Smart heater system

Abstract

A smart heating system is described that generally comprises at least one heater element, optionally, at least one temperature sensor, a set of predetermined or predictable performance information used to control the heating system; and, optionally, an electronic conditioning module (ECU) capable of storing and processing the performance information. The performance information may be stored as written text, a bar code, a data matrix, or a radio frequency identification (RFID) tag. The smart heating system heating system may further comprises a LIN or a CAN bus capable of providing a communication pathway between at least two of the system components.

What is claimed is: 
     
         1 . A smart heating system, the heating system comprising:
 at least one heater element;   a set of predetermined or predictable performance information used to control the heating system;   optionally, at least one temperature sensor; and   optionally, an electronic conditioning module (ECU) capable of storing and processing the performance information.   
     
     
         2 . The smart heating system according to  claim 1 , wherein the heating system further comprises at least one support bracket in contact with the at least one heater element and optionally with the at least one temperature sensor. 
     
     
         3 . The smart heating system according to  claim 1 , wherein the performance information includes heater information or a combination of heater and sensor information. 
     
     
         4 . The smart heating system according to  claim 1 , wherein the heating system further comprises a power switch that receives signals from the ECU or a switch control unit. 
     
     
         5 . The smart heating system according to  claim 4  wherein the performance information further includes switch information. 
     
     
         6 . The smart heating system according to  claim 5 , wherein the power switch is controlled by the switch control unit; the switch control unit using the switch information; optionally, the switch control unit being in communication with the ECU. 
     
     
         7 . The smart heating system according to  claim 3 , wherein the heater performance information includes a rate of heating at a desired voltage or under a specified flow condition, heater resistance, heater or sensor stability, temperature profile or distribution, flow uniformity or temperature conditions in a location adjacent to the heater element. 
     
     
         8 . The smart heating system according to  claim 5 , wherein the switch information includes a measurement of the current and/or voltage, as well as the rate of heating associated with the solid state components of the switch as a function of the amount of electrical current that is being switched. 
     
     
         9 . The smart heating system according to  claim 1 , wherein the heating system includes multiple heater elements and temperature sensors, the temperature sensors being a combination of individual sensors or a multiple junction sensor capable of providing more than one temperature measurement. 
     
     
         10 . The smart heating system according to  claim 1 , wherein the temperature sensor is selected as a thermocouple, a thermistor, or a resistance temperature device. 
     
     
         11 . The smart heating system according to  claim 1 , wherein the heater element is selected as a cable heater, a tubular heater, a cartridge heater, a flexible heater, a layered heater, a metal foil, or a metal fleece heater. 
     
     
         12 . The smart heating system according to  claim 1 , wherein the performance information is stored as written text, a bar code, a data matrix, a radio frequency identification (RFID) tag, or in memory of a conditioning module. 
     
     
         13 . The smart heating system according to  claim 1 , wherein the heating system further comprises a LIN or a CAN bus capable of providing a communication pathway between at least two system components. 
     
     
         14 . The smart heating system according to  claim 1 , wherein the heating system compensates for a thermal gradient present in a diesel oxidation catalyst (DOC), diesel particle filter (DPF), selectic catalytic reducer (SCR), lean NOx traps, or another exhaust component that includes an after-treatment catalyst. 
     
     
         15 . A diesel exhaust system that includes a smart heating system, the smart heating system comprising:
 at least one heater element;   a set of predetermined or predictable performance information used to control the heating system;   optionally, at least one temperature sensor; and   optionally, an electronic conditioning module (ECU) capable of storing and processing the performance information.   
     
     
         16 . The diesel exhaust system according to  claim 15 , wherein the smart heating system further comprises at least one support bracket in contact with the at least one heater element and optionally with the at least one temperature sensor. 
     
     
         17 . The diesel exhaust system according to  claim 15 , wherein the performance information includes heater information or a combination of heater and sensor information. 
     
     
         18 . The diesel exhaust system according to  claim 15 , wherein the smart heating system further comprises a power switch that receives signals from the ECU or a switch control unit. 
     
     
         19 . The diesel exhaust system according to  claim 18 , wherein the performance information further includes switch information. 
     
     
         20 . A method of providing thermal control in a predetermined application by compensating for a thermal gradient, the method comprising:
 providing a smart heating system constructed according to  claim 1 ; and   establishing thermal control by creating a desired temperature profile; the temperature profile being created by providing power to all or some of the heater elements in the smart heating system simultaneously or alternatingly.   
     
     
         21 . The method according to  claim 20 , wherein the power is applied to the heater elements in the smart heating system at either the same level or at different levels. 
     
     
         22 . The method according to  claim 20 , wherein establishing the thermal control uses a closed loop control mechanism or open loop control mechanism. 
     
     
         23 . An exhaust gas treatment system that comprises a smart heating system, the smart heating system providing an exhaust temperature that enhances performance of a diesel oxidation catalyst (DOC), diesel particle filter (DPF), selectic catalytic reducer (SCR), lean NOx traps, or another exhaust component that includes an after-treatment catalyst. 
     
     
         24 . The exhaust gas treatment system according to  claim 23 , wherein the smart heating system comprises:
 at least one heater element;   a set of predetermined or predictable performance information used to control the smart heating system;   optionally, at least one temperature sensor;   optionally, an electronic conditioning module (ECU) capable of storing and processing the performance information; and   optionally, a power switch that receives signals from the ECU or a switch control unit.   
     
     
         25 . The exhaust gas treatment system according to  claim 23 , wherein the predetermined or predictable performance information includes heater information or a combination of heater and sensor information, and, optionally, switch information. 
     
     
         26 . The exhaust gas treatment system according to  claim 25 , wherein the heater information, the combination of heater and sensor information, or the switch information is stored as written text, a bar code, a data matrix, a radio frequency identification (RFID) tag, or in memory of a conditioning module. 
     
     
         27 . An exhaust gas treatment system that provides for the heating of an exhaust component through the use of a smart heating system; the smart heating system comprising:
 one or more heater elements;   at least one temperature sensor;   a set of heater information or a combination of heater and sensor information used to control the smart heating system;   a power switch;   a switch control unit;   a set of switch information; and   optionally, an electronic conditioning module (ECU) capable of storing and processing the heater information or the combination of heater and sensor information;   wherein the switch control unit uses the switch information to control the power switch; optionally, the switch control unit is in communication with the ECU.   
     
     
         28 . The exhaust gas treatment system of  claim 27 , wherein the heater information, the combination of heater and sensor information, or switch information is stored as written text, a bar code, a data matrix, a radio frequency identification (RFID) tag, or in memory of a conditioning module. 
     
     
         29 . The exhaust gas treatment system of  claim 27 , wherein the smart heating system establishes thermal control by creating a desired temperature profile; the temperature profile being created by providing power to all or some of the heater elements in the smart heating system simultaneously or alternatingly.