Heating Control Gain Monitoring for Heat Retention Failure Detection
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Solution Overview
Problem
Existing heating device technologies cannot effectively detect changes related to heat retention of a heated item or detect failures in the heating device, such as heater deterioration and voltage variations.
Innovation Solution
A heating device with a system gain change rate calculation unit, heat retention change rate calculation unit, heater resistance value change rate calculation unit, and heater voltage change rate calculation unit, which together enable the detection of changes in heat retention and potential failures by comparing calculated rates with threshold values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a method for determining a state of a control target on the basis of a behavior of a feedback system when a transient state is caused to occur is used, then the state of the control target can be determined, but it is not possible to detect the extent of the respective changes related to heat retention of a heated item
Solution Approach 1:
The invention changes the parameter being measured from general feedback system behavior to specific system gain (ratio of temperature increase value to electric power input). By calculating the system gain change rate and heat retention change rate as specific parameters, the invention enables quantitative detection of heat retention changes that were previously undetectable.
Solution Approach 2:
The invention replaces qualitative behavioral observation with quantitative calculation based on physical relationships. By substituting the mechanical/physical measurement of temperature and power with calculated rates of change, the system can detect heat retention changes that are not apparent from transient state behavior alone.
2Reliability
If existing temperature control methods are used, then temperature control can be maintained, but failures in the heating device such as heater deterioration and voltage variations cannot be detected
Solution Approach 1:
The detection system uses the existing temperature control loop's own data (temperature values and power input) to perform self-diagnosis. By calculating system gain and its rate of change from operational data, the system detects heater deterioration and voltage variations without requiring separate external testing equipment, making the existing system serve its own monitoring needs.
Solution Approach 2:
The invention introduces a feedback mechanism where the calculated system gain change rate is compared against threshold values to detect abnormalities. This feedback loop continuously monitors the heating device's performance and provides information about heater deterioration and voltage variations, enabling proactive maintenance and reliability improvement.
3Measurement precision
If the system gain change rate and heat retention change rate are calculated and compared with threshold values, then accurate detection of heat retention changes and failures is enabled, but the calculation and monitoring complexity increases
Solution Approach 1:
The invention performs preliminary calculations of system gain and its rate of change during normal operation, before failures occur. By continuously computing these parameters from operational data and comparing them against pre-set threshold values, the system prepares detection information in advance, enabling accurate detection without requiring complex real-time analysis when failures occur.
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
Enables accurate detection of heat retention changes and failures in the heating device, including heater deterioration and voltage variations, thereby maintaining effective temperature control and preventing operational issues.
Implementation Method 1
a heater (10) configured to heat an item (1)
Implementation Method 2
a temperature detection unit (20) configured to detect a temperature of the heated item (1)
Data Source
AI summary
A heating device (100) comprises: a heater (10) for heating an item (1); a temperature detection unit (20) for detecting the temperature of the item (1); and a temperature adjustment unit (30) for controlling the heater (10) on the basis of a target temperature and the detected value of the temperature detection unit (20) so that the temperature of the item (1) reaches the target temperature. The heating device (100) determines, as a system gain change rate, the rate of change from the initial value of a system gain determined as a ratio of a temperature increase value of the item (1) with respect to electric power inputted to the heater (10), and determines the rate of change in the heat retention of the item (1) using the system gain change rate.