Patent Publication Number: US-7589299-B2

Title: Electronic power control for cooktop heaters

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. application Ser. No. 11/171,117, filed Jun. 30, 2005. U.S. application Ser. No. 11/171,117, filed Jun. 30, 2005, is a continuation-in-part of U.S. application Ser. No. 10/118,294, filed on Apr. 8, 2002, now U.S. Pat. No. 6,933,474, which is a continuation-in-part of U.S. application Ser. No. 09/973,096, filed Oct. 9, 2001, now abandoned. U.S. application Ser. No. 11/171,117, filed Jun. 30, 2005, is also a continuation-in-part of U.S. application Ser. No. 10/822,456, filed Apr. 12, 2004, now U.S. Pat. No. 7,022,949, which claims the benefit of U.S. provisional application No. 60/461,976, filed Apr. 10, 2003, now expired. All of the foregoing applications are incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to configurable electronic controls for cooktop heating elements. 
     2. Description of Related Art 
     Conventional controls for cooktop heating elements utilize switches, pushbuttons, indicator lights, potentiometers, and/or electronic controls. Controls are typically provided for controlling separate heating elements on a cooktop. Controls may be provided for simultaneously controlling multiple heating elements. It would be useful if a single interface device or multiple interface devices could be selectively associated with one or more heating elements. 
     Conventional controls for cooktop heating elements provide a single heating profile for a heating element. For example, a cooktop heating element may be controlled by a potentiometer having an adjustment knob for setting a desired heating element temperature. Each position of the adjustment knob along the available rotation of the potentiometer, for example, approximately one revolution, would correspond to a single heating element temperature. It would be useful if multiple heating profiles were available for the heating element so that multiple heating element temperatures could be selectively associated with a single interface device setting. 
     BRIEF SUMMARY OF THE INVENTION 
     In accordance with one aspect, the present invention provides a cooktop heating system that includes a first cooktop heating element, a second cooktop heating element, and an interface device. The system also includes a controller for selectively associating the interface device with any one or both of the first cooktop heating element and the second cooktop heating element. 
     In accordance with another aspect, the present invention provides a cooktop heating system. The system includes at least one cooktop heating element, a potentiometer manually operable to input a cooktop heating element setting, and controller arrangement operatively connected between the potentiometer and the at least one cooktop heating element to determine heating of the at least one cooktop heating element responsive to the input provided by the potentiometer and control power provision to the at least one cooktop heating element responsive to the determination. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic diagram illustrating a power control system for cooktop heating elements according to the present invention; and 
         FIG. 2  is a flowchart showing a method of controlling power to cooktop heating elements involving multiple heating profiles. 
     
    
    
