Abstract:
A supplemental controller for a fiber glass bushing actively performs heating and cooling of a connected segment of the bushing which is otherwise controlled by a primary controller. In one embodiment, the supplemental controller performs heating by means of current injection into a connected bushing segment and cooling by means of current diversion from or around the connected bushing segment. Initial start-up and balancing operations can be performed without activation of the supplemental controller. In another embodiment of the invention, the supplemental controller heats a bushing segment by injecting current in-phase with current from the primary bushing controller and cools the bushing segment by injecting current out-of-phase with current from the primary bushing controller.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This is a division of U.S. patent application Ser. No. 08/734,421, filed Oct. 16, 1996, now U.S. Pat. No. 5,787,728 which is a continuation of U.S. patent application Ser. No. 08/322,657, filed Oct. 12, 1994, now abandoned. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates in general to the control of glass fiber forming bushings and, more particularly, to an improved method and apparatus for controlling one or more segments of a multiple segment bushing to extend the range of control utilizing a given auxiliary power level by controlling both the heating and cooling of one or more segments of the bushing. 
     Glass fibers are commonly produced by drawing multiple streams of molten glass through nozzles or holes located in a heated container known in the industry as a bushing. The bushing is electrically resistance heated by passing high currents through it. Since the temperature of the bushing is one important factor in determining the characteristics of the glass fibers which are produced using the bushing, a variety of temperature control arrangements have been devised. All known fiber glass busing control circuits are based on either current diversion around all or one or more segments of a multiple segment bushing or current injection into one or more segments of a multiple segment bushing. 
     Temperature control using current diversion around a bushing or one or more segments of a multiple segment bushing is disclosed, for example, in U.S. Pat. No. 4,594,087. In the disclosed arrangement, a controller diverts current around a bushing or segments of a bushing using variable impedance circuits. The diverted current reduces the temperature of the bushing or segment of the bushing from which current was diverted. An improved bushing controller utilizing an auxiliary transformer in each of the variable impedance circuits of the &#39;087 controller to increase the current capacity of the controller is disclosed in U.S. Pat. No. 4,931,075. 
     Temperature control using current injection into a bushing is disclosed, for example, in U.S. Pat. No. 4,780,120. In the disclosed arrangement, current is injected into all but one segment of a multiple segment bushing and adjusts the supply of electrical energy to the entire bushing to control the temperature of each segment of the bushing. 
     Many of the known prior art arrangements are able to control fiber glass bushings to produce high quality glass fibers. Unfortunately, all known prior art arrangements require partial activation, preferably approximately 50%, during initial start-up and balancing of a fiber glass bushing which complicates these procedures. 
     There is an ongoing need for improvement in controlling fiber glass bushings to improve their operation and efficiency. Preferably, an improved bushing controller would not interfere with initial start-up and balancing operations, would provide increased range of bushing control without increasing the size of an auxiliary bushing power supply and would improve the coefficient of variation of glass fibers produced by controlled fiber glass bushings. 
     SUMMARY OF THE INVENTION 
     This need is met by the invention of the present application wherein a supplemental controller for a fiber glass bushing actively performs heating and cooling of a connected segment of the bushing which is otherwise controlled by a primary controller. In one embodiment of the supplemental controller of the present application, heating is performed by means of current injection into a connected bushing segment and cooling is performed by means of current diversion from or around the connected bushing segment. In another embodiment of the invention, heating is performed by injecting current into a segment in which the injected current is in-phase with current from a primary bushing controller while cooling is performed by injecting current which is out-of-phase with current from the primary bushing controller. With this improved positive control of both heating and cooling, initial start-up and balancing operations can be performed without activation of the supplemental controller. Since auxiliary power for heating does not have to be applied at approximately 50% during start-up and balancing operations, the effective control range is expanded. The control range is in fact approximately doubled over prior art arrangements with the same size auxiliary power supply. 
