Patent Document

RELATED APPLICATION 
       [0001]    This application is related to U.S. patent application Ser. No. 12/761,820 (Attorney Docket No. 315.8968USU) of Michael Andrew Theodos, Joshua Michael Cox, and Marie Antoinette Ketterman, which is assigned to the assignee of this application and is filed on the same date as this application. 
     
    
     FIELD OF THE DISCLOSURE 
       [0002]    This disclosure relates to a control system that controls the application of power to a plurality of loads in a food service system. In particular, the disclosure relates to a food holding cabinet system in which the loads are electrical heaters. 
       BACKGROUND OF THE DISCLOSURE 
       [0003]    Food holding cabinets are used to maintain optimal cooked food product temperatures until the food product is served. Individual trays are loaded into shelf like row assemblies within the cabinet with heating plates. Cooks within a restaurant typically cook food in small batches likely beyond the immediate need of the product. This excess food is placed in a tray within a holding cabinet shelf that is used to maintain the temperature of that food product until served. Various food products are typically cooked at different times (perhaps staggered in time). Thus, normal operational load is that of normal holding of already loaded food product as well as newly loaded food product creating additional periodic load. The wattage of the heaters is sized to properly maintain food quality and temperature. 
         [0004]    To better understand the problem, well over 100,000 holding cabinets exist in the field. Over time, the restaurants that use these holding cabinets have become densely populated with more equipment and at the same time, have increased their menu choices. Both of these drivers have created a need to provide more food storage within the existing holding cabinet space. Adding additional row assemblies or cabinet slots to existing holding cabinets increases the number of heaters. Pending the number of cabinet slots, it is possible that the plurality of heater demands could exceed the branch circuit limitations to the cabinet (for example, at morning cabinet start up and unusual high load times) thereby tripping the circuit breaker. 
         [0005]    Thus, there is a need for limiting total cabinet power consumption to electrical power distribution capabilities. 
       SUMMARY OF THE DISCLOSURE 
       [0006]    A control system of the present disclosure controls current flow in a plurality of loads of a food service system. The control system comprises a like plurality of switches and a controller. The controller operates the switches to connect the plurality of loads to a power source during a high demand time such that the total power consumption of the loads is limited to a rated power level or below of the power source at least during at least a portion of said high demand time. 
         [0007]    In another embodiment of the present disclosure, the controller controls on times of the switches at a duty cycle in which only X of the total number of the switches are turned on at the same time, where X is greater than two and wherein the duty cycle is less than 100 percent. 
         [0008]    In another embodiment of the present disclosure, the total number of switches is twelve, X is eight, and the duty cycle is 66.67%. 
         [0009]    In another embodiment of the present disclosure, the switches and the loads are connected in a feedback system, and wherein the on times are determined by feedback of at least one parameter of the loads. 
         [0010]    In another embodiment of the present disclosure, the on times are based on a difference between a current value of the parameter and a reference value of the parameter. 
         [0011]    In another embodiment of the present disclosure, the parameter is a temperature. 
         [0012]    In another embodiment of the present disclosure, the food service system is a food holding cabinet and the loads are heaters. 
         [0013]    In another embodiment of the present disclosure, the controller further comprises a processor that executes a heater multiplexing program and uses a heater mask to provide signals that operate the switches. 
         [0014]    In another embodiment of the present disclosure, if less than X heaters are requesting on time, the processor ignores the heater mask and operates the switches such that the duty cycle for each of the heaters is 100%. 
         [0015]    In another embodiment of the present disclosure, if the difference is within a range of a predetermined temperature and the reference temperature, the controller enters a tight regulation mode in which the switches are operated at the duty cycle of less than 100%. 
         [0016]    A method of the present disclosure controls current flow in a plurality of loads in a food service system. The method comprises: controlling a like plurality of switches to connect the plurality of loads to a power source during a high demand time such that the total power consumption of the loads is limited to a rated power level or below of the power source during at least a portion of said high demand time. 
