Patent Application
20190268978
The present invention relates generally to the field of induction hobs. More specifically, the present invention is related to a method for calibrating the power control loop of an induction hob.
Induction hobs for preparing food are well known in prior art. Induction hobs typically comprise at least one heating zone which is associated with at least one induction element. For heating a piece of cookware placed on the heating zone, the induction element is coupled with electronic driving means for driving an AC current through the induction element. Said AC current generates a time varying magnetic field. Due to the inductive coupling between the induction element and the piece of cookware placed above the induction element, the magnetic field generated by the induction element causes eddy currents circulating in the piece of cookware. The presence of said eddy currents generates heat within the piece of cookware due to the electrical resistance of said piece of cookware.
In order to control the power provided to the piece of cookware, induction hobs comprise a power control loop. For example, the voltage drop over a shunt resistor may be used as a measurand for controlling the power. However, the power control mechanism may be negatively affected by tolerances of electronic elements included in the power control loop. Said tolerances of electronic elements could be compensated by a manual calibration of the power control loop, which is time-consuming and therefore expensive.
It is an objective of the embodiments of the invention to provide a method for manufacturing an induction hob at reasonable costs. The objective is solved by the features of the independent claims. Preferred embodiments are given in the dependent claims. If not explicitly indicated otherwise, embodiments of the invention can be freely combined with each other.
According to an aspect, the invention relates to a method for calibrating one power control loop or at least two power control loops of an induction hob, the induction hob comprising one power stage or at least two power stages including one induction element or at least two induction elements and one measurement unit or at least two measurement units, the method comprising the steps of:
According to a further aspect, the invention relates to a method for calibrating a power control loop of an induction hob. The induction hob comprises a power stage including at least one induction element, a measurement unit and a control unit. The method comprises at least one or more of the steps of:
According to a further aspect, the invention relates to a method for calibrating one power control loop or at least two power control loops of an induction hob. The induction hob comprises one power stage or at least two power stages including one induction element or at least two induction elements, one measurement unit or at least two measurement units and at least one control unit. The method comprises at least one or more of the steps of:
The induction hob preferably comprises one power stage, at least two, at least three or at least four power stages, especially two, three, four or six power stages.
In embodiments, the induction hob comprises one driver unit, two or at least two driver units, the driver units preferably generating an output frequency between 10 kHz and 100 kHz.
The induction hob preferably comprises one bridge rectifier, two or at least two bridge rectifiers.
The induction hob preferably comprises one filter circuit, two or at least two filter circuits. The filter circuit or the filter circuits can improve the requirements of the electromagnetic compatibility (EMC).
The induction hob is preferably operated with a one-phase electric power supply and/or with a two-phase electric power supply and/or with a three-phase electric power supply. Using more than one phase can increase the maximum output power of the induction hob. The phases of the electric power supply refer preferably two different phases of an alternating-current electric power.
In an embodiment, each power stage is assigned to the same bridge rectifier. In another embodiment, each power stage is assigned to a separate bridge rectifier. In one of these embodiments or in another embodiment, at least two or at least three power stages are assigned to each bridge rectifier.
In further embodiments, each bridge rectifier, each power stage or at least two power stages is/are assigned to the same electric phase or to a separate electric phase.
In further embodiments, each bridge rectifier and/or each power stage is assigned to a filter circuit.
Each power stage preferably comprises one IGBT, one IGBT-pair or at least two IGBTs. Each driver unit preferably drives one or at least two power stages. A power stage and an assigned driver unit can form, in an embodiment, a generator or inverter, which generates an electromagnetic signal with a high frequency to heat at least one piece of cookware, especially a cooking vessel like a pot.
The induction elements are preferably arranged in at least two rows and/or at least two columns, especially in a matrix arrangement.
The induction elements are preferably covered by a surface, especially a cooking surface and/or a glass ceramic surface.
The induction hob is preferably operated with an, especially touch sensitive, user interface, preferably arranged on the surface, especially on the cooking surface of the induction hob.
In further embodiments, at least two power stages and/or induction elements can be coupled to a single cooking zone.
