the end of the resistance heating element.

[0015] Among other features, the modular heater unit also includes a connector section that connects to a set of at least three wires. The connector section is configured to connect directly or via connecting wires to another connector section. Only two of the three wires are connected to another electrical component to form part of a circuit.

[0016] Further applications will become apparent from the description provided herein. It should be understood that the descriptions and specific examples are for illustrative purposes only and are not intended to limit the scope of this disclosure. Attached Figure Description

[0017] To better understand this disclosure, its various forms, as illustrated in the accompanying drawings, will now be described by way of example:

[0018] Figure 1 This is a cross-sectional side view of a resistance heater with dual-use power supply pins constructed according to the teaching of this disclosure;

[0019] Figure 2 It is constructed based on the teaching structure of this disclosure. Figure 1 A perspective view of a resistance heater and a controller with leads;

[0020] Figure 3 This is a circuit diagram illustrating a switching circuit and a measuring circuit constructed according to one form of the present disclosure;

[0021] Figure 4 This is a cross-sectional side view of an alternative form of a heater with multiple heating zones constructed according to the teaching of this disclosure;

[0022] Figure 5 This is a side elevation view of an alternative form of the present disclosure constructed according to the teaching of the present disclosure, which illustrates a plurality of heaters connected in sequence;

[0023] Figure 6 This is a cross-sectional side view of another form of a heater with a continuously variable pitch resistive element constructed according to the teaching of this disclosure;

[0024] Figure 7 This is a cross-sectional side view of another form of a heater constructed according to the present disclosure, the heater having resistive elements with different pitches in multiple heating zones;

[0025] Figure 8 This is a cross-sectional side view of a heat exchanger with a heater constructed according to the teaching structure of this disclosure;

[0026] Figure 9 This is a cross-sectional side view illustrating a layered heater with dual-purpose power supply pins constructed according to the teaching configuration of this disclosure;

[0027] Figure 10 This is a flowchart illustrating a teaching method according to this disclosure;

[0028] Figure 11 This is a perspective view of a heater constructed according to the teachings of this disclosure for use in fluid immersion heating;

[0029] Figure 12 It is based on the teachings of this publication. Figure 11 A cross-sectional side view of a portion of the heater;

[0030] Figure 13 This illustrates the teachings based on this disclosure. Figure 10 A graph showing exemplary temperature differences at various junctions of the heater.

[0031] Figure 14 This is a perspective view of another form of the present disclosure, constructed according to the teaching of the present disclosure, having multiple heater cores in multiple regions;

[0032] Figure 15 An example is shown of a heater with a main sensing contact according to the teaching of this disclosure;

[0033] Figure 16 An example is shown of a heater with two main sensing contacts according to the teaching of this disclosure;

[0034] Figure 17A and Figure 17B This is a perspective view of a cylindrical heater with a main sensing contact, as shown in the teachings of this disclosure;

[0035] Figure 18 This is a perspective view of a tubular heater having a main sensing contact and a two-wire heating element, as taught according to this disclosure.

[0036] Figure 19 An example is shown of a main sensing contact with enhanced temperature measurement features according to the teachings of this disclosure;

[0037] Figure 20 This is a schematic diagram of a heater system comprising multiple heaters and a power control system constructed according to the teaching of this disclosure, wherein the power control system includes a wiring harness that connects multiple heaters in a first series connection to form a first modular heater assembly.

[0038] Figure 21A yes Figure 20 A magnified view of part A;

[0039] Figure 21B This is a schematic diagram of a modular heater unit, including a heater, a three-wire mechanism extending from the heater, and a connector section.

[0040] Figure 22 yes Figure 20 Electrical diagram;

[0041] Figure 23 This is a schematic diagram of a heater system including multiple heaters and a power control system constructed according to the teaching of this disclosure, wherein the power control system includes a wiring harness that connects multiple heaters in a second series connection to form a second modular heater assembly.

[0042] Figure 24 This is a schematic diagram of a heater system constructed according to the teaching of this disclosure, including multiple heaters and a power control system, wherein the power control system includes a wiring harness that connects multiple heaters in a third series connection to form a third modular heater assembly.

[0043] Figure 25 This is a schematic diagram of a heater system constructed according to the teaching of this disclosure, including multiple heaters and a power control system, wherein the power control system includes a wiring harness that connects multiple heaters into independent heaters and a fourth modular heater assembly.

[0044] Figure 26 yes Figure 25 Electrical diagram;

[0045] Figure 27 This is an electrical diagram of a heater system constructed according to the teaching of this disclosure, comprising multiple heaters and a power control system, wherein the power control system includes a wiring harness connecting the multiple heaters into independent heaters and a fifth modular heater assembly; and

[0046] Figure 28 The present disclosure provides an electrical diagram of a heater system comprising multiple heaters and a power control system, wherein the power control system includes a wiring harness that connects the multiple heaters into individual heaters and a sixth modular heater assembly.

[0047] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of this disclosure in any way. Detailed Implementation

[0048] The following description is exemplary in nature only and is not intended to limit this disclosure, application, or use. It should be understood that throughout the drawings, corresponding reference numerals indicate the same or corresponding parts and features.

[0049] Reference Figure 1 The figure illustrates a heater according to the teachings of this disclosure, and this heater is generally indicated by reference numeral 20. This type of heater 20 is a cylindrical heater; however, it should be understood that the teachings of this disclosure can be applied to other types of heaters as described in more detail below, while remaining within the scope of this disclosure. As shown, the heater 20 includes a resistance heating element 22 having two ends 24 and 26, and the resistance heating element 22 is in the form of a metal wire, such as a nickel-chromium alloy material. The resistance heating element 22 is wound or arranged around a non-conductive portion (or a core of this type) 28. The core 28 defines a proximal end 30 and a distal end 32, and also defines a first aperture 34 and a second aperture 36 extending at least through the proximal end 30.

[0050] The heater 20 also includes a first power pin 40 made of a first conductive material and a second power pin 42 made of a second conductive material different from the first conductive material of the first power pin 40. Further, the resistance heating element 22 is made of a material different from the first and second conductive materials of the first and second power pins 40 and 42, and forms a first contact 50 with the first power pin 40 at end 24 and a second contact 52 with the second power pin 42 at its other end 26. Because the resistance heating element 22 is made of a different material at contact 50 than the first power pin 40 and a different material at contact 52 than the second power pin 42, a thermocouple contact is effectively formed, thereby detecting voltage changes at the first and second contacts 50 (as described in more detail below) to determine the average temperature of the heater 20 without using separate / discrete temperature sensors.

[0051] In one configuration, the resistance heating element 22 is made of nickel-chromium alloy, and the first power supply pin 40 is... Nickel alloy, second power supply pin 42 is Nickel alloy. Alternatively, the first power pin 40 may be iron, and the second power pin 42 may be constantan. Those skilled in the art will understand that any number of different materials and combinations thereof can be used for the resistance heating element 22, the first power pin 40, and the second power pin 42, provided that the three materials are different and the thermocouple contacts are effectively formed at contacts 50 and 52. The materials described herein are merely exemplary and should not be construed as limiting the scope of this disclosure.

[0052] In one application, the average temperature of heater 20 can be used to detect the presence of moisture. If moisture is detected, a moisture management control algorithm can be implemented via a controller (described in more detail below) to remove the moisture in a controlled manner, rather than continuing to operate heater 20 and causing potential premature failure.

