Methods and systems for TRIAC set point based control of power delivery
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Solution Overview
Problem
Existing grill systems face challenges in achieving optimal smoke flavor production due to difficulties in monitoring and controlling the ignition of fuel sources, leading to inconsistent combustion and inefficient smoke output, while inductive loads like shaded-pole motors suffer from performance issues due to variations in supply voltages and low power factors.
Innovation Solution
A cooking device with a smoke unit and electronic controller that adjusts the igniter's energy supply and fan power based on measured energy rates and temperatures to optimize combustion, and a transfer function-based algorithm to accurately control the operating speed of inductive loads like shaded-pole motors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the igniter provides excessive energy to the fuel source, then ignition is achieved, but combustion region starves itself of oxygen and burns too vigorously
Solution Approach 1:
The system uses a temperature sensor to monitor the temperature of the fuel source in real-time during ignition. The controller receives temperature feedback and dynamically adjusts the power supplied to the igniter, reducing power when temperature exceeds a threshold to prevent excessive combustion, and maintaining power when temperature is below threshold to ensure reliable ignition.
Solution Approach 2:
The igniter power is made dynamic rather than static. The system transitions from a fixed-power igniter to one whose power output is continuously adjusted based on real-time temperature conditions, allowing the system to adapt to changing combustion states and prevent both under-ignition and over-combustion.
2Object-generated harmful factors
If the igniter provides insufficient energy to the fuel source, then oxygen supply is maintained, but combustion reaction is not sustained
Solution Approach 1:
The temperature sensor provides continuous feedback to the controller during the ignition phase. When the temperature rises above a threshold indicating successful ignition, the controller maintains sufficient igniter power to sustain the combustion reaction, ensuring reliable and consistent smoke production.
3Measurement precision
If a sensor is implemented to detect combustion products for closed loop control, then combustion monitoring is achieved, but system cost and reliability decrease due to sensor safety requirements
Solution Approach 1:
Instead of placing a sensor directly in the harsh combustion environment, the system uses temperature as an indirect measurement of combustion state. The temperature sensor is positioned near the fuel source but not in direct contact with flames or combustion products, serving as an intermediary that provides sufficient control information without requiring expensive, high-temperature-rated sensors.
Solution Approach 2:
The system replaces direct combustion product detection (which would require specialized high-temperature sensors) with temperature-based control. This substitution uses a simpler, more reliable temperature sensor to infer combustion state, avoiding the complexity and cost of sensors designed for direct exposure to flames and combustion gases.
4Ease of manufacture
If TRIAC is used to modulate inductive load speed, then cost effectiveness is improved, but performance is adversely affected by supply voltage variations and low power factor
Solution Approach 1:
The system dynamically adjusts the TRIAC firing angle based on measured supply voltage and motor current. When supply voltage varies or power factor is low, the controller modifies the TRIAC conduction angle to maintain accurate speed control, compensating for the adverse effects of voltage variations and maintaining motor performance across different operating conditions.
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 solution ensures consistent and efficient smoke production by optimizing fuel ignition and adjusts motor speeds precisely, improving the overall performance of both the grill system and inductive load devices.
Implementation Method 1
an igniter proximate the fuel box and configured to ignite fuel contained in the fuel box
Implementation Method 2
the physical outputs resulting from combustion of the fuel source are heat and combustion products such as smoke compounds
Implementation Method 3
determine an average rate of energy supplied to the igniter during a predetermined period of time of activation of the igniter
Implementation Method 4
determine an average temperature of a region proximate the igniter during the predetermined period of time
Implementation Method 5
a fan coupled to the housing, in fluid communication with the fuel box
Data Source
AI summary
In an aspect, data representative of an electrical value is received and a target value for an inductive load based on the electrical value is accessed from memory of the controller. A target value for an inductive load can be accessed based on the electrical value. A transfer function based algorithm can be implemented for determining a set point value using the electrical value the set point value can be applied on a triode for alternating current (TRIAC). Operation of the inductive load to the target power responsive to the applying of the set point value on the TRIAC can be adjusted. The operation of the inductive load at the target power causes operation of the inductive load at the target value.