Advantageously, by means of said pre-calculated correction value, an automated and precise calibration of the power control loop included in the induction hob is achieved and no manual calibration, for example, by trimming a potentiometer is necessary.
According to embodiments, the measurement value is derived based on the voltage drop at a shunt resistor being coupled with an arm of a bridge rectifier. By means of said shunt resistor, a measurement value indicative for the power provided from the bridge rectifier to one or more power stages included in the induction hob can be derived. The tolerance of the resistance value of the shunt resistor and other electronic components included in the induction hob may be high, e.g. 5%. Thereby, the electronic component costs of the induction hob can be reduced. By means of said automated calibration process, the tolerances of the electronic components can be compensated thereby obtaining a calibrated power control loop.
According to embodiments, the measurement value is derived based on the voltage drop at a shunt resistor being coupled with a switching element, specifically an insulated-gate bipolar transistor IGBT. Said switching element may be assigned to a certain power stage, i.e. by means of said shunt resistor, a measurement value indicative for the power provided to a certain power stage can be derived. Thus, a precise control power control of a respective power stage is possible. Multiple measurement values may be derived at multiple shunt resistors coupled with different switching elements in order to calibrate multiple power control loops.
According to embodiments, the voltage drop measured at a shunt resistor is received by the measurement unit, the measurement unit providing based on said measured voltage drop the measurement value to the control unit. In other words, the measurement unit converts the measured voltage into a measurement value suitable for the control unit. For example, the measurement unit may amplify the received voltage or may add an offset to said received voltage.
According to embodiments, the reference value and/or correction value is stored in a storage entity, the storage entity being accessible by the control unit. The storage entity may be included in the control unit or may be an external storage entity. The storage entity may comprise a non-volatile storage in order to permanently store the reference value.
According to embodiments, the reference value corresponds to a measurement value provided by the measurement unit based on a voltage drop over the shunt resistor having a nominal resistance value when powering the power stage at predefined working conditions and coupling the induction element with said reference load. In other words, the reference value may be indicative for the measurement value to be measured if the electronic components, specifically the shunt resistor, have component values (e.g. resistance values) equal to their nominal values (ideal electronic components without tolerances) and the induction element is coupled with said reference load. Thus, said reference value builds the fundamental reference (standard) for the calibration process.
According to embodiments, the correction value is the ratio between the measurement value and the reference value. After determining said correction value, the power control loop can be automatically calibrated by multiplying the currently received measurement value and the correction value.
According to a further aspect, the invention relates to a method for controlling the power transferred from one or at least two powers stage to one or at least two pieces of cookware in an induction hob, the induction hob comprising one induction element or at least two induction elements included in said one power stage or at least two power stages and one measurement unit or at least two measurement units, the method comprising the steps of:
According to a further aspect, the invention relates to a method for controlling the power transferred from a power stage to a piece of cookware in an induction hob, the induction hob comprising at least one induction element included in said power stage, a measurement unit and a control unit, the method comprising the steps of:
According to a further aspect, the invention relates to a method for controlling the power transferred from one power stage or at least two power stages to one piece or at least two pieces of cookware in an induction hob, the induction hob comprising one induction element or at least two induction elements included in said power stage, one measurement unit or at least two measurement units and at least one control unit, the method comprising at least one or more of the steps of:
Advantageously, by using the pre-calculated correction value, an automated and precise control of power transferred to the piece of cookware is achieved.
According to embodiments, the control unit is a software-based control unit comprising at least one processing entity, said processing entity modifying measurement values provided by the measurement circuit based on the correction value. In other words, during the operation of the induction hob a continuous modification of the measurement values is performed in order to derive a power value according to which the power stage is powered.
According to embodiments, the measurement value is derived based on the voltage drop at a shunt resistor being coupled with an arm of a bridge rectifier.
According to embodiments, the measurement value is derived based on the voltage drop at a shunt resistor being coupled with a switching element, specifically an insulated-gate bipolar transistor IGBT.
