Abstract: A heating apparatus for heating fluid includes a container body, a plurality of electric heater elements, and a support structure. The container body defines a perimeter of a flow path for a fluid flowing through the container body. The plurality heater elements are exposed to the flow path. Each heater element includes a resistance element, sheath, and insulating material disposed about the resistance element between the resistance element and the sheath. The support structure includes a plurality of support sheets. The heater elements extend transversely through each support sheet and contact each support sheet to restrict movement of the heater elements and support the heater elements in the container body. The support sheets contact the sheaths of the electric heater elements to increase heat transfer to the fluid flowing through the flow path. Opposite ends of each support sheet are connected to the container body.

Abstract: A method of calibrating temperature of a resistive element having a material with a Curie temperature includes generating a standard resistance-temperature (R-T) curve for the resistive element in isothermal conditions to identify values of the R-T curve and an inflection point at the Curie temperature, generating operational R-T curves for the resistive element over an operational time period, comparing the standard R-T curve to the operational R-T curves, and adjusting the operational curves to the standard R-T curve at the Curie temperature to calibrate temperature of the resistive element.

Abstract: A heating apparatus for a fluid flow system having a fluid conduit includes at least one heater element and a support member within the conduit. The at least one heater element includes a resistance wire, a sheath, and an electrically insulating material. The sheath has a closed profile shape that extends along a tortuous path through the container body and surrounds the resistance wire along the tortuous path. The insulating material is disposed about the wire between the wire and the sheath. The support member restricts movement of the at least one heater element relative to the fluid conduit. The support member defines a corrugated geometry that follows the tortuous path while contacting the sheath along a majority of a length of the sheath. The support member increases heat transfer from the at least one heater element to a fluid flowing through the fluid conduit.

Abstract: A method of predicting the temperature of a resistive heating element in a heating system is provided. The method includes obtaining resistance characteristics of resistive heating elements and compensating for variations in the resistance characteristics over a temperature regime. The resistance characteristics of the resistive heating element include, but are not limited to, inaccuracies in resistance measurements due to strain-induced resistance variations, variations in resistance due to the rate of cooling, shifts in power output due to exposure to temperature, resistance to temperature relationships, non-monotonic resistance to temperature relationships, system measurement errors, and combinations of resistance characteristics. The method includes interpreting and calibrating resistance characteristics based on a priori measurements and in situ measurements.

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 heating apparatus and method for use in an exhaust gas system is provided that includes a container body defining an exhaust gas pathway, a heater flange component attached to an exterior of the container body, and a heater assembly disposed in the exhaust gas pathway and secured to the heater flange component. The heater assembly includes at least one heater element, a bracket assembly that secures the at least one heater element in the container body, and a conformal bracket for securing the at least one heater element to the bracket assembly.

Abstract: A control system for use in a fluid flow application includes a heater and a control device. The heater has at least one resistive heating element and the heater is operable to heat fluid. The control device determines at least one flow characteristic of a fluid flow based on a heat loss of the at least one resistive heating element and determines a mass flow rate of the fluid based on the at least one flow characteristic and a property of the at least one resistive heating element. And the property of the at least one resistive heating element includes a change in resistance of the at least one resistive heating element under a given heat flux density.

Abstract: A control system for use in a fluid flow application is provided. The control system includes a heater having at least one resistive heating element. The heater is adapted to heat the fluid flow. The control system further includes a control device that uses heat loss from at least one resistive heating element to determine flow characteristics of the fluid flow.

Abstract: A heating apparatus for a fluid flow system having a fluid conduit includes at least one heater element and a support member within the conduit. The at least one heater element includes a resistance wire, a sheath, and an electrically insulating material. The sheath has a closed profile shape that extends along a tortuous path through the container body and surrounds the resistance wire along the tortuous path. The insulating material is disposed about the wire between the wire and the sheath. The support member restricts movement of the at least one heater element relative to the fluid conduit. The support member defines a corrugated geometry that follows the tortuous path while contacting the sheath along a majority of a length of the sheath. The support member increases heat transfer from the at least one heater element to a fluid flowing through the fluid conduit.

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 method of predicting temperature of at least one location in a fluid flow system that has a heating system for heating fluid. The method includes obtaining a mass flow rate of fluid flow of the fluid flow system, obtaining at least one of a fluid outlet temperature and a fluid inlet temperature of a heater of the heating system, obtaining power provided to the heater, and calculating temperature at the at least one location based on a model of the fluid flow system and the obtained mass flow rate, fluid outlet temperature, and fluid inlet temperature.