[0053] As further shown, heater 20 includes a sheath 60 surrounding a non-conductive portion 28 and a sealing member 62 disposed at the proximal end 30 of the non-conductive portion 28 and extending at least partially into the sheath 60 to complete the heater assembly. Additionally, a dielectric filler material 64 is disposed between the resistance heating element 22 and the sheath 60. Various constructions and additional structural and electrical details of the cylindrical heater are set forth in more detail in U.S. Patent Serial Nos. 2,831,951 and 3,970,822, which are jointly assigned with this application and whose contents are incorporated herein by reference in their entirety. Therefore, it should be understood that the forms illustrated herein are merely exemplary and should not be construed as limiting the scope of this disclosure.

[0054] Now refer to Figure 2 This disclosure also includes a controller 70 that communicates with power supply pins 40, 42 and is configured to measure voltage changes at a first contact 50 and a second contact 52. More specifically, the controller 70 measures millivolt (mV) changes at contacts 50, 52 and then uses these voltage changes to calculate the average temperature of the heater 20. In one embodiment, the controller 70 measures the voltage changes at contacts 50, 52 without interrupting the power supply to the resistance heating element 22. This can be achieved, for example, by taking a read at the zero-crossing of the AC input power signal. In another embodiment, the power supply is interrupted, and the controller 70 switches from heating mode to measurement mode to measure the voltage changes. Once the average temperature is determined, the controller 70 switches back to heating mode, as will be described in more detail below. More specifically, in one embodiment, a three-terminal bidirectional thyristor switch is used to switch the AC power supply to the heater 20 and collect temperature information at or near the zero-crossing of the power signal. Other forms of AC switching devices may be used while remaining within the scope of this disclosure. Therefore, the use of a three-terminal bidirectional thyristor switch is merely exemplary and should not be construed as limiting the scope of this disclosure.

[0055] Alternatively, such as Figure 3 As shown, FET 72 serves as a switching device and a means of measuring voltage during the off-cycle of the FET with a DC power supply. In one embodiment, three (3) relatively large resistors 73, 74, and 75 are used to form a protection circuit for the measurement circuit 76. It should be understood that this switching and measurement circuit is merely exemplary and should not be construed as limiting the scope of this disclosure.

[0056] Refer to the return Figure 2A pair of leads 80 are connected to the first power supply pin 40 and the second power supply pin 42. In one embodiment, the leads 80 are both made of the same material, such as copper. Leads 80 are provided to reduce the length of the power supply pins required to reach the controller 70, while introducing another contact using different materials at contacts 82 and 84. In this embodiment, signal lines 86 and 88 can be used to allow the controller 70 to determine which contact's voltage change is being measured, allowing the controller 70 to switch between signal lines 86 and 88 to identify the contact being measured. Alternatively, signal lines 86 and 88 can be eliminated, and the voltage change across contacts 82 and 84 can be ignored or compensated for by software in the controller 70.

[0057] Now refer to Figure 4 The teachings of this disclosure can also be applied to a heater 20' having multiple zones 90, 92, and 94. Each zone includes its own set of power supply pins 40', 42' and a resistance heating element 22' as described above (only one zone 90 is illustrated for clarity). In one form of such a multi-zone heater 20', a controller 70 (not shown) communicates with ends 96, 98, and 100 of each zone to detect voltage changes, thereby determining the average temperature of that particular zone. Alternatively, the controller 70 may communicate only with end 96 to determine the average temperature of the heater 20' and whether moisture is present, as described above. Although three (3) zones are shown, it should be understood that any number of zones can be employed while remaining within the scope of this disclosure.

[0058] Now go to Figure 5 The teachings of this disclosure can also be applied to multiple individual heaters 100, 102, 104, 106, and 108, which may be cylindrical heaters and connected sequentially as shown. As shown, each heater includes different power supply pins to a first and second contact of the resistance heating element, whereby the average temperature of each heater 100, 102, 104, 106, and 108 can be determined by the controller 70, as described above. In another form, each of the heaters 100, 102, 104, 106, and 108 has its own power supply pin, and a single power return pin is connected to all heaters to reduce the complexity of this multi-heater configuration. In this cylindrical heater configuration, each core will include a channel accommodating the power supply pins for each successive heater.

[0059] Now refer to Figure 6 and Figure 7 The pitch of the resistance heating element 110 can be varied according to another form of this disclosure in order to provide a customized heat distribution along the heater 120. In one form ( Figure 5The resistance heating element 110 defines a continuously variable pitch along its length. More specifically, the resistance heating element 110 has a continuously variable pitch that can adapt to an increase or decrease in the pitch P4-P9 on the next adjacent 360-degree coil loop. The continuously variable pitch of the resistance heating element 110 provides a gradual change in flux density on the heater surface (e.g., the surface of the sheath 112). Although the principle of this continuously variable pitch is shown as applied to a tubular heater with a filled insulating material 114, the principle can also be applied to any type of heater, including but not limited to the cylindrical heater described above. Additionally, as described above, the first power pin 122 is made of a first conductive material, the second power pin 124 is made of a second conductive material different from the first conductive material of the first power pin 122, and the resistance heating element 110 is made of a material different from the first and second conductive materials of the first and second power pins 122 and 124, such that voltage changes at the first contact 126 and the second contact 128 are detected to determine the average temperature of the heater 120.

[0060] In another form ( Figure 7 The resistance heating element 130 has pitches P1, P2, and P3 in regions A, B, and C, respectively. P3 is greater than P1, and P1 is greater than P2. The resistance heating element 130 has a constant pitch along the length of each region, as shown in the figure. Similarly, the first power pin 132 is made of a first conductive material, the second power pin 134 is made of a second conductive material different from the first conductive material of the first power pin 132, and the resistance heating element 130 is made of a material different from the first and second conductive materials of the first and second power pins 132 and 134, such that voltage changes at the first contact 136 and the second contact 138 are detected to determine the average temperature of the heater 120.

[0061] Reference Figure 8 The heater and dual-purpose power supply pin described herein have a variety of applications, including, for example, heat exchanger 140. Heat exchanger 140 may include one or more heating elements 142, and each heating element 142 may also include a zone or variable pitch resistance heating element as illustrated and described above, while remaining within the scope of this disclosure. It should be understood that the applications of the heat exchanger are merely exemplary, and the teachings of this disclosure can be used in any application where heat is provided while temperature measurement is also required, whether that temperature is absolute or for another environmental condition such as the presence of moisture as described above.

[0062] like Figure 9As shown, the teachings of this disclosure can also be applied to other types of heaters, such as the layered heater 150. Typically, the layered heater 150 includes a dielectric layer 152 applied to a substrate 154, a resistive heating layer 156 applied to the dielectric layer 152, and a protective layer 158 applied to the resistive heating layer 156. A contact 160 is formed between one end of the trace of the resistive layer 158 and a first lead 162 (only one end is shown for clarity), and similarly, a second contact is formed at the other end. Following the principles of this disclosure as described above, voltage changes at these contacts are detected to determine the average temperature of the heater 150. Such a layered heater is illustrated and described in more detail in U.S. Patent Serial No. 8,680,443, which is jointly assigned with this application, the contents of which are incorporated herein by reference in their entirety.

[0063] According to the teachings of this disclosure, other types of heaters may be used instead of the cylinder heaters, tubular heaters, and layered heaters described above, or other types of heaters in addition to the cylinder heaters, tubular heaters, and layered heaters described above. These additional types of heaters may include, for example, polymer heaters, flexible heaters, heat trace heaters, and ceramic heaters. It should be understood that these types of heaters are merely exemplary and should not be construed as limiting the scope of this disclosure.

