Virtual Temperature Sensing for Harsh Fluid Heater Control
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Solution Overview
Problem
In fluid flow systems, such as vehicle exhaust systems, existing temperature sensors face challenges due to harsh environmental conditions like vibration and thermal cycling, leading to delayed stability and potential damage, and external sensors introduce delays and component failure modes, resulting in heaters with lower watt density and increased size and cost to ensure safety.
Innovation Solution
A method to predict temperatures within fluid flow systems using mathematical models based on mass flow rate, fluid inlet and outlet temperatures, and power provided to the heater, eliminating the need for physical sensors by calculating temperatures through equations that account for heat transfer and fluid dynamics, allowing for proactive control and reduced safety margins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If physical temperature sensors are used in harsh fluid flow environments, then temperature measurement is achieved, but the sensors suffer from delayed stability and potential damage due to vibration and thermal cycling
Solution Approach 1:
The patent replaces physical temperature sensors with a virtual sensing system that uses mathematical models and calculations to determine temperature. This substitutes mechanical sensing components with computational methods, eliminating the reliability issues of physical sensors in harsh environments while maintaining temperature measurement capability.
Solution Approach 2:
The patent creates a virtual copy of the temperature measurement function through mathematical modeling rather than using a physical sensor. The virtual sensor replicates the temperature detection capability through calculations based on heat transfer equations and system parameters, avoiding the need for fragile physical components.
2Measurement precision
If external physical sensors are used for temperature control, then temperature monitoring is achieved, but response time is delayed due to thermal resistances between sensor wires and outputs
Solution Approach 1:
The patent replaces physical temperature sensing with computational temperature determination. By using mathematical models that calculate temperature based on heat transfer equations and measured parameters (mass flow rate, power input, inlet temperature), the system eliminates thermal resistance delays inherent in physical sensor wiring and achieves instantaneous temperature determination.
3Reliability
If physical sensors are used in heater control systems, then temperature control is achieved, but safety margins must be increased leading to larger and more expensive heaters
Solution Approach 1:
The patent replaces physical temperature sensors with a virtual sensing system that provides accurate, real-time temperature data through mathematical calculations. This eliminates the need for large safety margins in heater design, allowing for more compact and cost-effective heaters while maintaining or improving reliability through precise temperature control.
Solution Approach 2:
The patent changes the approach from using physical sensor data with built-in safety margins to using calculated temperature parameters from mathematical models. This parameter transformation allows for more precise heater control and optimization, reducing the required heater size while maintaining safety through accurate virtual temperature measurement.
4Measurement precision
If physical temperature sensors are installed in exhaust systems, then temperature data is obtained, but the system complexity and component failure modes increase
Solution Approach 1:
The patent replaces physical temperature sensors and their associated mounting hardware, wiring, and calibration systems with a virtual sensing approach. The temperature is calculated using mathematical models based on readily available parameters (mass flow rate from existing sensors, power input to heater, inlet temperature), significantly reducing system complexity and eliminating sensor-related failure modes.
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 approach enables quicker response times, improved accuracy, and the use of heaters with higher temperatures, reducing the need for physical sensors and enhancing system performance while decreasing safety margins and component failure risks.
Implementation Method 1
The heating element may include an electrical resistance wire, a susceptor, or other suitable heating element. The heating element may be surrounded by a sheath or insulation material, such as magnesium oxide (MgO) or aerogel insulation.
Implementation Method 2
obtain a mass flow rate of fluid flow of the fluid flow system... calculating temperature at the at least one location based on a model of the fluid flow system and the obtained mass flow rate and fluid outlet and inlet temperatures
Data Source
AI summary
A method of predicting temperature of at least one location in a fluid flow system that has a heating system for heating fluid. The method includes obtaining a mass flow rate of fluid flow of the fluid flow system, obtaining at least one of a fluid outlet temperature and a fluid inlet temperature of a heater of the heating system, obtaining power provided to the heater, and calculating temperature at the at least one location based on a model of the fluid flow system and the obtained mass flow rate, fluid outlet temperature, and fluid inlet temperature.