Abstract: A method of controlling temperature of a heater including a resistive heating element includes measuring a voltage count and a current count based on data from an analog-digital converter (ADC) circuit of a sensor circuit, where the sensor circuit is electrically coupled to the heater. The method includes selecting one or more dynamic gain levels of the ADC from among a plurality of dynamic gain levels based on a shift gain correlation, determining a resistance of the resistive heating element based on the voltage count, the current count, and the one or more dynamic gain levels, and controlling power to the heater based on the resistance.

Abstract: A control system for controlling an adjustable output voltage provided to a heater includes a controller configured to determine an input parameter based on an electrical characteristic of the heater, where the heater includes a resistive heating element that is operable to emit heat and as a sensor. The controller is further configured to determine an output voltage for the heater based on the input parameter and a desired setpoint, and to transmit a signal to a power converter to generate the output voltage. The desired setpoint is based on an operational state of the heater, and the input parameter includes data indicative of a temperature of the resistive heating element that is determined based on the electrical characteristic.

Abstract: A power converter system includes an input rectifier configured to rectify a line power having a line energy and a full-bridge isolating converter comprising a transformer, where the full-bridge isolating converter is configured to generate an isolated output voltage based on the rectified line power, and where the isolated output voltage is electrically isolated from the line energy. The power converter system includes a power controller configured to operate the full-bridge isolating converter to generate the isolated output voltage, determine whether the transformer is operating in a flux walk state based on an electric current of the transformer, and perform a corrective action in response to the transformer operating in the flux walk state.

Abstract: A method of dynamically calibrating a heater having a plurality of zones defined by one or more resistive heating elements includes controlling power to a heater having a plurality of zones based on a dynamic resistance-temperature (R-T) model to control a temperature of the heater to a temperature setpoint. For each of the plurality of zones, the method further includes measuring a temperature of a respective zone based on a resistance of the resistive heating elements of the respective zone and the dynamic R-T model, measuring a reference temperature for the respective zone, and incrementally adjusting a resistance value associated with the temperature setpoint provided in the dynamic R-T model for the respective zone to a calibrated resistance value. The method further includes providing the dynamic R-T model that correlates the calibrated resistance values of the plurality of zones with the temperature setpoint as a calibrated R-T model.

Abstract: A power converter system provides adjustable power to a heater and includes an input rectifier and a full-bridge isolating converter. The input rectifier is configured to rectify a line power having a line energy. The full-bridge isolating converter configured to generate an isolated output voltage based on the rectified line power. The isolated output voltage is electrically isolated from the line energy.

Abstract: A method includes selecting a state model control, as an operational state of the heater, from among a plurality of state model controls, measuring an electrical characteristic of the heater, where the electrical characteristic includes at least one of an electric current and a voltage, and controlling power to the heater based on the selected operational state and based on the measured electrical characteristic.

Abstract: A control system for controlling a heater includes a power converter, a sensor circuit, and a controller. The power converter supplies an adjustable power to the heater, and the sensor circuit is configured to measure an electrical characteristic of the heater. The controller is coupled to the power converter to control the power to the heater, and is configured to select a state model control, as an operation state of the heater, from among a plurality of defined state model controls. The controller controls the power supplied to the heater based on the operation state of the heater and on the electrical characteristics of the heater.

Abstract: The present disclosure is directed toward a control system for controlling a heater that includes at least one heating element. The control system includes a power converter operable to supply an adjustable voltage output to the heater, a sensor circuit that measures an electrical characteristic of the heating element of the heater, a reference temperature sensor that measures a reference temperature of a reference at the heater, and a controller. The controller is configured to calculate a primary temperature of a heater element based on the electrical characteristic and determines the voltage output to be applied to the heater based on at least one of the reference temperature and the primary temperature. The controller is configured to operate in at least one of an operation mode and a learn mode, and execute protection protocols when voltage is being supplied to the heater.

Abstract: A method for calibrating a control system configured to control a two-wire heater includes providing power to a load electrically coupled to the control system, generating, an initial measured characteristic and a calibrated measured characteristic of the load by the control system and a controller calibration system, respectively. The method further includes defining a calibrated measurement reference based on a correlation of the initial measured characteristic and the calibrated measured characteristic. With the calibrated measure reference, the control system is further calibrated to define a resistance-temperature calibration reference for determining a working temperature of the two-wire heater based on a measured resistance of the two-wire heater.

Abstract: A power converter system provides adjustable power to a heater and includes an input rectifier and a full-bridge isolating converter. The input rectifier is configured to rectify a line power having a line energy. The full-bridge isolating converter configured to generate an isolated output voltage based on the rectified line power. The isolated output voltage is electrically isolated from the line energy.

Abstract: The present disclosure generally describes a method and system for converting power to operate a load being supplied by line power having a line energy. The method includes rectifying the line power, bucking the rectified line power to generate a desired voltage output such that current is drawn from the line power in phase with the desired voltage output, and bypassing switching energy created during the bucking of the rectified line power.

Abstract: A control system includes a power converter being a step-down voltage converter and including a power switch. The power converter is operable to generate an adjustable output voltage and includes a sensor circuit configured to measure at least one of a voltage and an electric current of the heater. The control system includes a controller connected to the power converter and the sensor circuit. The controller is configured to determine an input parameter based on the at least one of the voltage and the electric current. The input parameter is indicative of a temperature of the heater. The controller is configured to set the output voltage applied for the heater based on the input parameter and a desired setpoint. The desired setpoint is based on an operational state of the heater. The controller is configured to operate the power switch of the power converter to generate the output voltage.

Abstract: The present disclosure generally describes a system that includes a heater, a power converter including a power switch, and a controller. The power converter is in communication with the heater and is operable to apply an adjustable voltage to the heater. The controller is in communication with the power switch to control the voltage output of the power converter based on at least one of a load current and a detected voltage at the heater. The controller operates the power switch to adjust the voltage output of the power converter.

Abstract: The present disclosure is directed toward a control system for controlling a heater that includes at least one heating element. The control system includes a power converter operable to supply an adjustable voltage output to the heater, a sensor circuit that measures an electrical characteristic of the heating element of the heater, a reference temperature sensor that measures a reference temperature of a reference at the heater, and a controller. The controller is configured to calculate a primary temperature of a heater element based on the electrical characteristic and determines the voltage output to be applied to the heater based on at least one of the reference temperature and the primary temperature. The controller is configured to operate in at least one of an operation mode and a learn mode, and execute protection protocols when voltage is being supplied to the heater.

Abstract: A control system for controlling a heater includes a power converter, a sensor circuit, and a controller. The power converter supplies an adjustable power to the heater, and the sensor circuit is configured to measure an electrical characteristic of the heater. The controller is coupled to the power converter to control the power to the heater, and is configured to select a state model control, as an operation state of the heater, from among a plurality of defined state model controls. The controller controls the power supplied to the heater based on the operation state of the heater and on the electrical characteristics of the heater.

Abstract: A 1/16 DIN power controller configuration is provided that includes a housing, a circuit board carrier disposed within the housing and capable of engaging at least three circuit boards within the housing, a power supply circuit board disposed within the housing and engaged by the circuit board carrier, and a communications circuit board disposed adjacent the power supply circuit board within the housing and engaged by the circuit board carrier. The communications circuit board includes Ethernet/IP and/or Modbus TCP protocols, and in alternate forms includes RS-232 and RS-485 with Modbus RTU protocol, DeviceNet, Profibus DP, CanOpen, and/or EtherCat.