Fluid Temperature Control Using Estimated Outlet Temperatures
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Solution Overview
Problem
Existing temperature control devices for fluids require multiple temperature sensors, increasing costs and the likelihood of faults, and are limited in control scope as they only manage the downstream heating tank.
Innovation Solution
A temperature control device with a reduced number of sensors, using a combination of fluid reservoir units in series or parallel, an inlet temperature sensor, and an outlet temperature sensor, along with an estimation means to model and estimate outlet temperatures, allowing for precise control of all units without additional sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple temperature sensors are provided for each heating tank, then temperature control accuracy is improved, but device cost and complexity increase
Solution Approach 1:
The patent uses a virtual copy of the temperature sensor through software estimation. Instead of installing physical sensors at every heating tank outlet, the system creates a virtual temperature measurement for unsensored tanks by estimating their outlet temperatures based on the dynamics model and actual measurements from other tanks. This virtual copying approach maintains measurement precision while dramatically reducing the number of physical sensors needed.
Solution Approach 2:
The patent introduces a dynamics model as an intermediary between the limited physical sensors and the control system. This model acts as a mediator that translates measurements from a few actual sensors into estimated temperature information for all heating tanks, enabling accurate temperature control without requiring direct measurement at every location.
2Measurement precision
If multiple temperature sensors are provided for each heating tank, then temperature control accuracy is improved, but reliability decreases due to increased fault possibility
Solution Approach 1:
By creating virtual temperature measurements through software estimation rather than using multiple physical sensors, the system eliminates the reliability issues associated with having numerous physical sensors that could fail. The virtual copy approach maintains temperature control accuracy while improving reliability by reducing the number of physical components that could malfunction.
3Adaptability or versatility
If temperature control is applied to all heating tanks, then control freedom is improved, but the number of temperature sensors must increase
Solution Approach 1:
The patent enables full control freedom for all heating tanks by creating virtual temperature measurements for unsensored tanks. This allows the control system to independently adjust each heater's output based on its individual target temperature and estimated outlet temperature, achieving complete control freedom without requiring physical sensors at every location.
Solution Approach 2:
The dynamics model serves as an intermediary that provides the control system with temperature information for all heating tanks, even those without physical sensors. This intermediary enables the control system to exercise full control freedom over each tank while avoiding the need to install additional sensors.
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 reduces sensor costs and fault likelihood while maintaining control freedom, enabling accurate temperature management across multiple fluid reservoir units.
Implementation Method 1
an outlet temperature sensor (16) which is provided to an outlet of one of said plurality of fluid reservoir units
Implementation Method 2
an inlet temperature sensor (14) which measures the inlet temperature of the fluid which flows into said temperature control device
Implementation Method 3
which comprise heat application or cooling means
Implementation Method 4
which comprise heat application or cooling means
Data Source
AI summary
A temperature control device includes an estimator that estimates the outlet temperature of fluid at an outlet of heating tanks to which no outlet temperature sensor is provided. The temperature control device includes a control unit. For a heating tank to which an outlet temperature sensor is provided, the control unit determines a manipulated variable on the basis of the outlet temperature which has been measured and an individual target temperature. For a heating tank to which no outlet temperature sensor is provided, the control unit determines a manipulated variable on the basis of the estimated temperature estimated by the estimator and an individual target temperature. The control unit controls the outlet temperature of the heating tanks on the basis of the manipulated variables.