Induction Heating Controller Overheating Prevention
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Solution Overview
Problem
Induction heating apparatuses face challenges in preventing container overheating without a fuse, leading to potential failures and inconvenience when the temperature sensor malfunctions or the container overheats, requiring component replacement.
Innovation Solution
The induction heating apparatus employs a method to control heating based on an overheating determination index calculated from the container's inductance value, allowing for continuous operation without a fuse by adjusting the heating based on predetermined reference values and indices, ensuring safe operation even if the temperature sensor fails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fuse is disposed in the induction heating apparatus for secondary overheating prevention, then container overheating can be prevented, but the apparatus requires component replacement when the fuse melts and cannot be used conveniently
Solution Approach 1:
The patent extracts the overheating prevention function from the physical fuse component and relocates it to the controller's processing logic. The controller now performs secondary overheating prevention by determining whether to stop heating based on the relationship between the temperature gradient and heating power, eliminating the need for a physical fuse that would melt and require replacement.
Solution Approach 2:
The patent replaces the mechanical/electrical fuse system with a software-based control system. Instead of using a physical fuse that melts when overheating occurs, the controller uses algorithmic processing to monitor temperature gradients and adjust heating power accordingly, substituting a mechanical protection mechanism with an intelligent control mechanism.
2Reliability
If a temperature sensor is used for primary overheating prevention, then heating can be controlled, but the sensor may malfunction or fail to detect rapid temperature changes accurately
Solution Approach 1:
The patent implements a feedback mechanism where the controller continuously monitors the temperature gradient (rate of temperature change) and uses this information to adjust heating power in real-time. This feedback loop enables the system to respond to rapid temperature changes and sensor readings dynamically, improving reliability by cross-validating temperature data through gradient analysis rather than relying solely on absolute temperature values.
Solution Approach 2:
The patent performs preliminary determination of the temperature gradient before making heating control decisions. By calculating the rate of temperature change in advance and comparing it with the heating power, the system can predict potential overheating conditions and take preventive action before critical temperatures are reached, reducing reliance on the temperature sensor alone.
3Reliability
If a fuse is installed for safety protection, then overheating can be prevented, but manufacturing cost increases due to additional components
Solution Approach 1:
The patent makes the controller perform multiple functions: it not only controls the heating process but also performs both primary and secondary overheating prevention functions that were previously handled by separate components (temperature sensor and fuse). This multi-functionality eliminates the need for additional safety components, reducing manufacturing cost while maintaining safety protection capability.
Solution Approach 2:
The patent merges the overheating prevention function into the controller's existing processing logic, combining temperature monitoring, gradient calculation, power control, and safety protection into a single integrated system. This consolidation eliminates separate safety components like fuses, reducing the number of parts needed and lowering manufacturing costs while maintaining comprehensive safety protection.
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 solution effectively prevents container overheating, reduces manufacturing costs by eliminating the need for a fuse, and allows for uninterrupted use without component replacement, enhancing user satisfaction and safety.
Implementation Method 1
As electric energy is supplied to a working coil included in an induction heating apparatus, a magnetic field is formed around the working coil. The magnetic field generates eddy current in a container that is placed on the working coil, to heat the container.
Implementation Method 2
The magnetic field generates eddy current in a container that is placed on the working coil, to heat the container.
Data Source
AI summary
A method for controlling an induction heating apparatus of one embodiment comprises starting to heat a container, obtaining an inductance value of the container, calculating an overheating determination index based on the inductance value, comparing the overheating determination index with a predetermined first reference value, and determining whether to stop heating the container based on results of the comparison between the overheating determination index and the first reference value.