WO2006060916A2 - Procede et appareil permettant de surveiller et de commander une zone de chauffage - Google Patents
Procede et appareil permettant de surveiller et de commander une zone de chauffage Download PDFInfo
- Publication number
- WO2006060916A2 WO2006060916A2 PCT/CA2005/001874 CA2005001874W WO2006060916A2 WO 2006060916 A2 WO2006060916 A2 WO 2006060916A2 CA 2005001874 W CA2005001874 W CA 2005001874W WO 2006060916 A2 WO2006060916 A2 WO 2006060916A2
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- WO
- WIPO (PCT)
- Prior art keywords
- heater
- heater element
- current
- monitoring
- zone
- Prior art date
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Classifications
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
- G05D23/00—Control of temperature
- G05D23/19—Control of temperature characterised by the use of electric means
- G05D23/20—Control of temperature characterised by the use of electric means with sensing elements having variation of electric or magnetic properties with change of temperature
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
- G05D23/00—Control of temperature
- G05D23/19—Control of temperature characterised by the use of electric means
- G05D23/1902—Control of temperature characterised by the use of electric means characterised by the use of a variable reference value
Definitions
- the present invention relates generally to temperature control and more specifically, to method and apparatus for monitoring and controlling a heater zone.
- moulding machines which use heat and pressure to melt, reshape and mould granular material into moulded articles, must be accurately controlled to ensure the integrity of the produced articles.
- Moulding machines of this nature include for example, injection moulding machines, blow moulding machines, extrusion moulding machines, die-cast moulding machines and thixo-moulding machines.
- Such moulding machines make use of heater elements positioned in heater zones to generate the heat that is necessary to melt and mix the granular material.
- the heater elements may be of the resistive, inductive or infrared type.
- blow moulding machines use infrared heater lamps arranged within an oven at various profiling positions to profile a preform to be stretched.
- Thixo-moulding machines operate injection barrels at temperatures of up to 1000 0 F using calrod heater elements to melt and mix the granular material.
- heater elements used in moulding machines unfortunately degrade over time due to environmental factors, such as for example, shock, vibration, high temperature, hydro-scopics, and misuse during replacement. As the heater elements degrade, their current carrying characteristics change. In less severe cases, degradation of heater elements can result in temperature fluctuations in the heater zones. In more severe cases, heater element degradation can result in short and open circuits rendering the heater zones inoperative. Whether less or more severe, temperature fluctuations can adversely affect moulded article quality. For example, temperature fluctuations can affect crystallinity in the moulded article, cause a chemical byproduct referred to as AA to be created, which may transfer to the moulded articles or cause carbonated elements in products held by the moulded articles to be released.
- AA chemical byproduct
- controllers are typically provided to control the supply of power to the heater elements in the heater zones to maintain the temperature in the heater zones.
- heater zone controllers employ solid state relays (SSRs) that are activated in a cyclical manner as temperature demands, set by moulding machine operating parameters, are met.
- SSRs solid state relays
- the SSRs are responsive to digital signals output by a processor that uses logarithmic formulae to generate the digital signals. As a result, the SSRs are cycled until stable temperatures in the heater zones are obtained.
- Monitoring of the heater zones to detect when the heater zones drop below desired levels can be carried out either actively or passively.
- thermocouples are employed in the heater zones, to provide active feedback to the processor concerning the temperature in the heater zones.
- passive feedback methods are employed to determine if the heater zones are maintaining their desired temperature levels. Such passive feedback methods include for example visual and/or chemical tests of moulded articles and predictive heater element analysis.
- temperature feedback methodologies lack accuracy and responsiveness. These temperature feedback methodologies also fail to detect heater element degradations that affect moulding machine performance and provide advance warning of potential heater zone failures. Monitoring of heater zones to ensure desired temperatures are maintained is important. It is however, also desired to monitor heater zones so that undesired operating conditions can be detected before moulding machine failures occur.