     DESCRIPTION OF AN EXAMPLE EMBODIMENT 
       FIG. 1  provides a schematic illustration of an example power control system for cooktop heating elements including multiple user interface devices and multiple heating elements, according to one embodiment of the present invention. The example power control system includes a first interface device  11 , a second interface device  12 , a third interface device  13 , and a fourth interface device  14 . 
     Each interface device  11 - 14  can include one or more electronic interface devices for inputting and/or outputting, displaying, or audibly broadcasting information, such as instructions, set points, and miscellaneous system conditions. Examples of such instructions, set points, and system conditions can include a desired heating element power setting, current heating element temperature, and a hot cooktop warning. Examples of electronic interface devices include, but are not limited to, membrane switches, capacitive or so-called field sensitive sensors, multi-segment light emitting diode (LED) displays, touch-screen displays, liquid crystal displays (LCDs), plasma displays, cathode ray tubes (CRTs), vacuum fluorescent displays (VFDs), and the like. 
     Each interface device  11 - 14  can also include one or more discrete devices, such as toggle switches, pushbuttons, multiple position rotary switches, discrete LEDs, incandescent lights, and the like. Furthermore, each interface device  11 - 14  can also include one or more analog devices, such as potentiometers and analog meters, for example. In addition, each interface device  11 - 14  can include a combination of one or more electronic interface devices, discrete interface devices, and analog interface devices. Interface devices  11 - 14  may be located locally near the heating elements or remotely. In  FIG. 1 , four interface devices are shown. However, the power control system of the present invention is not limited to four interface devices, and fewer or greater than four interface devices may be provided. 
     An interface controller  15  communicates with and/or monitors the interface devices  11 - 14 . Communication wiring  16  is provided between the interface controller  15  and the interface devices  11 - 14 . Communication wiring can include a digital communication line and/or a plurality of control and instrumentation conductors, depending on the composition of the interface devices  11 - 14 . The interface controller  15  monitors user-inputted information and controls output information for the interface devices  11 - 14 . 
     The power control system of the present invention controls power to one or more electric cooktop heating elements.  FIG. 1  shows a first heating element  21 , a second heating element  22 , a third heating element  23 , a fourth heating element  24 , a fifth heating element  25 , a sixth heating element  26 , a seventh heating element  27 , and an eighth heating element  28 . However, the power control system is not limited to controlling eight heating elements, and fewer or greater than eight heating elements may be provided. In one embodiment of the present invention, the heating elements  21 - 28  include electrical resistance heating elements. In another embodiment, the heating elements  21 - 28  include electrical induction heating elements. 
     A power unit  31  controls power output to the heating elements  21 - 28 . The power unit  31  includes a plurality of switches, for example relays, transistors, thyristors, silicon controlled rectifiers, and the like, for controlling power output to the heating elements. When the power unit  31  causes a switch or switches for a particular heating element to be closed, power is provided to the heating element. Conversely, when the power unit  31  causes a switch or switches for a particular heating element to be opened, power ceases to be supplied to the element. 
     A communications bus  32  allows for bi-directional communications between the interface controller  15  and the power unit  31 . Over the communications bus  32 , the interface controller  15  can provide information to the power unit  31  regarding the operation of the heating elements, such as instructions regarding heating element power level, runtime, and the like. The interface controller  15  can also receive information from the power unit  31 , such as status information regarding the heating elements  21 - 28 , for example, on/off and current temperature. Because the interface controller  15  communicates with and/or monitors the interface devices  11 - 14 , and communicates with the power unit  31 , information regarding the heating elements  21 - 28  and control of the heating elements  21 - 28  can be provided to a system user. For example, the user can input one or more heating element settings at an interface device for control of one or more heating elements. 
     The interface controller  15  and power unit  31  each include a processor, for example, a microprocessor, for carrying out programmed instructions. In one embodiment, the interface controller  15  and power unit  31  include separate processors. In another embodiment, the interface controller  15  and power unit  31  utilize a single processor, and the communications bus  32  between the interface controller  15  and power unit  31  is unnecessary. 
