Modular Power Module for Distributed Heating Control
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Solution Overview
Problem
Existing heating control systems face challenges in efficiently and precisely controlling a large number of spatially distributed heating elements, leading to increased cabling efforts and control complexity, especially when these elements are far apart, as they require extensive cabling and centralized control setups, which are inefficient and prone to errors.
Innovation Solution
A modular heating control and regulation system comprising a power module with integrated switching elements and a communication interface, allowing decentralized power supply and control, and an interface module that centralizes communication and power supply, reducing cabling and control efforts by enabling series connection of modules for efficient communication and power distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a centralized heating control system is used to control multiple spatially distributed heating elements, then control precision can be maintained, but cabling effort and device complexity increase significantly
Solution Approach 1:
The heating control system is divided into multiple independent power modules, each capable of controlling one or more heating elements. Each power module is a self-contained unit with local control electronics, switching elements, and power supply interfaces. This segmentation allows the system to maintain control precision at a distributed level while reducing the complexity of centralized cabling and control architecture.
2Measurement precision
If separate heating controls are provided for each spatially distributed heating element, then control precision is improved, but the number of heating controls and bus accesses increases
Solution Approach 1:
Multiple power modules are connected in series through daisy-chained interfaces, merging their control and power supply connections into a single continuous chain. This allows the system to provide individualized control for each heating element while reducing the number of separate control units and bus accesses required, as each power module can be addressed sequentially through the series connection.
3Reliability
If power modules are arranged in a control cabinet, then protection is improved, but cabling effort for supplying heating loads far apart increases
Solution Approach 1:
The system transitions from a two-dimensional arrangement (all modules in a control cabinet) to a three-dimensional distributed arrangement where power modules can be placed at various locations along the heating element chain. This spatial distribution reduces the physical distance cabling must travel while maintaining protection through IP65-rated module housings, effectively solving the contradiction between protection and cabling effort.
Data Source
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AI summary
The invention relates to a power module (1) for heating control and/or regulation, comprising a housing (2) with a first communication interface (3) and a second communication interface (4), a first power supply interface (5) and a second power supply interface (6) for supplying power to the power module (1), several power outputs (8) to which a heating element (9) can each be electrically connected, and a power input (7) that can be electrically connected to a power supply (10) for the heating elements (9). The power module (1), enclosed by the housing (2), includes: - a power distribution device (12) which is electrically connected on the input side to the power input (7) and on the output side via a branch (13) to each of the power outputs (9) to supply them with electrical current, - a switching element (14) in each of the branches (13).- a control and/or regulation unit (15) configured to control and/or regulate the switching state of the switching elements (14) depending on setpoints for the heating power of the heating elements (9), - a communication unit (16) configured to receive setpoints intended for the power module (1) via the first communication interface (3) and transmit them to the control and/or regulation unit (15), and to forward setpoints received via the first communication interface (3) that are not intended for the power module (1) to the second communication interface (4). The invention further relates to an interface module and a modular system for heating control and/or regulation.