According to a further aspect, the invention relates to an induction hob comprising a power stage with at least one switching element for enabling an alternating current flow through an induction element, a control unit for controlling the current flow through the induction element and a measurement unit, the measurement unit being adapted to provide a measurement value to the control unit, the measurement value being indicative for the power transferred from the induction element to a piece of cookware placed above the induction element, wherein the control unit is coupled with a storage entity, the storage entity storing a correction value determined during a calibration routine, wherein the control unit is adapted to modify the measurement value based on the correction value and deriving a power value based on the modified measurement value and wherein the control unit is adapted to control the power transferred to the piece of cookware based on the power value.
According to a further aspect, the invention relates to an induction hob comprising one or at least two power stages with at least one switching element for enabling an alternating current flow through one or at least two induction elements, at least one control unit for controlling the current flow through the one or at least two induction elements and one or at least two measurement units, the one or at least two measurement units being adapted to provide one or at least two measurement values to the at least one control unit, the one or at least two measurement values being indicative for the power transferred from the one or at least two induction elements to one or at least two pieces of cookware placed above the one or at least two induction elements, wherein the at least one control unit is coupled with one or at least two storage entities, the one or at least two storage entities storing one or at least two correction values determined during a calibration routine, wherein the at least one control unit is adapted to modify the one or at least two measurement value based on the one or at least two correction values and deriving one or at least two power values based on the one or at least two modified measurement values and wherein the at least one control unit is adapted to control the power transferred to the one or at least two pieces of cookware based on the one or at least two power values.
Advantageously, by calibrating the induction hob during operation by using the pre-calculated correction value, the manufacturing costs can be reduced because cheap electronic components can be used and no manual calibration is necessary.
According to embodiments, the control unit is a software-based control unit comprising at least one processing entity, said processing entity being adapted to modify measurement values provided by the measurement circuit based on the correction value.
According to embodiments, the storage entity comprises a non-volatile data storage.
The term “essentially” or “approximately” as used in the invention means deviations from the exact value by +/−10%, preferably by +/−5% and/or deviations in the form of changes that are insignificant for the function.
The various aspects of the invention, including its particular features and advantages, will be readily understood from the following detailed description and the accompanying drawings, in which:
The present invention will now be described more fully with reference to the accompanying drawings, in which example embodiments are shown. However, this invention should not be construed as limited to the embodiments set forth herein. Throughout the following description similar reference numerals have been used to denote similar elements, parts, items or features, when applicable.
Furthermore, the induction hob 1 may comprise a bridge rectifier 13, said bridge rectifier 13 being coupled with the power stage 10 for providing electrical power to the induction element of the power stage 10. The bridge rectifier 13 may be coupled with one or more phases of the mains supply network.
According to embodiments, the control unit 11 is coupled with the power stage 10 via a driver unit 14, said driver unit 14 being adapted to receive a pulsed electrical signal P by the control unit 11, modify said received pulsed electrical signal P and provide said modified pulsed electrical signal P′ to the power stage 10. According to other embodiments, the control unit 11 may be directly coupled with the power stage 10, i.e. may provide the pulsed electrical signal P directly to the power stage 10. Said pulsed electrical signal P, respectively, modified pulsed electrical signal P′ may be applied to a switching element comprised within the power stage 10 in order to enable an alternating current flow through the induction element.
In order to determine the power provided by the power stage 10 to a piece of cookware placed above the induction element of the power stage 10, the induction hob 1 comprises a measurement unit 12. According to an embodiment, the measurement unit 12 is coupled with the bridge rectifier 13 for receiving information regarding the amount of current flowing through the power stage 10. Thereby, the sum of power provided by all power stages 10 can be monitored because said power stages 10 may be powered by a single bridge rectifier 13. According to other embodiments, the measurement unit 12 is coupled with the power stage 10, specifically with the emitter path of the switching element comprised within the power stage 10 in order to receive information regarding the amount of current flowing through said switching element. So, due to the association of one or more switching elements to a certain power stage 10, the power provided by a certain power stage 10 to a piece of cookware can be determined.