- elements such as steel braid overlaid conductors, or semiconductor devices such as solid state relays (SSRs) that are used in moulding machines may cause fires or explode.
- SSRs solid state relays
- the heater elements in a heater zone are wired to a power circuit using steel braid overlaid conductors, under harsh environments the metal sheath or braid surrounding the conductors can break down to the extent that an arc may appear between the steel braid and the surface of the moulding machine being heated. This may result in a fire or explosion leading to failure of the moulding machine. Ensuring that a fire or explosion does not occur is particularly important in thixo-moulding machines, which use magnetism, a highly flammable material that requires constant monitoring.
- PET-type moulding machines which create preforms for such uses as bottles, often include a significant number of heater zones, in some cases as many as one-hundred and twenty- four (124) heater zones. Should a failure happen, the scrap rate of the moulding machine is 124 parts, typically per every nine seconds resulting in significant losses. Blow moulding machines often operate at rates of up to 60,000 parts/hr. Again should a failure happen, significant losses can result. Moulding machines used to produce articles for use in the automotive field typically operate on - A -
- U.S. Patent Nos. 6,718,283 and 6,336,083 to Lanham, et al. disclose a method and apparatus for predicting heater failure by using a laboratory model heater element against collected field data.
- the apparatus compares a laboratory model heater element bench marked against existing heater elements, to estimate the life of existence of the heater elements in order to predict their failure.
- the apparatus predicts heater element life expectancy, the predictions are based on a laboratory model and thus, they can be inaccurate.
- the apparatus is unable to provide real- time feedback concerning the operating conditions of heater elements.
- Improvements to enable heater zones and/or heater elements to be monitored substantially continuously so that heater element degradations can be detected prior to failure are desired.
- an apparatus for monitoring and controlling a heater zone comprising: a sensing device monitoring at least one heater element within said heater zone and outputting a signal representing the operation of said heater element; and a controller communicating with said sensing device and signaling an alarm condition when operation of said heater element deviates from normal operation.
- the sensing device is a Hall-effect sensor that senses current drawn by the heater element.
- the controller in this case signals the alarm condition when the current carrying characteristics of the heater element change signifying a potential failure condition.
- the controller also adjusts current flow to the heater element to compensate for the change in heater element current carrying characteristics.
- an apparatus for monitoring and controlling a heater zone having at least one heater element comprising: a switching device coupling said heater element to a power source and being actuable to allow power to be supplied to said heater element; a current sensing device sensing current supplied to said heater element when said switching device is actuated; and a controller coupled to said switching device and said current sensing device, said controller signaling an alarm condition when current drawn by said heater element deviates from normal operation and adjusting actuation of said switching device to compensate for the deviant heater element operation.
- a method of monitoring and controlling a heater zone comprising: generally continuously monitoring the current drawn by at least one heater element in said heater zone; determining when the drawn current signifies heater element degradation and a potential failure condition; and signaling an alarm condition.
- a circuit comprising: a housing having terminals for coupling between a power supply and load and having an output terminal; and a series circuit within said housing comprising a switching device and a current sensor, said current sensor monitoring current drawn by said load when said circuit is electrically coupled between said power supply and said load and said switching device is actuated, said current sensor providing an output signal on said output terminal representative of said sensed current.
- Figure l is a schematic circuit diagram of a heater zone monitoring and controlling circuit
- FIG. 2 is a block diagram of the heater zone monitoring and controlling circuit of Figure 1;
- Figure 3 are graphs showing adaptive heater zone control using the heater zone monitoring and controlling circuit of Figure 1;
- Figure 4a is a plan view of another embodiment of a heater zone monitoring and controlling circuit
- Figures 4b and 4c are plan views of yet another embodiment of a heater zone monitoring and controlling circuit
- Figure 5 is a side elevation view of yet another embodiment of a heater zone monitoring and controlling circuit
- Figure 6 is a side elevation view of still yet another embodiment of a heater zone monitoring and controlling circuit
- Figure 7 is a perspective view of still yet another embodiment of a heater zone monitoring and controlling circuit
- FIG. 8 is a schematic circuit diagram of still yet another embodiment of a heater zone monitoring and controlling circuit. Detailed Description of the Embodiments
- the apparatus comprises a sensing device which monitors at least one heater element within the heater zone and outputs a signal representing the operation of the heater element.
