Smart Heating System with RFID Performance Data
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Solution Overview
Problem
Manufacturing variability in heater elements leads to inconsistent heat flux, reducing reliability and increasing costs due to the need for safety factors that lower Watt density, which affects temperature control and performance in thermal systems like diesel exhaust systems.
Innovation Solution
A smart heating system that includes performance information storage via text, bar codes, RFID tags, or digital buses, with communication pathways like LIN or CAN buses, and incorporates temperature sensors and power switches to adjust heating rates and prevent overheating, using multiple sensors to measure temperature gradients and control heating elements effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a safety factor is applied to compensate for manufacturing variability, then reliability is improved, but Watt density is reduced
Solution Approach 1:
The patent applies preliminary action by measuring and recording the actual heat flux of each heater element during manufacturing, then using this pre-acquired data to adjust control parameters before operation. This allows the system to compensate for manufacturing variability without applying conservative safety factors, thereby maintaining both reliability and optimal Watt density.
Solution Approach 2:
The patent implements feedback by continuously monitoring the actual temperature and heat flux of heater elements, then using this information to dynamically adjust control parameters. This closed-loop feedback system enables the system to maintain reliability through real-time compensation while operating at optimal Watt density, eliminating the need for conservative safety factors.
2Reliability
If a safety factor is applied to compensate for manufacturing variability, then reliability is improved, but heating rate is reduced
Solution Approach 1:
The patent measures and stores the actual heat flux characteristics of each heater element during manufacturing, creating a preliminary database of performance data. This pre-acquired information enables the control system to optimize heating rates for each specific element without compromising reliability, as compensation is based on actual measured data rather than conservative estimates.
Solution Approach 2:
The patent uses real-time feedback from temperature sensors and heat flux measurements to dynamically adjust heating control parameters. This allows the system to maintain high heating rates while ensuring reliability through continuous monitoring and adjustment based on actual element performance, eliminating the need for reduced heating rates that would result from safety factors.
3Ease of manufacture
If heater surface area is reduced to lower cost, then manufacturing cost is reduced, but heat flux capability is reduced
Solution Approach 1:
The patent changes the control parameters based on the actual measured heat flux of each heater element, allowing optimization of the heating process without requiring increased surface area. By adjusting control parameters such as power distribution and timing based on measured performance, the system achieves optimal heat flux capability from smaller, more cost-effective heater elements.
Solution Approach 2:
The patent implements feedback control that monitors actual heat flux and temperature, then adjusts control parameters to maximize the performance of each heater element. This allows smaller surface area elements to achieve the required heat flux capability through optimized control, reducing manufacturing costs while maintaining performance.
4Measurement precision
If multiple temperature sensors are used to measure temperature gradients, then measurement precision is improved, but device complexity is increased
Solution Approach 1:
The patent applies segmentation by placing multiple temperature sensors at specific locations along the heater element to measure temperature gradients. This segmented measurement approach provides precise spatial temperature data without requiring a single complex sensor, achieving high measurement precision through distributed simple sensors.
Solution Approach 2:
The patent implements local quality by positioning temperature sensors at specific critical locations where temperature gradients are most significant. This targeted placement provides precise measurement of temperature gradients without the need for continuous or dense sensor arrays, optimizing measurement precision while minimizing device complexity.
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
Enhances diagnostic capabilities, maximizes heat flux, and lowers manufacturing costs by allowing for precise control of heating elements, reducing the risk of overheating and improving the reliability and performance of thermal management systems.
Implementation Method 1
The flux density exhibited by a heater element is defined as Watt density (watts/mm2)
Implementation Method 2
temperature sensors being a combination of individual sensors or a junction sensor capable of providing more than one temperature measurement
Implementation Method 3
The temperature sensor may be selected as a thermocouple, a thermistor, or a resistance temperature device
Data Source
Figure 1A~1B
Figure 2
Figure 3A~3C
AI summary
A smart heating system is described that generally comprises at least one heater element, optionally, at least one temperature sensor, a set of predetermined or predictable performance information used to control the heating system; and, optionally, an electronic conditioning module (ECU) capable of storing and processing the performance information. The performance information may be stored as written text, a bar code, a data matrix, or a radio frequency identification (RFID) tag. The smart heating system heating system may further comprises a LIN or a CAN bus capable of providing a communication pathway between at least two of the system components.