Heating Element Sensor Failure Detection via Thermal Model
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Solution Overview
Problem
Conventional methods for detecting temperature sensor failures in heating elements are unreliable, particularly when the measured temperature is near maximum or minimum voltage, and rely on additional sensors, which can lead to inaccurate and delayed failure detection, reducing the system's ability to control the cooling system effectively.
Innovation Solution
A method and system that estimate the temperature of a heating element using a heat transfer model, calculate variations in estimated and measured temperatures, and determine sensor failure based on a calculated ratio, allowing for rapid and accurate failure detection and emergency cooling system operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods use additional temperature sensors to detect sensor failure, then failure detection coverage is improved, but system complexity and cost increase
Solution Approach 1:
The system uses the existing temperature sensor to detect its own failure by monitoring whether measured temperature values fall within the expected range based on heating power and thermal model, eliminating the need for additional sensors
Solution Approach 2:
The patent replaces physical additional sensors with a computational detection method using thermal modeling and data processing to substitute for hardware-based failure detection
2Reliability
If conventional methods use cooling water temperature sensors to detect sensor failure, then failure detection is possible, but detection accuracy is reduced due to thermal disturbance from water circulation
Solution Approach 1:
The patent extracts the temperature measurement function from the cooling water system and places it directly at the heating element, eliminating the thermal disturbance introduced by water circulation
Solution Approach 2:
The patent introduces a thermal model as an intermediary to predict expected temperature and compare with actual measurements, enabling failure detection without direct physical contact that causes disturbance
3Reliability
If the system waits for temperature sensor failure to be detected before taking action, then false alarms are reduced, but response time to prevent overheating increases
Solution Approach 1:
The system performs preliminary failure detection continuously by comparing measured temperature with model-predicted temperature, enabling early warning before critical overheating occurs
Solution Approach 2:
The patent implements a feedback mechanism where the detected temperature discrepancy triggers immediate cooling system activation, creating a rapid response loop that prevents overheating while maintaining system stability
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 reliable and rapid detection of temperature sensor failures within the measurement range, allowing for accurate control of the cooling system without relying on additional sensors, thereby preventing overheating and ensuring system stability.
Implementation Method 1
A temperature sensor generally senses a voltage in order to measure a temperature in an environment such as a heating element in which an exothermic reaction occurs
Implementation Method 2
estimating a temperature of the heating element based on a heat transfer model of the heating element
Data Source
AI summary
A method for controlling a temperature of a heating element can include: measuring a temperature of the heating element using a temperature sensor; estimating a temperature of the heating element based on a heat transfer model of the heating element; calculating a variation of the estimated temperature and a variation of the measured temperature; and determining whether a failure of the temperature sensor occurs based on the calculated variation of the estimated temperature and the calculated variation of the measured temperature.