Integrated Temperature Controller With Solid State Relay
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing temperature controllers often require multiple components and complex setups, making them difficult to use and costly for applications that only need basic temperature control for heating or cooling loads, and they lack efficient handling of high voltage/current loads.
Innovation Solution
A self-contained temperature controller integrated with a solid-state relay that includes internal circuitry for generating temperature control outputs for heating and cooling loads, using a single low-current isolated DC supply, and featuring isolated power output, thermocouple input, and indicators for easy setup and operation, capable of handling loads up to 530 VAC and 90 A.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate components are used for temperature control, then functionality can be comprehensive, but device complexity and setup difficulty increase
Solution Approach 1:
The patent combines multiple separate components (temperature controller, solid state relay, power supply) into a single integrated assembly. The controller and relay are housed together in one enclosure, and the power supply is internally coupled to the controller, eliminating the need for external power supplies and reducing the number of separate devices required.
Solution Approach 2:
The integrated assembly performs multiple functions within a single device: temperature sensing, control logic processing, power switching via solid state relay, and internal power supply. This multi-functional design allows one device to replace what previously required multiple separate components.
2Adaptability or versatility
If multiple separate components are used for temperature control, then functionality can be comprehensive, but ease of operation and setup decrease
Solution Approach 1:
By integrating the controller, relay, and power supply into one assembly, the patent reduces the number of components that need to be installed, wired, and configured. Users only need to install one device rather than coordinating multiple separate components, significantly simplifying setup and operation.
3Reliability
If traditional temperature controllers are used, then basic control is achieved, but cost increases for applications needing only simple control
Solution Approach 1:
The patent extracts only the essential functions needed for basic temperature control and implements them in a simplified integrated assembly. By removing unnecessary features and focusing on core functionality (temperature sensing, control logic, and power switching), the design reduces component count and complexity while maintaining reliable temperature control.
4Power
If traditional controllers handle high voltage/current loads, then load capacity is sufficient, but safety and isolation concerns increase
Solution Approach 1:
The patent uses a solid state relay as an intermediary device between the low-voltage control circuitry and the high-voltage/load side. The relay provides electrical isolation, allowing the controller to safely switch high voltage and current loads without exposing the control electronics or users to dangerous voltages. This mediator approach enables high power handling while maintaining safety.
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
Provides a simple, cost-effective solution for temperature control in various industrial processes by integrating all necessary functions into a single package, ensuring rapid and accurate temperature maintenance with high voltage/current load management.
Implementation Method 1
Temperature Controller 100 is a solid state relay with internal circuitry that generates temperature control output for heating element loads or cooling compressor loads
Implementation Method 2
Thermocouple Terminals 130 receive the leads from a type J or type K thermocouple from the heating element or cooling motor
Data Source
AI summary
A temperature controller that combines a solid state relay with internal circuitry that generates temperature control output for heating element loads or cooling compressor loads ranging from 24VAC up to 530VAC and at 25A up to 90A. A logic supply and control connectors provides connectors for various inputs. Power switch terminals connect the temperature controller to the heating element or cooling motor to be temperature controlled. Thermocouple terminals receive the leads from a type J or type K thermocouple from the heating element or cooling motor. The temperature controller rapidly and accurately senses, controls, and maintains the temperature of any process associated with a load. The temperature control output signal leaving the power switch controls the load in order to maintain a constant temperature delivered to the process. The temperature controller requires only a single non-regulated low current isolated DC supply to work the logic circuitry.