Heater Current Sequencing for Breaker-Limited Test Chambers
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Solution Overview
Problem
Existing electronic component testing apparatuses face inefficiencies in power supply utilization due to high peak electric currents when heaters are turned on simultaneously, necessitating larger power supply systems and underutilization during maintenance phases.
Innovation Solution
A controller manages electric current distribution to heaters in a predetermined sequence based on priority settings, ensuring the total current remains within breaker limits, balancing phase currents, and adjusting priorities based on chamber requirements and temperature differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heaters are turned on simultaneously to reach target temperatures, then temperature control is achieved, but peak electric current increases requiring larger power supply system
Solution Approach 1:
The controller performs preliminary assessment of heater states before activating them. It calculates required electric currents for each heater and determines activation sequence in advance, preventing simultaneous activation that would cause peak current surges while ensuring all heaters eventually reach their target temperatures
Solution Approach 2:
The system dynamically adjusts the activation sequence and timing of heaters based on real-time temperature measurements and power consumption calculations. The controller continuously monitors chamber temperatures and modifies which heaters are active at any given moment to maintain target temperatures while keeping total power consumption within breaker ratings
2Power
If heaters are activated in sequence to reduce peak current, then power supply system size is optimized, but temperature uniformity may be affected
Solution Approach 1:
The controller implements continuous feedback monitoring of chamber temperatures and adjusts the heater activation sequence accordingly. Temperature sensors provide real-time data to the controller, which modifies which heaters are active to maintain temperature uniformity across all chambers while adhering to power consumption constraints and breaker ratings
3Ease of operation
If breaker rated current is increased to handle peak currents, then all heaters can operate simultaneously, but power supply system becomes larger and less efficient
Solution Approach 1:
The system changes the operational parameters of heaters by adjusting their activation timing and duty cycles. Instead of maintaining constant simultaneous operation, the controller varies which heaters are active at different times based on chamber temperature requirements, allowing smaller breakers to be used while still achieving effective heating across all chambers
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
Optimizes power supply system size and enhances utilization by preventing excessive peak currents, allowing efficient operation across different thermal stress application and removal phases.
Implementation Method 1
a plurality of heaters for adjusting the temperature in each of the chambers are provided
Data Source
AI summary
A heater drive controlling apparatus for an electronic component testing apparatus includes a breaker disposed between a power source and heaters, and a controller that controls electric currents supplied from the power source to the heaters in order according to a first priority set for the heaters such that a sum of the supplied electric currents is within a rated current of the breaker. The electronic component testing apparatus includes a test chamber, a thermal-stress applying chamber, and a thermal-stress removing chamber each of which includes the heaters.