         [0017]    In another embodiment of the method of the present disclosure, the controlling step controls on times of the switches at a duty cycle in which only X of the total number of the switches are turned on at the same time, where X is greater than two and wherein the duty cycle is less than 100 percent. 
         [0018]    In another embodiment of the method of the present disclosure, the total number of switches is twelve, X is eight, and the duty cycle is 66.67%. 
         [0019]    In another embodiment of the method of the present disclosure, the switches and the loads are connected in a feedback system, and wherein the on times are determined by feedback of at least one parameter of the loads. 
         [0020]    In another embodiment of the method of the present disclosure, the on times are based on a difference between a current value of the parameter and a reference value of the parameter. 
         [0021]    In another embodiment of the method of the present disclosure, the parameter is a temperature. 
         [0022]    In another embodiment of the method of the present disclosure, the food service system is a food holding cabinet and the loads are heaters. 
         [0023]    In another embodiment of the method of the present disclosure, the controlling step comprises a processor that executes a heater multiplexing program and uses a heater mask to provide signals that operate the switches. 
         [0024]    In another embodiment of the method of the present disclosure, if less than X heaters are requesting on time, the processor ignores the heater mask and operates the switches such that the duty cycle for each of the heaters is 100%. 
         [0025]    In another embodiment of the method of the present disclosure, if the difference is within a range of a predetermined temperature and the reference temperature, the controller enters a tight regulation mode in which the switches are operated at the duty cycle of less than 100%. 
         [0026]    In order to avoid excess load during peak demand loads, modulation of the individual heaters with thyristor based switches as well as unique modulation algorithms are used to time multiplex load to each shelf such that maximum power draw from the restaurant branch circuit is limited to rated levels. In addition, during periods of non-peak demand, full shelf power is available to maximize recovery due to heavy loading and maintain tighter control of the food product being stored. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0027]    Other and further objects, advantages and features of the present invention will be understood by reference to the following specification in conjunction with the accompanying drawings, in which like reference characters denote like elements of structure and: 
           [0028]      FIG. 1  is a front view of a food holding cabinet of the present disclosure; 
           [0029]      FIG. 2  is a front view of the food holding cabinet of  FIG. 1  with bezels and front panel removed; 
           [0030]      FIG. 3  is a perspective view of a row assembly of the food holding cabinet of  FIG. 1 ; 
           [0031]      FIG. 4  is a perspective view of the row assembly of  FIG. 3  with bezels removed; 
           [0032]      FIG. 5  is a cross-sectional view taken along line  5  of  FIG. 1 ; 
           [0033]      FIG. 6  is a front perspective view of a bezel of the food holding cabinet of  FIG. 1 ; 
           [0034]      FIG. 7  is a schematic diagram of the heater controller of the food holding cabinet of  FIG. 1 ; 
           [0035]      FIG. 8  is a block diagram of the computer of the heater controller of  FIG. 7 ; 
           [0036]      FIG. 9  is a flow diagram of the temperature measurement program of the computer of  FIG. 8 ; 
           [0037]      FIG. 10  is a flow diagram of the proportional integrator program of the computer of  FIG. 8 ; and 
           [0038]      FIG. 11  is a flow diagram of the heater service program of the computer of  FIG. 8 . 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0039]    It is contemplated that the heater control system of the present disclosure can be used in any food service equipment for distribution of power to multiple loads. However, by way of example and completeness of description, the heater control system will be described herein for a food holding cabinet. 
         [0040]    Referring to  FIGS. 1-4 , a food holding cabinet  70  of the present disclosure comprises a base  72 , a first outer side panel  74 , a second outer side panel  76  and an outer top panel  78 . A first inner side panel  80  and a second inner side panel  82  are spaced from first outer side panel  74  and second outer side panel  76  by gaps  88  and  90 , respectively (shown in  FIG. 2 ). Outer top panel  78  is spaced from an inner top panel  84  by a gap  86 . A user interface  92 , a time query button  64  and a temperature query button  65  are disposed on a front panel  94  (shown in  FIG. 1 ). 