     In accordance with one aspect of the present invention, a method for supplemental control of a segment of a fiber glass bushing controlled by a bushing primary controller comprises the steps of: coupling a heating and cooling circuit to the segment of the fiber glass bushing; generating a control signal for the segment of the fiber glass bushing; determining whether the control signal commands heating or cooling of the segment of the fiber glass bushing; and, operating the heating and cooling circuit to heat and cool the segment of the fiber glass bushing in accordance with the determined requirements of the control signal. 
     The step of determining whether the control signal commands heating or cooling of the segment of the fiber glass bushing may comprise the step of comparing the control signal to a threshold. The step of generating a control signal for the segment of the fiber glass bushing may comprise the steps of determining the temperature of the segment of the fiber glass bushing, and utilizing the determined temperature of the segment of the fiber glass bushing in a temperature controller to generate the control signal. In one embodiment of the invention, the step of operating the heating and cooling circuit to heat and cool the segment of the fiber glass bushing in accordance with the determined requirements of the control signal may comprise the steps of connecting in-phase current to the segment of the fiber glass bushing for heating the segment, and connecting out-of-phase current to the segment of the fiber glass bushing for cooling the segment. 
     The step of coupling a heating and cooling circuit to the segment of the fiber glass bushing may comprise the steps of coupling a current diversion circuit to the segment of the fiber glass bushing and coupling a current injection circuit to the segment of the fiber glass bushing. The step of operating the heating and cooling circuit to heat and cool the segment of the fiber glass bushing in accordance with the determined requirements of the control signal may comprise the steps of operating the current diversion circuit for cooling of the segment of the fiber glass bushing, and operating the current injection circuit for heating of the segment of the fiber glass bushing. 
     The heating and cooling circuit is controlled to conduct portions of cycles of ac electrical energy to the segment of the fiber glass bushing for heating and to conduct portions of cycles of ac electrical energy from the segment of a fiber glass bushing for cooling. And the step of operating the heating and cooling circuit to heat and cool the segment of the fiber glass bushing in accordance with the determined requirements of the control signal comprises the steps of determining current flow in the heating and cooling circuit, generating a current flow signal corresponding to the current flowing in the heating and cooling circuit, combining the current flow signal and the control signal to generate a control error signal, determining a conduction control signal for the heating and cooling circuit in response to the control error signal, and operating the heating and cooling circuit in response to the conduction control signal. 
     Where the heating and cooling circuit comprises a first current control switch for connecting supplemental current to the segment of the fiber glass bushing and a second current control switch for diverting current around the segment of the fiber glass bushing, the step of operating the heating and cooling circuit in response to the conduction control signal comprises the step of controlling an onset of current conduction through the first and second current control switches for controlling heating and cooling of the segment of the fiber glass bushing, respectively. 
     In accordance with another aspect of the present invention, a supplemental controller is provided for a segment of a fiber glass bushing controlled by a primary bushing controller. The supplemental controller is responsive to a control signal and comprises a heating and cooling circuit coupled to the segment of the fiber glass bushing, and a controller circuit for operating the heating and cooling circuit to heat and cool the segment of the fiber glass bushing in accordance with the control signal. 
     The heating and cooling circuit comprises a transformer having a primary winding connected to a power source and a secondary winding connected across the segment of a fiber glass bushing to be controlled. A first current switch is connected in series between the power source and the primary winding for controllably passing current to the transformer for heating the segment of a fiber glass bushing. A second current switch is connected in shunt across the primary winding of the transformer between the first current switch and the primary winding for controllably passing current therethrough for diverting current from the segment of a fiber glass bushing for cooling the segment. In an illustrative embodiment, each of the first and second current switches comprises a pair of silicon controlled rectifiers connected anti-parallel to one another. 
     The controller circuit comprises a heat-cool detector circuit responsive to the control signal for determining whether the control signal commands heating or cooling of the segment of a fiber glass bushing. The heat-cool detector also provides for generating heat-cool signals. A driver circuit is coupled between the heat-cool detector circuit and the heating and cooling circuit. The driver circuit is enabled by the heat-cool signals for operating the first current switch for heating the segment of a fiber glass bushing and for operating the second current switch for cooling the segment. 