[0064] Now refer to Figure 10 This invention illustrates a method for controlling at least one heater according to the present disclosure. The method includes the following steps:

[0065] (A) Activate the heating mode to supply power to the power supply pin, which is made of a first conductive material, and return power through the power return pin, which is made of a conductive material different from the first conductive material;

[0066] (B) Power is supplied to the power supply pin, and to a resistance heating element having two ends and made of a material different from the first and second conductive materials of the power supply pin and the power return pin, the resistance heating element forming a first contact with the power supply pin at one end and a second contact with the power return pin at the other end, and further powered through the power return pin;

[0067] (C) Measure the voltage change at the first and second contacts to determine the average temperature of the heater;

[0068] (D) Based on the average temperature determined in step (C), adjust the power supply to the heater as needed; and

[0069] (E) Repeat steps (A) to (D).

[0070] In another form of the method, as indicated by the dash, when the controller switches to measurement mode to measure voltage changes, step (B) is interrupted, and then the controller switches back to heating mode.

[0071] Figures 11 to 13 Another form of this disclosure is illustrated, wherein a heater for fluid immersion heating is illustrated, and the heater is generally indicated by reference numeral 200. The heater 200 includes: a heating portion 202 configured to be immersed in a fluid, the heating portion 202 including a plurality of resistance heating elements 204; and at least two non-heating portions 206, 208 adjacent to the heating portion 202. Figure 11 Only one non-heated portion 206 is shown in the diagram. Each non-heated portion 206, 208 defines a length and includes corresponding sets of power pins electrically connected to a plurality of heating elements 204. More specifically, each set of power pins includes a first power pin 212 made of a first conductive material and a second power pin 214 made of a second conductive material different from the first conductive material of the first power pin 212. The first power pin 212 within the non-heated portions 206, 208 is electrically connected to the second power pin 214 to form contacts 220, 230, and 240. As further shown, the second power pin 214 extends into the heating portion 202 and is electrically connected to the corresponding resistance heating element 204. Further, the second power pin 214 defines a cross-sectional area larger than the corresponding resistance heating element 204 so that no additional contact or measurable heat is generated at the connection between the second power pin 214 and the resistance heating element 204.

[0072] As further shown, the termination portion 250 is adjacent to the non-heated portion 206, and a plurality of first power pins 212 exit the non-heated portion 206 and extend into the termination portion 250 for electrical connection to leads and a controller (not shown). Similar to the previous description, each resistive heating element 204 is made of a first conductive material and a second conductive material different from the first power pin 212 and the second power pin 214, and wherein each of the contacts 220, 230, and 240 of the first power pin 212 to the second power pin 214 is arranged at different locations along the length of the non-heated portions 206, 208. More specifically, and for example, contact 220 is at a distance L1, contact 230 is at a distance L2, and contact 240 is at a distance L3.

[0073] like Figure 13As shown, as the temperature of contacts 220, 230, and 240 changes with time "t", contact 220 is submerged in the fluid F, contact 230 is submerged in the fluid but not to a great depth, and contact 240 is not submerged. Therefore, detecting the voltage change at each of contacts 220, 230, and 240 can provide an indication of the liquid level in the heating element 202. Especially when the fluid is oil in a cooking / frying pan application, it is desirable that the heating element 202 not be exposed to air during operation to prevent fire. Using contacts 220, 230, and 240 as taught according to this disclosure, the controller can determine whether the liquid level is too close to the heating element 202 and thereby disconnect the power supply to the heater 200.

[0074] Although three (3) contacts 220, 230 and 240 are illustrated in this example, it should be understood that any number of contacts may be used while remaining within the scope of this disclosure, as long as the contacts are not in the heating section 202.

[0075] Now refer to Figure 14 Another form of this disclosure includes a plurality of heater cores 300 arranged in a region of heater system 270, as shown. The heater cores 300 in this exemplary form are cylindrical heaters as described above; however, it should be understood that other types of heaters as described herein may also be used. Therefore, this form of cylindrical heater construction of the present disclosure should not be construed as limiting the scope of the disclosure.

[0076] As shown in the figure, each heater core 300 includes multiple power pins 301, 302, 303, 304, and 305. Similar to the above configuration, the power pins are made of different conductive materials. More specifically, power pins 301, 304, and 305 are made of a first conductive material, and power pins 302, 303, and 306 are made of a second conductive material different from the first conductive material. As further shown, at least one jumper 320 is connected between the different power pins; in this example, it is connected between power pin 301 and power pin 303 to obtain a temperature reading near the location of jumper 320. Jumper 320 can be, for example, a lead or other conductive component sufficient to obtain a millivolt signal indicating the temperature near the location of jumper 320, which also communicates with controller 70, as illustrated and described above. Any number of jumpers 320 can be used across different power pins, and another location is illustrated between regions 3 and 4 at jumper 322 between power pins 303 and 305.

[0077] In this exemplary form, power supply pins 301, 303, and 305 are the neutral pins of the heater circuit between adjacent power supply pins 302, 304, and 306, respectively. More specifically, the heater circuit in region 1 will be located between power supply pins 301 and 302, wherein the resistive heating element (e.g., Figure 1 The element 22 shown is positioned between these power supply pins. The heater circuit in region 2 will be positioned between power supply pins 303 and 304, with the resistance heating element positioned between these two power supply pins. Similarly, the heater circuit in region 3 will be positioned between power supply pins 305 and 306, with the resistance heating element positioned between these two power supply pins. It should be understood that these heater circuits are merely exemplary and are based on the teachings of the above-described cylindrical heater and reference to... Figure 1 The heater circuit can be constructed using any number and configuration of heater cores 300 and zones, while remaining within the scope of this disclosure. The illustrations of the four (4) zone and cylindrical heater construction are merely exemplary and it should be understood that different power pins and jumpers can be used with other types of heaters and can be used for different numbers and / or configurations of zones, while remaining within the scope of this disclosure.

[0078] Now refer to Figure 15 In one embodiment, heater 400 is configured to include a main sensing contact, which may be disposed within or outside heater 400, for measuring temperature. Heater 400 includes a resistance heating element 402, a first power supply pin 404, and a second power supply pin 406. Resistance heating element 402 has a first end and a second end. The first power supply pin 402 is connected to the first end of resistance heating element 402 to form a first contact 408, and the second power supply pin 406 is connected to the second end of resistance heating element 402 to form a second contact 410. The first power supply pin 404 and the second power supply pin 406 are operable to supply power to heating element 402 by means of a controller.

[0079] The second power supply pin 406 includes a first lead 412 and a second lead 414. The first lead 412 is connected to a second end of the resistance heating element 402 to form a second contact 410, and the second lead 414 is connected to the first lead 412 to form a main sensing contact 416 in a first reference region. The second lead 414 is configured to connect the resistance heating element 402 to a controller via the first lead 412.

[0080] In one embodiment, the first lead 412 and the second lead 414 are made of different conductive materials, or more specifically, of materials with different Seebeck coefficients. For example, nickel alloys, iron, constantan, etc., can be used. Various combinations of, etc. The material difference between the first lead 412 and the second lead 414 is due to... Figure 15 Different types of lines are represented in the diagram (e.g., dashed lines for the second lead 414, and dotted lines for the first lead 412). Due to the different materials, the main sensing contact 416 is actually a thermocouple to generate a voltage change, which is measured to determine the temperature of the first reference region. Therefore, in this form, the contacts 408 and 410 for connecting to the resistance heating element 402 are separated from the sensing location. Thus, the heater 400 is not limited to detecting the temperature at the end of the heating element 402, but can detect temperature measurements at various locations within the heater 400. Furthermore, in one form, the first lead 412 and the second lead 414 are configured to have the main sensing contact 416 outside the heater 400.

[0081] Such as about Figure 2 The controller (discussed) Figure 15 (Not shown) communicates with first power pin 404 and second power pin 406, and is configured to supply power to the resistance heater element 402 via power pins 404 and 406. The controller is also configured to calculate the temperature at the first reference region based on the voltage change generated by the sensing contact 416 using the Seebeck coefficient of the material.

