Heater Fault Detection Using Phase Loss and Current Surge Signals
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Solution Overview
Problem
Current temperature monitoring systems in manufacturing fail to detect abnormalities early, leading to increased production costs and scrap rates due to temperature-related product deformations and electrical failures.
Innovation Solution
A temperature control and detection system that includes a control apparatus connected to detectors for trip, phase loss, current, overheating, and resistance, issuing early warnings and terminating heater operation when abnormalities are detected, with optional warning and communication units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional temperature monitoring devices (thermocouple and heat detector) are used to monitor temperature of the entire device or product, then temperature monitoring coverage is achieved, but temperature abnormalities are detected too late leading to product deformation and electrical failure
Solution Approach 1:
The system performs preliminary detection of electrical status (current, voltage, phase balance) before temperature abnormalities occur. By monitoring electrical parameters that precede thermal issues, the system can terminate heater operation in advance, preventing product deformation and electrical failure before they happen.
Solution Approach 2:
The system introduces intermediate electrical parameter detection (current detector, voltage detector, phase loss detector) as mediators between the heater and final temperature effects. These detectors monitor electrical status that indirectly indicates potential temperature problems, providing early warning before direct temperature measurement would show abnormalities.
2Measurement precision
If multiple detection devices and control mechanisms are added to detect electrical status and terminate heater operation early, then detection accuracy and prevention capability are improved, but device complexity increases
Solution Approach 1:
The control apparatus serves multiple functions: it receives signals from various detectors (current, voltage, phase loss, trip), processes different types of abnormality signals, and controls the heater termination. This multi-functional design consolidates what could be separate complex systems into a single integrated control unit, reducing overall system complexity while maintaining high detection precision.
Solution Approach 2:
The system combines multiple detection functions (current detection, voltage detection, phase loss detection, trip detection) into a unified temperature control and detection system. By merging these detection mechanisms and their control logic into one integrated system, the patent reduces the complexity that would arise from having separate independent systems while maintaining comprehensive monitoring capability.
3Manufacturing precision
If early detection and termination of heater operation is implemented, then product quality and yield are improved, but production time management becomes more complex
Solution Approach 1:
The system implements feedback control by continuously monitoring electrical parameters and automatically terminating heater operation when abnormalities are detected. This closed-loop feedback mechanism ensures high product quality by preventing temperature-related defects while maintaining relatively simple control logic that responds automatically to detected conditions without requiring complex external control systems.
Data Source
AI summary
A temperature control and detection system is configured to detect an electrical status and a thermal status of a heating device, and includes a control apparatus, a trip detector, a phase loss detector, and a current detector. When detecting that the leakage circuit breaker trips out, the trip detector generates a first abnormal signal and sends the first abnormal signal to the control apparatus. When detecting that a three-phase voltage is unbalanced, the phase loss detector generates a second abnormal signal and sends the second abnormal signal to the control apparatus. When detecting that a continuous current surge or a current is continuously lower than a threshold, the current detector generates a third abnormal signal and sends the third abnormal signal to the control apparatus. When receiving the first abnormal signal, the second abnormal signal, or the third abnormal signal, the control apparatus terminates operation of the heater.