     The supplemental controller may further comprise a current sensor for determining current flow in the primary winding of the transformer and generating a current flow signal representative of the current flow. When the current sensor is present, the controller circuit further comprises a conduction control circuit for combining the control signal with the current flow signal to generate a conduction control signal. A timer circuit is coupled to the driver circuit and the conduction control circuit for generating conduction control signals which determine conduction angles for the first and second current switches. Preferably, the conduction control circuit comprises a proportional plus integral controller. 
     In accordance with yet another aspect of the present invention, a supplemental controller for a segment of a fiber glass bushing controlled by a primary bushing controller comprises a transformer having a secondary winding connected to the segment and a primary winding connectable to an ac power source used by the primary bushing controller. A first current switch is connected in series with the primary winding for connecting the primary winding of the transformer to the ac power source. A second current switch is connected in shunt across the primary winding. Heat-cool control means is provided for receiving a control signal representative of a commanded temperature for the segment and generating heat enable signals and cool enable signals. Current monitoring means is provided for monitoring current flow in the primary winding of the transformer and generating a current flow signal. 
     Conduction setting means responsive to the control signal and the current flow signal is provided for generating a conduction setting signal. Timer means is provided for generating conduction control signals in response to the conduction setting signal. Driver means is responsive to the conduction control signals and the heat enable signals for operating the first current switch to heat the segment, and is responsive to the conduction control signals and the cool enable signals for operating the second current switch to cool the segment. 
     The heat-cool control means may comprise scaling and shifting means for receiving an input control signal and scaling and shifting the input control signal to generate the control signal. For such operation, comparator means is provided for comparing the control signal to a threshold signal above which supplemental current is to be connected to the segment for heating the segment and below which current is to be diverted around the segment for cooling the segment. Logic circuit means is connected to the comparator means for generating the heat enable signals and the cool enable signals. 
     The conduction setting means may further comprise first rectifier means for rectifying the control signal to generate a rectified control signal and second rectifier means for rectifying the current flow signal to generate a rectified current flow signal. The conduction setting means combines the rectified control signal and the rectified current flow signal to generate the conduction setting signal. The conduction control means preferably comprises a proportional plus integral controller. 
     In accordance with still another aspect of the present invention, a system for controlling a fiber glass bushing having at least three segments including first and second end segments located at opposite ends of the bushing comprises a primary controller connected across all segments of the fiber glass bushing, a first end supplemental controller connected across the first end segment for heating and cooling the first end segment, and a second end supplemental controller connected across the second end segment for heating and cooling the second end segment. 
     The first end supplemental controller is responsive to a first control signal and comprises a heating and cooling circuit coupled to the first end segment of the fiber glass bushing. A controller circuit operates the heating and cooling circuit to heat and cool the first end segment of the fiber glass bushing in accordance with the first control signal. The second end supplemental controller is responsive to a second control signal and comprises a heating and cooling circuit coupled to the second end segment of the fiber glass bushing. A controller circuit operates the heating and cooling circuit to heat and cool the second end segment of the fiber glass bushing in accordance with the second control signal. 
     It is, thus, an object of the present invention to provide an improved supplemental controller for a fiber glass bushing which actively performs both heating and cooling of a segment of the bushing; to provide an improved supplemental controller for a segment of a fiber glass bushing which injects current to heat the segment and diverts current to cool the bushing; and, to provide an improved supplemental controller for a segment of a fiber glass bushing which connects current in-phase with current from a primary bushing controller to heat the bushing segment and connects current out-of-phase with current from the primary bushing controller to cool the bushing segment. 
     Other objects and advantages of the invention will be apparent from the following description, the accompanying drawings and the appended claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a schematic block diagram of a controller for a multiple segment bushing operable in accordance with the present invention; 
     FIG. 2 is a schematic block diagram of a heating and cooling controller which can be used in the controller of FIG. 1; and 
     FIG. 3 is a partial schematic block diagram of a modified embodiment of the heating and cooling controller of FIG. 2 which applies in-phase current for heating and out-of-phase current for cooling. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Reference will now be made to the drawing figures wherein FIG. 1 schematically illustrates a system  100  for controlling and maintaining the temperature of a multiple segment mineral or glass bushing  102 . The system  100  is illustrated as using thermocouples as temperature sensors. It is noted, however, that other temperature sensing arrangements can be used in the present invention. For example, resistance or voltage sensing can be used for temperature sensing as disclosed in U.S. Pat. No. 4,780,120 which is hereby incorporated by reference. 
