Microcomputer Temperature Controller with Phase and Zero-Cross Control
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Solution Overview
Problem
Existing SCR phase controllers and zero-cross cycle controllers are expensive and large in volume, posing challenges in cost and space usage for accurate temperature control.
Innovation Solution
A temperature controller with phase control and zero-cross cycle control functions using a microcomputer to generate control signals for a triac, which replaces expensive SCR controllers with inexpensive SSRs or triacs, including a power supply synchronization circuit and triac drive part for insulation and user-selectable control functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an SCR phase controller or SCR zero-cross cycle controller is used to accurately control temperature, then temperature control accuracy is improved, but cost and device volume increase
Solution Approach 1:
The patent merges the functions of the temperature controller and the phase control/zero-cross control into a single integrated device. The microcontroller unit (MCU) incorporates both the temperature control logic and the phase control/zero-cross control functionality, eliminating the need for separate external controllers. This integration reduces overall device volume, component count, and cost while maintaining accurate temperature control capability.
Solution Approach 2:
The MCU is designed to perform multiple functions: it acts as both the temperature controller and the phase controller/zero-cross controller. By making the MCU universal and capable of executing different control algorithms (temperature control, phase control, zero-cross control), the patent eliminates the need for dedicated separate controllers, thereby reducing device complexity and cost while preserving temperature control accuracy.
2Temperature
If an SCR phase controller or SCR zero-cross cycle controller is used to control power to the load, then temperature control accuracy is improved, but device volume and cost increase
Solution Approach 1:
The patent combines the temperature control function and the power control function (phase control/zero-cross control) into a single integrated controller. The MCU handles both temperature regulation and power switching operations, eliminating the need for separate external SCR controllers. This integration significantly reduces the overall controller volume while maintaining accurate temperature control.
3Device complexity
If a microcomputer with integrated phase control and zero-cross cycle control functions is used, then cost and device volume are reduced, but control functionality complexity increases
Solution Approach 1:
The MCU is designed as a universal controller capable of performing multiple control functions: temperature control, phase control, and zero-cross control. By programming the MCU to handle different control algorithms and modes, the patent achieves multi-functionality within a single device, reducing overall system complexity and cost while maintaining versatile control capabilities.
Solution Approach 2:
The patent implements dynamic control modes that can switch between different control strategies (phase control, zero-cross control, temperature control) based on operating conditions. The MCU dynamically adjusts its control algorithm and parameters to optimize performance for different scenarios, providing adaptability and versatility without requiring multiple dedicated controllers.
4Measurement precision
If separate SCR controllers are used for phase control and zero-cross cycle control, then control precision is improved, but ease of operation and space usage deteriorate
Solution Approach 1:
The patent merges separate control functions (temperature control, phase control, zero-cross control) into a single integrated MCU-based controller. This eliminates the need for multiple separate controllers and their associated connections, simplifying installation and operation while maintaining precise control capability. The unified interface and centralized control logic improve ease of operation and reduce space requirements.
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 reduces costs and improves space usability by enabling accurate temperature control using inexpensive, compact components, allowing users to select phase or zero-cross cycle control functions directly with a microcomputer and triac or SSR, replacing expensive SCR controllers.
Implementation Method 1
The power supply synchronization circuit is provided with a photo coupler to maintain insulation between the AC power supply and the microcomputer
Implementation Method 2
Further, the power triac drive part is provided with a photo coupler to maintain insulation between the microcomputer and the load side triac
Implementation Method 3
an AC power supply is connected to a first coil of a transformer, and a drive power generation part and a triac trigger power generation part are respectively furnished on a second coil
Data Source
AI summary
The present invention relates to a temperature controller having phase control and zero-cross cycle control function that can be achieved at a low cost by controlling power that is supplied to a load, by generating a phase control signal or a zero-cross control signal according to control target temperature of a load, using a microcomputer.