Apparatus and Method for Control of a Thermostat

• US 20120230661A1
• Filed: 05/10/2012
• Published: 09/13/2012
• Est. Priority Date: 11/11/2008
• Status: Abandoned Application

• Current Assignee: Emerson Electric Company
• Original Assignee: Emerson Electric Company
• Inventors: Alhilo, Esan A.
• Application Number:
  US13/468,304
• Publication Number:
  US 20120230661A1
• Time in Patent Office: Days
• US Class Current: 392/441
• CPC Class Codes: G05B 11/28 using pulse-height modulation; using pulse-width modulation
• CPC Class Codes: G05B 13/021 in which a variable is automatically adjusted to optimise the performance
• CPC Class Codes: G05B 5/01 electric

Abstract

Controllers and methods for activating a switching device to apply electrical power to a heating element are provided. One example controller includes a temperature sensor disposed within the fluid and configured to sense an ambient temperature of the fluid, a switching device configured to apply electrical power to a heating element, and a processor coupled to the temperature sensor and the switching device. The processor is configured to determine a temperature delta value based on the sensed ambient temperature from the temperature sensor and a set point temperature, to determine an offset based on an average duty cycle of a switching device for a predetermined number of historical time intervals, and to calculate a duty cycle based on the temperature delta value and the offset.

Claims

1. A controller for activating a switching device to apply electrical power to a heating element, the controller comprising:

a processor configured to receive, from a temperature sensor, a temperature signal indicative of an ambient temperature of a fluid within a space, to determine a temperature delta value indicative of a difference between the ambient temperature and a set point temperature, and to determine an offset based on an average duty cycle of a switching device for a predetermined number of historical time intervals;

wherein the processor is configured to calculate a duty cycle for controlling the switching device based on the temperature delta value and the offset and to activate the switching device according to the calculated duty cycle, to thereby control the extent of electrical power applied to the heating element.

2. The controller of claim 1, wherein the processor is configured to apply, via the switching device, a line voltage source to the heating element according to the calculated duty cycle.

3. The controller of claim 1, wherein the offset includes a heat dissipation offset to compensate for a response of the temperature sensor to the heat generated by the switching device.

4. The controller of claim 3, wherein the processor is configured to calculate said duty cycle based on the heat dissipation offset and the temperature delta value, only when the temperature delta value is below a threshold, the threshold representative of at least about 2 degrees Celsius.

5. The controller of claim 3, wherein the processor is configured to calculate the duty cycle to reduce the temperature delta to less than about 2 degrees Celsius.

6. The controller of claim 1, further comprising a housing, a switching device disposed within the housing, and a temperature sensor disposed within the housing and positioned proximate to the switching device;

wherein the switching device is coupled to the processor and configured to apply electrical power to the heating element based on the calculated duty cycle.

7. The controller of claim 1, wherein the processor is further configured to store a duty cycle for each of the predetermined number of historical time intervals, the predetermined number of historical time intervals including time intervals within a last hour.

8. The controller of claim 1, wherein the offset includes a duty cycle offset, the processor configured to determine the duty cycle offset based on the average duty cycle of the switching device and a duty cycle multiplier.

9. The controller of claim 1, wherein the processor is configured to determine the offset based on a current drawn through the switching device during at least one of the historical time intervals.

10. A controller for activating a switching device to apply electrical power to a heating element for heating a fluid within a space, the controller comprising:

a temperature sensor disposed within the fluid and configured to sense an ambient temperature of the fluid;

a switching device configured to apply electrical power to a heating element; and

a processor coupled to the temperature sensor and the switching device, the processor configured to determine a temperature delta value based on the sensed ambient temperature from the temperature sensor and a set point temperature, to determine an offset based on an average duty cycle of a switching device for a predetermined number of historical time intervals, and to calculate a duty cycle based on the temperature delta value and the offset;

wherein the processor is configured to activate the switching device according to the calculated duty cycle, to thereby control the extent of electrical power applied to the heating element.

11. The controller of claim 10, further comprising a housing in which are disposed the temperature sensor and the switching device.

12. The controller of claim 10, wherein the temperature sensor is disposed proximate to the heating element for heating the fluid within the space.

13. The controller of claim 10, wherein:

the offset includes a heat dissipation offset indicative of a response of the temperature sensor to the heat generated by the switching device; and

the processor is configured to determine a present duty cycle based on the temperature delta value and to calculate said duty cycle based on the present duty cycle and the heat dissipation offset.

14. The controller of claim 10, wherein the controller includes a thermostat for controlling a heating system.

15. A method for activating a switching device to apply electrical power to a heating element, the method comprising:

receiving, from a temperature sensor, a temperature signal indicative of an ambient temperature of a fluid within a space;

determining, at a processor, a temperature delta value indicative of a difference between the ambient temperature and a set point temperature;

determining, at the processor, an offset based on an average duty cycle of a switching device for a predetermined number of historical time intervals;

calculating a duty cycle for controlling the switching device based on the temperature delta value and the offset; and

activating the switching device according to the calculated duty cycle, to thereby control the extent of electrical power applied to the heating element.

16. The method of claim 15, wherein the offset includes a heat dissipation offset indicative of a response of the temperature sensor to the heat generated by the switching device.

17. The method of claim 15, wherein determining the temperature delta includes periodically determining the temperature delta.

18. The method of claim 17, wherein determining the offset based on the average duty cycle of the switching device includes determining the offset based on the average duty cycle of the switching device at least once per hour.

19. The method of claim 17, wherein determining the offset includes retrieving a default offset when there is less than the predetermined number of historical time intervals.

20. The method of claim 15, further comprising storing the calculated duty cycle in memory.