The measurement unit 12 is configured to receive an input signal IS, said input signal IS being indicative for the power, specifically, for the amount of current being provided to the power stage 10 and derive a measurement signal MS based on the input signal IS. The measurement unit 12 is further coupled with the control unit 11 in order to provide said measurement signal MS to the control unit 11. The measurement unit 12 is configured to derive a measurement signal MS which can be directly processed by the control unit 11, i.e. the values of the measurement signal MS are adapted to the value range directly processible by the control unit 11. For example, the control unit 11 may be adapted to receive voltage values in the range of 0V to 5V. Therefore, the measurement unit 12 may be adapted to provide measurement signals MS with voltage values within upper-mentioned voltage range.
The collector of the switching element 20 may be coupled via a filtering circuitry (comprising one or more capacitors) to an oscillating circuit 23, said oscillating circuit 23 comprising the induction element 21 and a capacitor 22. The power stage 10 may comprise a quasi-resonant power stage architecture. On the opposite side of the capacitor 22, the induction element 21 may be coupled with the bridge rectifier 13 in order to power the oscillating circuit 23 by means of the mains supply network. By enabling a current flow through the switching element 20 using the modified pulsed electrical signal P′, an alternating current flow through the induction element 21 is obtained which induces eddy currents in a piece of cookware placed above the induction element 21 thereby providing heat to said induction element 21.
In order to determine the power, specifically, the amount of current provided by the bridge rectifier 13 to the power stage 10, the induction hob 1 comprises a shunt resistor Rshunt. Said shunt resistor Rshunt is coupled on the one hand with the negative port of the bridge rectifier 13, i.e. the node of the bridge rectifier 13 at which the anodes of two adjacent diodes are directly coupled. On the other hand, the shunt resistor Rshunt is further coupled with ground. The voltage drop over the shunt resistor Rshunt is indicative for the electric current provided by the bridge rectifier 13 to the power stage 10 and might be used as input signal IS of the measurement unit 12.
In case that the tolerance of the nominal value of the shunt resistor Rshunt is high (e.g. 5%), the power value derived by measuring the voltage drop over said shunt resistor Rshunt also has a high error deviation, i.e. the determined power value is not precise but shows also a inaccuracy which may be not acceptable for power control purposes.
In further embodiments, the invention comprises one power stage 10, at least two power stages 10, at least three or at least four power stages 10, especially two, three, four or six power stages 10. Each power stage 10 includes one induction element 21 or at least two induction elements 21. Furthermore, the embodiments comprise one measurement unit 12 or at least two measurement units 12.
The induction hob 1 can comprise one driver unit 14, two or at least two driver units 14. The driver units can generate an output frequency between 10 kHz and 100 kHz. The driver unit 14 or the driver units 14 can stimulate the induction element 1 or the induction elements 1 to oscillate.
The induction hob 1 can comprise one bridge rectifier 13, two or at least two bridge rectifiers 13. The induction hob 1 can comprise one filter circuit, two or at least two filter circuits.
The induction hob 1 can be operated with a one-phase electric power supply and/or with a two-phase electric power supply and/or with a three-phase electric power supply.
Each power stage 10 can be assigned to the same bridge rectifier 13 or to a separate bridge rectifier 13. At least two or at least three power stages 10 can be assigned to each bridge rectifier 13.
Each bridge rectifier 13, each power stage 10 or at least two power stages 10 can be assigned to the same electric phase or to a separate electric phase. Each bridge rectifier 13 and/or each power stage 10 is assigned to a filter circuit, so that preferably a filter circuit is arranged between the power supply and the rectifier. The filter circuit can prevent that distortions caused by the oscillation of the induction element 1 or the induction elements 1 are transferred into the external power supply system.
Each power stage 10 can comprise one IGBT, one IGBT-pair or at least two IGBTs. Each driver unit 14 preferably drives one or at least two power stages 10. A power stage 10 and an assigned driver unit 14 can form a generator or inverter, which generates an electromagnetic signal with a high frequency to heat at least one piece of cookware, especially a cooking vessel like a pot.
The induction elements 21 can be arranged in at least two rows and/or at least two columns, especially in a matrix arrangement.
The induction elements 21 can be covered by a surface, especially a glass ceramic surface or glass ceramic plate. The induction hob 1 is operated with an, especially touch sensitive, user interface, preferably arranged on the surface of the induction hob 1.
