Fuzzy logic-based control of microwave dryers

• US 8,299,409 B2
• Filed: 10/30/2009
• Issued: 10/30/2012
• Est. Priority Date: 10/31/2008
• Status: Active Grant

• Current Assignee: Corning Incorporated
• Original Assignee: Corning Incorporated
• Inventors: Harihara, Parasuram Padmanabhan, Terwilliger, Brett Alan
• Primary Examiner(s): Thomas, Tom
• Assistant Examiner(s): Liu, Benjamin Tzu-Hung
• Application Number:
  US12/609,646
• Publication Number:
  US 20100108667A1
• Time in Patent Office: 1,096 Days
• Field of Search: 219/704, 219/702, 706/52, 706/47
• US Class Current: 219/704
• CPC Class Codes: H05B 2206/046 Microwave drying of wood, ink, food, ceramic, sintering of ceramic, clothes, hair
• CPC Class Codes: H05B 6/68 for monitoring or control
• CPC Class Codes: H05B 6/78 Arrangements for continuous movement of material

Abstract

A fuzzy logic-based system and method for controlling the drying of material by a microwave applicator. The system includes power output controller that controls applicator output power; material sensor that detects amount of material in the applicator; and fuzzy logic controller that receives a signal from the material sensor indicating the current amount of material in the applicator and adjusts the microwave output power based on the current amount of material in accordance with fuzzy logic rules by sending a control signal to the power output controller. A membership function divides the expected range for the amount of material into multiple regions, each region having precomputed regional output settings. The regional output settings of the regions that include the current amount of material are used to compute the control signal.

Claims

1. A system for controlling the drying of material by a microwave applicator, the system comprising:

a power output controller that controls the microwave output power of the applicator;

a material sensor that detects the amount of material in the applicator;

a fuzzy logic controller operatively connected to the material sensor and the power output controller,

wherein the fuzzy logic controller receives a sensor signal from the material sensor indicating the current amount of material in the applicator and adjusts the microwave output power based on the current amount of material in accordance with fuzzy logic rules by sending a control signal to the power output controller;

and wherein the fuzzy logic controller comprises;

a storage module for storing fuzzy logic information, including a minimum expected value and a maximum expected value for the amount of the material in the applicator which defines an expected range for the amount of material in the applicator,

a fuzzification module for storing a membership function that divides the expected range for the amount of material in the applicator into multiple regions, and for each region of the membership function storing a minimum regional value, a maximum regional value and precomputed regional output settings;

a selection module for selecting each region of the membership function including the current amount of material in the range between the minimum regional value and the maximum regional value for that region; and

an output processor for computing the control signal based on the precomputed regional output settings of each of the regions of the membership function selected by the selection module, wherein the output processor comprises;

a preselected maximum output power value;

a defuzzification module for calculating a minimum output power value based on the precomputed regional output settings of each region of the membership function selected by the selection module; and

a control signal processor calculator for calculating a set of polynomial coefficients based on the maximum output power value and the minimum output power value; and

for calculating the control signal based on the set of polynomial coefficients and the current amount of material in the applicator.

2. The system of claim 1 wherein the material sensor comprises a photoeye positioned prior to the entrance of the applicator that detects at least one dimension of the material entering the applicator.

3. The system of claim 2 wherein the material sensor further comprises a weight sensor that detects the weight of the material entering the applicator.

