Heating System Temperature Control via Feedback Sensors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing heating systems for industrial processes lack precise and accurate temperature control of process media, often relying on voltage monitoring which can lead to undershoot or overshoot of target temperatures due to time-lags and unreliable voltage measurements.
Innovation Solution
A heating system comprising an inverter, transformer, sensor arrangement, and controller that regulates temperature based on thermodynamic parameters such as temperature, pressure, or viscosity of the process medium, using sensors like thermocouples or infrared sensors to provide real-time feedback for precise control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If voltage monitoring is used to control the heating arrangement, then the system structure is simple, but the temperature control precision deteriorates due to time-lags and unreliable voltage measurements
Solution Approach 1:
The patent implements a feedback control system where a sensor arrangement continuously monitors the actual temperature of the process medium and feeds this information back to the controller. The controller compares the actual temperature with the target temperature and adjusts the heating arrangement accordingly, eliminating time-lags and improving temperature control precision.
Solution Approach 2:
The patent replaces voltage monitoring (an indirect electrical measurement) with direct temperature sensing using sensor arrangements (thermal measurement). This substitution provides more reliable and accurate control data, resolving the issue of unreliable voltage measurements leading to temperature control imprecision.
2Device complexity
If voltage monitoring is used for temperature control, then the control system is simple, but temperature accuracy deteriorates due to undershoot or overshoot
Solution Approach 1:
The feedback mechanism continuously adjusts the heating output based on real-time temperature measurements, preventing both undershoot (failure to reach target temperature) and overshoot (exceeding target temperature). This closed-loop control ensures accurate temperature maintenance.
Solution Approach 2:
The controller anticipates temperature changes by adjusting the heating arrangement in advance based on the feedback signal, preventing temperature deviations before they occur. This proactive control eliminates undershoot and overshoot conditions.
3Manufacturing precision
If sensor arrangement with thermodynamic parameter monitoring is implemented, then temperature control precision is improved, but device complexity increases
Solution Approach 1:
The sensor arrangement provides direct temperature feedback to the controller, enabling precise temperature control. Although this increases device complexity, the improved temperature control precision justifies the additional components.
Solution Approach 2:
The sensor arrangement acts as an intermediary between the heating arrangement and the controller, providing accurate thermal information that enables precise control. This intermediary component resolves the contradiction by enabling sophisticated control without requiring complex direct control mechanisms.
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 configuration enables more accurate and precise temperature control of process media, reducing the likelihood of undershoot or overshoot and ensuring the process medium is maintained within a predetermined target range, thereby improving the efficiency and safety of the heating process.
Implementation Method 1
an inverter configured to receive an input direct-current voltage from a power supply and to produce an intermediate alternating-current voltage
Implementation Method 2
a transformer configured to receive the intermediate alternating-current voltage produced by the inverter and to supply an output alternating-current voltage to the heating arrangement
Implementation Method 3
a heating arrangement for heating a process medium
Implementation Method 4
The sensor arrangement may comprise a thermocouple in a proximity to the process medium or the heating arrangement, and the thermocouple may be configured to generate the first sensor output signal
Implementation Method 5
Alternatively, the sensor arrangement may comprise an infrared sensor configured to generate the first sensor output signal
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
The present disclosure relates to a heating system comprising: a heating arrangement for heating a process medium; an inverter configured to receive an input direct-current voltage from a power supply and to produce an intermediate alternating-current voltage; a transformer configured to receive the intermediate alternating-current voltage produced by the inverter and to supply an output alternating-current voltage to the heating arrangement; a sensor arrangement configured to generate a first sensor output signal indicative of a thermodynamic parameter of the process medium or the heating arrangement; and a controller configured to control the inverter based on the first sensor output signal.