     The power unit  31  monitors the temperature of each heating element  21 - 28  through a temperature sensor located at each heating element  21 - 28 .  FIG. 1  shows a first temperature sensor  41 , a second temperature sensor  42 , a third temperature sensor  43  a fourth temperature sensor  44 , a fifth temperature sensor  45 , a sixth temperature sensor  46 , a seventh temperature sensor  47 , and an eighth temperature sensor  48  located at heating elements  21 - 28 , respectively. Temperature information obtained from the temperature sensors  41 - 48  can be displayed at the interface devices  11 ,  12 , 13 ,  14 , or used by program control algorithms of the interface controller  15  and/or power unit  31 . The temperature sensors  41 - 48  can include such devices as thermocouples or thermistors, for example. The power unit  31  and/or interface controller  15  can also monitor ambient temperature through an additional temperature sensor or sensors (not shown). The power unit  31  and/or interface controller  15  can be programmed to control an auxiliary device based on measured ambient temperature, such as energizing control relay to start a fan when the ambient temperature exceeds a desired level. 
     As stated above, the interface controller  15  communicates with and/or monitors the interface devices over communication wiring  16 . The interface controller  15  is programmed to selectively associate any one or more interface devices  11 - 14  with any one or more heating elements  21 - 28 . This is possible because the interface devices  11 - 14  are not directly connected to the heating elements  21 - 28 . The interface devices  11 - 14  are directly connected to the interface controller  15 , which communicates with the power unit over the communications bus  32 . The power unit  31  controls power output to the heating elements  21 - 28 . Accordingly, through communications with the power unit  31 , the interface controller  15  can selectively associate any one or more interface devices  11 - 14 , and, therefore, their respective input and output information, with any one or more heating elements  21 - 28 . 
     For example, the third interface device  13  can be selectively associated with the second heating element  22  and the seventh heating element  27 . Accordingly, input and output information related to the second  22  and seventh  27  heating elements, which can include, for example, the desired power setting for the heating elements (input) and the current temperature of the heating elements (output), can be respectively inputted and outputted at the third interface device. As stated above, any one or more interface devices  11 - 14  can be selectively associated with any one or more heating elements  21 - 28 . 
     The selective association of interface devices  11 - 14  with heating elements  21 - 28  performed by the interface controller  15  can be based upon user-inputted information. For example, selectable or configurable inputs can be provided at the interface devices  11 - 14  by which the user can instruct the interface controller  15  to selectively associate any one or more interface devices  11 - 14  with any one or more heating elements  21 - 28 . Alternatively, a dedicated interface device for system setup could be provided for allowing a user to selectively associate other interface devices with heating elements  21 - 28 . Still alternatively, a system setup communications port could be provided for allowing communications with the interface controller  15  from a device such a personal computer so that one or more interface devices  11 - 14  could be selectively associated with one or more heating elements  21 - 28 . The interface controller  15  is programmed to perform the above-described selective associations and does not need to be reprogrammed in order to change the association of interface devices  11 - 14  and heating elements  21 - 28 . 
     According to one aspect of the present invention, any one or more interface devices  11 - 14  can be selectively associated with any two or more of the heating elements  21 - 28 . According to another aspect of the present invention, any one or more interface devices  11 - 14  can be selectively associated with any three or more of the heating elements  21 - 28 . According to another aspect of the present invention, any one or more interface devices  11 - 14  can be selectively associated with any four or more of the heating elements  21 - 28 . According to another aspect of the present invention, any one or more interface devices  11 - 14  can be selectively associated with any five or more of the heating elements  21 - 28 . According to another aspect of the present invention, any one or more interface devices  11 - 14  can be selectively associated with any six or more of the heating elements  21 - 28 . According to another aspect of the present invention, any one or more interface devices  11 - 14  can be selectively associated with any seven or more of the heating elements  21 - 28 . According to another aspect of the present invention, any one or more interface devices  11 - 14  can be selectively associated with all eight of the heating elements  21 - 28 . It will be understood that, as limited by the capabilities of utilized hardware, for example, processor addressing capabilities, any number of interface devices could be selectively associated with any number of heating elements. 
