Segmented Heated Hose Control for Precise Fluid Temperature
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Solution Overview
Problem
Existing heated hoses for fluid transport in spray systems lack efficient temperature control and fault tolerance, leading to inconsistent fluid temperatures and reduced performance in multi-component sprayer applications.
Innovation Solution
A multi-segment heated hose with temperature sensors at each segment and independent heater power control, allowing for precise temperature regulation and fault-tolerant operation by adjusting power to each segment based on real-time temperature data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single heating element is used throughout the entire hose length, then the structure is simple and easy to manufacture, but the temperature control precision deteriorates and inconsistent fluid temperatures occur
Solution Approach 1:
The hose is divided into multiple heating zones with independent heating elements (first heating element 40 in first zone, second heating element 42 in second zone, third heating element 44 in third zone). Each zone can be controlled independently through separate power controllers, allowing precise temperature regulation at different segments while maintaining overall system simplicity.
2Manufacturing precision
If independent temperature control is implemented for each hose segment, then temperature control precision is improved, but the device complexity increases due to multiple sensors and controllers
Solution Approach 1:
The control system is segmented into independent power controllers for each heating zone. Each power controller receives temperature data from its corresponding temperature sensor and independently adjusts power to its heating element, simplifying the control architecture while achieving precise segment-specific temperature control.
Solution Approach 2:
Temperature sensors (first temperature sensor 32, second temperature sensor 34, third temperature sensor 36) are positioned at the outlet of each hose segment to provide real-time temperature feedback. This feedback is sent to the power controllers which automatically adjust heating power to maintain desired temperatures, enabling precise control despite increased system complexity.
3Stability of the object's composition
If continuous heating is applied to maintain fluid temperature, then temperature consistency is improved, but energy consumption increases and waste heat is generated
Solution Approach 1:
The heating system operates periodically rather than continuously. Power controllers receive temperature feedback and activate heating elements only when temperature drops below the desired setpoint, then deactivate when the setpoint is reached. This periodic heating maintains fluid temperature consistency while minimizing energy consumption and reducing waste heat generation.
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
Ensures consistent fluid temperatures and improved performance in multi-component sprayer systems by maintaining precise temperature control and fault tolerance, reducing waste heat and enhancing heat transfer efficiency.
Implementation Method 1
an electrical heating element disposed within the fluid conduit. The electrical heating element is configured to provide a heat source within the fluid conduit
Implementation Method 2
temperature sensors at or near the outlet of each hose segment
Data Source
AI summary
A multi-segment, heated hose has temperature sensors at or near the outlet of each hose segment. Each hose segment also has separate means for heating a fluid in the hose segment. A heater power controller receives temperature data from each temperature sensor and independently adjusts the power to the heater in each hose segment to obtain and maintain a preselected fluid temperature at the outlet of each hose segment.