     The bushing  102  is segmented into three sections: a first or left end segment  104 , a second or center segment  106  and a third or right end segment  108 . It is noted that the present invention is described with reference to the three segment bushing  102  for purposes of example and illustration only. It is to be understood that the present invention can be used with bushings having not only three segments, as illustrated, but also with bushings having fewer than three segments or more than three segments as are appropriate for given applications. 
     Alternating current (ac) electrical energy is connected across the entire bushing  102  by a pair of conductors  110 ,  112  which are connected between the bushing  102  and a secondary winding  114  of a first power transformer  116 . Electrical energy from a power source V ac  provided on the conductors  120  is connected to a primary winding  118  of the first power transformer  116  through a power controller  122 . The power controller  122  is typically a solid state control device which is connected to the power source V ac  and receives a control signal from a first process controller  124  via a conductor  126 . 
     The first process controller  124  receives a temperature representative voltage signal from a first thermocouple  128  secured to the center segment  106  of the bushing  102  via a conductor  130 . The first process controller  124  may be like or similar to the Models 6810 or 6403 controllers manufactured by Electronic Control Systems of Fairmont, W. Va. or the Leeds and Northrop Emax V controller. It is noted that although the first thermocouple  128  senses only the temperature of the center segment  106  of the multiple segment bushing  102 , its output signal controls the application of electrical energy to the entire bushing  102 . Accordingly, the power controller  122  may typically have a capacity of between approximately 10 and 35 kilowatts of electrical power and apply a maximum current of about 1,000 amps. 
     A second thermocouple  129  generates a voltage signal representative of the temperature of the first or left end segment  104  of the bushing  102  which is carried to a second process controller  131  via a conductor  133 . The second process controller  131  can be the same type as the first process controller  124  previously described. The output signal from the second process controller  131  is carried to a first heating and cooling or supplemental controller  132  via a conductor  134 . The output signal from the second process controller  131  serves as an input control signal for the first supplemental controller  132  which controls the current flow through and temperature of the first or left end segment  104  of the bushing  102  via a second power transformer  136 . 
     A third thermocouple  138  generates a voltage signal representative of the temperature of the second or right end segment  108  of the bushing  102  which is carried to a third process controller  140  via a conductor  142 . The third process controller  140  can be the same type as the first and second process controllers  124 ,  131  previously described. The output signal from the third process controller  140  is carried to a second heating and cooling or supplemental controller  144  via a conductor  146 . The output signal from the third process controller  140  serves as an input control signal for the second supplemental controller  144  which controls the current flow through and temperature of the second or right end segment  108  of the bushing  102  via a third power transformer  148 . 
     Since the first supplemental controller  132  and the second supplemental controller  144  are identical to one another, only the first supplemental controller  132  will be described herein. With reference to FIG. 2, the supplemental controller  132  is responsive to an input control signal received on the conductor  134 . As illustrated, the input control signal is the output signal generated by the second process controller  131  which output signal is representative of a desired temperature for the first or left end segment  104  of the bushing  102 . An input control signal can also be provided to the supplemental controller by other means. For example, a control signal can be generated by a potentiometer  150  which can be manually adjusted by an operator of a machine including the bushing  102  with the potentiometer  150  being connected to a reference voltage V. 
     The supplemental controller  132  includes a heating and cooling circuit  152  coupled to the first or left end segment  104  of the bushing  102 . A controller circuit  154  operates the heating and cooling circuit  152  to heat and cool the segment  104  in accordance with the input control signal received on the conductor  134 . The heating and cooling circuit  152  drives the second power transformer  136  which has a primary winding  156  and a secondary winding  157  connected across the segment  104 , see FIG.  1 . 