- a controller communicates with the sensing device and signals an alarm condition when operation of the heater element deviates from normal operation.
- heater zone monitoring and controlling circuit 10 is coupled to a heater zone 12 within a moulding machine to monitor and control the heater zone.
- heater zone 12 is shown as including a single heater element 14.
- Heater zone 12 may include a plurality of heater elements 14.
- the heater element 14 is coupled to lines Li and L 2 of an ac or dc power supply 16 via supply conductors 18 and 20 and protection circuitry 21.
- a switching device 22 in the form of a silicon controlled rectifier (SCR) is provided along conductor 18.
- SCR 22 is coupled to a controller 24 in the form of a personal computer (PC) or programmable logic controller (PLC).
- PC/PLC 24 provides switching signals to the SCR 22 to control current flow to the heater element 14.
- Heater zone monitoring and controlling circuit 10 includes a Hall- effect sensor 30 positioned along supply conductor 18 between the heater element 14 and the SCR 22.
- the Hall-effect sensor 30 senses current flow to the heater element 14 and generates signal output I HES that is proportional to the level of the sensed current.
- the signal output I HES generated by the Hall-effect sensor 30 is conveyed to the controller 24 via a Field-bus 34 such as for example, Profibus or CANbus.
- the signal output IH ES generated by the Hall-effect sensor 30 may be provided to the controller 24 via a multiplexer 36.
- SCR 22, Hall-effect sensor 30 and multiplexer 36 are mounted on an open face printed circuit board 38.
- a suitable power supply provides the necessary power for the components on the circuit board 88.
- the controller 24 executes a heater zone monitoring and controlling program. During program execution, the controller 24 uses the analog output signal I HES received either from the Field-bus 34 or multiplexer 36 to determine the current supplied to the heater zone 12 and the operating condition of the heater element 14. When the temperature of the heater zone 12 drops below a desired level, the controller 24 adjusts the switching signal output provided to the SCR 22 thereby to change the duty cycle of the SCR 22 and alter the current supplied to the heater element 14 until the temperature within the heater zone 12 returns to the desired level. The controller 24 also monitors the level of current drawn by the heater element 14 to detect situations where the current carrying characteristics of the heater element 14 have changed signifying a potential heater element failure condition.
- an alarm signal S A is generated by the controller 24 to provide advance warning to the moulding machine operator allowing preventive maintenance to be performed on the moulding machine before a heater element failure occurs. If the current carrying characteristics of the heater element 14 have changed dramatically signifying an unsafe operating condition, the controller 24 in addition to generating the alarm signal S A , conditions the SCR 22 to electrically isolate the heater element 14 from the power supply 16.
- the controller 24 provides switching signals to the SCR 22 causing the SCR to switch on and off according to a programmed duty cycle so that the heater zone 12 is heated in a manner to meet the moulding machine operating demands.
- the SCR 22 is actuated and turns on, current is supplied to the heater element 14 causing the heater element to be energized and thus, to generate heat.
- the duty cycle is selected so that the heater element 14 heats the heater zone 12 to a desired temperature.
- the Hall-effect sensor 30 generates the signal output I HES , which as mentioned previously, is proportional to the current drawn by the heater element 14.
- the controller 24 which receives the signal output I HES generated by the Hall-effect sensor 30, compares the sensed current level to a set-point current level, representing the current level that should be drawn by the heater element 14 when it is operating properly. When the sensed current level is at or near to the set- point current level, the controller 24 continues to operate the SCR 22 at the programmed duty cycle.
