Multi-Sensor Heating Control for Abnormality Detection
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Solution Overview
Problem
Existing heating devices with temperature sensors and heaters struggle to accurately detect abnormalities in temperature detection or heating, leading to incorrect temperature control of the heating object.
Innovation Solution
A heating device equipped with multiple temperature sensors and a temperature regulator that identifies heat transfer functions and detects changes in coefficients to determine abnormalities in the heater or temperature sensors, using a determination unit to set thresholds for accurate detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple temperature sensors are used to improve detection reliability, then the ability to identify abnormal parts improves, but the device complexity increases
Solution Approach 1:
The temperature detection system is segmented into multiple independent temperature sensors (first temperature sensor and second temperature sensor) positioned at different locations. Each sensor independently monitors temperature at its location, allowing the system to detect abnormalities by comparing readings from different segments of the heating object.
Solution Approach 2:
Heat transfer functions serve as mathematical intermediaries that model the relationship between heater output and temperature sensor readings. These transfer functions enable the determination unit to infer the actual heating state by mediating between raw sensor data and heater control signals, resolving the contradiction between using multiple sensors and maintaining system simplicity.
2Measurement precision
If heat transfer functions are identified and coefficients are monitored to detect abnormalities, then the precision of abnormality detection improves, but the computational complexity increases
Solution Approach 1:
Heat transfer functions are identified and stored in advance during a calibration phase before actual heating operations begin. This preliminary action captures the thermal characteristics of the system, allowing the determination unit to later detect abnormalities by simply comparing current readings against pre-established baseline coefficients without performing complex real-time calculations.
Solution Approach 2:
The determination unit continuously monitors temperature sensor readings and compares them against expected values derived from the stored heat transfer functions and actual heater output. This feedback mechanism automatically identifies deviations that indicate abnormalities, providing precise detection while maintaining relatively simple control logic through systematic comparison rather than complex computation.
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 enables reliable detection of temperature sensor accuracy and heater functionality, preventing defective product molding in machines like injection molding machines by identifying and addressing abnormalities in real-time.
Implementation Method 1
a heater (10) that heats a heating object (1)
Implementation Method 2
a temperature detection unit (20) that detects a temperature of the heating object (1)
Implementation Method 3
heat transfer functions between the heater (10) and the plurality of temperature sensors (21, 22) and a heat transfer function between the plurality of temperature sensors (21, 22)
Data Source
AI summary
This heating device (100) includes: a heater (10) for heating an object (1) to be heated; a temperature detection unit (20) for detecting a temperature of the object (1) to be heated; and a temperature regulator (30) which controls the heater (10) so as to make the temperature of the object (1) to be heated equal to the target temperature. The temperature detection unit (20) comprises temperature sensors (21, 22). An identification unit (34) identifies, from temperature data detected by the temperature sensors (21, 22) and manipulation quantity data corresponding to electric power applied to the heater (10), a heat transfer function between the heater (10) and the temperature sensors (21, 22), and a heat transfer function between the respective temperature sensors (21, 22). A determination unit (36) detects a change of the transfer functions, and determines an abnormality in the heater (10) or the temperature sensors (21, 22).