     The primary winding  156  of the transformer  136  is selectively connected to the power source V ac  connected to the conductors  120  via a first current switch  158 . The first current switch  158  is connected in series between the power source V ac  and the primary winding  156  for controllably passing current to the transformer  136  for heating the segment  104  of the bushing  102 . 
     A second current switch  160  is connected in shunt across the primary winding  156  of the transformer  136  between the first current switch  158  and the primary winding  156 . The second current switch  158  provides for controllably passing current therethrough to divert current from the segment  104  for cooling the segment  104 . In the illustrated embodiment, the first and second current switches each comprise a pair of silicon controlled rectifiers  162  connected antiparallel to one another. Of course, other current switches can be used in the present invention as will be apparent to those skilled in the art. 
     The controller circuit  154  includes heat-cool control means, comprising a heat-cool detector circuit  164  in the illustrated embodiment. The heat-cool detector circuit  164  is responsive to the control signal received on the conductor  134  for determining whether the control signal commands heating or cooling of the segment  104  of the bushing  102  and for generating heat-cool signals on conductors  166 ,  168 , i.e. heating signals on the conductor  166  and cooling signals on the conductor  168 . 
     Driver means comprising driver circuitry  170  is coupled between the heat-cool detector circuit  164  and the heating and cooling circuit  152 . In the illustrated embodiment, the driver circuitry  170  comprises a first driver circuit  170   a  which is enabled by the heating signals on the conductor  166  for operating the first current switch  158  for heating the segment  104  of the bushing  102  and a second driver circuit  170   b  which is enabled by the cooling signals on the conductor  168  for operating the second current switch  160  for cooling the segment  104 . 
     The supplemental controller  132  further comprises a current sensor or current transformer  172  for determining current flow in the primary winding  156  of the transformer  136 . The current transformer  172  generates a current flow signal representative of current flow in the primary winding  156  which is carried on conductors  174  to the controller circuit  154 . 
     The controller circuit  154  further comprises conduction setting means, a conduction control circuit  176  as illustrated, for combining the control signal with the current flow signal to generate a conduction control signal. A timer circuit  178  is coupled to the first and second driver circuits  170   a ,  170   b  and is driven by the conduction control circuit  176  for generating conduction control signals which determine conduction angles for the first and second current switches  158 ,  160 . The conduction control circuit  176  preferably is a proportional-plus-integral (P-I) controller; however, it can also be a proportional-plus-integral-plus-derivative (PID) controller or other appropriate control circuit known in the art. The timer circuit  178  can be a  555  timer circuit, an LM  122 H or a number of other commercially available timer circuits. 
     More particularly, the input control signal on the conductor  134  is received by a scaling amplifier  180  which scales the input control signal to form an internal control signal for the heat-cool detector circuit  164 . In a working embodiment of the invention of the present application, the scaling amplifier  180  also is configured for off-setting the resulting control signal such that it defines scaling and shifting means for the heat-cool detector circuit  164 . The resulting control signal then extends from approximately −7 volts to approximately +7 volts in a substantially linear manner, see FIG. 2, 
     The resulting control signal is passed to comparator means, comprising a comparator circuit  182  having hysteresis as illustrated, for comparing the control signal to a threshold signal. When the control signal is above the threshold signal, supplemental current is to be connected to the segment  104  for heating the segment, and when the control signal is below the threshold signal, current is to be diverted around the segment  104  for cooling the segment  104 . 
     The output of the comparator circuit  182  is passed to a logic circuit  184  for generating heating signals on the conductor  166  and for generating cooling signals on the conductor  168 . By both scaling and shifting the input control signal to generate the control signal, the threshold is approximately 0 volts. Hysteresis in the comparator circuit  182  prevents the heating and cooling signals from jumping back and forth for command signals near the threshold. Further, the logic circuit  184  includes internal delays to ensure that the first and second current switches  158 ,  160  are never turned on at the same time. 
