Heating Element Control Circuit With Reduced Wiring Harness
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Solution Overview
Problem
The existing power control circuits for heating elements in appliances require a high number and length of power conductors due to the distances between the power source, infinite switch, and heating element, increasing complexity and cost.
Innovation Solution
A power control circuit design that includes a jumper wire connecting the ON/OFF switch to the temperature level control switch in series, reducing the number of conductors needed by allowing the infinite switch to control power through a single hot conductor, thereby simplifying the wiring and reducing the overall length of wire used.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a traditional infinite switch with separate power conductors is used to control heating element temperature, then temperature control capability is achieved, but the number and length of power conductors increase significantly
Solution Approach 1:
The patent combines the functions of multiple power conductors into a single hot conductor by integrating the ON/OFF switch and temperature control switch within the infinite switch housing. This merging eliminates the need for separate power conductors running between the infinite switch and heating element, directly reducing the quantity of conductors while preserving temperature control capability through the integrated switching mechanism
2Reliability
If multiple separate power conductors are used to supply power from the source through the infinite switch to the heating element, then reliable power control is achieved, but the wiring complexity and cost increase
Solution Approach 1:
The patent merges multiple switching functions into a single integrated infinite switch unit that houses both the ON/OFF switch and temperature control switch. This consolidation reduces wiring complexity by eliminating the need for separate conductor runs between distributed switching components, while maintaining reliable power control through the coordinated operation of integrated switches and the bi-metallic temperature sensing mechanism
3Ease of operation
If the infinite switch is positioned away from the heating element to allow access for temperature adjustment, then user accessibility is improved, but the length of power conductors required increases
Solution Approach 1:
The patent integrates the switching components within the infinite switch housing, allowing the unit itself to be positioned in accessible locations without requiring additional long conductor runs to separate switching components. The integrated design means the entire control function is contained in one unit that can be mounted where users can access the temperature control knob, eliminating the need for conductors to reach distributed switching components
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 design reduces the complexity and cost of the wiring harness by minimizing the number of conductors required, enhancing the efficiency and reliability of power control to heating elements while maintaining precise temperature control.
Implementation Method 1
typically employs a bi-metallic strip and heater combination for this purpose
Implementation Method 2
heating element in accordance with a temperature setting of the infinite switch
Data Source
Figure 1
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AI summary
A power control circuit includes first and second electrical power terminals connected across a source of electrical power. A heating element is connected to the first terminal. A heating element controller is connected in series with the heating element, between the heating element and the second terminal. The controller is configured to control a temperature level of the element, and includes a control input configured to receive a range of temperature settings, and an OFF command for the element. The controller includes an ON/OFF switch to disconnect the element from the second terminal, and a temperature level control switch to intermittently connect/disconnect the element to the second terminal. A jumper wire series-connects the ON/OFF switch to the temperature level control switch. The ON/OFF switch, the jumper wire, the temperature level control switch, and the element are electrically connected in series.