[0082] In one configuration, the first leads 412 of the resistance heating element 402, the first power supply pin 404, and the second power supply pin 406 are made of the same conductive material or a material with similar Seebeck properties (i.e., approximately the same Seebeck coefficient). Therefore, the voltage change generated by the first contact 408 and the second contact 410 is approximately zero, and the temperature measurement determined by the controller is based on the voltage change generated by the main sensing contact 416.

[0083] In another configuration, the first leads 412 of the resistance heating element 402, the first power pin 404, and / or the second power pin 406 are made of different conductive materials. In this configuration, the material of the second lead 414 is chosen such that the Seebeck coefficient of the second lead 414 is most different from the Seebeck coefficient of the first leads 412 of the resistance heating element 402, the first power pin 404, and the second power pin 406. Therefore, the main sensing contact 416 is provided as the largest contributor to the overall temperature measurement, and any temperature measurements from the first contact 408 and the second contact 410 are minimized.

[0084] As described above, temperature can be detected at the zero-crossing of the power signal. Alternatively, the controller is configured to switch between a heating mode for directing power to the resistive heating element and a measurement mode for measuring voltage changes at the main sensing contact 416 to determine the temperature at a reference area.

[0085] Reference Figure 16In one embodiment, heater 420 includes two sensing contacts close to each other to detect temperature at a virtual point between the two sensing contacts. Here, heater 420 includes a resistance heating element 422, a second power pin 424, and a first power pin 426. The resistance heating element 422 includes a first end and a second end. The first power pin 426 forms a first contact 428 with the first end of heating element 422, and the second power pin 424 forms a second contact 430 with the second end of heating element 422. The second power pin 424 is connected to... Figure 15 The second power supply pin 406 is configured in a similar manner, thereby including a first lead 432 connected to the resistive heating element 422 to form a second contact 430 and a second lead 434 connected to the first lead 432 to form a first main sensing contact 440 at a first reference region within the heater 420.

[0086] In this configuration, the first power supply pin 426 is configured similarly to the second power supply pin 424 and includes two leads (i.e., a third lead 436 and a fourth lead 438) to form a sensing contact. More specifically, the third lead 436 is connected to a first end of the resistive heating element 422 to form a first contact 428, and the fourth lead 438 and the third lead 436 form a second main sensing contact 442 at a second reference region. The second main sensing contact 442 is located in a second reference region of the heater 420, which is adjacent to and close to the first reference region having the first main sensing contact 440. Although sensing contacts 440 and 442 are located within the heater 420, they can also be located outside the heater 420.

[0087] Similar to the second power pin 424, the third lead 436 is made of a different conductive material than the fourth lead 438, and also a different conductive material than the second lead 434 of the second power pin 424. Therefore, the second main sensing contact 442 is effectively used in conjunction with the first main sensing contact to determine the temperature between the first and second reference regions. Furthermore, the resistance heating element 422, the first lead 432 of the second power pin 424, and the third lead 436 of the first power pin 426 are made of the same conductive material or a material with similar Seebeck properties, such that the voltage change between the first contact 428 and the second contact 430 is approximately zero, and the temperature measurement determined by the controller is based on the voltage change at sensing contacts 440 and 442.

[0088] Controller ( Figure 16(Not shown) is configured to supply power to the heating element 422 via a first power pin 426 and a second power pin 424, and to measure the temperature at a virtual point between the two sensing contacts 440 and 442 based on the voltage change generated by contacts 440 and 442. In one form, it is assumed that the temperatures at the first reference region and the second reference region are approximately the same, thereby associating the temperature detected by the controller with the virtual point between the first reference region and the second reference region.

[0089] Reference Figure 17A and Figure 17B In one form, the main sensing contact is located in the cylindrical heater for measuring the temperature at a virtual point outside the heater or at a reference area inside the heater. Figure 17A A cylindrical heater 450 is illustrated, which includes a resistance heating element 452 in the form of a metal wire, a first power supply pin 454, and a second power supply pin 456. The cylindrical heater 450 is configured to include two sensing contacts disposed outside the heater 450 to measure the temperature at a virtual point between the two sensing contacts.

[0090] More specifically, in one form, the resistance heating element 452 is wound or arranged around a non-conductive portion (or a core of this form), as per [reference to...]. Figure 1 The discussion focuses on the first power pin 454, which includes a first lead 458 and a second lead 460. The first lead 458 is connected to a first end of the resistance heating element 452 to form a first contact 462, and the second lead 460 forms a first main sensing contact 464 with the first lead 458 at a first reference region outside the heater 450. The second power pin 456 includes a third lead 466 and a fourth lead 468. The third lead 466 is connected to the resistance heating element 452 to form a second contact 470. The fourth lead 468 is connected to the third lead 466 to form a second main sensing contact 472 at a second reference region outside the heater 450. The first main sensing contact 464 and the second main sensing contact 472 are positioned adjacent to and close to each other.

[0091] In one configuration, the resistance heating element 452, the first lead 458 of the first power supply pin 454, and the third lead 466 of the second power supply pin 456 are made of the same material or a material with similar Seebeck properties, and are made of a different material than the second lead 460 of the first power supply pin 454 and the fourth lead 468 of the second power supply pin 456. Furthermore, the material of the second lead 460 of the first power supply pin 454 is different from the material of the fourth lead 468 of the second power supply pin 456. Therefore, the first main contact 464 and the second main contact 472 operate as thermocouples to detect the temperature at a virtual point between the two contacts 464 and 472.

[0092] Figure 17BAn example is a cylindrical heater 480, which has a main sensing contact located within the heater. The cylindrical heater 480 includes a resistance heating element 482 with two ends, a first power supply pin 484, and a second power supply pin 486. The first power supply pin 484 forms a first contact 488 with a first end of the heating element 482, and the second power supply pin 486 forms a second contact 490 with a second end of the heating element 482. Figure 15 Similar to the heater, the second power pin 486 includes a first lead 492 and a second lead 494 made of different materials (i.e., having different Seebeck coefficients). The first lead 492 is connected to a second end of the resistance heating element 482 to form a second contact 490, and the second lead 494 is connected to the first lead 492 to form a main sensing contact 496 in a first reference region within the heater 480. Therefore, the main sensing contact 490 can operate as a thermocouple to measure the temperature at the first reference region.

[0093] In one configuration, the first leads 492 of the resistance heating element 482, the first power supply pin 484, and the second power supply pin 486 are made of the same conductive material or a material with similar Seebeck properties. Therefore, the voltage change generated by the first contact 488 and the second contact 490 is approximately zero, and the temperature measurement determined by the controller is based on the voltage change generated by the main sensing contact 490.

[0094] Reference Figure 18 The main sensing contact of this disclosure can also be used as part of a heat flux sensor to estimate the temperature between the inner and outer surfaces of the heater. More specifically, in one form, the heater 500 is operable to heat a fluid (e.g., gas) flowing through a pipe and includes a resistance heating (i.e., thermal) element 502 (shown in dashed lines), a first power supply pin 504, and a second power supply pin 506. Although Figure 18 Not fully illustrated, but the resistance heating element 502 is configured to extend through the heater 500 and is protected by a cover. A first power pin 504 and a second power pin 506 extend into the cover of the heater 500 to form a first contact with a first end of the heating element 502 and a second contact with a second end of the heating element 502, respectively.

