The present disclosure relates to an induction cooking appliance and more particularly to a system and method for controlling the induction cooking appliance to promote improved operation of the cooktop appliance.
Induction cooking appliances are more efficient, have greater temperature control precision and provide more uniform cooking than other conventional cooking appliances. In conventional cooktop systems, an electric or gas heat source is used to heat cookware in contact with the heat source. This type of cooking is inefficient because only the portion of the cookware in contact with the heat source is directly heated. The rest of the cookware is heated through conduction that causes non-uniform cooking throughout the cookware. Heating through conduction takes an extended period of time to reach a desired temperature.
In contrast, induction cooking systems use electromagnetism which turns cookware of the appropriate material into a heat source. Such appropriate materials may include ferromagnetic materials in order to effectively capture the magnetic field produced by the induction cooking coil. Other materials, such as aluminum, will be very inefficient for cooking on an induction cooking system. A power supply provides a signal having a frequency to the induction coil. When the coil is activated a magnetic field is produced which induces a current on the bottom surface of the cookware. The induced current on the bottom surface then induces even smaller currents (Eddy currents) within the cookware thereby providing heat throughout the cookware.
A typical power supply of an induction cooking system may include a resonant inverter to achieve soft-switching conditions such as zero voltage switching and zero current switching. However, when there is poor magnetic coupling between a cookware and the induction coil, e.g., due to cookware of inappropriate material and/or dimensions, undesirable operating conditions, including hard switching can occur.
Therefore, a need exists for a system and method of controlling an induction cooking appliance that overcomes the above mentioned disadvantages. A system and method that could control an induction cooking appliance to ensure that the induction cooking appliance operates within a safe operating zone would be useful.
The present invention provides induction cooktop appliances and related methods of controlling such appliances to maintain power levels within a safe operating zone, e.g., to avoid or minimize hard switching. Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
In one exemplary aspect of the present subject matter, an induction cooktop appliance is provided. The induction cooktop appliance includes a user interface, an induction heating element, a power supply circuit, and a control circuit. The user interface includes a user input. The induction heating element is operable to inductively heat a load with a magnetic field. The power supply circuit is configured to supply a power signal to the induction heating element. The power supply circuit includes an inverter. The control circuit is configured to control the power supply circuit. The control circuit is also configured to activate the power supply circuit in response to a request received via the user input, detect a current of the power signal supplied to the induction heating element, detect a phase angle of the power signal supplied to the induction heating element and determine a maximum current based on the detected phase angle. The control circuit is further configured to compare the detected current to the determined maximum current and modify an operating parameter of the power supply circuit when the detected current is greater than the determined maximum current.
In another exemplary aspect of the present subject matter, a method of operating an induction cooktop appliance is provided. The method includes supplying a power signal to an induction heating element of the induction cooktop appliance in response to a request received via a user input of the cooktop appliance. The method also includes detecting a current of the power signal supplied to the induction heating element and detecting a phase angle of the power signal supplied to the induction heating element. The method may further include determining a maximum current based on the detected phase angle, comparing the detected current to the determined maximum current, and modifying an operating parameter of the induction cooktop appliance when the detected current is greater than the determined maximum current.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
The systems and methods of the present disclosure are described with reference to an induction cooking system. Those of ordinary skill in the art, using the disclosures provided herein, will appreciate that the systems and methods of the present disclosure are more broadly applicable to many resonant power supply technologies.
Cooktop 10 is provided by way of example only. The present invention may be used with other configurations. For example, a cooktop having one or more induction heating elements in combination with one or more electric or gas burner assemblies. In addition, the present invention may also be used with a cooktop having a different number and/or positions of heating elements.
A user interface 30 may have various configurations and controls may be mounted in other configurations and locations other than as shown in
Referring still to
Comparator 340 can be configured to compare the feedback signal 325 with a reference signal to generate an output signal 345 that can be provided to controller 350. In one implementation, the output signal 345 can be provided to an analog-to-digital converter. As will be discussed in more detail below, the output signal 345 provides information to the controller 350 concerning the current, e.g., amperage, and the phase angle of a power signal provided to the induction heating system 300. The controller 350 is capable of and may be operable to perform any methods and associated method steps as disclosed herein. For example, in some embodiments, methods disclosed herein may be embodied in programming instructions stored in a memory and executed by the controller 350.