     The control signal from the scaling amplifier  180  is passed through a first rectifier means to take its absolute value. This results in a signal taking the shape of a “V” going from +7 volts to 0 volts for maximum cooling to no cooling or heating and from 0 volts to +7 volts for no heating or cooling to maximum heating, see FIG.  2 . The rectifier means comprises a rectifier circuit  186  as illustrated. 
     The current flow signals on the conductors  174  are also passed through a scaling amplifier  188  and passed to a second rectifier means, comprising a rectifier circuit  190  as illustrated, to result in a positive going signal ranging from 0 volts to +7 volts, see FIG.  2 . The positive going signal is representative of current flow in the primary winding  156  whether supplemental current is being provided to the segment  104  of the bushing  102  or whether current is being diverted from the segment  104  of the bushing  102 . In a working embodiment of the supplemental controller  132 , the rectifier circuits  186 ,  190  were constructed as precision rectifiers using operational amplifiers; however, other rectifier circuits such as simple diode rectifier circuits can be used in the invention. 
     The conduction setting means then also comprises a summer  192  which combines the rectified control signal and the rectified current flow signal to generate the conduction setting signal in cooperation with the conduction control circuit  176 . That is, the summer  192  combines the rectified control signal and the rectified current flow signal to generate a control error signal which is processed by the conduction control circuit  176  to generate the conduction setting signal which is in turn processed by the timer circuit  178  to generate conduction angle signals for the first and second current switches  158 ,  160 . 
     In summary, an input control signal representative of a desired bushing segment temperature is generated by a process controller or other control device, such as the potentiometer  150 . The input control signal is processed and evaluated to determine whether it is calling for heating or cooling of the segment  104  of the bushing  102 . The processed input control signal is also compared to a current level in the primary of the transformer  136  to determine the amount of current which is being injected into or diverted around the segment  104  of the bushing  102 . The resulting error signal is processed by the conduction control circuit  176  to generate the conduction setting signal which is in turn processed by the timer circuit  178  to generate conduction control signals for the first and second current switches  158 ,  160 . That is, the current switches  158 ,  160  are activated in response to the conduction control signals to pass from 0° to 180° of each half cycle of injection current or diversion current to thereby inject from 0 to approximately 200 amps of auxiliary current to the segment  104  or to divert from 0 to approximately 200 amps of current from the segment  104 . 
     An alternate embodiment of a supplemental controller  132 ′ is illustrated in a partial schematic block diagram form in FIG.  3 . Components of the supplemental controller  132 ′ which are the same as the supplemental controller  132  of FIG. 2 are labeled with the same identification numerals. Further, since the portion of the supplemental controller  132 ′ to the left of the logic circuit  184  and the timer circuit  178  are the same as in FIG. 2, this portion of the supplemental controller  132 ′ is not shown in FIG.  3 . 
     As shown in FIG. 3, the heating and cooling circuit  152 ′ drives the second power transformer  136 . The primary winding  156  of the transformer  136  is selectively connected to the power source V ac  connected to the conductors  120  via a current switch  158 ′ and a reversing switch  194  which is controlled by a reversing control circuit  196 . The reversing control circuit  196  controls the reversing switch  194  in response to the heating and cooling signals on the conductors  166 ,  168  such that the reversing switch  194  directly connects the power source V ac  to the primary  156  when heating is called for and crosses the connection of the power source V ac  to the primary winding  156  when cooling is requested. In this way, in-phase current is injected into the segment  104  when heating is called for and out-of-phase current is injected to subtract current from the segment  104  when the segment  104  is to be cooled. 
     The current switch  158 ′ is connected in series between the power source V ac  and the primary winding  156  for controllably passing current to the transformer  136  for heating the segment  104  of the bushing  102 . Since control of heating and cooling is performed by the reversing control circuit  196  and the reversing switch  194 , the current switch  158 ′ is controlled only by the conduction control signals generated by the timer  178  in this embodiment. 
     Since operation of the controllers illustrated in FIGS. 2 and 3 in the system of FIG. 1 in accordance with the present invention is readily apparent in view of the above description, it will not be further described herein. 
     Having thus described the invention of the present application in detail and by reference to preferred embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims.