Abstract: A heater system includes a heater bundle having a plurality of heater assemblies and a plurality of power conductors. More than one of the heater assemblies includes a plurality of heater units, and more than one of the heater units defines at least one independently controlled heating zone. The plurality of power conductors are electrically connected to the independently controlled heating zones. The heater system further includes means for determining temperature, and a power supply device including a controller configured to modulate power to the independently controlled heating zones through the power conductors based on the determined temperature to provide a desired power output along a length of more than one of the heater assemblies.

Abstract: A heater system includes a heater bundle having a plurality of heater assemblies and a plurality of power conductors. More than one of the heater assemblies includes a plurality of heater units, and more than one of the heater units defines at least one independently controlled heating zone. The plurality of power conductors are electrically connected to the independently controlled heating zones. The heater system further includes means for determining temperature, and a power supply device including a controller configured to modulate power to the independently controlled heating zones through the power conductors based on the determined temperature to provide a desired power output along a length of more than one of the heater assemblies.

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 layered heater is provided with a dielectric layer formed by a first layered process, a resistive layer formed on the dielectric layer, the resistive layer formed by a second layered process, and a protective layer formed on the resistive layer, wherein the protective layer is formed by one of the first or second layered processes or yet another layered process. The first layered process is different than the second layered process in order to take advantage of the unique processing benefits of each of the first and second layered processes for a synergistic result The layered processes include, by way of example, thick film, thin film, thermal spraying, and sol-gel Additional functional layers are also provided by the present invention, along with methods of forming each of the individual layers.

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 modular heater system is provided that includes a heat trace assembly and a connector assembly. The heat trace assembly has a heat trace section that defines a plurality of fins, an insulation jacket surrounding the heat trace section, and at least one terminating member disposed at an end of the heat trace section. The connector assembly has a shell, including a plurality of outer walls and inner walls defining cavities therebetween, and a fitting heater assembly that includes a fitting adapter, a heat trace section disposed around the fitting adapter, and an outer casing disposed around the fitting adapter.

Abstract: A heat trace assembly is provided that includes a heat trace section, an insulation jacket surrounding the heat trace section, and a plurality of standoffs disposed between the heat trace section and the insulation jacket. A corresponding plurality of passageways are formed between the heat trace section and the insulation jacket and between the plurality of standoffs. The standoffs can be a part of the insulation jacket and/or the heat trace section, and the standoffs can furthermore be integrally formed with or separately attached to the insulation jacket and/or the heat trace section.

Abstract: A heat trace assembly for heating a conduit is provided that comprises at least one preformed heat trace section adapted to be placed around at least a portion of the conduit and a connector secured to the heat trace section. The connector is adapted for coupling the heat trace section to an adjacent heat trace section, and the heat trace section and the connector have mating mechanical features to allow the heat trace section to be quickly connected to and disconnected from the conduit. Additionally, a heat trace junction is provided that preferably defines a cross configuration and comprises a plurality of arms extending from a central portion of the heat trace junction. The plurality of arms are deformable to conform to a junction within a conduit system. Thermal insulation jacket configurations are also provided in accordance with several embodiments of the present invention.

Abstract: A heater system and related methods of heating a surface are provided by the present disclosure that includes, in one form, a substrate defining a heating surface and a layered heater formed on the heating surface. A plurality of nodes are disposed along the heating surface and are in electrical contact with a resistive heating layer of the layered heater, along with a plurality of lead wires connected to the plurality of nodes. In one form, a multiplexer is in communication with the plurality of nodes through the plurality of lead wires, and a controller is in communication with the multiplexer, wherein the multiplexer sequences and transmits resistances from the plurality of nodes to the controller, and the controller controls an amount of power provided to each of the plurality of nodes based on the differences in resistances between the nodes.

Abstract: Methods of assembling a high heat transfer and tailored heat transfer layered heater systems are provided. One method includes a step of pressing one of a target part and a layered heater into the other one of the target part and the layered heater to create an interference fit between the layered heater and the target part. When the target part is disposed within the layered heater, the layered heater includes a substrate defining an inner periphery less than or equal to an outer periphery of the target part. When the layered heater is disposed within the target part, the layered heater includes a substrate defining an outer periphery larger than or equal to an inner periphery of the target.

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: Methods of forming a layered heater are provided with a dielectric layer formed by a first layered process, a resistive layer formed on the dielectric layer, the resistive layer formed by a second layered process, and a protective layer formed on the resistive layer, wherein the protective layer is formed by one of the first or second layered processes or yet another layered process. The first layered process is different than the second layered process in order to take advantage of the unique processing benefits of each of the first and second layered processes for a synergistic result. The layered processes include, by way of example, thick film, thin film, thermal spraying, and sol-gel. Additional functional layers are also provided by the present invention, along with methods of forming each of the individual layers.

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 layered heater is provided that comprises a dielectric layer formed by a first layered process, a resistive layer formed on the dielectric layer, the resistive layer formed by a second layered process, and a protective layer formed on the resistive layer, wherein the protective layer is formed by one of the first or second layered processes or yet another layered process. The first layered process is different than the second layered process in order to take advantage of the unique processing benefits of each of the first and second layered processes for a synergistic result. The layered processes include, by way of example, thick film, thin film, thermal spraying, and sol-gel. Additional functional layers are also provided by the present invention, along with methods of forming each of the individual layers.

Abstract: A tailored heat transfer layered heater system is provided that comprises a target part defining a room temperature periphery and a layered heater disposed around or within the target part, the layered heater comprising a substrate having a room temperature periphery that is sized such that an interference fit is formed between the layered heater and the target part either through mechanical or thermal methods. The layered heater in one form is disposed around the target part and in another form is disposed inside the target part. Additionally, heat transfer is tailored along the layered heater using other devices such as thermal spacers, insulative pads, and a transfer substrate in other forms of the present invention.

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.