Method for operating a heating device and heating device
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Solution Overview
Problem
Existing heating devices with resistance heating elements face reliability issues due to overheating risks when there is no fluid, low or high fluid velocity, or disrupted heat transfer from dirt particles, leading to potential damage.
Innovation Solution
A method using an induction heating coil to monitor temperature changes on a ferromagnetic heating support, comparing the change to predefined values to determine sufficient heat dissipation, ensuring the resistance heating element operates only when sufficient fluid is present, thereby preventing overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a resistance heating element with high power density is used to rapidly heat fluid, then heating efficiency is improved, but the risk of overheating and damage increases when fluid is absent or heat transfer is disrupted
Solution Approach 1:
The patent applies preliminary action by performing a safety check before activating the high-power resistance heating element. An induction heating coil first heats the heating support slightly, and temperature sensors verify that heat dissipation is functioning properly. Only after this preliminary verification confirms safe operating conditions is the high-power heating element activated, thus preventing overheating while maintaining rapid heating capability
Solution Approach 2:
The patent implements feedback through continuous temperature monitoring using multiple temperature sensors positioned on the heating support and heating chamber. The control unit receives real-time temperature data and dynamically adjusts or terminates heating operations based on detected temperature changes. This feedback mechanism enables the system to respond immediately to abnormal conditions such as fluid absence or heat transfer disruption, preventing overheating while allowing high-power operation under normal conditions
2Measurement precision
If discrete temperature sensors are placed on the heating element to monitor temperature, then localized temperature detection is improved, but measurement reliability is insufficient to prevent overheating damage
Solution Approach 1:
The patent applies segmentation by dividing the temperature monitoring function across multiple discrete temperature sensors positioned at different locations on the heating support and heating chamber. Rather than relying on a single sensor, the system uses an array of sensors to provide comprehensive spatial coverage of temperature conditions. The control unit evaluates temperature changes at multiple points to determine overall thermal state, providing more reliable overheating detection than any single sensor could achieve alone
Solution Approach 2:
The patent implements partial or excessive action by using more temperature sensors than the minimum single sensor would require. This excessive instrumentation ensures that no critical temperature change goes undetected, even if one sensor fails or is positioned suboptimally. The redundant sensing capability provides measurement precision and reliability that exceeds basic requirements, enabling confident prevention of overheating damage
3Area of stationary object
If temperature detection operates over a wide area using leakage currents, then detection coverage is improved, but response time is too slow to prevent damage before heating element activation
Solution Approach 1:
The patent applies preliminary action by conducting a pre-heating verification step using the induction heating coil before activating the high-power resistance heating element. During this preliminary phase, temperature sensors monitor temperature changes over a wide area of the heating support. Only after this preliminary verification confirms adequate heat dissipation capability does the system proceed to high-power heating, ensuring both wide detection coverage and sufficient response time
Solution Approach 2:
The patent introduces an intermediary verification process between the temperature detection system and the high-power heating activation. The induction heating coil serves as an intermediary tool to perform a controlled test heating, while the temperature sensors act as intermediaries to measure the thermal response. This intermediary verification step bridges the gap between wide-area detection capability and rapid response requirement, allowing the system to safely activate high-power heating only when thermal management is confirmed functional
4Productivity
If the resistance heating element operates at maximum power without pre-check, then productivity is maximized, but the heating support may overheat and cause damage when fluid is absent
Solution Approach 1:
The patent applies preliminary action by requiring a pre-operational safety check using the induction heating coil and temperature sensors before allowing the resistance heating element to operate at maximum power. This preliminary verification confirms that fluid is present and heat dissipation is functioning. Only after this preliminary check passes does the system permit maximum-power heating operation, thus maximizing productivity while preventing thermal damage under abnormal conditions
Solution Approach 2:
The patent implements feedback through continuous temperature monitoring during high-power heating operation. Temperature sensors provide real-time data to the control unit, which dynamically adjusts or terminates heating if temperature changes indicate inadequate heat dissipation. This feedback mechanism enables the system to maintain maximum productivity under normal conditions while automatically preventing thermal damage when fluid absence or heat transfer disruption occurs
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
Ensures reliable operation of the resistance heating element by preventing overheating, allowing safe and efficient heating only when sufficient heat dissipation is confirmed, reducing the risk of damage to the device.
Implementation Method 1
A current and/or voltage through or at the induction heating coil is monitored and evaluated to determine a temperature change on the heating support. A changing temperature of the heating support results in changes in its ferromagnetic properties
Implementation Method 2
activate the induction heating coil to heat the heating support
Implementation Method 3
a resistance heating element is provided in a flat, distributed form. This resistance heating element is intended to be operable with a high power density in order to very rapidly heat fluid flowing through the heating chamber
Data Source
Figure 1~2
Figure 3
AI summary
In a method for operating a heating device with a resistance heating element with a high nominal power, which is arranged in a heating chamber, a part of the heating chamber itself or on the chamber is designed as a heating carrier so that it can be heated inductively. An induction heating coil is provided for this purpose. It partially heats the heating carrier to determine whether there is sufficient heat dissipation for operation of the resistance heating element because water flows through it. If it can be determined from a slow temperature rise during inductive heating that the heat dissipation is sufficient, heating operation with the high-power resistance heating element can begin. If the temperature rise is too rapid, the heat dissipation is insufficient, and the resistance heating element or the heating device will not operate.