         [0041]    Referring also to  FIG. 5 , a plurality of row assemblies  100 ,  102 ,  104 ,  106 ,  108  and  110  are supported by first inner side panel  80  and second inner side panel  82 . Each row assembly, e.g., row assembly  102 , comprises an upper heater assembly  111  and a lower heater assembly  113  (shown in  FIG. 5 ). Upper heater assembly  111  and lower heater assembly  113  each comprises an upper heater plate  112  and a lower heater plate  114 , respectively. Upper heater plate  112  and lower heater plate  114  are supported by a pair of spacer side rails  116  and  118  (shown in  FIGS. 3 and 4 ). 
         [0042]    Spacer side rails  116  and  118  are attached to upper heater plate  112  by any suitable fastener, for example set screws  302  (shown in  FIG. 3 ) and to lower heater plate  114  by similar set screws (not shown). Spacer side rails  116  and  118  are also attached to first and second inner side panels  80  and  82  by screws (not shown) in top and bottom of spacer side rails  116  and  118 . Spacer side rails  116  and  118  each include an upper slot  120  and a lower slot  122  that extend from front to back. Opposite side edges of upper heating plate  112  fit into upper slots  120  of spacer side rails  116  and  118  (shown in  FIG. 6 ). Opposite side edges of lower heating plate  114  fit into lower slots  122  of spacer side rails  116  and  118  (shown in  FIG. 4 ). As shown in  FIG. 2 , inner top panel  84  is spaced by a gap  96  from a panel  95 , which is spaced by a gap  98  from top heater in row  100 . 
         [0043]    Upper heater assembly  111  further comprises, e.g., a vulcanized heater  124 , although other types of heaters may be used. Vulcanized heater  124 , for example, may be obtained from Watlow Company. Heater  124  is disposed on the upper surface of heater plate  112  and carries a temperature sensor  126 . Temperature sensor  126  may be any suitable temperature sensor and, preferably, may be a Resistor Temperature Device (RTD), also available from Watlow Company. 
         [0044]    Lower heater assembly  113  further comprises a similar vulcanized heater (not shown) that is disposed on the lower surface of lower heater plate  114  and that carries a temperature sensor (not shown). Upper and lower slots  120  and  122  are spaced to provide a gap or cavity  128  to permit the insertion of a food tray. Upper and lower heater plates  112  and  114  may be any suitable material that transfers heat from the vulcanized heaters  124  to cavity  128 . For example, upper and lower heater plates  112  and  114  may be formed of a metal, for example, aluminum, stainless steel, or other metals. 
         [0045]    A thermal insulation layer  130  is wrapped around row assembly  102  and spacer side rails  116  and  118 . Insulation layer  130  lowers any heat transfer from upper heater plate  112  of row assembly  102  to row assembly  100  and from lower heater plate  114  of row assembly  102  to row assembly  104 . A similar insulation layer  130  of row assemblies  100  and  104  further limits heat transfer from adjacent row assemblies  100  and  104  to row assembly  102 . Row assemblies  106 ,  108  and  110  are similarly wrapped with an insulation layer  130  to limit heat transfer to and from adjacent row assemblies. 
         [0046]    Referring to  FIGS. 1 ,  3 ,  5  and  6 , a bezel  132  and a bezel  133  are provided for each row assembly. Bezel  132  for row assembly  102  covers a front edge of upper heater plate  112  of row assembly  102  and a front edge of lower heater plate  114  of row assembly  100  as shown in  FIG. 5 . Bezel  132  for row assembly  104  covers a front edge of upper heater plate  112  of row assembly  104  and a front edge of lower heater plate  114  of row assembly  102  and so on for row assemblies  106 ,  108  and  110 . Bezel  132  for row assembly  100  covers only a front edge of the upper heater assembly  112  of row assembly  100  as row assembly  100  is the topmost row assembly. Bezel  133  covers a back edge of upper heater plate  112  of row assembly  102  and, though not shown in the drawing, covers a front edge of lower heater plate  114  of row assembly  100 . Bezel  133  is otherwise identical to bezel  132 . A bezel  133  is similarly provided for each of the other row assemblies. Bezels  132  and  133  are attached to inner side panels  80  and  82  and to the row assemblies by a suitable fastener (not shown). 
         [0047]    Referring to  FIGS. 5 and 6 , bezel  132  comprises an elongated C-shaped body that has a display face  134  (shown in  FIG. 6 ) and a pair of legs  136  and  138 . Legs  136  and  138  have one or more portions or hooks  140  at their respective terminal ends. Legs  136  and  138  and hooks  140  are dimensioned so that hooks  140  fit snugly into mating portions or slots  142  of lower heater plate  114  of row assembly  100  and upper heater plate  112  of row assembly  102  with a snap-in action. This provides an interlock that minimizes unsealed interfaces or provides a seal to heater plates  112  and  114 , thereby mitigating oil and/or grease migration. 