[0095] The resistance heating element 502 is a "two-wire" heating element, enabling it to function as both a heater and a temperature sensor. This two-wire capability is disclosed, for example, in U.S. Patent Serial No. 7,196,295, which is jointly assigned with this application and is incorporated herein by reference in its entirety. Typically, for two-wire systems, the heating element 502 is made of a material with a high temperature coefficient of resistance (TCR). The controller ( Figure 18(Not shown) communicates with first power supply pin 504 and second power supply pin 506, and is configured to measure voltage (i.e., mV) changes across power supply pins 504 and 506. Using the voltage changes, the controller calculates the average temperature of the resistance heating element 502 (e.g., approximately R1).

[0096] The first power supply pin 504 includes a first lead 508 and a second lead 510 made of different materials (i.e., having different Seebeck coefficients). The first lead 508 forms a second contact with the heating element 502, and the second lead 510 and the first lead 508 form a main sensing contact 512 at a second reference region along the outer surface (i.e., R2) of the heater 500 (i.e., along a plane different from the plane of the heating element 502). Therefore, the main sensing contact 512 is operable as a thermocouple to measure the temperature at the second reference region based on the voltage change generated by the sensing contact 512. The resistance heating element 502, the second power supply pin 506, and the first lead 508 of the first power supply pin 504 are made of the same material or a material with similar Seebeck properties.

[0097] In one configuration, the controller is configured to estimate the temperature at a virtual point between the inner surface (i.e., the first reference region) and the outer surface (the second reference region) of the heater 500 based on a temperature measurement of the heating element 502, the temperature at the main sensing contact 512, and the power supplied from the controller to the heater 500. More specifically, the controller uses the voltage variation across power supply pins 506 and 504 to determine the average temperature of the heating element at the first reference region, as described with respect to a two-wire system. The controller also determines the temperature at the second reference region based on the voltage variation generated by the main sensing contact 512 and the Seebeck coefficients of the first lead 508 and the second lead 510. Using these two measurements, the supplied power supply, and the heater geometry, the controller can calculate the temperature at a third reference region at a desired location within the heater 500 (e.g., any location within the heater). Alternatively, if the geometry of the heater 500 is known, the controller can also be configured to determine the heat flux between the inner and outer surfaces of the heater 500. The heat flux can be used, for example, to detect the entry area of ​​cold fluid, adjust the temperature setpoint, and / or other suitable system controls. Although heater 500 is illustrated as a tube, the heater may be configured in other suitable shapes (e.g., a flat plate) and still within the scope of this disclosure.

[0098] Furthermore, in one embodiment, before the heater 500 is energized, the heater 500 is approximately at room temperature, such that the main sensing contact 512 is at the same or approximately the same temperature as the high TCR element line (i.e., the heating element 502). The controller is configured to measure the temperature using the main sensing contact 512 and further measure the resistance of the heating element 502. The controller correlates the resistance of the heater 500 with the temperature measured by the main sensing contact 512 and uses this baseline value to convert other resistances into temperature, thereby calibrating the heater element 502.

[0099] Reference Figure 19 The main sensing contact can be configured in various suitable ways to improve temperature measurement along the surface. For example, in one form, the main sensing contact 550 is formed by a first lead 552 and a second lead 554 made of different materials. The sensing contact 550 has a planar shape (i.e., flat) and is surrounded by a heat diffuser 556, which is a thermally conductive material (e.g., copper), to improve thermal contact with the surface and diffuse heat from the heating element.

[0100] The main sensing contact of this disclosure operates as a thermocouple, enabling temperature measurement at various locations, both inside and outside the heater. Therefore, temperature measurement is not limited to the ends of the heating element. Furthermore, the heater no longer requires discrete temperature sensors, thus reducing its complexity.

[0101] Reference Figure 20 A heater system 700 is shown, comprising a power control system 600 and a plurality of heaters 602, 604, 606, and 608 connected to and controlled by the power control system 600. The power control system 600 includes a controller 610, a wiring harness 612, and multiple sets of auxiliary lines 632, 634, and 636 connected to and extending from the plurality of heaters. The wiring harness 612 and the multiple sets of auxiliary lines 632, 634, and 636 connect the controller 610 to the plurality of heaters 602, 604, 606, and 608. The plurality of heaters includes a first heater 602, a second heater 604, a third heater 606, and a fourth heater 608. The wiring harness 612 can be used to connect some or all of the plurality of heaters 602, 604, 606, and 608 in series to form different modular heater assemblies or as independent heaters or combinations thereof, as will be described in more detail below. Any number of heaters can be connected via the wiring harness 612 without departing from the scope of this disclosure, and the heaters can be of any type. The controller 610 is configured to supply power to a plurality of heaters 602, 604, 606, 608, determine the temperature of the plurality of heaters 602, 604, 606, 608 based on temperature signals transmitted from the heaters, and control the temperature of the plurality of heaters 602, 604, 606, 608 based on the measured temperature and the target temperature.

[0102] Wiring harness 612 includes multiple connectors 614, 616, 618, and 620 and multiple wires for connecting controller 610 to multiple heaters 602, 604, 606, and 608. In one form, the multiple connectors 614, 616, 618, and 620 may be circular plastic connectors (CPC) that include built-in pins and sockets to allow a wide range of power and signal transmission options, and are structurally designed to allow for easy and quick connection / disconnection between the connectors and wires. Figure 20 In the illustrative example, the number of connectors 614, 616, 618, 620 is equal to the number of heaters 602, 604, 606, 608, such that each heater is connected to another heater or controller 610 via a corresponding connector.

[0103] exist Figure 20 In the illustrative example, the multiple wires include a main power supply line 622, a main power return line 624, and multiple connecting lines 626, 628, and 630. The main power supply line 622 and the main power return line 624 are directly connected to the controller 610 to direct current to and from the multiple heaters 602, 604, 606, and 608, respectively. The multiple connecting lines include a first connecting line 426, a second connecting line 428, and a third connecting line 430 for connecting one of connectors 614, 616, 618, and 620 to another of connectors 614, 616, 618, and 620. Multiple sets of auxiliary lines are arranged between connectors 614, 616, 618, and 620 and the multiple heaters 602, 604, 606, and 608. It should be understood that the three (3) connecting lines and four (4) heaters are merely exemplary, and the illustrations and descriptions herein should not be construed as limiting the scope of this disclosure. It should also be understood that, without departing from the scope of this disclosure, multiple sets of auxiliary lines may alternatively be configured in the form of conductive pins.

[0104] Reference Figure 21A Each set of auxiliary lines for the corresponding heater comprises three wires, two of which are made of different materials and are connected to form a thermocouple junction 635, which is also connected to the end of the resistance heating element 637 of the heater 602. More specifically, each set of auxiliary lines includes a temperature sensing line 432, an auxiliary power supply line 634, and an auxiliary power return line 636. The temperature sensing line 632 is made of a first conductive material (as shown by the dashed line), while the auxiliary power supply line 634 and the auxiliary power return line 634 are made of a second conductive material different from the first conductive material (as shown by the solid line).

[0105] Temperature sensing line 632 (made of a first conductive material) is connected to one of auxiliary power supply line 634 and auxiliary power return line 634 (made of a second conductive material) to form a thermocouple junction 635 between them. Figure 21A As shown, the temperature sensing line 632 of each set of auxiliary lines is connected to the auxiliary power supply line 634 and to one of a pair of terminal areas of the resistance heating element 637 to form a thermocouple junction 635 between them. The auxiliary power return line 636 is connected to the other terminal area of ​​the resistance heating element 637. Thus, current flows from the temperature sensing line 632 through the resistance heating element 637 to the auxiliary power return line 636. The three lines can be fixed to the terminal areas of the resistance heating element 637 of the heater to become part of the heater.