At least two power stages 10 and/or induction elements 21 can be coupled to a single cooking zone. Within a single cooking zone, preferably all power stages 10 and/or induction elements 21 are operated with the same power.
For calibrating one power control loop or at least two power control loops of the induction hob 1, one or more of the following steps are or can be performed, preferably in the described order:
For controlling the power transferred from one power stage 10 or at least two power stages 10 to one piece or at least two pieces of cookware in an induction hob 1, one or more of the following steps are or can be performed, preferably in the described order:
First, the induction element 21 is coupled with a reference load (S110). Said reference load may be made of a ferromagnetic material and may comprise predetermined load properties in order to constitute a calibration load. For example, the reference load may be placed on the heating zone 2 which is associated with said induction element 21.
After coupling the induction element 21 with the reference load, the power stage 10 including the induction element 21 coupled with the reference load is powered (S120). Specifically, the induction element 21 is powered at predefined working conditions by means of the control unit 11 and the driver unit 14. Said predefined working conditions may cause a preset transfer of electric power to the induction element 21. The predefined working conditions may specify a certain electrical signal P or a certain modified certain electrical signal P′, for example, with a certain pulse duration and a certain pulse amplitude.
When powering the power stage 10 at predefined working conditions, a measurement value is derived, said measurement value being indicative for the power transferred from the induction element 21 to the reference load (S130). Said measurement value may be derived at a shunt resistor Rshunt, i.e. the measurement value may be a voltage value indicating the voltage dropping at said shunt resistor Rshunt. As shown in
Following up, the measurement value is provided to the control unit 11 (S140). The control unit 11 may start a calibration routine based on said measurement value. For example, the control unit 11 may compare the measurement value with a reference value. Said reference value may be stored in a storage entity coupled with the control unit 11. The reference value may be obtained as a measurement value if the real value of the shunt resistor Rshunt is the nominal value of the shunt resistor Rshunt, i.e. the resistance value of the shunt resistor Rshunt does not deviate from its nominal value (error deviation 0%) and the induction element is coupled with the reference load.
Based on the measurement value and the reference value, the control unit 11 may calculate a correction value (S150). For example, the correction value may be the ratio between the measurement value and the reference value. Due to the proportional dependency of the measurement value from the resistance value of the shunt resistor Rshunt, the correction value indicates the ratio between the real resistance value of the shunt resistor Rshunt and its nominal value.
Finally, the correction value is stored in a storage entity coupled with the control unit 11 (S160). The control unit 11 may have access to said storage entity in order to read out said correction value from the storage entity and modify measurement values derived when operating the induction hob 1 (e.g. after putting the induction hob into operation by a user) based on said correction value. For example, a measurement value may be multiplied with the correction value in order to obtain a modified measurement value. Thereby, a calibration of the power control loop included in the induction hob is obtained.
It is worth mentioning that upper-mentioned calibration routine has to be performed for each shunt resistor Rshunt separately, i.e. for each shunt resistor Rshunt a correction value is determined and stored for calibrating the power measurement performed by using said shunt resistor Rshunt.
The control unit may be adapted to calculate a power value based on said measurement value and a correction value (S230). The power value may be indicative for the actual power transferred from the power stage 10 to a piece of cookware. The correction value may have been obtained during calibrating routine and may be stored in a storage entity. For example, a modified measurement value may be calculated based on the measurement value. The modified measurement value may be, for example, the measurement value multiplied with/divided by the correction value. The power value may be calculated based on said modified measurement value.
Finally, said power value may be used for controlling the power transferred from the power stage 10 to the piece of cookware (S240). In other words, the power control of the induction hob 1 may use a modified measurement value for controlling the power transferred to the piece of cookware.
The collector of the first transistor T1 is coupled with the supply voltage Vcc via a first collector resistor Rc1. The emitter path of said first transistor T1 comprises a first emitter resistor Re1 and an emitter capacity Ce, wherein the first emitter resistor Re1 is coupled at a first contact with the emitter of the first transistor T1 and at a second contact with the emitter capacity Ce. The emitter capacity Ce is coupled at a further contact opposite to the first emitter resistor Re1 with ground. In other words, the first emitter resistor Re1 and the emitter capacity Ce are serially coupled within the emitter path of the first transistor T1.