Abstract: A heating apparatus for an exhaust gas system, or a fluid flow system, is provided by the present disclosure. The heating apparatus has a container body and includes at least one heater element and a support member disposed inside the container body and configured for restricting movement of the at least one heater element in the container body. The support member defines a tortuous geometry and flanks opposed sides of the at least one insulated heater element along a majority of a length of the at least one insulated heater element, wherein the support member increases heat transfer from the at least one heater element to an exhaust gas flowing through the container body.

Abstract: A control system for a heating system of an exhaust system is provided. The control system includes at least one electric heater disposed within an exhaust fluid flow pathway, and a control device adapted to receive at least one input selected from the group consisting of mass flow rate of an exhaust fluid flow, mass velocity of an exhaust fluid flow, flow temperature upstream of the at least one electric heater, flow temperature downstream of the at least one electric heater, power input to the at least one electric heater, parameters derived from physical characteristics of the heating system, and combinations thereof. The control device is operable to modulate power to the at least one electric heater based on at least one input.

Abstract: A control system includes an electric heater disposed within an exhaust fluid flow pathway, and a control device for receiving at least one input selected from the group consisting of temperature readings along the exhaust fluid flow pathway, alternator power/current/voltage, battery power/current/voltage/state of charge, IAT and EAT profiles, mass flow rate of an exhaust fluid flow, NH3 slip, TCR characteristics of the heater, alternator speed, engine speed, state of aging of an aftertreatment component, state of aging of engine, aging degradation characteristics, a dosing rate and a temperature of DEF, NH3 storage condition of aftertreatment system, an ambient temperature, and combinations thereof. The control device modulates power to the heater based on the at least one input such that the heater provides different power output as a function of the at least one input and a continuously variable power output during operation of the exhaust system.

Abstract: A heating apparatus for an exhaust gas system, or a fluid flow system, is provided by the present disclosure. The heating apparatus has a container body and includes at least one heater element and a support member disposed inside the container body and configured for restricting movement of the at least one heater element in the container body. The support member defines a tortuous geometry and flanks opposed sides of the at least one insulated heater element along a majority of a length of the at least one insulated heater element, wherein the support member increases heat transfer from the at least one heater element to an exhaust gas flowing through the container body.

Abstract: A method of predicting the temperature of a resistive heating element in a heating system is provided. The method includes obtaining resistance characteristics of resistive heating elements and compensating for variations in the resistance characteristics over a temperature regime. The resistance characteristics of the resistive heating element include, but are not limited to, inaccuracies in resistance measurements due to strain-induced resistance variations, variations in resistance due to the rate of cooling, shifts in power output due to exposure to temperature, resistance to temperature relationships, non-monotonic resistance to temperature relationships, system measurement errors, and combinations of resistance characteristics. The method includes interpreting and calibrating resistance characteristics based on a priori measurements and in situ measurements.

Abstract: A control system for use in a fluid flow application is provided. The control system includes a heater having at least one resistive heating element. The heater is adapted to heat the fluid flow. The control system further includes a control device that uses heat loss from at least one resistive heating element to determine flow characteristics of the fluid flow.

Abstract: A smart heating system is described that generally comprises at least one heater element, optionally, at least one temperature sensor, a set of predetermined or predictable performance information used to control the heating system; and, optionally, an electronic conditioning module (ECU) capable of storing and processing the performance information. The performance information may be stored as written text, a bar code, a data matrix, or a radio frequency identification (RFID) tag. The smart heating system heating system may further comprises a LIN or a CAN bus capable of providing a communication pathway between at least two of the system components.

Abstract: A heating apparatus and method for use in an exhaust gas system is provided that includes a container body defining an exhaust gas pathway, a heater flange component attached to an exterior of the container body, and a heater assembly disposed in the exhaust gas pathway and secured to the heater flange component. The heater assembly includes at least one heater element, a bracket assembly that secures the at least one heater element in the container body, and a conformal bracket for securing the at least one heater element to the bracket assembly.

Abstract: A sensor adaptor circuit housing assembly and method of manufacturing includes a circuit board, a housing, an input wire, and a connector. The circuit board includes an electrical circuit configured for receiving a sensor signal and generating a sensor characteristic in response to the received sensor signal. The housing includes a body and a cavity defined by inner surfaces of the body and adapted for receiving the circuit board, the circuit board being positioned within the cavity. The input wire is configured for receiving the signal from a sensor and can be formed with an insulated solid or stranded conductor. The connector includes a unitary body, a first end of the unitary body attached directly to an end of the input wire, a second end of the unitary body positioned within the cavity and attached directly to the circuit board and making a first electrical connection with the electrical circuit.