[0106] Although three wires extend from each heater and connect to the corresponding connector, only two of the three wires are used to carry current during each mode of heater operation, and the remaining one is bypassed. Which of the three wires is bypassed depends on how the heater is connected via the wiring harness, specifically via connectors 614, 616, 618, and 620, which respectively include a first connector portion and a second connector portion. For example, as... Figure 21A As shown, connector 614 includes a first connector portion 614a and a second connector portion 614b. All three wires are connected to the first connector portion of a particular connector, but the second connector portion of that particular connector only connects two of the three wires via a connecting wire, a main power supply wire, or a main power return wire to the second connector portion of another connector or controller 610. Figure 21A Combination Figure 20 As shown, the temperature sensing line 632 for the first heater 602 and the auxiliary power return line 636 are used to carry current, and the auxiliary power supply line 634 is bypassed. Figure 20 As clearly shown, the auxiliary power supply line 634 and auxiliary power return line 636 for the other heaters 604, 606, and 608 are used to carry current, and the temperature sensing line 632 is bypassed. Thermocouple contacts 635 on the first heater 602 measure the temperature of the first heater, and the temperature sensing line 632 and auxiliary power return line 636 for the first heater 602 transmit signals related to the heater's temperature to the controller 610.

[0107] As an example, the first conductive material can be a copper-nickel alloy such as constantan, and the second conductive material can be such as... A nickel-chromium alloy. Without departing from the scope of this disclosure, any combination of a first conductive material and a second conductive material suitable for forming thermocouple contacts for temperature sensing purposes may be used.

[0108] Reference Figure 21B Each of connectors 614, 616, 618, and 620 may include a first connector portion and a mating second connector portion (e.g., it may be a socket and plug assembly). For example, connector 614 may include a first connector portion 614a and a second connector portion 614b. Heater 602 and a corresponding set of auxiliary lines (i.e., temperature sensing line 632, auxiliary power supply line 634, and auxiliary power return line 636) are attached to the first connector portion 614a to form a modular heater unit 603. By using mating connector portions and appropriate connecting wires to achieve various wiring connections (all variations thereof should be interpreted as falling within the scope of this disclosure), modular heater unit 603 can be easily connected to other electrical components, such as another modular heater unit or controller 610.

[0109] A set of auxiliary lines extending from the corresponding heater constitutes a three-wire mechanism, allowing the heater to function as both a heater and a temperature sensor. Figure 20 In the first modular heater assembly, the second heater 604, the third heater 606, and the fourth heater 608 are connected via a wiring harness 612, such that the second, third, and fourth heaters function solely as heaters to generate the desired heat output. In the second heater 604, the third heater 606, and the fourth heater 608, the auxiliary power supply line 634 and the auxiliary power return line 636 are selectively used to form part of the circuit, while the temperature sensing line 632 is bypassed. By selectively using the temperature sensing line 632 and the auxiliary power supply line 634 to form part of the circuit, and by bypassing the auxiliary power supply line 634, the first heater 602 is used as both a heater and a temperature sensor. During temperature sensing mode, the thermocouple contact 635 on the first heater 602 is used to measure the temperature of the heater, and the temperature sensing line 632 and the auxiliary power return line 636 for the first heater, along with other lines in the circuit, are used to transmit the temperature signal to the controller 610.

[0110] Reference Figure 22 An example is shown. Figure 20 An electrical diagram of a heater system 700 including a power control system 600 and multiple heaters is provided. Multiple heaters 602, 604, 606, and 608 are connected in series in this order to form a first modular heater assembly. The main power supply line 622 is made of the same first conductive material as the temperature sensing line 632, as shown by the dashed line. The main power return line 624 and connecting lines 626, 628, and 630 are made of the same second conductive material as the auxiliary power supply line 634 and the auxiliary power return line 636, as shown by the solid line. As an example, the first conductive material may be constantan, and the second conductive material may be...

[0111] When the control system 600 is in power mode, power is supplied from CH2+ of the controller 610 through the main power supply line 622, temperature sensing line 632, and auxiliary power return line 636 of the first heater 602; the connection line 626, auxiliary power supply line 634, and auxiliary power return line 636 of the second heater 604; the connection line 628, auxiliary power supply line 634, and auxiliary power return line 636 of the third heater 606; and the connection line 630, auxiliary power supply line 634, and auxiliary power return line 636 of the fourth heater 608. Current returns to CH2- of the controller 610 through the main power return line 624.

[0112] When the control system 600 is in temperature sensing mode, the current path is the same as in power supply mode. Thermocouple contacts 635 of the first heater 602 are used to measure the temperature of the first heater 602. The temperature of the first heater 602 is also the temperature of the first modular heater assembly, since the first heater, second heater, third heater, and fourth heater are connected in series. The signal related to the temperature measurement is transmitted to the controller 610 via the temperature sensing line 632 of the first heater 602, the auxiliary power return line 636, and other lines forming the circuit.

[0113] Only one of the thermocouple contacts 635 in the first modular heater assembly is used for temperature sensing. In the first modular heater assembly, the thermocouple contact 635 in the first heater 602, which is directly connected to the controller 610 via the main power supply line 622, is used for temperature sensing. The main power supply line 622 is made of the same first conductive material as the temperature sensing line 632 and can be considered as an extension of the temperature sensing line in the first modular heater assembly.

[0114] Reference Figure 23 The figure shows a heater system 702, which includes a power control system 600 and a plurality of heaters 602, 604, 606, and 608 connected to and controlled by the power control system 600. The power control system 600 includes a wiring harness 612' which lays the plurality of heaters 602, 604, 606, and 608 in a second series connection. In the following figures, the same elements will be indicated by the same reference numerals, and their description will be omitted for clarity.

[0115] In this wiring connection, the second heater 604, the first heater 602, the third heater 606, and the fourth heater 608 are connected in series in this order to form a second modular heater assembly, and power is supplied first to the second heater 604. In this wiring connection, by selectively using the temperature sensing line 632 and the auxiliary power return line 636 for the second heater to form part of the circuit, only the second heater 604 serves as both a heater and a temperature sensor. By selectively using the auxiliary power supply line 634 and the auxiliary power return line 636 to form part of the circuit and by bypassing the temperature sensing line, the other heaters 602, 606, and 608 are used to perform only the function of heaters. Only the thermocouple contact 635 of the second heater 604 is used for temperature sensing of the second modular heater assembly. Figure 20 Similar to the first modular heater assembly, the main power supply line 622 and the temperature sensing line 632 are made of a first conductive material (such as constantan), and the remaining lines are made of a second conductive material (such as...). It is made of ( ). The main power supply line 622 can be considered as an extension of the temperature sensing line 632 of the second heater 604 for temperature sensing purposes.

[0116] Reference Figure 24 The diagram illustrates a heater system 704, which includes a power control system 600 and multiple heaters 602, 604, 606, and 608 connected and controlled by the power control system 600. The power control system 600 includes a wiring harness 612” which lays the multiple heaters 602, 604, 606, and 608 in a third series connection. In this wiring connection, the third heater 606, the second heater 604, the first heater 602, and the fourth heater 608 are connected in series in this order to form a third modular heater assembly, and power is supplied first to the third heater 606. In this wiring connection, only the third heater 606 performs both the functions of a heater and a temperature sensor, and the thermocouple contact 635 of the third heater 606 is used for temperature sensing. The other heaters 602, 604, and 608 are used only as heaters by bypassing the temperature sensing lines 632 associated with these heaters. Similarly, the main power supply line 622 and the temperature sensing line 632 are made of a first conductive material (such as constantan), and the remaining wires are made of a second conductive material (such as...). It is made of ( ). The main power supply line 622 can be considered as an extension of the temperature sensing line 632 of the third heater 606 for temperature sensing purposes.

