APPARATUS AND METHOD FOR CONTROLLING ELECTRIC BURNER ELEMENT INPUT

Abstract

An apparatus and method for restricting the rotation of a dial control knob on the high setting of an electric cooking range using one of three methods. The first method adds a detent stop internally to the switch. The second method adds a detent stop externally attaching to the control panel behind the top burner knob. Both of the aforementioned methods are designed to prevent rotation of the control knob to a maximum of 227 rotation. A third limits the on/off cycling of the top element switch while in operation to reduce the overall output of the switch.

Claims

1. A current limiting device for an electric cooking range comprising: a mechanical stop detent member extending from a mounting bracket where the mounting bracket has a central through hole; a rotary switch having a shaft mounted to control the rotational position of the rotary switch and said shaft extends from said rotary switch and through the central through hole of the mounting bracket; and a control knob having a rear cavity and a shaft collar extending from the rear cavity and mounted on said shaft and further having a knob stop plate pin extending from the cavity and said stop plate pin positioned to engage the mechanical stop detent when the control knob rotates the shaft and rotary switch to its maximum setting.

2. The current limiting device as recited in claim 1, where the maximum setting of the rotary switch is rotated about approximately 227 degrees from an off position.

3. A current limiting device for an electric cooking range comprising: a rotary switch having a shaft mounted to control the rotational position of the rotary switch and said shaft extends from said rotary switch; and a detent mounted on the rotary switch and position to engage and stop rotation of the shaft and the rotary switch at its maximum setting.

4. The current limiting device as recited in claim 3, where the maximum setting of the rotary switch is about approximately 227 degrees from an off position.

5. The current limiting device as recited in claim 3, further comprising: a control knob having a rear cavity and a shaft collar extending from the rear cavity and mounted on said shaft.

6. A current limiting device for an electric cooking range comprising: a limitless rotary switch having a shaft mounted to control the rotational position of the limitless rotary switch, where the rotation of the shaft varies the flow of current through a circuit to a load element, where the rotary switch cycles current flow through the circuit on and off at a frequency which depends upon the rotational position of the shaft; and a cam attached to the shaft where rotation of the shaft effects rotation of the cam where the cam is configured to vary the circuit operation to thereby vary the on and off cycle of the current flow such that the frequency of the on and off cycle doesn't allow the load element to exceed a specified temperature.

7. The current limiting device as recited in claim 6, whereby the cam applies a varying pressure against a heated bi-metal where when the heated bi-metal gets enough current flowing heats up and the bi-metal becomes more flexible thereby bending under varying pressure of the rotating cam to thereby break a contact in the limitless switch thereby causing an on and off cycles of the switch based on the varying pressure of the cam.

8. The currently limiting device as recited in claim 7, where the cam configuration is designed to apply the desired varying pressure to cycle the switch off at the desired point in order to achieve an about approximately 50% on and 50% off result.

9. A method to current limit an electric cooking range comprising: rotating a control knob having a rear cavity and a shaft collar extending from the rear cavity and mounted on a shaft extending from a rotary switch and where said control knob further having a knob stop plate pin extending from the cavity and said stop plate pin is positioned to engage a mechanical stop detent when the control knob rotates the shaft and the rotary switch to its maximum setting; rotating the shaft mounted to the rotary switch with the control knob thereby controlling the rotational position of the rotary switch; and controlling a current applied to a top burner element of an electric cooking range by rotating the control knob to thereby rotate the stop plate pin to engage a mechanical stop detent.

10. A method to current limit an electric cooking range comprising: rotating a control knob having a rear cavity and a shaft collar extending from the rear cavity and mounted on a shaft extending from a rotary switch; rotating the shaft mounted to the rotary switch with the control knob thereby controlling the rotational position of the rotary switch; and controlling a current applied to a top burner element of an electric cooking range by rotating the control knob to thereby rotate the shaft to engage a mechanical stop detent of the rotary switch when the rotary switch is at its maximum setting.

11. A method to current limit an electric cooking range comprising: rotating a limitless rotary switch having a shaft mounted to control the rotational position of the limitless rotary switch, where the rotation of the shaft varies the flow of current through a circuit to a load element, where the rotary switch cycles current flow through the circuit on and off at a frequency which depends upon the rotational position of the shaft; and rotating a cam attached to the shaft where rotation of the shaft effects rotation of the cam where the cam is configured to vary the circuit operation to thereby vary the on and off cycle of the current flow such that the frequency of the on and off cycle doesn't allow the load element to exceed a specified temperature.

