Electrically Heated Mould Current Sensing for Resistor Wear Detection
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Solution Overview
Problem
Existing systems for monitoring and controlling electric heating elements in product forming processes lack a simple and efficient method for measuring electric current and detecting defects or wear of resistors.
Innovation Solution
A system comprising an electrically heated mould with integrated measurement devices that measure electric current through resistors using inductive elements, allowing for continuous monitoring and detection of resistor defects or wear, powered by the flowing current itself or an optional battery, and controlled by a central unit for periodic or threshold-triggered measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If measurement devices are integrated on the mould part to measure electric current through resistors, then measurement precision and defect detection capability are improved, but device complexity increases due to additional inductive elements and electronic components
Solution Approach 1:
The measurement device is integrated directly on the mould part, combining the measurement functionality with the existing mould structure. The inductive elements are incorporated into the mould part itself, merging multiple functions (heating support and current measurement) into a single integrated component, thereby improving measurement precision without proportionally increasing overall device complexity.
Solution Approach 2:
Inductive elements are introduced as intermediary components that non-invasively measure the electric current flowing through the resistors. These intermediaries detect the magnetic field generated by the current without directly contacting the high-voltage conductors, enabling safe and precise current measurement while maintaining electrical isolation.
2Reliability
If current measurements are performed continuously during production cycles, then defect detection capability is improved, but productivity decreases due to potential production interruptions
Solution Approach 1:
The measurement device enables continuous current monitoring throughout the production cycle without interruption. The inductive elements continuously detect current flow, and the electronic components continuously process measurements, allowing real-time defect detection while maintaining uninterrupted production flow. This eliminates the need to stop production for periodic checks.
Solution Approach 2:
The system incorporates feedback mechanisms where measurement data is continuously analyzed and compared against threshold values. When deviations indicating potential defects are detected, the system can trigger alerts or adjustments without stopping production, enabling proactive maintenance while maintaining continuous operational flow.
3Measurement precision
If inductive elements are used to measure current through conductors, then measurement precision is improved, but energy consumption increases due to additional measurement components
Solution Approach 1:
The system replaces direct electrical measurement methods (which would require physical contact and potentially high-power measurement circuits) with inductive sensing. The inductive elements detect current through magnetic field coupling, substituting a low-power electromagnetic sensing mechanism for what would otherwise require high-power direct measurement circuits, thereby reducing energy consumption while maintaining measurement precision.
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
Enables continuous and efficient monitoring of resistor performance without interrupting production, facilitating early detection of defects and wear, thereby ensuring consistent product quality and reducing maintenance downtime.
Implementation Method 1
an inductive element is provided for measuring the electric current through the at least one electrical conductor
Implementation Method 2
electrical resistors for heating a cavity inside the mould
Data Source
AI summary
Product forming system, e.g. by a rotational moulding process, comprising an electrically heated mould of which at least one mould part is provided with a plurality of electrical resistors for heating a cavity inside the mould, means for applying electric current to the electrical resistors, and a measurement device for measuring the electric current flowing through the electric resistors. The measurement device comprises a plurality of openings, with at least one electrical conductor running through each opening, each of which is connected in series to at least one of the electrical resistors. At each opening, an inductive element is provided for measuring the electric current through the respective at least one electrical conductor. The measurement device comprises electronic components for converting the measured currents into measurement data and for storing and/or transmitting the measurement data.