         [0048]    Referring to  FIGS. 3 and 6 , display face  134  comprises displays  144 ,  146  and  148  and buttons  150 ,  152  and  154 . Displays  144 ,  146  and  148  display information concerning food items placed in corresponding locations on lower heating plate  114  of a corresponding row assembly. Buttons  150 ,  152  and  154  are manually operable to activate and deactivate timers that control food hold times. Buttons  150 ,  152  and  154  also play a role in manual programming. 
         [0049]    Bezel  132  also comprises side legs  164 . Each side leg  164  includes an open portion  166  and a notch  168 . Bezel  132  also provides a duct  160  for cooling air to flow and cool a component, for example, components disposed on a display control board  162  (shown in  FIG. 5 ) for displays  144 ,  146  and  148 . 
         [0050]    Bezels  132  and  133  are formed of a suitable material, for example, plastic or metal. Preferably, bezels  132  and  133  are composed of a plastic part and a molded in graphic overlay, which has a thermal conductivity lower than metal, although metallic bezels may be used in some embodiments. Buttons  150 ,  152  and  154  are attached to bezel  132  or  133  by any suitable fasteners, but are preferably heat staked in plastic bezels  132  and  133 . 
         [0051]    Referring to  FIGS. 1 and 7 , an electrical cord  71  connects heater controller  202  to an outlet plug  73  that provides alternating current (AC) power from an AC source  206  via an ON/OFF switch  75  to a power module (not shown) that distributes operating power to various electrically operated components of food holding cabinet  70  that require AC power. The power module includes an AC to DC (direct current) converter (not shown) to provide DC power to those components that require DC operating power. Pending the number of cabinet cavities, it is possible that the plurality of heater demands could exceed the branch circuit limitations to the cabinet (for example, at morning cabinet start up and other unusually high load times), thus tripping a circuit breaker, which, for example, is located in AC source  206 . AC source  206  also includes connections to the AC power grid to receive a suitable AC power, for example, 220 volts. AC source  206  is also connected to a circuit reference, shown as circuit ground  208 . 
         [0052]    Referring to  FIG. 7 , upper heater controller  202  controls the application of AC power to the upper and lower heaters  124  of row assemblies  100 ,  102  and  104 . Lower heater controller  204  controls the application of AC power to the upper and lower heaters  124  of row assemblies  106 ,  108  and  110 . Upper heater controller  202  and lower controller  204  in all other respects are identical so that only upper heater controller  202  will be described in detail. 
         [0053]    Upper heater controller  202  comprises a plurality of switches  210  and a plurality of heater assemblies  212 . Heater assemblies  212  includes heaters  124  and temperature sensors  126  of row assemblies  100 ,  102  and  104 . In  FIG. 7 , the upper heaters of row assemblies  100 ,  102  and  104  are denoted by reference characters  124 T 1 ,  124 T 2  and  124 T 3 , respectively. The lower heaters of row assemblies  100 ,  102  and  104  are denoted by reference characters  124 B 1 ,  124 B 2  and  124 B 3 , respectively. In  FIG. 7 , upper temperature sensors  126  of row assemblies  100 ,  102  and  104  are denoted as  126 T 1 ,  126 T 2  and  126 T 3 , respectively. Lower temperature sensors  126  of row assemblies  100 ,  102  and  104  are denoted as  126 B 1 ,  126 B 2  and  126 B 3 , respectively. 
         [0054]    Switches  210  include switches  210 T 1 ,  210 B 1 ,  210 T 2 ,  210 B 2 ,  210 T 3  and  210 B 3  that are connected in circuit with heaters  124 T 1 ,  124 B 1 ,  124 T 2 ,  124 B 2 ,  124 T 3  and  124 B 3 , respectively. Switches  210 T 1 ,  210 B 1 ,  210 T 2 ,  210 B 2 ,  210 T 3  and  210 B 3  may be any suitable switches that can handle the power used by cabinet  70 . Preferably, switches  210  are thyristors that include three leads. For example, switch  210 B 3  comprises leads  214 ,  216  and  218 . Lead  218  is a control lead that when activated by a signal B 3  turns switch  210 B 3  on so that electrical current flows between leads  214  and  216 . That is, with ON/OFF switch  75  in the ON position and thyristor  210 B 3  turned on by signal B 3 , AC source  206  is connected in circuit with heater  124 B 3 . Similarly, signals T 1 , B 1 , T 2 , B 2  and T 3  turn on switches  210 T 1 ,  210 B 1 ,  210 T 2 ,  210 B 2  and  210 T 3 , respectively, to connect respective heaters  124 T 1 ,  124 B 1 ,  124 T 2 ,  124 B 2  and  124 T 3  in circuit with AC source  206 . 
