Sensor system and integrated heater-sensor for measuring and controlling performance of a heater system
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Solution Overview
Problem
Conventional heating systems with multiple independent sensors are complex and can only detect large incremental changes, making them ineffective for precise measurement of performance characteristics such as fluid temperature, ambient temperature, and fluid level.
Innovation Solution
An integrated heater device with a multiportion resistive element, comprising conductive materials of varying temperature coefficients of resistance, functions as both a heater and a sensor to measure performance characteristics, and a control system determines these characteristics based on electrical responses, allowing for precise measurement and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple independent sensors are used to measure different performance characteristics, then measurement coverage is improved, but device complexity increases significantly
Solution Approach 1:
The patent combines multiple sensor functions into a single integrated heater-sensor device. The heater element serves dual purposes: heating the fluid and acting as a temperature sensor through resistance measurement. This eliminates the need for separate temperature sensors, reducing system complexity while maintaining measurement capability.
Solution Approach 2:
The heater element is designed to perform multiple functions: it serves as both a heating element and a temperature sensor. By making the heater universal, the system reduces the number of components needed while achieving comprehensive performance characterization through electrical resistance measurements that reflect temperature, fluid presence, and heating efficiency.
2Measurement precision
If multiple independent sensors are used, then various performance characteristics can be measured, but the system can only detect large incremental changes
Solution Approach 1:
The system uses the heater's electrical resistance as a feedback mechanism to detect changes in operating conditions. By monitoring resistance variations, the system can detect subtle changes in temperature, fluid presence, and heating efficiency. This feedback approach enables precise detection of incremental changes without requiring multiple independent sensors.
Solution Approach 2:
The heater serves itself as a sensor by utilizing its own electrical resistance characteristics to detect performance changes. This self-service capability allows the heater to provide both heating and sensing functions, enabling detection of small incremental changes in operating conditions through its inherent electrical properties without requiring external sensing components.
3Productivity
If the heater operates at high power, then heating efficiency is improved, but temperature measurement accuracy deteriorates due to self-heating effects
Solution Approach 1:
The system employs periodic switching between heating mode and sensing mode. During sensing intervals, power to the heater is reduced or interrupted, allowing temperature measurement with minimal self-heating. During heating intervals, the heater operates at full power for efficient heating. This periodic alternation enables both high heating efficiency and accurate temperature measurement.
Solution Approach 2:
The system performs preliminary sensing measurements before applying high power heating. By measuring the initial temperature and resistance characteristics before heating begins, the system establishes a baseline that accounts for any self-heating effects. This preliminary action allows the system to compensate for measurement errors and maintain accuracy even during high-power operation.
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
The integrated heater device enables precise measurement and control of fluid temperature, ambient temperature, and fluid level, reducing system complexity and improving detection accuracy beyond large incremental changes.
Implementation Method 1
The multiportion resistive element is operable as a heater to generate heat
Implementation Method 2
a first portion defined by a first conductive material and a second portion defined by a second conductive material having a lower temperature coefficient of resistance (TCR) than that of the first conductive material
Implementation Method 3
a first member and a second member having a different Seebeck coefficient than that of the first member, where the first member and the second member form a temperature sensing junction to measure a temperature at a first location
Data Source
AI summary
A heater system includes an integrated heater device and a control system. The integrated heater device includes a thermocouple for measuring temperature and one or more multiportion resistive elements that are operable as heaters to create a temperature differential between the fluid and air to detect the fluid, and as sensors to measure a fluid level. The control device operates the integrated heater device as a sensor or heater based on one or more performance characteristics of the heater system and self-calibrates the heater device.