Abstract: A method of forming a layered heater assembly includes: forming a plurality of layers onto a substrate, the plurality of layers including a resistive element layer; forming electrical terminations in contact with the resistive element layer; securing a protective cover over the layers using a laser welding process, wherein edges of the protective cover are welded circumferentially around raised end portions of the substrate and welded longitudinally along a slotted portion of the substrate; securing a pair of lead wires to the electrical terminations; and securing a lead cap assembly around the pair of lead wires and to the protective cover using a laser welding process.

Abstract: A heater assembly is provided that includes a substrate having opposed end portions defining raised flanges, a slot extending between the opposed end portions, and opposed chamfered surfaces extending along the slot and across the raised flanges. A plurality of layers are disposed onto the substrate, along with a pair of terminal pads. A protective cover defining at least one aperture is disposed over the layers and is secured to the raised flanges and the opposed chamfered surfaces of the substrate, and the aperture is disposed proximate the terminal pads. A pair of lead wires is secured to the pair of terminal pads, and a lead cap assembly is disposed around the pair of lead wires and is secured to the protective cover.

Abstract: A method of forming a layered heater assembly includes: forming a plurality of layers onto a substrate, the plurality of layers including a resistive element layer; forming electrical terminations in contact with the resistive element layer; securing a protective cover over the layers using a laser welding process, wherein edges of the protective cover are welded circumferentially around raised end portions of the substrate and welded longitudinally along a slotted portion of the substrate; securing a pair of lead wires to the electrical terminations; and securing a lead cap assembly around the pair of lead wires and to the protective cover using a laser welding process.

Abstract: A heater assembly is provided that includes a substrate having opposed end portions defining raised flanges, a slot extending between the opposed end portions, and opposed chamfered surfaces extending along the slot and across the raised flanges. In one form, a plurality of layers are disposed onto the substrate, along with a pair of terminal pads. A protective cover defining at least one aperture is disposed over the layers and is secured to the raised flanges and the opposed chamfered surfaces of the substrate, and the aperture is disposed proximate the terminal pads. A pair of lead wires is secured to the pair of terminal pads, and a lead cap assembly is disposed around the pair of lead wires and is secured to the protective cover. Methods of manufacturing the heater assembly are also provided in accordance with the present disclosure.

Abstract: A control system and methods are provided that limit power provided to a power receiving device to a value less that that produced at full line voltage. The system includes at least one power receiving device and a power controller operatively associated with the power receiving device, the power controller comprising a power limiting function that limits the power provided to the power receiving device to a value less than that produced at a full line voltage through the use of a scaling function.

Abstract: A heater is provided that includes a resistive layer formed by a layered process (e.g., thick film, thin film, thermal spray, and sol-gel) and two electrical lead wires connected to the resistive layer. The resistive layer has sufficient temperature coefficient of resistance characteristics such that the resistive layer is a heater element and a sensor, and the resistive layer is in communication with a two-wire controller through the two electrical lead wires. Preferably, the sensor is a temperature sensor, and the heater includes additional layers formed by layered processes.

Abstract: A hot runner nozzle heater is provided that includes a sleeve defining a slot extending along a length of the sleeve. A first dielectric layer is disposed over an outer surface of the sleeve, and a resistive element layer is disposed over the first dielectric layer, wherein the resistive element layer defines a resistive circuit pattern that is preferably formed by a laser trimming process. A pair of terminal leads are secured to a portion of the resistive element layer thus defining a termination area, and the termination area is positioned proximate the slot and away from the proximal end and the distal end of the sleeve. A second dielectric layer is disposed over the resistive element layer but not over the termination area, a third dielectric layer is disposed over the termination area, and a protective layer disposed over the second dielectric layer and the third dielectric layer.

Abstract: A hot runner nozzle heater system is provided with a layered heater in communication with a two-wire controller, wherein a resistive layer of the layered heater is both a heater element and a temperature sensor. The two-wire controller thus determines temperature of the layered heater using the resistance of the resistive layer and controls heater temperature through a power source.

Abstract: A method of diagnosing a distributed operational system having a field device, a field processing module coupled to the field device, a bitbus, a fieldbus, and an auxiliary processing module communicating with the bitbus and the fieldbus. The method includes generating a field operating characteristic at the field device, processing the field operating characteristic at the field processing module, and generating field operating data including a field diagnostic parameter as a function of the field operating characteristic. The method also includes communicating the field operating data including the field diagnostic parameter over the bitbus from the field processing module to the auxiliary processing module. The method further includes generating at the auxiliary processing module auxiliary field data as a function of the received field operating data and communicating the auxiliary field data over the fieldbus.

Abstract: A temperature sensing and diagnostics system having a temperature sensor for generating a temperature characteristic and a bitbus includes a field processing module and an auxiliary processing module. The field processing module is adapted for coupling to the temperature sensor and for receiving the temperature characteristic from the temperature sensor. The field processing module includes a field diagnostic component and a field communication component configured for communication over the bitbus and is adapted to generate field operating data including a temperature diagnostic parameter as a function of the temperature characteristic. The auxiliary processing module is configured for communicating with the bitbus and for receiving the field operating data and includes an auxiliary diagnostic component and an auxiliary communication component having a fieldbus interface and a gateway component.

Abstract: A distributed operations system having integrated diagnostics, a bitbus and a fieldbus and includes a field device for generating a field operating characteristic and a field processing module for receiving the field operating characteristic from the field device. The field processing module includes a field diagnostic component and a field communication component configured for communication over the bitbus. The field processing module is configured for generating field operating data including a field diagnostic parameter as a function of the field operating characteristic. An auxiliary processing module is configured for communicating with the bitbus and receiving the field operating data. The auxiliary processing module includes an auxiliary diagnostic component and an auxiliary communication component having a fieldbus interface and a gateway component.

Abstract: A method of diagnosing a temperature sensing system having a temperature sensor, a field processing module coupled to the temperature sensor, a bitbus, a fieldbus, and an auxiliary processing module communicating with the bitbus and the fieldbus. The method includes generating a temperature characteristic at the temperature sensor, processing the temperature characteristic at the field processing module, and generating field operating data including a temperature diagnostic parameter as a function of the temperature characteristic. The method also includes communicating the field operating data including the temperature diagnostic parameter over the bitbus from the field processing module to the auxiliary processing module, generating at the auxiliary processing module auxiliary field data as a function of the received field operating data, and communicating the auxiliary field data over the fieldbus.

Abstract: A heater system is provided that comprises a layered heater in communication with a two-wire controller, wherein a resistive layer of the layered heater is both a heater element and a temperature sensor. The two-wire controller thus determines temperature of the layered heater using the resistance of the resistive layer and controls heater temperature through a power source. Furthermore, a heater system using a layered heater in communication with a two-wire controller for a specific application of a hot runner nozzle in an injection molding system is provided by the present invention.