Abstract: A heating system includes a plurality of heater elements, a plurality of switches connected to the plurality of heater elements, a set of predetermined performance information including heater information specific for each heater element, at least one temperature sensor measuring temperature of at least one heater element from among the plurality of heater elements, and a heater control unit in communication with the temperature sensor(s). The heater control unit controls the heater elements differently, via the switches, based on the heater information and the measured temperature from the temperature sensor(s).

Abstract: A heating system includes at least one electric heater disposed within a fluid flow system and a control device that is configured to determine a temperature of the at least one electric heater based on a model, at least one fluid flow system input, and at least one heater input. The at least one heater input includes at least one physical characteristic of the heating system, the at least one physical characteristic includes at least one of a resistance wire diameter, a heater insulation thickness, a heater sheath thickness, a conductivity, a specific heat and density of the material of the heater, an emissivity of the heater and the fluid flow pathway, and combinations thereof. The control device is configured to provide power to the at least one electric heater based on the temperature of the at least one electric heater.

Abstract: A heater system is provided, which includes a plurality of heaters, a controller for supplying power to the plurality of heaters, a plurality sets of auxiliary wires extending from the plurality of heaters, and a wire harness for connecting the plurality sets of auxiliary wires to the controller. Each set of auxiliary wires includes three wires, two of the three wires being made of different materials and being joined to form a thermocouple junction, such that each of the plurality of heaters is operable to function as both a heater and a temperature sensor.

Abstract: An electric heater system includes an inlet, an outlet, a plurality of heat exchanger assemblies, and one or more connectors. The plurality of heat exchanger assemblies are connected in series. Each heat exchanger assembly includes a vessel, heating elements disposed within the vessel, and a fluid guide member. The connectors secure the vessels of the plurality of heat exchanger assemblies to each other. The connectors are also in fluid communication with the vessels. Fluid entering the inlet flows through the heat exchanger assemblies and through one or more connectors where it exits the outlet. The fluid guide members of the heat exchanger assemblies are of different or the same combinations to generate a predetermined pressure drop between the inlet and the outlet.

Abstract: A heater system includes a plurality of heater cores defining zones, a plurality of power pins extending through each of the heater cores and made of different conductive materials, and at least one jumper connected between two of the plurality of power pins being made of dissimilar materials. The jumper is in communication with a controller to obtain a temperature reading of the heater system proximate the jumper.

Abstract: A thermal insulation structure includes an insulation layer having a first surface proximate a cooling device and a second surface opposing the first surface. A heater is disposed proximate the second surface, and a protective layer is disposed proximate the heater layer such that the heater layer is disposed between the insulation layer and the protective layer. The heater layer is configured to reduce frost or ice buildup on an exterior surface of the insulation layer.

Abstract: A fluid sensor system detects one or more performance characteristics of a heating system that heats a fluid. The sensor system includes a probe having a finite length a portion of which is to be immersed in the fluid. The probe includes a resistive heating element and a fluid temperature sensor for measuring one or more performance characteristics, wherein the fluid temperature sensor is configured to measure a fluid temperature, and the resistive heating element is operable as a heater to create a temperature differential between the fluid and air to detect the fluid, and as a sensor to measure a fluid level.

Abstract: An industrial control device includes a display, a body, a first sensor, and a controller. The body includes a facia wall, an inner shroud, and an outer shroud. The facia wall includes a window that is a transparent material aligned to permit the display to be viewed through the window. The inner shroud extends rearward from a rear side of the facia wall. The outer shroud is disposed about the inner shroud and extends rearward from the rear side of the facia wall and is spaced apart from the inner shroud to define a cavity. A seal member is within the cavity forms a seal with a facia plate disposed about the inner shroud. The first sensor detects contact with a front surface of the facia wall. The controller is coupled to an output of the first sensor. The controller is coupled to the display and controls the display.

Abstract: An electrostatic chuck is formed by depositing a diffuser layer onto an electrostatic puck and removing areas of the diffuser layer to form discrete diffuser segments separated by gaps. The discrete diffuser segments may define continuous concentric rings, discontinuous concentric rings, or a combination of continuous concentric rings and discontinuous concentric rings. The discrete diffuser segments are separated from each other by forming at least one trench in the diffuser layer. The trench may extend partially through the diffuser layer, completely through the diffuser layer to the electrostatic puck, or have a first portion that extends partially through the diffuser layer and a second portion that extends completely through the diffuser layer. Also, the trench can have a constant width or have a variable width.

