초록 ▼

A heater control system that utilizes electronic temperature control at each of a number of interconnected heaters is provided for monitoring and operating heaters within a narrow temperature range. In one embodiment, a heater control system is provided that is adapted for controlling a number of he

A heater control system that utilizes electronic temperature control at each of a number of interconnected heaters is provided for monitoring and operating heaters within a narrow temperature range. In one embodiment, a heater control system is provided that is adapted for controlling a number of heaters positioned on pipe and components of a piping system from a remote location. The heater control system includes satellite controllers mounted on each heater connected daisy chain fashion and includes a monitoring station with a user interface for allowing a user to monitor and to remotely control the operating status or temperature of each heater in the heater control system. To satisfy the user's space requirements, the size of each controller is maintained at a small form factor and a single cord is used to provide power and communications lines to and between the controllers. Each controller integrates power supply and control with electronic temperature control to minimize the use of mechanical switching and to increase the accuracy of temperature control. The temperature set point is adjustable at each controller and, in one embodiment, the temperature set point is remotely adjustable from a remote monitoring station. The operating status of each controller is displayed on the exterior of the controller's housing and in one embodiment, the operating status, such as temperature, is displayed at a base station for each line of controllers and heaters and on a user interface monitor at a monitoring station.

대표청구항 ▼

1. In pipe heater apparatus comprising a plurality of pipe heaters configured for mounting on one or more pipes, wherein each of said pipe heaters has a heat producing element that is capable of producing heat from electric power derived from line voltage electricity and a power controlling circuit