The second transistor T2 also comprises a collector path and an emitter path. The collector path comprises a second collector resistor Rc2, the second collector resistor Rc2 being coupled with one resistor contact with the supply voltage Vcc and with the further contact with the collector of the second transistor T2. The measurement signal MS may be derived at the collector of the second transistor T2, i.e. at the node between the collector of the second transistor T2 and the second collector resistor Rc2. In the emitter path of the second transistor T2, a second emitter resistor Re2 is arranged wherein the emitter of the second transistor T2 is coupled with ground via said second emitter resistor Re2.
Furthermore, the bases or gates (in case of using field effect transistors) are directly coupled with each other, i.e. coupled via an electrical connection without any electrical device. In addition, there is also a direct electrical connection (without any electrical device) between the collector and the base or gate of the first transistor T1. Thereby, the voltage applied to the collector of the first transistor T1 is equal to the voltage applied to the bases or gates of the first and second transistor T1, T2.
For deriving the measurement signal MS based on the input signal IS, the input of the measurement unit 12 is coupled with node 25 between the bridge rectifier 13 and the power stage 10. Keeping in mind the flow direction of the electric current through the shunt resistor Rshunt, the voltage URshunt is negative. Thereby, also the input signal IS comprises a negative voltage with respect to ground level. So, in case that the current flowing through the bridge rectifier 13 is rising, the voltage URshunt is also rising, i.e. the voltage at node 26 between the first emitter resistor Re1 and the emitter capacity Ce is increasing in the negative range. Thereby, also the current flowing through the first transistor T1 is rising.
Due to the upper-mentioned coupling of the first and second transistor T1, T2, the rising of the electric current flowing through the first transistor T1 may cause a rising current flow through the second transistor T2. The rising current flow through the second transistor T2 causes a rising voltage at the collector of said second transistor T2, i.e. the measurement signal MS also shows a rising voltage.
Conversely, a decreasing current flow through the bridge rectifier 13 may cause a reduced current flow through the second transistor T2 and therefore may cause a decreasing voltage at the collector of said second transistor T2, i.e. the measurement signal MS also shows a decreasing voltage.
Due to switching the switching element 20 based on the pulsed electrical signal P and the high currents flowing through the induction element 21, the current measurement within the measurement unit 12 is very noisy, i.e. the input signal IS may vary due to parasitic side effects which may worsen the measurement results provided by the measurement unit 12. In order to suppress said noise, the measurement unit 12 comprises several capacitors which suppress said input signal fluctuations and/or measurement signal fluctuations. At the input of the measurement unit 12 signal fluctuations of the input signal IS maybe suppressed by the emitter capacitor Ce comprised within the emitter path of the first transistor T1. As already mentioned above, the emitter capacitor Ce may be arranged between the first emitter resistor Re1 and ground. Thereby, the emitter capacitor Ce is connected in parallel to the shunt resistor Rshunt. In addition, at the input of the measurement unit 12, a collector capacitor Cc may be provided which connects the input of the measurement unit 12 with the collector of the first transistor T1. Said emitter capacitor Ce and said collector capacitor Cc may lower signal fluctuations of the input signal IS.
Furthermore, the measurement unit 12 comprises a low pass filter 24, said low pass filter 24 being provided at the output of the measurement unit 12, i.e. the low pass filter is connected with the collector path of the second transistor T2. For example, the low pass filter 24 comprises a resistor Rf and a capacitor Cf forming a passive first-order low pass filter. Of course, also other low pass filters may be used. By means of said low pass filter 24, a smoothing of the measurement signal MS is achieved. In other words, the low pass filter 24 provides an averaged measurement signal MS thereby filtering out high-frequency signal fluctuations. For example, the low pass filter 24 may be chosen such that the variations of the measurement signal MS are very slow with respect to the timing of the control unit 11.
It should be noted that the description and drawings merely illustrate the principles of the proposed methods and systems. Those skilled in the art will be able to implement various arrangements that, although not explicitly described or shown herein, embody the principles of the invention.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2016/075643 | 10/25/2016 | WO | 00 |
