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Everything You Need to Know About Electrical Heating Control and Monitoring


Heating from power sources is commonly used in manufacturing processes with thousands of widely differing applications. They shall include:

  • Heating water or other fluids for washing components or for moving heat to other conditions
  • Increase the temperature of the metal components.
  • Ecological conditioning

Although the primary goal of that and other implementations may differ, the overarching goals are to heat what is needed, heat to a given temperature, and sustain that temperature for the amount of time necessary by the requirement.

Everything You Need to Know About Electrical Heating Control and Monitoring

Primitive temperature control can be accomplished by merely turning the circuit on and off utilizing a switch or a contactor. The inclusion of a thermostat will increase the accuracy of the volume of heat applied. The addition of a temperature sensing element will further improve the control of the heating operation.

For the most accurate and controlled effect on the treated substance, the most common approach is to control the power used by SCR’s. These solid-state systems enable the electronic system to be switched on and off if desired, allowing only part of the power and potential to be added to the components.

The SCR arrangement widely used for heating controls incorporates two diodes with adequate power to adjust the current. The system used to change the intensity by changing each cycle is generally referred to as phase angle shooting. On the other hand, the method of allowing complete or half loops to be carried out is called burst-or time-proportional shooting.

Both approaches have benefits and drawbacks. The system’s selection to be used depends on the type of heat source being monitored and the need to handle problems such as low power efficiency or decreased lifespan of the element.

Time-Proportioned Firing

In this method of cycling, the heating components are energized for individual cycles and de-energized for specific processes. This results in a substantial reduction in the harmonic content while also maintaining reasonable temperature stability.

The burst-fired solution works very well where the heated components are resistant, but loads like infrared Cartridge heaters are prone to flicker to an inappropriate degree. One of the critical problems related to this flicker is calculating the current currently used by the load. It is useful to understand as soon as possible if one factor fails.

The most rational way to perform this calculation is to track the current used by each variable in a three-phase delta-connected array. The current measuring signal will then have to be diluted and highly modified to produce an overall movement that is directly proportional to the amount of current used. A phase angle-coupled SCR system is preferable for transformer-coupled loads or heaters with variable resistance, such as silicon carbide or MoSi2 elements.

The current sensor allows energy control

One of the new sensors will track burst-fired, SCR-driven flows with no ripple in the performance. It was developed after months of planning, circuit development, and implementation using computational models and realistic energized load monitoring.

The microprocessor-based camera is utilized to measure the magnitude of the primary circuit current and calculate the current level over time, allowing the sensor’s output to reflect the real power used by the heaters.
Methods for controlling electrically heated processes are continually being created, resulting in reduced energy consumption, better quality and performance of treated materials, and more stable controllers. Innovations in the calculation of electrical parameters are catching up, maintaining the precision and efficiency required by today’s processes.


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