- the controller 24 changes the switching signal output to alter the duty cycle of the SCR 22 so that the heater element 14 is energized more or less depending on whether the sensed current level signifies an increase or decrease of the heater zone temperature from the desired heater zone temperature. If the sensed current level deviates from the set-point current level by more than a threshold upper margin, the controller 24 also generates an alarm signal S A signifying a potential heater element failure condition. If the sensed current level signifies an unsafe operating condition, the controller 24 conditions the SCR 22 to electrically isolate the heater element 14 from the power supply 16 in addition to generating the alarm signal
- SA Figure 3 presents a number of graphs showing heater zone temperature
- HZ T SCR switching and Hall-effect sensor signal output I HES during operation of the heater zone monitoring and controlling circuit 10.
- line 102 represents the desired heater zone temperature.
- the SCR 22 is switched according to the programmed duty cycle 104 as shown in graph 106 to maintain the temperature HZ T in the heater zone at or near to the desired temperature 102.
- the Hall- effect sensor 30 generates signal output I HES that in effect mirrors the SCR duty cycle as identified by reference number 108 in graph 110.
- Point 112 represents a condition where the current I HE drawn by the heater element 14 drops below the threshold upper margin resulting in a temperature drop in the heater zone 12 below the desired temperature 102.
- the signal output I HES of the Hall-effect sensor 30 reflects the drop in drawn current as identified by reference number 114 in graph 110 allowing this operating condition to be detected by the controller 24.
- the controller 24 in turn adjusts the duty cycle of the SCR 22 as identified by reference number 116 in graph 106 to increase the current I HE drawn by the heater element 14 until the temperature of the heater zone 12 returns to the desired temperature level 102 as shown at point 118.
- the controller 24 alters the switching signal output to the SCR 22 so that it again is switched according to the programmed duty cycle 104.
- Graph 130 shows an alternative method of altering the duty cycle of the SCR 22 during the interval between points 112 and 118 to return the heater zone temperature HZ T to the desired temperature level 102.
- Graph 140 in Figure 3 shows the signal output I H E S of the Hall-effect sensor 30 when a partial short circuit condition occurs at point 112 that is not compensated for by the protection circuitry 21.
- the controller 24 generates the alarm signal S A and conditions the SCR 22 to electrically isolate the heater element 14 from the power supply 16 as identified by reference number 152 in graph 150 allowing the heater zone to be repaired. After repair at point 118, the operation of the heater zone monitoring and controlling circuit returns to normal operation.
- the SCR 22, Hall-effect sensor 30 and multiplexer 36 are described as being mounted on an open face printed circuit board 38.
- the physical layout of the heater zone monitoring and controlling circuit components may vary depending on the environment in which the circuit 10 is to be employed.
- Figure 4a shows an alternative layout of the heater zone monitoring and controlling circuit 10.
- the components of the heater zone monitoring and controlling circuit 10 are mounted within a housing 200 rather than on an open face printed circuit board.
- Terminal 202 on the housing 200 receive conductor 18 coupled to the power supply.
- Terminal 204 on the housing 200 is connected to the conductor leading to the heating element 14.
- SCR 22 and Hall-effect sensor 30 are in series and connected between terminals 202 and 204.
- the Hall-effect sensor 30, which is in series with the SCR 22 and heater element 14, generates the signal output I HES that is supplied to the controller 24 via output terminal 205.
- Terminals 206 and 208 are coupled to the controller allowing the switching signal input to be provided to SCR 22.
- FIGs 4b and 4c show yet another layout of the heater zone monitoring and controlling circuit 10.
- the components of the heater zone monitoring and controlling circuit are mounted in two separate housings 200a and 200b.
- Housing 200a includes terminals 202a to 208a.
- SCR 22 is accommodated by the housing 200a and is connected across terminals 202a and 204a.
- Housing 200b includes terminals 250b to 256b.
- Hall-effect sensor 30 is accommodated by the housing 200b and is connected across terminals 252b and 254b.
