DC Power Converter Heating System with Real-Time Temperature Feedback
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Solution Overview
Problem
Existing heating systems for industrial processes lack precise and accurate temperature control of process media, often relying on voltage monitoring which can lead to undershoot or overshoot due to time-lags and inaccuracies.
Innovation Solution
A heating system comprising a DC power converter, a sensor arrangement to monitor thermodynamic parameters, and a controller that adjusts the output voltage based on these parameters, enabling precise temperature control of the process medium or heating element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If voltage monitoring is used to control the heating element, then the system structure is simple, but the temperature control precision deteriorates due to time-lags and inaccuracies
Solution Approach 1:
The patent implements a feedback control system where a sensor continuously monitors the actual temperature of the process medium or heating element and feeds this information back to the controller. The controller adjusts the power converter output based on the difference between the setpoint and actual temperature, eliminating time-lags and inaccuracies associated with simple voltage monitoring. This closed-loop feedback mechanism resolves the contradiction by maintaining simple system structure while dramatically improving temperature control precision.
2Device complexity
If voltage-based control is used, then the control system is simple, but the response accuracy deteriorates due to time-lags
Solution Approach 1:
The control system uses real-time temperature feedback from the sensor to immediately adjust the power converter output when temperature deviations are detected. This eliminates the time-lags inherent in voltage-based control because the system directly monitors and responds to actual temperature conditions rather than relying on voltage proxies. The feedback loop ensures high response accuracy while keeping the control system relatively simple through the use of standard control components.
3Measurement precision
If thermodynamic parameter monitoring is implemented, then temperature control accuracy improves, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical temperature measurement and control mechanisms with electronic sensing and power conversion systems. The sensor arrangement uses electronic components to detect thermodynamic parameters, and the DC power converter uses electronic switching and control circuits to regulate heating. This substitution of electronic systems for mechanical ones achieves high temperature control accuracy while minimizing the increase in device complexity through the use of compact, integrated electronic components.
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 provides more accurate and real-time control of the process medium's temperature, reducing the risk of undershoot or overshoot and allowing for safer and more efficient heating operations with smaller heating elements and wiring.
Implementation Method 1
an electrical heating system including an electric heating element may be used for heating the process medium
Implementation Method 2
a DC power converter which, in use of the electrical heating system, receives a substantially constant input voltage. The power converter supplies, in use, a controllable output voltage to the heating element
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
The present disclosure relates to a heating system comprising: a heating element for heating a process medium; a DC power converter configured to receive an input direct-current voltage from a power supply and to deliver an output direct-current voltage to the heating element; a sensor arrangement configured to generate a first sensor output signal indicative of a thermodynamic parameter of the process medium or the heating element; and a controller configured to control the DC power converter based on the first sensor output signal.