Smart DC Heating Controller With Temperature Sensitive Resin
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Solution Overview
Problem
Existing DC heating devices, such as electric mats and seat cushions, face challenges in precise temperature control, particularly at folded or locally overheated areas, due to the limitations of temperature sensors and bimetal sensors, which are costly, difficult to install, and unable to detect local overheating effectively.
Innovation Solution
A smart heating controller using a heat sensing wire with temperature sensitive insulating resin is employed, where the heating wire is covered with temperature sensitive insulating resin and a heat sensing wire is wound spirally around it, allowing for accurate temperature sensing through a pulse signal voltage, enabling precise temperature control and preventing local overheating without the need for additional sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature sensors or bimetal sensors are installed at various measurement locations to detect temperature and control supplied electric power, then normal temperature control is enabled when the electric mat is used in an unfolded state, but the temperature may not be properly detected causing local overheating when a heavy object is placed over the electric mat or when portions of the electric mat are folded
Solution Approach 1:
The heating cable is divided into multiple heating sections with individual temperature sensors and control circuits. Each section can be independently controlled based on its own temperature conditions, allowing localized temperature management even when parts of the mat are folded or covered by heavy objects.
Solution Approach 2:
Different sections of the heating cable have different control characteristics tailored to their specific locations and usage conditions. The control circuit adjusts heating parameters locally based on temperature feedback from each section, ensuring appropriate temperature control in folded or covered areas while maintaining overall system reliability.
2Ease of manufacture
If temperature sensors or bimetals are installed at 2 or 3 locations in the electric mat, then manufacturing cost is reduced, but precise temperature detection is structurally unattainable if the electric mat is overheated due to folding at portions where sensors are not installed
Solution Approach 1:
The heating cable is segmented into multiple heating sections, each with its own temperature sensor. This segmentation allows comprehensive temperature monitoring across the entire mat surface at reasonable cost, preventing undetected overheating in folded or covered areas while maintaining manufacturing feasibility.
Solution Approach 2:
Each heating section has a temperature sensor providing real-time feedback to its dedicated control circuit. The control circuit continuously monitors temperature and adjusts heating power accordingly, ensuring precise temperature detection and control even in areas that are folded or covered by heavy objects.
3Measurement precision
If heat sensing wires are wound on nylon resin with temperature-sensitive impedance between heating wires and heat sensing wires, then temperature can be detected at every location and local overheating is prevented, but the technique cannot be applied to DC-powered heating devices because nylon resin blocks DC signals
Solution Approach 1:
The insulating resin is specifically selected or modified to have temperature-sensitive electrical impedance characteristics that work with DC signals. By changing the material parameters to be compatible with DC operation, the heat sensing wire technique can be successfully applied to DC-powered heating devices while maintaining comprehensive temperature detection coverage.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution allows for precise temperature control throughout the heating device, reduces manufacturing costs, and improves workability by enabling accurate temperature sensing and quick response to local overheating, while eliminating the risk of electromagnetic fields and electric shock.
Implementation Method 1
temperature sensitive insulating resin, of which impedance decreases when the temperature rises
Implementation Method 2
heat is generated, elevating the temperature. When the electric currents flow into the heating wires, heat is generated
Data Source
AI summary
A smart heating controller for a DC powered heating device that can control the temperature accurately and prevent a local overheating by use of a heat sensing wire using a temperature sensitive insulating resin is provided. A heating cable of the heating device includes: a heating wire covered with a temperature sensitive insulating resin and configured to be heated by the DC power source; and a heat sensing wire on which the temperature sensitive insulating resin is spirally wound on an exterior thereof, wherein the heating controller is configured to: alternatingly have a heating period, in which the heating wire is heated by supplying DC power to the heating wire through a power control element, and a temperature sensing period, in which a temperature sensing current is generated by supplying a pulse signal voltage to the heating wire; and receive a temperature sensing voltage signal by the temperature sensing current flowing in the heat sensing wire through the temperature sensitive insulating resin by the pulse signal voltage in the temperature sensing period, and control a heating temperature of the heating device by controlling the power control element in the heating period according to the received temperature sensing voltage signal.