     According to one aspect of the present invention, any two or more interface devices  11 - 14  can be selectively associated with any one or more of the heating elements  21 - 28 . According to another aspect of the present invention, any two or more interface devices  11 - 14  can be selectively associated with any two or more of the heating elements  21 - 28 . According to another aspect of the present invention, any two or more interface devices  11 - 14  can be selectively associated with any three or more of the heating elements  21 - 28 . According to another aspect of the present invention, any two or more interface devices  11 - 14  can be selectively associated with any four or more of the heating elements  21 - 28 . According to another aspect of the present invention, any two or more interface devices  11 - 14  can be selectively associated with any five or more of the heating elements  21 - 28 . According to another aspect of the present invention, any two or more interface devices  11 - 14  can be selectively associated with any six or more of the heating elements  21 - 28 . According to another aspect of the present invention, any two or more interface devices  11 - 14  can be selectively associated with any seven or more of the heating elements  21 - 28 . According to another aspect of the present invention, any two or more interface devices  11 - 14  can be selectively associated with all eight of the heating elements  21 - 28 . 
     According to one aspect of the present invention, any three or more interface devices  11 - 14  can be selectively associated with any one or more of the heating elements  21 - 28 . According to another aspect of the present invention, any three or more interface devices  11 - 14  can be selectively associated with any two or more of the heating elements  21 - 28 . According to another aspect of the present invention, any three or more interface devices  11 - 14  can be selectively associated with any three or more of the heating elements  21 - 28 . According to another aspect of the present invention, any three or more interface devices  11 - 14  can be selectively associated with any four or more of the heating elements  21 - 28 . According to another aspect of the present invention, any three or more interface devices  11 - 14  can be selectively associated with any five or more of the heating elements  21 - 28 . According to another aspect of the present invention, any three or more interface devices  11 - 14  can be selectively associated with any six or more of the heating elements  21 - 28 . According to another aspect of the present invention, any three or more interface devices  11 - 14  can be selectively associated with any seven or more of the heating elements  21 - 28 . According to another aspect of the present invention, any three or more interface devices  11 - 14  can be selectively associated with all eight of the heating elements  21 - 28 . 
     According to one aspect of the present invention, all four of the interface devices  11 - 14  can be selectively associated with any one or more of the heating elements  21 - 28 . According to another aspect of the present invention, all four of the interface devices  11 - 14  can be selectively associated with any two or more of the heating elements  21 - 28 . According to another aspect of the present invention, all four of the interface devices  11 - 14  can be selectively associated with any three or more of the heating elements  21 - 28 . According to another aspect of the present invention, all four of the interface devices  11 - 14  can be selectively associated with any four or more of the heating elements  21 - 28 . According to another aspect of the present invention, all four of the interface devices  11 - 14  can be selectively associated with any five or more of the heating elements  21 - 28 . According to another aspect of the present invention, all four of the interface devices  11 - 14  can be selectively associated with any six or more of the heating elements  21 - 28 . According to another aspect of the present invention, all four of the interface devices  11 - 14  can be selectively associated with any seven or more of the heating elements  21 - 28 . According to another aspect of the present invention, all four of the interface devices  11 - 14  can be selectively associated with all eight of the heating elements  21 - 28 . 
     In one embodiment of the present invention, the power control system includes means for sensing the presence of a cooking receptacle at any one or more of the heating elements  21 - 28 . The terms “cooking receptacle” as used herein refer to a utensil into or onto which food items are placed for cooking, such as a pan, pot, skillet, cooking sheet, or other cooking vessel. The means for sensing the presence of a cooking receptacle may include any structure to accomplish such function. As examples, the means for sensing may include antenna array systems in which a frequency change or disturbance in a received signal can indicate the presence of a cooking receptacle, mechanical systems in which a switch closure or pressure sensor can indicate the presence of a cooking receptacle, rate-of-change systems in which a rate of heat loss can indicate the presence of a cooking receptacle, and metal detector type systems. Such means may include separate structure or may be structure that is within the system that also provides another function. For example, such means could be incorporated into the sensors  41 - 47  and/or the power unit  31  and/or the controller  15 . The inclusion of separate structure to accomplish the function of sensing the presence of a cooking receptacle or the use of existing structure to accomplish the function are not limitations on the present invention. 