4. The system of claim 1, wherein the regions of the membership function are overlapping.

5. The system of claim 1, wherein the regions of the membership function are non-overlapping.

6. A fuzzy logic-based method of controlling the drying of material by a microwave applicator, the method comprising:

predetermining an expected minimum amount of material in the applicator and an expected maximum amount of material in the applicator which defines an expected range for the amount of material in the applicator;

dividing the expected range for the amount of the material in the applicator into multiple regions using a membership function;

precomputing regional output settings for each of the multiple regions of the membership function;

determining a current amount of material in the applicator;

determining the regions of the membership function that include the current amount of material in the applicator,

determining the current output settings based on the regional output settings for each of the regions of the membership function that include the current amount of material in the applicator;

computing a desired output power for the applicator based on the current output settings; and

sending a control signal to the microwave controller of the applicator with the desired output power;

wherein the precomputing regional output settings for each of the multiple regions of the membership function step comprises;

precomputing a minimum power setpoint for the applicator for each region of the membership function based on the range of the amount of material covered by that region of the membership function;

precomputing a weight-to-power-difference function relating the weight of the material to a power difference needed to overcome a temperature difference due to a variation in the amount of the material in the microwave applicator; and

determining the minimum power setpoint for the microwave applicator using the weight-to-power-difference function.

7. The method of claim 6, wherein the determining a current amount of material step comprises:

sensing a dimension of the material entering the applicator using a dimension sensor positioned prior to the entrance of the applicator; and

determining a current amount of material in the applicator based on the sensed dimension of the material entering the applicator.

8. The method of claim 7, wherein the determining a current amount of material step further comprises:

sensing the weight of the material entering the applicator using a weight sensor; and

determining a current amount of material in the applicator based on both the dimension and the weight of the material entering the applicator.

9. The method of claim 6, further comprising:

predetermining a maximum power setpoint for the applicator; and

wherein the computing a desired output power for the applicator based on the current output settings comprises;

computing a set of polynomial coefficients based on the minimum power setpoint for the applicator and the maximum power setpoint for the applicator; and

calculating the desired output power of the applicator using the set of polynomial coefficients.

10. The method of claim 9, wherein the calculating the desired output power of the applicator using the set of polynomial coefficients step comprises:

calculating an independent variable based on the difference between the expected maximum amount of material in the applicator and the current amount of material in the applicator; and

calculating the desired output power of the applicator using the independent variable with the set of polynomial coefficients.

11. A fuzzy logic-based method of controlling the drying of material by a microwave applicator, the method comprising:

predetermining a maximum power setpoint for the applicator;

predetermining an expected minimum amount of material in the applicator and an expected maximum amount of material in the applicator, defining an expected range for the amount of material in the applicator;

creating a membership function dividing the expected range for the amount of the material in the applicator into a plurality of regions;

precomputing a regional minimum power setpoint for each of the plurality of regions of the membership function;

determining a current amount of material in the applicator;

determining the regions of the plurality of regions of the membership function that include the current amount of material in the applicator,

determining an output minimum power setpoint based on the regional minimum power setpoint for each of the plurality of regions of the membership function that include the current amount of material in the applicator;

computing a desired output power for the applicator based on the output minimum power setpoint and the maximum power setpoint; and

sending a control signal to the microwave controller of the applicator with the desired output power;

wherein the computing a desired output power for the applicator step comprises;

computing a set of polynomial coefficients based on the output minimum power setpoint and the maximum power setpoint for the applicator; and

calculating the desired output power of the applicator using the set of polynomial coefficients.

12. The method of claim 11, wherein the precomputing a regional minimum power setpoint for each of the plurality of regions of the membership function step comprises:

precomputing a material-to-power-difference function relating the amount of material in the applicator to a power difference needed to overcome a temperature difference due to a variation in the amount of material in the microwave applicator; and

determining the regional minimum power setpoint for each of the plurality of regions of the membership function using the material-to-power-difference function.

13. The method of claim 12, wherein the precomputing a material-to-power-difference function step comprises:

precomputing a material-to-power-difference function covering ranges where the amount of material in the applicator is less than or equal to the expected maximum amount of material in the applicator.

14. The method of claim 11, wherein the calculating the desired output power of the applicator using the set of polynomial coefficients step comprises:

calculating an independent variable based on the difference between the expected maximum amount of material in the applicator and the current amount of material in the applicator; and

calculating the desired output power of the applicator using the independent variable with the set of polynomial coefficients.