Heater Control Device for Reducing Agent Supplier Current Management
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Solution Overview
Problem
The existing heater control systems in reducing agent suppliers for urea SCR systems require high current capacity when both tank and piping heaters are operated, necessitating specialized and costly components to handle peak currents, which is inefficient and costly.
Innovation Solution
A heater control device and method that strategically manage the operation of tank and piping heaters by using a common current supply circuit with a main relay and feedback control, ensuring the total current through the circuit does not exceed the rated capacity by controlling the start timing and duration of heater operation, particularly by delaying the start of the piping heater until the tank heater current reduces below a certain threshold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If both tank heater and piping heater are operated simultaneously, then heating effectiveness is improved, but current demand increases requiring specialized high-current components
Solution Approach 1:
The control device determines whether to operate the tank heater or piping heater in advance based on temperature sensor readings before actual heating begins. By preliminarily assessing the thermal state of the urea aqueous solution and selecting the appropriate heating strategy, the system avoids simultaneous operation of both heaters, thereby controlling peak current demand while ensuring heating effectiveness when needed.
Solution Approach 2:
The system changes the operational parameters of the heating system by switching between different heating modes (tank heater only, piping heater only, or both) based on real-time temperature conditions. This parameter change approach allows the system to optimize the balance between heating effectiveness and current consumption, using full-power dual-heating only when absolutely necessary.
2Power
If specialized high-current components are used to handle peak currents, then current handling capability is improved, but system cost increases
Solution Approach 1:
The system uses standard, cost-effective current supply circuit components rather than specialized high-current components. By controlling the operation timing of heaters through intelligent control, the system avoids the need for expensive high-current-rated components, achieving cost savings while maintaining adequate current handling capability through proper operational management.
Solution Approach 2:
The control device uses feedback from temperature sensors to dynamically adjust heater operation. This feedback mechanism allows the system to respond to actual thermal conditions and activate heating only when and where needed, preventing the need for continuously high-current-capable components and reducing overall system cost.
3Temperature
If tank heater is operated to heat large thermal capacity, then heating capability is improved, but current consumption increases
Solution Approach 1:
The system applies partial heating action by selecting either the tank heater or piping heater based on specific thermal conditions, rather than always operating both. The control device determines the appropriate heating approach - using the tank heater when bulk heating is needed, or the piping heater when localized heating suffices - thereby optimizing energy consumption while maintaining adequate heating capability.
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 approach effectively suppresses the maximum current flowing through the supply circuit, allowing the use of general-purpose components for the main relay, reducing costs and improving system reliability by preventing excessive current flow and optimizing heater operation.
Implementation Method 1
a positive temperature coefficient (PTC) heater including a PTC element is used as the heater provided in the tank... the PTC element has such a characteristic that a resistance value thereof is increased with a temperature increase
Implementation Method 2
the heater provided in the tank... and the PTC element has such a characteristic that a resistance value thereof is increased with a temperature increase. Even in the case where a large current is supplied to the PTC heater at a start of driving and the large amount of heat is thereby generated
Data Source
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Figure 5
AI summary
The present invention provides a heater control device and a heater control method capable of suppressing a maximum value of a current flowing through a current supply circuit to a heater in a reducing agent supplier. The heater control device is a heater control device including: a tank heater for heating a reducing agent stored in a tank; and a piping heater for heating the reducing agent in a flow channel including a supply channel, and includes: a first current supply circuit that supplies a current to the tank heater; a second current supply circuit that supplies a current to the piping heater; a common current supply circuit that connects between a battery and each of the first current supply circuit and the second current supply circuit; and a heater control unit that controls driving of the tank heater and the piping heater. The heater control unit controls driving of the tank heater and the piping heater on the basis of a total value of the current supplied to the tank heater and the current supplied to the piping heater and a rated current value of the common current supply circuit.