12. The method to current limit as recited in claim 11, whereby rotating the cam applies a varying pressure against a heated bi-metal where when the heated bi-metal gets enough current flowing heats up and the bi-metal becomes more flexible thereby bending under varying pressure of the rotating cam to thereby break a contact in the limitless switch thereby causing an on and off cycles of the switch based on the varying pressure of the cam.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] For a better understanding of the present technology as disclosed, reference may be made to the accompanying drawings in which:

[0017] FIG. 1 is an illustration of a control knob rotated to the off position;

[0018] FIG. 2 is an illustration of a mechanical stop detent;

[0019] FIG. 3 is an illustration of a control knob set to High and rotated approximately 227 degrees from the Off position;

[0020] FIG. 4 is a perspective view of a mechanical stop detent;

[0021] FIG. 5 is a top plan view of a mechanical stop detent;

[0022] FIG. 6 is an illustration of a dimensional implementation of a mechanical stop detent;

[0023] FIG. 7 is a perspective view of a control knob;

[0024] FIG. 8A is a plan elevation view of the control panel and a shaft;

[0025] FIG. 8B is a sectional view of a control knob;

[0026] FIG. 8C is a sectional view of the control knob;

[0027] FIG. 8D is an end view of a shaft;

[0028] FIG. 9 illustrates an infinite rotary switch with a built in detent stop;

[0029] FIGS. 10A and 10B are isometric views of a switch assembly;

[0030] FIG. 10C is an illustration of a switching diagram;

[0031] FIG. 11 is a an illustration of a wiring diagram and element schematic; and

[0032] FIG. 12 is an illustration of an output graph;

[0033] FIG. 13 is a perspective view of one implementation of the cam design;

[0034] FIG. 14 is a front view of one implementation of the cam design; and

[0035] FIG. 15 is a rear view of one implementation of the design.

[0036] While the technology as disclosed is susceptible to various modifications and alternative forms, specific implementations thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description presented herein are not intended to limit the disclosure to the particular implementations as disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present technology as disclosed and as defined by the appended claims.

DESCRIPTION

[0037] According to the implementation(s) of the present technology as disclosed, various views are illustrated in FIG. 1-15 and like reference numerals are being used consistently throughout to refer to like and corresponding parts of the technology for all of the various views and figures of the drawing. Also, please note that the first digit(s) of the reference number for a given item or part of the technology should correspond to the Fig. number in which the item or part is first identified.

[0038] One implementation of the present technology as disclosed comprising a mechanical detent teaches a novel apparatus and method for limiting current input to a top burner element of an electric cooking range.

[0039] The details of the technology as disclosed and various implementations can be better understood by referring to the figures of the drawing. Referring to FIG. 1, an illustration of a control knob rotated to the off position is provided. A stop detent, not shown in this illustration, can be provided as a stop for both the OFF and HI ends of the rotational range.

[0040] Referring to FIG. 2, an illustration of a mechanical stop detent is provided that is mounted to the control panel of an electric cooking range. The arrow on the control panel above the control knob is positioned to align with the indicia (OFF, LO, HI and numbers and tic marks) along the periphery of the control knob indicative of the current level setting of the rotational switch, thereby indicative of the level of current being provided to the top burner elements and the cooking temperature of the elements.

[0041] Referring to FIG. 3, an illustration of a control knob set to High and rotated approximately 227 degrees from the Off position is provided. A stop detent, not shown in this illustration, can be provided as a stop for both the OFF and HI ends of the rotational range. The arrow on the control panel above the control knob is aligned with the HI indicia along the periphery of the control knob indicative of the current level setting of the rotational switch set to HI, thereby indicative of the highest level of current being provided to the top burner elements and the cooking temperature is at its highest setting for the elements.

[0042] Referring to FIG. 4, a perspective view of a mechanical stop detent 400 is provided. The stop detent 402 is positioned to engage the knob stop plate pin when the rotational switch is rotated to a highest level. The mechanical stop detent 400 also has a central through hole 404 through which a rotational shaft from a rotational switch can extend.

