Heating Component Sensor Layout for Safe Startup Control
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Solution Overview
Problem
Conventional heating systems for domestic appliances face challenges in compact design and cost-effectiveness due to the limitations of temperature monitoring and control elements, which often result in slow response times and the inability to directly mount temperature sensors near the heating unit, leading to inefficient heat transfer and potential overheating issues.
Innovation Solution
A method for controlling a heating system component that includes a carrier unit with a wet side for fluid contact and a dry side for the heating unit, featuring a temperature sensor, such as an NTC thermistor, effectively thermally isolated and electrically connected to the dry side, allowing for a test routine to ensure safe startup and continuous operation by verifying sensor functionality and monitoring temperature thresholds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If temperature sensors are directly mounted near the heating unit to improve response time, then temperature monitoring speed is improved, but the sensor is exposed to excessive temperatures exceeding its operational limits
Solution Approach 1:
The patent introduces a thermally conductive element as an intermediary between the heating unit and the temperature sensor. This element conducts heat from the heating unit to the sensor, allowing the sensor to monitor temperature changes rapidly while remaining physically separated from the extreme heat source. The intermediary transfers the thermal information without exposing the sensor to damaging temperatures.
Solution Approach 2:
The system is divided into separate functional components: the heating unit, the thermally conductive element, and the temperature sensor. This segmentation allows each component to operate within its optimal temperature range while maintaining functional connectivity. The sensor is isolated from direct thermal exposure through this segmented architecture.
2Device complexity
If conventional temperature monitoring elements are used with mounting plates and screws, then the system structure is simplified, but the response time becomes unacceptable due to heat transfer through multiple components
Solution Approach 1:
The patent extracts the temperature sensor from the conventional mounting plate and screw assembly structure. By removing the sensor from this indirect mounting arrangement, the design eliminates the thermal resistance introduced by multiple intermediate components (mounting plate, screws, flanges), achieving both structural simplicity and fast response time.
Solution Approach 2:
The thermally conductive element serves as a dedicated intermediary that provides a direct thermal pathway from the heating unit to the sensor. This specialized intermediary component replaces the multi-component mechanical mounting structure, simplifying the overall design while optimizing heat transfer efficiency.
3Reliability
If expensive high-temperature resistant temperature sensors are used to withstand temperatures above 100°C, then temperature monitoring reliability is improved, but manufacturing costs increase
Solution Approach 1:
The thermally conductive element acts as a protective intermediary that shields inexpensive temperature sensors from high-temperature exposure. This allows the use of cost-effective NTC thermistors and other standard temperature sensors that would otherwise be damaged by temperatures exceeding 100°C, significantly reducing manufacturing costs while maintaining monitoring reliability.
Solution Approach 2:
The system enables the use of inexpensive, standard temperature sensors instead of expensive high-temperature resistant sensors. The thermally conductive element protects these economical sensors, making them suitable for continuous operation in heating applications without requiring costly specialized 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 approach enables a safe and efficient startup procedure, prevents overheating, and allows for a compact, cost-effective design by ensuring the temperature sensor is not exposed to excessive temperatures, thereby enhancing the reliability and safety of the heating system.
Implementation Method 1
the temperature sensor is effectively in thermal contact and electrically isolated with at least a part of an upper surface of the dry side of the carrier unit
Implementation Method 2
heating unit coupled to the carrier unit
Implementation Method 3
a heating unit arranged on the carrier unit and a heat transfer element which is arranged on the carrier unit and comprises a material which is a good conductor of heat
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
The invention relates to a heating system component (100) for a heating system for heating a fluid medium, with a carrier unit (110), and a heating unit (120) coupled to said carrier unit (110), and a controller; wherein said carrier unit (110) comprises a wet side and a dry side, wherein said wet side corresponds to a surface of said carrier unit (110) configured to be in contact with said fluid medium, wherein said dry side is located on a surface opposite to said wet side. A temperature sensor (170a, 180a, 270a, 370a, 460, 470a, 480, 770), in particular an NTC thermistor, is effectively in thermal contact with at least a part of an upper surface of said dry side of the carrier unit (110), the method (1) comprising: receiving (2) a starting signal (S1) at the controller (30) for starting the heating system component (100); carrying out a test routine (3) for at least the at least one temperature sensor (170a, 180a, 270a, 370a, 460, 470a, 480,770); and in case the test routine is not successful: entering a safe state (16) of the heating system component.