     The means for sensing the presence of a cooking receptacle is monitored by the interface controller  15  as an auxiliary input  52 ,  53  to the interface controller  15 . Alternatively, the means for sensing the presence of a cooking receptacle could be monitored by the power unit  31 . The power control system is adapted to permit a power output to a particular heating element  21 - 28  only when a cooking receptacle is sensed to be present at the particular heating element. It will be appreciated that the power output to any one or more of heating elements  21 - 28  can be prevented based on the absence of a cooking receptacle at any one or more heating elements  21 - 28 . 
     The interface controller  15  includes a plurality of auxiliary inputs  52 ,  53  and auxiliary outputs  54 ,  55  which can be analog and/or digital inputs and outputs. Examples of auxiliary inputs  52 ,  53  are contact closure inputs, discrete voltage inputs, for example 5 VDC, and voltage and current signal inputs. Examples of auxiliary outputs  54 ,  55  are contact closure outputs, for example relay outputs, discrete voltage outputs, for example 5 VDC, and voltage and current signal outputs. The interface controller  15  can monitor the auxiliary inputs  52 ,  53  and take actions in response to the inputs. For example, the interface controller  15  could monitor a contact closure on a remote fan controller, indicating a fan running condition, and display this information on an interface device  11 - 14 . In a further example, the interface controller  15  could monitor an ambient temperature through a temperature sensor connected to one of the auxiliary inputs  52 ,  53  and call for a remote fan or fans to run, via one or more auxiliary outputs  54 ,  55 . In a still further example, a user could call for a remote device to run, for example, a fan, by inputting such a call at one of the interface devices  11 - 14 . The interface controller  15  would receive the call and assert the appropriate auxiliary output  54 ,  55  to run the fan. 
     Each of the electric heating elements  21 - 28  is separately connected to the power unit  31  so that its power output can be adjusted as required by the user interface controller  15 . As described above, switches on the power unit  31  control the power output to the heating elements  21 - 28 . The power unit  31  can vary the level of power provided to each heating element  21 - 28  by controlling output switches and varying the duty cycle, in terms of the percentage of the time that the heating element is permitted to draw electrical current, of a pulse-width modulated output. 
     The interface controller  15  can monitor the interface devices  11 - 14  for the heating element power setting, which would typically be input by the user as a magnitude setting, for example, heat setting 3 (of 10, of 15, of 20, of 25, etc.) or a specific temperature setting, for example 200° Fahrenheit. The interface controller  15  outputs a heating element power level to the power unit  31  based on the heating element power setting. For example, a heating element power setting of 3 could correspond to a heating element power level of 30% duty cycle. In an alternative embodiment, the interface controller  15  outputs the heating element power setting directly to the power unit  31 , which converts the heating element power setting to the heating element power level. 
     Multiple heating profiles may be programmed into the interface controller  15 , or, alternatively, into the power unit  31 , which allow a heating element power setting to correspond to multiple heating element power levels. For example, in a low temperature operation, such as a “simmer mode,” all of the available heating element power settings could correspond to low duty cycle heating element power levels (for example, less than 50% duty cycle). In a high temperature operation, all of the available heating element power settings could correspond to high duty cycle heating element power levels (for example, greater than 50% duty cycle). It is to be appreciated that various other profiles could be provided, including specialty settings such as wok or grilling settings. Multiple heating profiles could thus be provided. The heating profile selection can be based upon a user input at an interface device  11 - 14 , upon the state of an auxiliary input  52 ,  53 , or upon a programmed control algorithm. Also, it is to be appreciated that because of the ability to program, various additional aspects can be controlled or provided, such as star-K compliance (e.g., delay start time), demo mode (e.g., operation without actual heating of the elements), cook-top lock-out (e.g., maintenance of non-heating of the elements), etc. 
     Each of following tables provides an example of a unique heating profile. Ten heating element power settings and corresponding power levels are provided in each example heating profile. It will be understood that the current invention is not limited to heating profiles including ten heating element power settings and corresponding power levels, and that the scope of the invention includes heating profiles including fewer and greater than ten heating element power settings and levels. Similarly, the current invention is not limited four heating profiles, and that the scope of the invention includes greater and less than four heating profiles. From the example heating profiles below, it will be apparent that the relationship between heating element power settings and corresponding power levels can be either linear or non-linear. 
     