[0117] Reference Figure 25 and Figure 26The diagram illustrates a heater system 706, which includes a power control system 600' and multiple heaters 602, 604, 606, and 608 connected to and controlled by the power control system 600'. The power control system 600' includes a wiring harness 720 comprising two sets of main power supply lines 622 and a main power return line 624, for laying one of the heaters (i.e., the fourth heater 608) as an independent heater and for laying the remaining heaters (i.e., the first heater 602, the second heater 604, and the third heater 606) in series connection.

[0118] The first set of main power supply lines and main power return lines connects the first heater 602, the second heater 604, and the third heater 606 in series in this order to form the fourth modular heater assembly, and first supplies power to the first heater 602 from the controller 610. The second set of main power supply lines and main power return lines directly connects the fourth heater 608 to the controller 610, making the fourth heater 608 an independent heater. The fourth heater 608 is controlled independently of the fourth modular heater assembly.

[0119] In this fourth modular heater assembly, only the first heater 602 serves as both a heater and a temperature sensor, and the thermocouple junction 635 of the first heater 602 is used for temperature sensing. The fourth heater, as an independent heater, also serves as both a heater and a temperature sensor, and the thermocouple junction 635 of the fourth heater is also used to measure the temperature of the fourth heater 608.

[0120] Similarly, the two main power supply lines 622 and the temperature sensing line 632 are made of a first conductive material (such as constantan), and the remaining lines are made of a second conductive material (such as...). Made from ).

[0121] Reference Figure 27 The diagram illustrates a heater system 708, which includes a power control system 600” and a plurality of heaters 650, 652, 654, and 656 connected to and controlled by the power control system 600”. The power control system 600” includes multiple sets of auxiliary lines 632', 634', 636', 660, and 662 attached to the plurality of heaters 650, 652, 654, and 656, and a wiring harness 722 for connecting the multiple sets of auxiliary lines to a controller 610. The wiring harness 722 includes two sets of main power supply lines 622 and a main power return line 624, which are used to lay one of the heaters (e.g., the fourth heater 656) as an independent heater and to lay the remaining heaters (i.e., the first heater 650, the second heater 652, and the third heater 654) in series connection. The first heater 650, the second heater 652, and the third heater 654 are connected in series in this order to form a fifth modular heater assembly.

[0122] Each set of auxiliary lines is attached to the corresponding heater and includes five wires: a temperature sensing wire 632', an auxiliary power supply wire 634', an auxiliary power return wire 636', a first laying wire 660, and a second laying wire 662. The structure and function of the temperature sensing wire 632', auxiliary power supply wire 634', and auxiliary power return wire 636' are the same as those of the temperature sensing wire 632, auxiliary power supply wire 634, and auxiliary power return wire 636; therefore, for clarity, their detailed description is omitted herein. The first laying wire 660 and the second laying wire 662 in each set are connected to each other and are used to assist in connecting the first heater, second heater, and third heater in a desired order. Of the five wires in each set, only four of the five wires in each set are used in each heater operating mode, and one of the five wires in each set is bypassed.

[0123] The first set of main power supply lines 622 and main power return lines 624 are connected to the fifth modular heater assembly. In the fifth modular heater assembly, the third heater 654 is the master heater, with its thermocouple contact 635 and temperature sensing line 632 used for temperature sensing. By selectively using the temperature sensing line 632' for the third heater 654 as part of the circuit, the third heater 654 serves as both a heater and a temperature sensor. The temperature sensing lines 632 of the first heater 650 and the second heater 652 are bypassed, and the first and second heaters only perform the function of heaters. The second set of main power supply lines 622 and main power return lines 624 connects only one heater (i.e., the fourth heater 656) to the controller 610. The thermocouple contact 635 and temperature sensing line 632 of the fourth heater 656 are also used to measure the temperature of the fourth heater 656.

[0124] Unlike the wiring harnesses 612, 612', 612", 720 in the first to fourth modular heater assemblies, this type of wiring harness 722 includes multiple pairs of connectors 614, 614', 616, 616', 618, 618', 620, 620' corresponding to the plurality of heaters 650, 652, 654, 656. Each heater is connected to one pair of connectors. Furthermore, the temperature sensing wire is attached to the auxiliary power return line in each set of auxiliary wires extending from the heater, rather than the auxiliary power supply line. Therefore, a thermocouple junction is formed between the auxiliary power return line 636' and the temperature sensing wire 632' in each set of auxiliary wires. The temperature sensing wire 632' and the main power return line 624' are made of a first conductive material (e.g., constantan), and the remaining wires are made of a second conductive material (e.g.,...). It is made of ( ). The main power return line 624' is considered to be an extension of the temperature sensing line 632' for temperature sensing purposes.

[0125] Reference Figure 28The diagram shows a heater system 710, which includes a power control system 600”' and a plurality of heaters 650, 652, 654, 656 connected to and controlled by the power control system 600”'. The power control system 600" includes a wiring harness 720 comprising two sets of main power supply lines 622 and main power return lines 624 for laying one of the heaters (i.e., the fourth heater 656) as an independent heater and for laying the remaining heaters (i.e., the first heater 650, the second heater 652, and the third heater 654) in series. The first heater 650, the second heater 652, and the third heater 654 are connected in series in this order to form a sixth modular heater assembly. In the sixth modular heater assembly, the second heater 652 is the master heater, and its thermocouple junction 635 and temperature sensing line 632' are used for temperature measurement and temperature signal transmission. The master heater is located at the center of the sixth modular heater assembly. The first set of main power supply lines 622 and main power return lines 624 are connected to the sixth modular heater assembly. The second set of main power supply lines 622 and main power return lines 624 connects only the fourth heater 656 to the controller 610, making the fourth heater an independent heater.

[0126] Three connectors and six auxiliary wires are used to connect the second heater 652 to the controller 610, the first heater 650, and the third heater 654. Two connectors and five auxiliary wires are used to connect each of the first heater 650 and the third heater 654 to the other heater. Two connectors and five auxiliary wires are used to connect the fourth heater 656 to the controller 610. Each set of auxiliary wires for the first heater 650, the third heater 654, and the fourth heater 656 includes five wires, including a temperature sensing wire 632', an auxiliary power supply wire 634', an auxiliary power return wire 636', a first laying wire 660, and a second laying wire 662, similar to... Figure 27 The main heater has a set of auxiliary wires. However, the auxiliary wires used for the second heater 652, which serves as the main heater, consist of six wires. These six wires include a temperature sensing wire 632', an auxiliary power supply wire 634', and four laying wires 664. All six wires are used in each heater operating mode.

[0127] In this configuration, the thermocouple contact 635 for the second heater 652 is formed between the temperature sensing line 632' and the resistance heating element 637. Thermocouple contacts 635 for the first heater 650 and the third heater 654 are formed between the temperature sensing line 632', the auxiliary power supply line 634', and the resistance heating element 637. Thermocouple contacts 635 for the fourth heater 656 are formed between the temperature sensing line 632', the auxiliary power return line 636', and the resistance heating element 637. All temperature sensing lines 632' and the two main power return lines 624 are made of a first conductive material (material A, such as constantan), while the remaining lines (including the two main power supply lines 622, the connecting line 640 connected to the same or adjacent connectors, the auxiliary power supply line 634', the auxiliary power return line 636', and the laying lines 660, 662) are made of a second conductive material (material B, such as...). Made from ).

[0128] In summary, the power control system 600, 600', 600” or 600”' constructed according to the teaching configuration of this disclosure includes wiring harnesses 612, 612', 612”, 720, 722 or 724, which allow various wires to be laid via connectors to achieve various wiring connections. Some or all of the multiple heaters can be connected in series in different orders, while other heaters can be laid as independent heaters and controlled independently of the other heaters. Although not shown in any form, it should be understood that the wiring harness may include multiple sets of main power supply lines and main power return lines corresponding to multiple heaters. Each set of main power supply lines and main power return lines connects only one heater to the controller, such that each heater is an independent heater and is controlled independently.