- housing 200b is mechanically and electrically coupled to housing 200a via terminals 204 and 252b. Terminals 254b and 256b are for a connection to a power source from the Hall-effect sensor 30.
- Terminals 206a and 208a receive the switching signal output of the controller to drive the SCR 22.
- Terminal 202 receives the conductor 18 coupled to the power supply.
- Terminal 250b is connected to the conductor leading to the heating element 14.
- the Hall-effect sensor 30 is connected in series with the SCR 22 and heater element 14 allowing the signal output I HES generated by the Hall-effect sensor to be supplied to the controller 24 via output terminal 205b.
- Terminals 206a and 208a are coupled to the controller allowing the switching signal input to be provided to SCR 22.
- FIG. 5 shows another embodiment of the heater zone monitoring and controlling circuit 10.
- the heater zone 12 includes a plurality of SCRs 22 and heater elements 14.
- the heater zone monitoring and controlling circuit 10 includes a plurality of Hall-effect sensors 30.
- Each Hall-effect sensor 30 is connected in series with an SCR 22 and heater element 14 allowing the current drawn by each heater element 14 in the heater zone 12 to be monitored.
- the SCRs 22 and Hall-effect sensors 30 are mounted on an open face printed circuit board 38.
- FIG. 6 shows yet another heater zone monitoring and controlling circuit 10 similar to that of Figure 5.
- the components of the heater zone monitoring and controlling circuit are accommodated within a housing 300.
- Multi-terminal connectors 302 and 304 are provided to enable the Hall-effect sensors 30 to be connected in series with the SCRs 22 and heater elements 14 and to allow the signal output I HES of the Hall-effect sensors 30 to be supplied to the controller 24.
- Figure 7 shows still yet another embodiment of the heater zone monitoring and controlling circuit 10.
- the Hall-effect sensor 30 is accommodated by a terminal housing 400 mounted on a DIN rail 402.
- the housing 400 includes terminals 404 to 414.
- Terminals 404 and 408 receive power supply conductors that provide power for the Hall-effect sensor.
- Terminal 410 leads to the heater zone 14.
- Terminal 412 is coupled to the SCR 22 and terminal 414 provides the signal output I HES to the controller 24.
- Terminal 406 is a spare.
- the Hall-effect sensor 30 is connected in series with the SCR 22 and heater element 14 thereby to allow the signal output I HES to be supplied to the controller 24.
- FIG. 8 shows still yet another embodiment of a heater zone monitoring and controlling circuit 10.
- the SCR and Hall-effect sensor are integrated and packaged in a single common housing 500.
- Housing 500 has an input terminal 502 receiving conductor 18 coupled to the power supply.
- a series circuit within the housing including SCR 22 and Hall-effect sensor 30 extends across input terminal 502 and terminal 504.
- Terminal 504 is connected to the conductor leading to heating element, hi this manner, SCR 22 and the Hall-effect sensor 30 are in series with the heating element, similar to the previous embodiments.
- SCR 22 is driven by a control circuit 550 including an optoisolator
- Optoisolator 552 and LED 554 are in parallel and extend between terminals 506 and 508 on the housing 500. Terminals 506 and 508 are coupled to the controller 24 and receive the switching signal output thereof. Switching signals received on the terminals 506 and 508 drive the optoisolator 552 and switch 556 resulting in switching pulses being supplied to the SCR 22.
- a voltage regulator 560 and power source 562 are also provided.
- Hall-effect sensor 30 is shown comprising a magnetic concentrator 530 surrounding the conductor on which the load current drawn by the heating element appears.
- the output of the Hall-effect sensor 30 is fed to amplifying and filtering circuitry 570.
- Amplifying and filtering circuitry 570 performs dynamic offset cancellation, amplifies and filters the Hall-effect sensor output.
- the output of the amplifying and filtering circuitry 570 is then applied to signal conditioning circuitry 572, which conditions the input signal prior to providing the signal output I HES on output terminal 505.