1. In pipe heater apparatus comprising a plurality of pipe heaters configured for mounting on one or more pipes, wherein each of said pipe heaters has a heat producing element that is capable of producing heat from electric power derived from line voltage electricity and a power controlling circuit for controlling the electric power to the heat producing element, the improvement comprising:a socket on each of said pipe heaters comprising: (i) an inlet daisy chain connector, (ii) an outlet daisy chain connector; (iii) a modular receptacle connector, (iv) a first electric power trace extending between the inlet daisy chain connector and the outlet daisy chain connector and connected electrically to the heat producing element; (v) a second electric power trace extending between the inlet daisy chain connector and the outlet daisy chain connector and connected electrically to the modular receptacle connector; and (vi) a third electric power trace extending between, and connected electrically to, the modular receptacle connector and the heat producing element; and a local controller module comprising said power controlling circuit and a mating modular plug connector configured for mating, releasable connection with the modular receptacle connector of the socket in a manner that connects the power controlling circuit electrically in a releasable manner between the second electric power trace and the third electric power trace for controlling the electric power to the heat producing element. 2. The improvement of claim 1, wherein the inlet daisy chain connector includes a plug connector.3. The improvement of claim 1, wherein the outlet daisy chain connector includes a plug connector.4. The improvement of claim 1, wherein said power controlling circuit includes a power switching device connected electrically between the second electric trace and the third electric trace for controlling electric power to the heat producing element.5. The improvement of claim 4, wherein said power controlling circuit includes a local controller process circuit associated with the power switching device to control operation of the power switching device in a manner that causes the heat producing element to produce heat to maintain said pipe at a desired temperature.6. The improvement of claim 5, wherein said power controlling circuit is powered by a low voltage DC power supply, which is remote from the local controller module and from the heat producing element so that heat produced by the heat producing element does not affect the low voltage DC power supply.7. The improvement of claim 6, wherein said socket also comprises a pair of low voltage traces extending between the inlet daisy chain connector and the outlet daisy chain connector and to the modular receptacle connector, and wherein said local controller module also comprises electrical connections between the local controller process circuit and the modular plug connector such that connection of the modular plug connector of the local controller module to the modular receptacle connector of the socket also connects the local controller process circuit to the low voltage DC power traces in the socket.8. The improvement of claim 5, including a temperature sensor associated with the pipe heater and connected to the local controller process circuit, said temperature sensor being capable of producing signals that are indicative of temperature of the pipe heater and said local controller process circuit being capable of utilizing such signals for comparing the temperature of the pipe heater to a set point temperature and controlling the power switching device in a manner that causes the heat producing element to produce heat as needed to maintain the temperature of the pipe heater at or near the set point temperature.9. The improvement of claim 5, wherein the local controller process circuit is capable of receiving and processing temperature control signals from a remote source for controlling the power switching device in accordance with such control signals from the remote source.10. The improvement of claim 5, including a temperature sensor associated with the pipe heater and connected to the local controller process circuit, said temperature sensor being capable of producing signals that are indicative of temperature of the pipe heater and said local controller process circuit being capable of receiving and processing such signals for transmission of temperature data indicative of the temperature of the pipe heater to a base unit located remotely from the local controller module.11. The improvement of claim 8, wherein the temperature sensor is positioned adjacent the heat producing element.12. The improvement of claim 8, including a pair of electrically conductive temperature traces extending through the socket from the temperature sensor to the modular receptacle connector, and wherein the local controller module includes electrically conductive connections from the local controller process circuit to the modular plug connector such that connection of the modular plug connector of the local controller module to the modular receptacle connector of the socket also electrically connects the local controller process circuit to the temperature sensor.13. The improvement of claim 8, wherein the local controller process circuit is capable of receiving set point temperature signals from a remote source and of utilizing such set point temperature signals for determination of the set point temperature.14. The improvement of claim 8, wherein the local controller process circuit is capable of transmitting data indicative of pipe heater temperature to a remote unit.15. The improvement of claim 13, including at least one electrically conductive data trace extending between the inlet daisy chain connector and the outlet daisy chain connector and to the modular receptacle connector, and wherein said local controller module also comprises an electrically conductive data connection between the local controller process circuit and the modular plug connector such that connection of the modular plug connector of the local controller module to the modular receptacle connector of the socket also connects, the local controller process circuit to the data trace in the socket.16. The improvement of claim 14, including at least one electrically conductive data trace extending between the inlet daisy chain connector and the outlet daisy chain connector and to the modular receptacle connector, and wherein said local controller module also comprises an electrically conductive data connection between the local controller process circuit and the modular plug connector such that connection of the modular plug connector of the local controller module to the modular receptacle connector of the socket also connects the local controller process circuit to the data trace in the socket.17. In pipe heater apparatus comprising a plurality of pipe heaters configured for mounting on one or more pipes, wherein each of said pipe heaters has a heat producing element that is capable of producing heat from electric power derived from line voltage electricity and a power controlling circuit for controlling the electric power to the heat producing element, the improvement comprising:a socket on each of said pipe heaters comprising: (i) an inlet daisy chain connector; (ii) an outlet daisy chain connector; (iii) a module receptacle connector; (iv) line voltage power traces extending from the inlet daisy chain connector to the outlet daisy chain connector, to the module connector, and to the heat producing element; (v) low voltage DC power traces extending from the inlet daisy chain connector to the outlet daisy chain connector and to the module connector; and (vi) at least one data trace extending from the inlet daisy chain connector to the outlet daisy chain connector; a plurality of daisy chain cords extending between and releasably connected to respective ones of the sockets of the pipe heaters, wherein each of the daisy chain connectors has daisy chain connectors has line voltage power conductors, low voltage DC power conductors and at least one data conductor that connect with the line voltage power traces, low voltage DC power traces, and the data trace in the socket when the daisy chain cords are connected to the daisy chain inlet and/or outlet connectors of the socket such that a combination of a plurality of daisy chain cords connecting together the sockets of a plurality of pipe heaters constitutes a continuous line voltage power circuit, a continuous low voltage DC power circuit, and a continuous data circuit extending to and through the plurality of pipe heaters; and a local controller module at each of the pipe heaters comprising; (i) a power switch device for controlling electric power to the heat producing element; (ii) a local controller process circuit for controlling the power switch device; and (iii) a module plug connector that is configured for mating, releasable physical and electrical connection with the module receptacle connector of a socket in such a manner that physical plug-in connection of the local controller module to the socket also effects simultaneous electrical connection of the power switch device to the line voltage power traces and to the heat producing device and simultaneous electrical connection of the local controller process circuit to the low voltage DC power traces and to the data trace. 18. The improvement of claim 17, including a base unit that has voltage electric power, low voltage DC power, a data transmitter and receiver, and a daisy chain connector configured for electrical connection of the line voltage electric power, the low voltage DC power, and the data transmitter and receiver to at least one of the daisy chain cords, which is also connected to the socket to of least one oft e pipe heaters.19. The improvements of claim 18, including a temperature sensor at each of the pipe heaters that produces a signal, which is indicative of a temperature at such pipe heater.20. The improvement of claim 19, wherein the local controller process circuit is capable of comparing the temperature at the pipe heater to a set point temperature and of controlling the power switch device to cause the heat producing element to produce sufficient heat to maintain the temperature at the pipe heater at or near the set point temperature.21. The improvement of claim 20, wherein the base unit is capable of transmitting the set point temperature onto the data conductor of the daisy chain, and wherein the local controller process circuit of each local controller module is capable of receiving such set point from the data trace of the socket.22. The improvement of claim 21, wherein the local controller process circuit is capable of transmitting the pipe beater temperature data onto the data trace in the socket, and wherein the base unit is capable of receiving the pipe heater temperature data from the daisy chain cord data conductor.23. A method of controlling a plurality of pipe heaters, each of which has a heat producing element, comprising:providing a socket on each pipe heater with line voltage electric power, with low voltage DC power from a source remote from the pipe heaters, and with data communications, all through a plurality of daisy chain cords, each of which comprises line voltage power conductors, low voltage DC power conductors, and at least one data communication conductor so that only one of such daisy chain cords is needed between respective adjacent pipe heaters; providing a local control module for each of the pipe heaters with temperature data processing functions by a local controller processing circuit for comparing temperatures sensed at the pipe heater with a set point temperature and with a power switching device for controlling line voltage electric power to the heat producing device in response to variations of the temperatures sensed at the pipe heater in relation to the set point temperature; and connecting the line voltage power controlled by the power switching device to the heat producing element and connecting the low voltage DC power and the data communications to the local controller processing circuit by plugging the local controller module into the socket.