         [0055]    Temperature sensors  126 T 1 ,  126 B 1 ,  126 T 2 ,  126 B 2 ,  126 T 3  and  126 B 3  are connected in a circuit that provides currents ST 1 , SB 1 , ST 2 , SB 2 , ST 3  and SB 3  that vary with the temperature of respective heaters  124 T 1 ,  124 B 1 ,  124 T 2 ,  124 B 2 ,  124 T 3  and  124 B 3 . This current flow is derived from the AC power supplied by AC source  206 . For example, the current flow may suitably be DC current derived from an AC to DC converter (not shown). 
         [0056]    The two leads of each temperature sensor  126 T 1 ,  126 B 1 ,  126 T 2 ,  126 B 2 ,  126 T 3  and  126 B 3  are also connected as inputs to an Analog to Digital (ND) converter  220 . ND converter  220  provides output signals that are proportional to the current temperatures of the respective heaters  124 T 1 ,  124 B 1 ,  124 T 2 ,  124 B 2 ,  124 T 3  and  124 B 3  based on currents ST 1 , SB 1 , ST 2 , SB 2 , ST 3  and SB 3 ) to a computer  230 . Computer  230  uses the current temperatures to determine an error or deviation from a set point temperature of each of the respective heaters  124 T 1 ,  124 B 1 ,  124 T 2 ,  124 B 2 ,  124 T 3  and  124 B 3 . Computer  230 , based on the errors, provides signals T 1 , B 1 , T 2 , B 2 , T 3  and B 3  to operate switches  210  to apply power as needed to restore the temperatures of the respective heaters  124 T 1 ,  124 B 1 ,  124 T 2 ,  124 B 2 ,  124 T 3  and  124 B 3  to the set point temperatures. That is, temperature sensors  126 T 1 ,  126 B 1 ,  126 T 2 ,  126 B 2 ,  126 T 3  and  126 B 3 , A/D converter  220 , computer  230  and switches  210 T 1 ,  210 B 1 ,  210 T 2 ,  210 B 2  and  210 T 3  are in a feedback loop to bring heaters  124 T 1 ,  124 B 1 ,  124 T 2 ,  124 B 2 ,  124 T 3  and  124 B 3  to the predetermined temperatures and to maintain them there as they drift due to heater off time, loading changes, voltage changes at AC source  206 , and the like. 
         [0057]    Referring to  FIG. 8 , computer  230  comprises a processor  232 , an Input/Output (I/O) unit  234  and a memory  236  that are interconnected via a bus  238 . Memory  236  comprises a heater time multiplexing program  239  that includes a temperature measurement program  240 , a proportional integrator program  260  and a heat service program  280 . Memory  236  also comprises a heater mask  228  that is used as a tool to time multiplex the heater on times. Memory  236  further comprises other programs (not shown), such as an operating system, utility programs, maintenance programs, and the like. 
         [0058]    I/O unit  234  interfaces with input and output devices. For example, the outputs of ND converter  220  are inputs to I/O unit  234  and the output signals T 1 , B 1 , T 2 , B 2 , T 3  and B 3  are output signals that issue from I/O unit  234  to switches  210 . 
         [0059]    Processor  232  executes heater time multiplexing program  239 . For example, processor  232  runs temperature measurement program  240  to provide temperature enable pulses at a temperature sampling rate or frequency via bus  238  and I/O unit  234  to A/D converter  220 . A/D converter  220  responds to the temperature enable pulses to provide digital values that correspond to the current temperatures of heaters  124 T 1 ,  124 B 1 ,  124 T 2 ,  124 B 2 ,  124 T 3  and  124 B 3 . These digital values are received by I/O unit  220  and supplied via bus  238  to processor  232  for use by temperature measurement program  240 . Measurement program  240 , when executed by processor  232  processes the digital measurement values to provide corresponding current temperature values for use by proportional integrator program  260 . Proportional integrator program  260  calculates requested heater on times for the heaters based on the current digital temperature values. Heater service program  280  uses the calculated heater on times and heater mask  228  to time multiplex the AC power to the heaters. 
         [0060]    Due to the multiplicity of loads (the 12 heaters of food holding cabinet  70 ), the likelihood is high that the power draw from AC source  206  will exceed the rating of a typical 220 volts branch circuit of the power grid and trip a breaker during high peak demands, such as during start up of food holding cabinet  70 . Heater controller  200  avoids excessive load during these peak demand times by modulating or time multiplexing the on and off times of the individual heaters to supply AC power to each heater such that maximum power draw from the restaurant branch circuit is limited to rated levels or below at any time. 
         [0061]    At the time of turning ON/OFF switch  75  on, processor  232  executes a program (not shown) that executes typical power up routines. When the power up routines have been completed, processor  232  begins execution of heater service program  240 , temperature measurement program  260  and proportional integrator program  270 . 
         [0062]    Referring to  FIG. 9 , temperature measurement program  240  at box  242  causes processor  232  to take a multi-point average of each RTD. That is, each RTD current is sampled at a plurality of time points to obtain a plurality of current values or temperature points during a sample period. The temperature points are averaged to yield an averaged multipoint value for each RTD. At box  244 , the averaged multipoint values are checked for a probe error that may be open or a short, i.e., a failed probe. If a probe error is found, an error message is posted. 