       
         
           
               
             
               
                 TABLE 1 
               
             
            
               
                   
               
               
                 Example Heating Profile No. 1 
               
            
           
           
               
               
               
            
               
                   
                 Power Setting 
                 Power Level (Duty Cycle %) 
               
               
                   
                   
               
            
           
           
               
               
               
            
               
                   
                 1 
                 10 
               
               
                   
                 2 
                 20 
               
               
                   
                 3 
                 30 
               
               
                   
                 4 
                 40 
               
               
                   
                 5 
                 50 
               
               
                   
                 6 
                 60 
               
               
                   
                 7 
                 70 
               
               
                   
                 8 
                 80 
               
               
                   
                 9 
                 90 
               
               
                   
                 10 
                 100 
               
               
                   
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 2 
               
             
            
               
                   
               
               
                 Example Heating Profile No. 2 
               
            
           
           
               
               
               
            
               
                   
                 Power Setting 
                 Power Level (Duty Cycle %) 
               
               
                   
                   
               
            
           
           
               
               
               
            
               
                   
                 1 
                 4 
               
               
                   
                 2 
                 8 
               
               
                   
                 3 
                 12 
               
               
                   
                 4 
                 16 
               
               
                   
                 5 
                 20 
               
               
                   
                 6 
                 24 
               
               
                   
                 7 
                 28 
               
               
                   
                 8 
                 32 
               
               
                   
                 9 
                 36 
               
               
                   
                 10 
                 40 
               
               
                   
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 3 
               
             
            
               
                   
               
               
                 Example Heating Profile No. 3 
               
            
           
           
               
               
               
            
               
                   
                 Power Setting 
                 Power Level (Duty Cycle %) 
               
               
                   
                   
               
            
           
           
               
               
               
            
               
                   
                 1 
                 50 
               
               
                   
                 2 
                 51 
               
               
                   
                 3 
                 53 
               
               
                   
                 4 
                 55 
               
               
                   
                 5 
                 57 
               
               
                   
                 6 
                 62 
               
               
                   
                 7 
                 70 
               
               
                   
                 8 
                 80 
               
               
                   
                 9 
                 90 
               
               
                   
                 10 
                 100 
               
               
                   
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 4 
               
             
            
               
                   
               
               
                 Example Heating Profile No. 4 
               
            
           
           
               
               
               
            
               
                   
                 Power Setting 
                 Power Level (Duty Cycle %) 
               
               
                   
                   
               
            
           
           
               
               
               
            
               
                   
                 1 
                 2 
               
               
                   
                 2 
                 5 
               
               
                   
                 3 
                 9 
               
               
                   
                 4 
                 15 
               
               
                   
                 5 
                 25 
               
               
                   
                 6 
                 37 
               
               
                   
                 7 
                 50 
               
               
                   
                 8 
                 65 
               
               
                   
                 9 
                 80 
               
               
                   
                 10 
                 100 
               
               
                   
                   
               
            
           
         
       
     
     The power unit  31  monitors the temperature of the heating elements  21 - 28  via the temperature sensors  41 - 48 . This allows the interface controller  15  and/or power unit  31  to perform closed-loop or feedback temperature control of the heating elements, for example proportional-integral-derivative (PID) control. Multiple heating profiles may be programmed into the interface controller  15 , or, alternatively, into the power unit  31 , which allow the heating element power settings to correspond to multiple heating element power levels, wherein the power levels correspond to specific heating element temperatures, rather than duty cycle percentages as described above. 
     A method of controlling power to cooktop heating elements involving multiple heating profiles will now be described. Referring to  FIG. 2 , at step  71  heating element power settings are obtained. Heating element power settings are typically provided by the user at the interface devices  11 - 14 . However, heating element power settings could also be generated by the interface controller  15  itself according to a control algorithm, or by another controller, for example, an oven controller  51  or power unit  31 . 
     At step  72 , a heating profile setting is obtained. The heating profile setting can be based upon a user input at an interface device  11 - 14 , upon the state of an auxiliary input  52 ,  53 , or upon a programmed control algorithm. After the heating profile setting is obtained, as shown in step  73 , the corresponding heating profile is selected from the one or more programmed heating profiles. The power control system can be delivered to the user with multiple heating profiles pre-programmed and/or the heating profiles can be user-definable. 
     As shown in step  74 , the heating element power level that corresponds to the heating element power setting is selected from the chosen heating profile. The selected heating element power level is then outputted to the power unit  31  for control of the appropriate heating element or elements, as shown in step  75 . 
     The power control system can be provided on a cooking device including a range and an oven, wherein power distribution to the oven is controlled by the oven controller  51 . The oven controller can communicate with the interface controller  15  and/or power unit  31 , which allows for the coordinated control of oven heating elements and cooktop heating elements  21 - 28 . 
     It should be evident that this disclosure is by way of example and that various changes may be made by adding, modifying or eliminating details without departing from the fair scope of the teaching contained in this disclosure. For example, a different number of interface devices may be provided, a different number of heating devices may be provided, and/or a different number of elements per heater may be provided. The invention is therefore not limited to particular details of this disclosure except to the extent that the following claims are necessarily so limited.