Wireless Heat Trace Modules for Precise Temperature Control
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Solution Overview
Problem
Conventional heat trace systems rely on centralized power control devices, which can be inefficient and lack flexibility in temperature control and monitoring, especially in large industrial piping systems.
Innovation Solution
Distributing power control devices, such as wireless sensor modules, throughout the heat trace system, allowing for wireless control and monitoring, enabling real-time temperature adjustments and condition reporting via a wireless communication network.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If centralized power control devices are used at the main power distribution system, then system simplicity is maintained, but temperature control precision and system flexibility deteriorate
Solution Approach 1:
The patent divides the centralized power control system into distributed power control modules, with each wireless field device containing its own power control device (solid state relay) that independently controls a specific heat trace cable. This segmentation enables localized temperature control at each monitoring point, improving temperature control precision while maintaining overall system manageability through modular architecture.
2Adaptability or versatility
If distributed power control devices are used at wireless modules, then temperature control precision and flexibility are improved, but device complexity increases
Solution Approach 1:
The patent combines multiple functions into the wireless field device: temperature sensing, wireless communication, and power control (via solid state relay) are integrated into a single distributed unit. This merging approach enables flexible and precise temperature control at each location while simplifying installation and maintenance compared to separate centralized control systems with extensive wiring.
3Device complexity
If centralized power distribution is used, then infrastructure needs are reduced, but real-time monitoring and control responsiveness deteriorate
Solution Approach 1:
The patent implements a feedback mechanism where wireless field devices continuously monitor temperature conditions and wirelessly transmit this data to the host system. The host system processes the temperature information and sends control commands back to the wireless field devices, which adjust their local power control devices accordingly. This closed-loop feedback enables real-time monitoring and rapid response to temperature changes without requiring extensive physical infrastructure.
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 enhances temperature control precision, reduces infrastructure needs, and allows for real-time monitoring and adjustment of heat trace cables, improving energy efficiency and system responsiveness.
Implementation Method 1
the heat trace cable connected to it conducts current, and thereby heats the vessel contacting the heat trace cable
Data Source
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AI summary
A heat trace system heats (or maintains the temperature of) vessels of a piping system. Heat trace cables are connected to power control devices in respective wireless modules such that when the power control device in a wireless module is on, the heat trace cable connected to that wireless module conducts current, and thereby heats the vessel contacting the heat trace cable. The wireless module receives control commands for controlling its power control device wirelessly from the main power distribution and control system via a wireless communication network. A wireless module can include a sensor, where the wireless module report backs conditions sensed by the sensor to the main power distribution and control system via the wireless network. The main power distribution and control system can use that information in its control loops to control the switching of the power control devices in the wireless modules, to thereby control whether the associated heat trace cable conducts current or not, to thereby control the temperature at the vessel that is heated by the heat trace cable.