         [0063]    At box  246 , the multipoint averaged RTD current values are stored. At box  248 , after a plurality of sample periods (shown, e.g., as four) of the RTD multipoint averages of the sample periods are averaged and converted to temperature values. At box  250 , the temperature values yielded by box  248  are modified based on addition or subtraction of temperature off set values (due to factory calibration of the RTDs) to calibrate the current temperature values. At box  252 , the calibrated temperature values are stored to memory  236 . 
         [0064]    Referring to  FIG. 10 , proportional integrator program  260  at box  262  obtains the temperature values stored in memory  236  (see box  252  in  FIG. 9 ). At box  264  the error for each heater is calculated by algebraically summing the set point temperature and the associated current temperature value. At box  266  if the error of a heater is greater than a reference difference, the requested heater on time is set based on a maximum duty cycle, which is a predetermined duty cycle M that is less than 100%. At box  268 , if the error is less than the reference difference and all heaters have reached set point, the heater on time is calculated using the calculated error multiplied by a proportional gain term and a historical integrator term of N milliseconds. At box  270  the calculated heater on times are stored to memory  236 . 
         [0065]    Referring to  FIG. 11 , heater service program  280  at box  282  obtains the current requested on times and error probes (see box  270  of  FIG. 10  and box  246  of  FIG. 9 ). At box  283  heater service program  280  determines the number of heaters with a non-zero requested on time, the number of heaters with a probe error and the number of heaters that have reached set point temperature. At box  284 , heater service program  280  determines whether all heaters (other than those with an probe error) have reached their respective set point temperatures. If not, heater service program  280  at box  286  determines if X or more heaters (other than those with a probe error) of a maximum or total of Y heaters have requested on time. If so, heater service program  280  at box  288  multiplexes the heater on times (other than those with a probe error) with heater mask  228  at the duty cycle M, which yields an on time pattern of the heaters in which X of the heaters are not all on at any one time. Due to the power rating of AC source  206 , if more than X of the heaters are on at the same time, the breaker is likely to trip. 
         [0066]    If the determination of box  286  is that less than X heaters have requested on time at box  290  heater service program  280  ignores heater mask  228  and uses full on for each on time request (other than those with a probe error). That is, each of the heaters is operated at a 100% duty cycle with no off time. If the determination of box  284  is that all the heaters (other than those with a probe error), have reached set point temperature, heater service program at box  292  enters a tight regulation mode in which all heaters that are requesting on time have an error within the reference difference. The heaters that are not requesting on time are turned off, i., e., their respective switch  210  is turned off. 
         [0067]    The activities represented by boxes  284 ,  286 ,  288  and  290  constitute a loose regulation or high peak demand mode in which the on times of the heaters are time multiplexed so that only X of the total of Y heaters are on at the same time. For the illustrated embodiment, X=4 and Y=6 for each heater controller  202  and  204 . The duty cycle is two thirds or 66.67%. The period of each duty cycle for this embodiment is 300 milliseconds (ms), for which each heater is on for 200 ms and off for 100 ms. Temperature samples are taken every 200 microseconds (μs). 
         [0068]    Heater mask  228  is a tool that is used by heater service program  280  to limit the heaters serviced by each heater controller  202  and  204  to four out of six heaters being on at any time any one time in either the tight regulation mode or the loose regulation mode, except when the heater mask is ignored as at box  290  ( FIG. 11 ) in the loose regulation mode. Heater mask  228  comprises a bit position for each heater that it is used to control. If the bit value is “1”, the associated heater is on. If the bit value is “0”, the associated heater is off. The bit values are changed periodically to impart the 66.67% duty cycle for each heater. For the illustrated embodiment, this rate is once every 50 ms. At each change point, two of the bit values change. The Table below shows the bit values of heater mask for six 50 ms intervals (i.e., one 300 ms period) for heaters  124 HT 1 ,  124 B 1 ,  124 HT 2 , HB 2 ,  124 HT 3  and  124 B 3 . 
         [0000]    
       