Abstract: A wireless sensor assembly includes a housing defining a first aperture for receiving an external sensor, and a second aperture defining a communication port, a wireless power source mounted within the housing, and electronics mounted to the housing and configured to receive power from the wireless power source and to be in electrical communication with the external sensor. The electronics include a wireless communications component, and firmware configured to manage a rate of data transmittal from the wireless communications component to an external device. The communication port is configured to receive a wire harness connected to the external sensor.

Abstract: An exhaust gas heating unit for an engine includes a housing and a heating element. The housing includes a tubular peripheral wall and has an interior hollow space. The heating element has first and second ends and extends longitudinally therebetween to form a spiral shape within the interior hollow space. The heating element includes a thermally conductive sheath, an electrically conductive resistance element that extends longitudinally within the external sheath, and an electrically insulating material disposed about the resistance element between the resistance element and the sheath. A heat transfer member is positioned within the interior hollow space and is formed from one or more strips of thermally conductive material. The strips contact the external sheath at a plurality of locations between the first end and the second end. The heat transfer member has a corrugated shape that follows the spiral shape of the heating element.

Abstract: A metal heater includes a metal substrate with a groove, a resistive heater disposed within the groove, and a fill metal disposed over the resistive heater and substantially filling the groove, wherein the fill metal has a lower melting temperature than the metal substrate. The fill metal can be indium and a cover plate can be bonded to the metal substrate and over the indium. A method of manufacturing the metal heater and a method of operating the metal heater are also provided.

Abstract: An exhaust gas heater system for an exhaust system of an internal combustion engine includes a housing and a heating element. The housing includes an outer peripheral wall disposed about a central axis and defining an interior hollow space configured to receive exhaust gas from an exhaust pipe of the exhaust system such that the exhaust gas flows through the interior hollow space. The heating element is positioned within the hollow space and including a first end and a second end. The heating element forms a zig-zag shape extending in a radial direction relative to the central axis.

Abstract: A multi-zone heater with a plurality of thermocouples such that different heater zones can be monitored for temperature independently. The independent thermocouples may have their leads routed out from the shaft of the heater in a channel that is closed with a joining process that results in hermetic seal adapted to withstand both the interior atmosphere of the shaft and the process chemicals in the process chamber. The thermocouple and its leads may be enclosed with a joining process in which a channel cover is brazed to the heater plate with aluminum.

Abstract: A heating system includes at least one electric heater disposed within the fluid flow system. A control device includes a microprocessor and is configured to determine a temperature of the at least one electric heater based on a model and at least one input from the fluid flow system. The control device is configured to provide power to the at least one electric heater based on the temperature of the at least one electric heater.

Abstract: A heater assembly includes a continuous series of perforated helical members and a plurality of electrical resistance heating elements. The perforated helical members cooperate to define a geometric helicoid disposed about a longitudinal axis of the heater assembly. Each perforated helical member defines opposed edges and a predetermined pattern of perforations. The perforations extend through each perforated helical member parallel to the longitudinal axis. The heating elements extend through the perforations.

Abstract: A support pedestal includes a support member including a resistive layer having a plurality of zones, a routing layer, and a plurality of conductive vias. The plurality of zones are defined by a plurality of independently controllable resistive heating elements. The resistive layer and the routing layer are disposed in different planes of the support member and are connected by the plurality of conductive vias.

Abstract: An industrial control device includes a display, a body, a first sensor, and a controller. The body includes a facia wall, an inner shroud, and an outer shroud. The facia wall includes a window that is a transparent material aligned to permit the display to be viewed through the window. The inner shroud extends rearward from a rear side of the facia wall. The outer shroud is disposed about the inner shroud and extends rearward from the rear side of the facia wall and is spaced apart from the inner shroud to define a cavity. A seal member is within the cavity forms a seal with a facia plate disposed about the inner shroud. The first sensor detects contact with a front surface of the facia wall. The controller is coupled to an output of the first sensor. The controller is coupled to the display and controls the display.