Heating Element Monitoring via Segment Voltage Comparison
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Solution Overview
Problem
The existing method of monitoring heating devices with series-connected heating elements using electric resistance change rates hinders accurate detection of sparks and recognition of spark precursory indications due to changing electric resistance values with temperature control.
Innovation Solution
A state monitoring method that acquires potential differences across different conductive path portions and compares them to determine anomalies, allowing for efficient identification of heating element issues and preventing spark-related breakdowns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electric resistance change rate is used to monitor heating element state, then temperature control is achieved, but accurate detection of sparks and spark precursory indications is hindered
Solution Approach 1:
The conductive path is divided into multiple conductive path portions, each monitored separately for potential difference. This segmentation allows localized anomaly detection in specific portions without being affected by changes in other portions, enabling accurate spark detection while maintaining overall temperature control.
Solution Approach 2:
Potential difference measurement is introduced as an intermediary parameter between the heating elements and the monitoring system. By measuring potential difference across each conductive path portion rather than relying solely on electric resistance, the system can detect sparks and precursory indications more accurately while temperature control continues to function.
2Loss of information
If total electric resistance value is used for monitoring, then overall heating element state is tracked, but detailed anomaly detection in specific portions is reduced
Solution Approach 1:
The monitoring system segments the conductive path into multiple portions and measures potential difference across each segment independently. This provides both overall state tracking (by monitoring all portions) and detailed portion-specific anomaly detection, resolving the information loss problem.
Solution Approach 2:
The system transitions from a single-dimensional total resistance measurement to a multi-dimensional approach by measuring potential difference across multiple conductive path portions simultaneously. This dimensional expansion enables both overall monitoring and specific portion analysis without information loss.
3Temperature
If electric resistance values change with temperature control, then temperature regulation is achieved, but anomaly detection accuracy deteriorates
Solution Approach 1:
Potential difference is used as an intermediary measurement that is less sensitive to temperature-induced resistance changes. By monitoring potential difference across conductive path portions rather than electric resistance directly, the system maintains anomaly detection accuracy while temperature control continues to regulate heating element values.
Solution Approach 2:
The monitoring parameter is changed from electric resistance to potential difference. This parameter change makes the measurement less affected by temperature-induced resistance variations, allowing accurate anomaly detection to coexist with temperature regulation that necessarily changes resistance values.
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 method effectively monitors the state of heating devices, enabling early detection of anomalies and reducing maintenance needs in glass manufacturing facilities by identifying problematic heating elements before they break.
Implementation Method 1
A heating device including a conductive path electrically connecting heating elements may be used to heat, for example, a heating subject such as a glass raw material, molten glass
Implementation Method 2
a potential difference acquisition step that obtains a potential difference of a conductive path portion including at least one of the heating elements
Data Source
AI summary
Disclosed are state monitoring method and system for a heating device including a conductive path that electrically series-connects heating elements. The method includes obtaining a potential difference of a conductive path portion including at least one of the heating elements, obtaining monitoring information used to monitor a state of the heating elements, and determining occurrence of an anomaly in the conductive path portion based on the obtained monitoring information. The step of obtaining the potential difference includes obtaining a first potential difference of a first conductive path portion and obtaining a second potential difference of a second conductive path portion that differs from the first conductive path portion. The monitoring information includes comparison information obtained by comparing potential differences including the first potential difference and the second potential difference.