         
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
             
           
               
                 TABLE 
               
               
                   
               
               
                   
                 124HT1 
                 124HB1 
                 124HT2 
                 124HB2 
                 124HT3 
                 124HB3 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 0 
                 0 
                 1 
                 1 
                 1 
                 1 
               
               
                   
                 0 
                 1 
                 1 
                 1 
                 1 
                 0 
               
               
                   
                 1 
                 1 
                 1 
                 1 
                 0 
                 0 
               
               
                   
                 1 
                 1 
                 1 
                 0 
                 0 
                 1 
               
               
                   
                 1 
                 1 
                 0 
                 0 
                 1 
                 1 
               
               
                   
                 1 
                 0 
                 0 
                 1 
                 1 
                 1 
               
               
                   
               
             
          
         
       
     
         [0069]    The bit values of the first row show that heaters  124 HT 1  and  124 HB 1  are off and heaters  124 HT 2 ,  124 HB 2 ,  124 HT 3  and  124 HB 3  are on for this 50 ms interval. To achieve this, computer  230  uses heat mask  228  to provide signals T 1  and B 1  to maintain switches  210 T 1  and  210 B 1  off so that no AC current is provided to heaters  124 T 1  and  124 B 1  and to provide signals T 2 , B 2 , T 3  and B 3  to maintain switches  210 T 2 ,  210 B 2 ,  210 T 3  and  210 B 3  on so that AC current flows through heaters  124 T 2 ,  124 B 2 ,  124 T 3  and  124 B 3 . At the end of this 50 ms interval, processor  232  changes heat mask  228  to the bit pattern shown in the second row of the Table, which causes signals T 1  and B 3  to maintain switches  210 T 1  and  210 B 3  off so that no AC current is provided to heaters  124 T 1  and  124 B 3  and to provide signals B 1 , T 2 , B 2  and T 3  to maintain switches  210 B 1 ,  210 T 2 ,  210 B 2  and  210 T 3  on so that AC current flows through heaters  124 B 1 ,  124 T 2 ,  124 B 2  and  124 T 3 . The processor continues to change heater mask  228  for each of the remaining rows and then starts another cycle with the first row and so on. 
         [0070]    In the illustrated embodiment, step  242  of temperature measurement program  240  is repeated at a rate of four times a second with 8 sample points being taken each time for a total of 32 sample points per second. 
         [0071]    The heater controller of the present disclosure controls power to the heating elements and unique power time multiplexing under peak demand to ensure total power remains well within the branch supply circuit limitations in these restaurants. In a similar fashion, heavy loads (such as an electric fryer) can utilize a similar method to reduce peak demand within a store. 
         [0072]    It is contemplated that the heater controller described above can employ alternate time based methods (time base changes, sample periods, and so on). The basic restricting the absolute number of heaters on at the same time to limit power to the overall cabinet is disclosed in this disclosure. Other possible embodiments include but are not limited to: 
         [0000]    1. Leaving four rows (8 heaters) on full until set point to allow the customer to begin holding food in those positions earlier. The remaining four heaters would get some heating from convection and conduction generated by powered plates to give them a head start. The remaining two rows (4 heaters) would immediately follow without allowing the first eight to fall too far out of set point.
 
2. Since most of the energy for holding comes from the bottom plate, all six bottom plates in addition to two upper plates could be powered. The remaining four heaters would come on once the first eight reached their set point.
 
3. In combination with #1, staggering rows to be heated to set point would allow other rows in between to attain some energy from convection and conduction through the cabinet.
 
4. Wattage could be adjusted on the heater plates to allow more or less heaters to be on at any given time.
 
         [0073]    The present invention having been thus described with particular reference to the preferred forms thereof, it will be obvious that various changes and modifications may be made therein without departing from the spirit and scope of the present invention as defined in the appended claims.

Technology Category: 5