An exemplary resonant power inverter circuit is illustrated in
The resonant inverter module 360 can be coupled to AC power source 308. The resonant inverter module 360 can be provided with switching elements Q1 and Q2, which can provide power to the load, including the induction heating coil 22 and any cookware or object thereon. The direction A, B of the current flow through the induction heating coil 114 can be controlled by the switching of switching elements Q1 and Q2. A switching unit (not shown) can provide the controlled switching of the switching elements Q1, Q2 based on a switching control signal provided from controller 350 (
Switching elements Q1 and Q2 may be bidirectional, e.g., metal-oxide-semiconductor field-effect transistors (MOSFETs). In other embodiments, switching elements Q1 and Q2 may be unidirectional, e.g., insulated-gate bipolar transistors (IGBTs). In alternate embodiments, any suitable switching elements can be used. Snubber capacitors C1, C2 and resonant capacitors C3, C4 can be connected between a positive power terminal and a negative power terminal to successively resonate with the induction heating coil 22. The induction heating coil 22 can be connected between the switching elements Q1, Q2 and can induce an eddy current in the cookware 170 (
The resonant inverter module 360 can power the induction heating coil 22 with high frequency current. The switching of the switching elements Q1 and Q2 by controller 350, e.g., via a switching unit, can control the direction A, B and frequency of this current. If switching element Q1 is turned on and switching element Q2 is turned off, the resonance capacitor C3 and the induction coil 22 (including any cookware thereon) can form a resonant circuit. If the switching element Q1 is turned off and switching element Q2 is turned on, the resonance capacitor C4 and the induction coil 22 (including any cookware thereon) can form the resonant circuit. In each case, the resonant circuit may be damped by a resistor R.
A desirable loading condition and resonant characteristics for the resonant inverter module 360 (
An equation describing a relationship between current and phase angle, e.g., ∥iL(θ(jω))∥ or θ(∥iL(jω))∥), within the operating frequency range 400 can be determined. Generally, the relationship between current and phase angle is linear within the operational frequency range 400. Such linear relationship may generally take the form of: iL_MAX=m×PhaseDeg+b; where “m” and “b” are constants which may be selected based on the particular application, e.g., based on the particular inverter module used in various embodiments, such as based on the switch type, e.g., IGBT or MOSFET, provided. For example,
Method 500 may further include a step 508 of determining a maximum current based on the detected phase angle. For example, the maximum current may be determined based on a linear relationship between the maximum current and the detected phase angle. One possible example of such linear relationship is iL_MAX=m×PhaseDeg+b, as described above. The current detected at step 504 may be compared to the calculated or determined maximum current from step 508 at step 510. When the detected current is less than the determined maximum current, the method 500 may end at 514. In other embodiments, the method 500 may include continuous or repeated monitoring, e.g., the method 500 may return to step 504 after step 510 when the detected current is less than the determined maximum current, e.g., directly after step 510 or after a predetermined time delay following step 510. When the detected current is greater than the determined maximum current at step 510, the method 500 may proceed to a step 512 of modifying an operating parameter of the induction cooktop appliance, in particular the power supply circuit thereof, when the detected current is greater than the determined maximum current.
For example, in some embodiments, the step 512 of modifying the operating parameter may include performing a cycle-skipping mode. The cycle-skipping mode may include activating the power supply circuit for a first period of time, deactivating the power supply circuit for a second period of time after the first period of time, and activating the power supply circuit for a third period of time after the second period of time.
As another example, in additional embodiments, the step 512 of modifying the operating parameter may include increasing a switching frequency of the inverter. As may be seen with reference to
As another example, in additional embodiments, the step 512 of modifying the operating parameter may include deactivating the power supply circuit when the detected current is greater than the determined maximum current. In particular, when the detected current is significantly greater than the determined maximum current, the power supply circuit may simply be deactivated. For example, the power supply circuit may be deactivated when the detected current is approximately one hundred twenty percent (120%) of the determined maximum current or greater, such as approximately one hundred fifty percent (150%) of the determined maximum current or greater, such as approximately two hundred percent (200%) of the determined maximum current or greater.
In various embodiments, for example but not limited to embodiments wherein the step 512 includes deactivating the induction cooktop appliance and/or the power supply circuit thereof, method 500 may further include providing an indication via a display (e.g., display 32 in
One of skill in the art will understand that the risk of hard switching and other undesirable operations is increased at higher power operation. Accordingly, in some embodiments, the activation request received at step 501, as described above, may be a request for high-power operation. For example, a user input 31 may provide options to a user ranging from “Low” to “High,” from 1 to 10, or any other suitable range. In such embodiments, a request for high-power operation may include setting the heating element 20 to, e.g., “High” or “Medium-High,” or to a setting of 6 or more out of 10. The foregoing examples of “a request for high-power operation” are provided for illustrative purposes only and are not intended to be limiting. Further, in some embodiments, the method 500 may include or proceed to the detection steps 504 and 506 and the determination step 508 as well as other subsequent steps only when the request received via the user input is a request for high-power operation.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.