[0129] Furthermore, the power control system includes multiple sets of auxiliary lines arranged between multiple connectors and heaters. These auxiliary lines can always be attached to adjacent connector portions (either male or female) of the heater and connector to form multiple modular heater units. Multiple modular heater units can be easily connected in series in any order, or used as independent heaters by connecting connector portions to other connector portions via appropriate wiring. Therefore, the wiring harness improves the modularity of the multiple heaters.

[0130] Furthermore, in some forms, each of the multiple sets of auxiliary lines comprises three wires, including a temperature sensing wire, an auxiliary power supply wire, and an auxiliary power return wire. Two of the three wires are connected to form a thermocouple junction. Depending on whether the associated heater is used solely as a heater or as both a heater and a temperature sensor in the circuit, one of the two connected wires is selected to form part of the circuit. The three-wire arrangement extending from each heater allows each heater to be selectively used as both a heater and a temperature sensor, thereby eliminating the need for an additional temperature sensor in the heater system and providing a heater system with a simpler design.

[0131] In other configurations, the auxiliary wiring harness may include five or six wires. In addition to the temperature sensing wire, auxiliary power supply wire, and auxiliary power return wire, extra cabling may be included in each auxiliary wiring harness to increase cabling options, allowing the heaters to be connected in different orders and any one of the heaters to be used as the master heater, which serves as both the heater and the temperature sensor housing.

[0132] In the accompanying drawings, the direction of the arrows, as indicated by the arrows, generally indicates the flow of information of interest (such as data or instructions). For example, when components A and B exchange various types of information, but the information transmitted from component A to component B is relevant to the illustration, the arrow can point from component A to component B. This unidirectional arrow does not mean that no other information is transmitted from component B to component A. Furthermore, for information sent from component A to component B, component B can send a request for information or receive a response from component A.

[0133] In this application, the terms “module” and / or “controller” may refer to, be part of, or include the following: application-specific integrated circuit (ASIC); digital, analog, or mixed analog / digital discrete circuit; digital, analog, or mixed analog / digital integrated circuit; combinational logic circuit; field-programmable gate array (FPGA); processor circuitry (shared, dedicated, or grouped) that executes code; storage circuitry (shared, dedicated, or grouped) that stores code executed by the processor circuitry; other suitable hardware components that provide the aforementioned functionality; or combinations of some or all of the foregoing, such as in a system-on-a-chip.

[0134] The term "memory" is a subset of the term "computer-readable medium." As used herein, the term "computer-readable medium" does not cover transient electrical or electromagnetic signals propagated through a medium (such as on a carrier wave); therefore, the term "computer-readable medium" can be considered tangible and non-transient. Non-limiting examples of non-transient tangible computer-readable media are non-volatile memory circuits (such as flash memory circuits, erasable programmable read-only memory circuits, or mask read-only circuits), volatile memory circuits (such as static random access memory circuits or dynamic random access memory circuits), magnetic storage media (such as analog or digital magnetic tape or hard disk drives), and optical storage media (such as CDs, DVDs, or Blu-ray discs).

[0135] The apparatus and methods described in this application can be implemented, in part or in whole, by a special-purpose computer created by configuring a general-purpose computer to perform one or more specific functions specifically implemented in a computer program. The aforementioned functional blocks, flowchart components, and other elements serve as software specifications that can be routinely converted into computer programs by skilled technicians or programmers.

[0136] Unless otherwise expressly indicated herein, in describing the scope of this disclosure, all numerical values ​​indicating mechanical / thermal properties, percentages of composition, dimensions and / or tolerances or other characteristics shall be understood to be modified by the words “about” or “approximately”. Such modification is expected for various reasons, including industrial practice; material, manufacturing and assembly tolerances; and testing capabilities.

[0137] As used in this article, the phrases A, B, and C at least one should be interpreted as meaning the use of non-exclusive logical OR (A or B or C), and should not be interpreted as meaning "at least one of A, at least one of B, and at least one of C".

[0138] The description in this disclosure is exemplary in nature only, and thus, variations without departing from the spirit and scope of this disclosure are intended to be within its scope. Such variations should not be considered as departing from the spirit and scope of this disclosure.

Claims

1. A heater system, comprising: A plurality of heaters, each of the plurality of heaters including a resistance heating element; A controller for supplying power to the plurality of heaters; Multiple sets of auxiliary lines extend from the resistance heating elements of the multiple heaters; as well as A wiring harness for connecting the plurality of auxiliary wires to the controller, the wiring harness including a plurality of connector portions connected to the plurality of auxiliary wires, each connector portion being configured to be detachably connected to another connector portion, either directly or via a connecting wire. Each set of auxiliary lines includes a temperature sensing line, an auxiliary power supply line, and an auxiliary power return line. In each set of auxiliary lines, the temperature sensing line is connected to one of the auxiliary power supply line and the auxiliary power return line to form a thermocouple junction; the thermocouple junction is connected to the end of the resistance heating element of each heater; and the material of the temperature sensing line is different from the material of the auxiliary power supply line and the auxiliary power return line, so that each of the plurality of heaters can operate to function as both a heater and a temperature sensor.

2. The heater system according to claim 1, wherein, The temperature sensing line is made of a first conductive material, and the auxiliary power supply line and the auxiliary power return line are made of a second conductive material.

3. The heater system according to claim 2, wherein, The first conductive material is a copper-nickel alloy, and the second conductive material is a nickel-chromium alloy.

4. The heater system according to claim 1, wherein, The wiring harness also includes a main power supply line and a main power return line directly connected to the controller, wherein one of the main power supply line and the main power return line is made of the same material as the temperature sensing line in the plurality of auxiliary lines.

5. The heater system of claim 1 further includes a plurality of connectors directly connected to the plurality of auxiliary lines.

6. The heater system according to claim 5, wherein, The wiring harness also includes a main power supply line and a main power return line, wherein the main power supply line and the main power return line are selectively connected to the same connector to lay one of the heaters as an independent heater.

7. The heater system according to claim 5, wherein, The wiring harness also includes a main power supply line and a main power return line, wherein the main power supply line and the main power return line are selectively connected to different connectors, such that at least some of the heaters are connected in series.

8. A modular heater unit, comprising: Heater, the heater including a resistance heating element; An auxiliary wiring harness is connected to and extends from the resistance heating element of the heater, and the auxiliary wiring harness includes a temperature sensing line, an auxiliary power supply line, and an auxiliary power return line. as well as Multiple connector portions are connected to the auxiliary wire assembly, and each connector portion is configured to be detachably connected to another connector portion, either directly or via a connecting wire. The temperature sensing line is connected to one of the auxiliary power supply line and the auxiliary power return line to form a thermocouple junction, which is then connected to the end of the resistance heating element. The material used to make the temperature sensing line is different from the material used to make either the auxiliary power supply line or the auxiliary power return line, so that the heater can operate to function as both a heater and a temperature sensor.

9. The modular heater unit according to claim 8, wherein, The temperature sensing line is made of a first conductive material, and the auxiliary power supply line and the auxiliary power return line are made of a second conductive material.

10. The modular heater unit of claim 9, further comprising a connector portion connected to the auxiliary wire assembly, the connector portion being configured to be connected directly or via a connecting wire to another connector portion.

11. The modular heater unit according to claim 9, wherein, Only two wires in the auxiliary wire group are connected to another electrical component to form part of the circuit.

12. The modular heater unit according to claim 9, wherein, The first conductive material is a copper-nickel alloy, and the second conductive material is a nickel-chromium alloy.

Images