Power Modulator for Infrared Conveyor Oven Peak-Load Management
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Solution Overview
Problem
Conveyor ovens face challenges during peak-loads, such as cold startups, where the current draw of heating elements exceeds the available power, leading to inefficiencies and potential system overload.
Innovation Solution
The implementation of a control system that manages the energization of multiple heating zones using relays and an electronic controller. This system ensures that no more than three heating zones are energized simultaneously by following a predetermined sequence of energization and de-energization based on predefined time periods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If all heating zones are energized simultaneously to maximize heating capacity, then the heating speed is improved, but the current draw exceeds the available power causing system overload
Solution Approach 1:
The patent implements periodic action by cycling the energization of heating zones in a predetermined sequence. The controller energizes heating zones for a first period of time, then de-energizes them for a second period of time, repeating this cycle. This periodic operation ensures that no more than three heating zones are energized simultaneously, preventing current draw from exceeding available power while maintaining effective heating through continuous cycling.
Solution Approach 2:
The patent applies segmentation by dividing the heating system into multiple zones that can be independently controlled. The controller selectively energizes specific heating zones (first, second, or third) based on a predetermined sequence, rather than energizing all zones simultaneously. This segmentation allows the system to distribute power load across time while maintaining heating capacity.
2Power
If heating zones are energized in a predetermined sequence to reduce current draw, then the power supply capacity is improved, but the heating response time increases
Solution Approach 1:
The controller implements periodic energization and de-energization cycles for heating zones, where each cycle consists of a first period of energization followed by a second period of de-energization. This periodic action distributes the power load over time, preventing simultaneous energization of all heating zones and thereby improving power supply capacity utilization.
Solution Approach 2:
The system performs preliminary action by following a predetermined sequence of energization and de-energization that is pre-programmed in the controller. The sequence is designed to optimize power distribution while maintaining heating effectiveness, preparing the heating zones to be energized in a controlled manner rather than all at once.
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 effectively reduces the average current draw during peak-loads, preventing system overload and ensuring efficient heating by strategically managing the energization of heating zones.
Implementation Method 1
a first heating zone (350) controlled by a first relay (325), a second heating zone (355) controlled by a second relay (330), and a third heating zone (360) controlled by a third relay (335)
Data Source
AI summary
A system and method to control the power supplied to heating zones of a conveyor oven. The conveyor oven includes a plurality of heating zones to evenly distribute heat in an oven compartment. During peak-loads, the current draw of the heating zones may exceed available power of a power supply. Therefore, a system and method to reduce the total current draw of the plurality of heating zones is provided. The system includes a controller configured to perform the methods disclosed herein. The methods effectively lower the total current draw by rapidly cycling a plurality of relays connected to each of the plurality of heating zones to achieve even distribution of heat and reduced current draw during peak-loads.