- Hall-effect sensor is described as being connected in series between the SCR and heater element, those of skill in the art will appreciate that the Hall-effect sensor may be positioned at any suitable location that permits the current drawn by the heater element to be sensed. Also, other sensing devices that provide real-time output concerning the operating state of the heater element can be used. Further, those of skill in the art will appreciate that other suitable switching devices, such as far example, triacs may be used instead of SCRs.
- the heater zone monitoring and controlling circuit 10 is described with reference to moulding machines. It will however be appreciated by those skilled in the art that the heater zone monitoring and controlling circuit 10 can be used in other machines and equipment having heater zones, such as for example, printing and thermography devices, extruders etc.
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- Automation & Control Theory (AREA)
- Control Of Resistance Heating (AREA)
Abstract
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US63455404P | 2004-12-10 | 2004-12-10 | |
US60/634,554 | 2004-12-10 |
Publications (2)
Publication Number | Publication Date |
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WO2006060916A2 true WO2006060916A2 (fr) | 2006-06-15 |
WO2006060916A3 WO2006060916A3 (fr) | 2007-11-08 |
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Application Number | Title | Priority Date | Filing Date |
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PCT/CA2005/001874 WO2006060916A2 (fr) | 2004-12-10 | 2005-12-12 | Procede et appareil permettant de surveiller et de commander une zone de chauffage |
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WO (1) | WO2006060916A2 (fr) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN114536616A (zh) * | 2022-03-01 | 2022-05-27 | 国能神东煤炭集团有限责任公司 | 一种温度控制方法、电路、装置、系统及存储介质 |
Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4307775A (en) * | 1979-11-19 | 1981-12-29 | The Trane Company | Current monitoring control for electrically powered devices |
US4523084A (en) * | 1981-09-02 | 1985-06-11 | Oximetrix, Inc. | Controller for resistive heating element |
US5158132A (en) * | 1989-03-20 | 1992-10-27 | Gerard Guillemot | Zone-regulated high-temperature electric-heating system for the manufacture of products made from composite materials |
US5340964A (en) * | 1992-09-29 | 1994-08-23 | Cincinnati Milacron Inc. | Method and apparatus for monitoring electrical loads |
US5552998A (en) * | 1990-11-05 | 1996-09-03 | Watlow/Winona, Inc. | Method and apparatus for calibration and controlling multiple heaters |
WO1997003538A1 (fr) * | 1995-07-11 | 1997-01-30 | Technology Licensing Corporation | Systeme de diagnostic intelligent a sondes multiples pour appareil de traitement alimentaire |
-
2005
- 2005-12-12 WO PCT/CA2005/001874 patent/WO2006060916A2/fr active Application Filing
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4307775A (en) * | 1979-11-19 | 1981-12-29 | The Trane Company | Current monitoring control for electrically powered devices |
US4523084A (en) * | 1981-09-02 | 1985-06-11 | Oximetrix, Inc. | Controller for resistive heating element |
US5158132A (en) * | 1989-03-20 | 1992-10-27 | Gerard Guillemot | Zone-regulated high-temperature electric-heating system for the manufacture of products made from composite materials |
US5552998A (en) * | 1990-11-05 | 1996-09-03 | Watlow/Winona, Inc. | Method and apparatus for calibration and controlling multiple heaters |
US5340964A (en) * | 1992-09-29 | 1994-08-23 | Cincinnati Milacron Inc. | Method and apparatus for monitoring electrical loads |
WO1997003538A1 (fr) * | 1995-07-11 | 1997-01-30 | Technology Licensing Corporation | Systeme de diagnostic intelligent a sondes multiples pour appareil de traitement alimentaire |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN114536616A (zh) * | 2022-03-01 | 2022-05-27 | 国能神东煤炭集团有限责任公司 | 一种温度控制方法、电路、装置、系统及存储介质 |
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WO2006060916A3 (fr) | 2007-11-08 |
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