[0043] Referring to FIG. 5, an illustration of a top plan view of a mechanical stop detent 400 is provided. The OFF detent 502 and the HI detent 402 are shown. The range of rotation 504, is illustrated as approximately 227 degrees of rotation. The mechanical stop detent 400 has a mounting through hole 508 for mounting the mechanical stop detent 400 to a control panel of an electric range with a fastener 510. The mechanical stop detent 400 is shown with a central through hole 404. An end of a shaft 506 is shown extending through the through hole 404 of the mechanical stop detent 400. FIG. 6 is an illustration of a dimensional implementation of a mechanical stop detent illustrating representative dimensions, however, these dimensions are only representative of one set of dimensions, but is in no way intended to narrow the scope of the technology as claimed to these specific dimensions.

[0044] Referring to FIG. 7, a perspective view of a control knob 700 is illustrated. One implementation of the control knob 700 is illustrated having a backward facing cavity whose opening would face the control panel when the knob is installed. The control knob 700 includes a knob stop plate pin 706 extending in the cavity and an elongated shaft collar 702 extending in the cavity where the collar 702 has a central channel 704 for receiving a shaft of a rotational switch.

[0045] FIG. 8A is a plan elevation view of the control panel and a shaft extending from the rotary switch. The various levels of rotation are illustrated by an alphanumeric such as OFF, LO and HI as well as graduated tic marks indicative of the level of rotation and hence the level of current flow and level of temperature. FIG. 8D is an end view of a shaft.

[0046] FIG. 8B is a sectional view of a control knob 700, which also illustrates the elongated collar 702 having a central channel 704 for receiving the shaft 506. The control knob stop plate pin is designed to engage the detent. FIG. 8C is a sectional view of the control knob.

[0047] Referring to FIG. 9, an infinite rotary switch 900 with a built in detent stop is illustrated. For one implementation, the infinite rotary switch includes a lanced tab down 902 on the infinite switch face plate that creates a detent stop in order to stop rotation of the shaft (stem) of the rotary switch. For one implementation, the shaft (stem) can include a disc on the back side of the face plate of the infinite switch that engages the detent stop at 227 degrees from the OFF position.

[0048] FIGS. 10 through 12 provide an illustration of the third method and apparatus to provide a limiting switch. Referring to FIGS. 10A and 10B, isometric illustrations of a continuous switch assembly 1000 is provided illustrating a rotational switch stem 1002 that can be rotated in clockwise and counter clockwise rotational directions as illustrated by the directional arrows 1004. FIG. 10C provides a switching diagram where the light area indicates a transition from on to off or vice versa. The darkened area indicates continuous contact being made while the switch is in this area. FIG. 11 provides a wiring diagram and element schematic 1100. The cam 1102 in the continuous switch is utilized to increase or decrease pressure to control and limit the output. FIG. 11 is an illustration of an infinite switch. The switch operates in a manner where it cycles on and off at a frequency that depends on the current rotational position of the switch. Traditionally for many infinite switches utilized for this function when rotated to its full potential to the high setting, it may not cycle off at all. In many cases the switch stays on and the element is continuously powered and heats up and will continue to heat up as high as that element can get, which is unacceptable for regulatory standards. As the infinite switch is rotated down (counter clockwise) to lower settings, it cycles on and off with an increasing frequency as the switch is rotated further downward to lower settings. The frequency of how often the switch turns on and off, thereby controlling the on time and the off time will regulated the temperature of the element to the desired level. The present method and apparatus of the technology as disclosed and claimed herein is designed such that the maximum setting is at point to where the switch is on about 50% of the time and off about 50% of the time such that the method and apparatus as claimed reduces the output of the switch to the element to reduce the cycling of that on and off of the switch. With the method and apparatus the element can't overrun the temperature because it won't stay on long enough to overrun the temperature. It heats for a while then shuts off, it heats again and shuts off at a cycle where it is on approximately 50% of time and off 50% of the time, plus or minus 10%. By configuring the cam design, the technology as disclosed and claims controls and limits the length of time, that the limitless switch is on and the off time, to approximately 50% on, 50% off, plus or minus 50%.

[0049] The limitless switch includes a temperature sensing input that is indicative of the temperature of the element or the pan placed on the element and once the temperature sensed reaches a temperature level that is higher than desired based on the current setting, then the limitless switch is going to shut off its output to the element and the switch is not going to turn back on until the temperature of the element and thereby the pan drops to a certain point, and that's how the limitless switch design is preventing the pan from overheating. The present design utilizes the specially configured cam design to control and limit the switch. For one implementation of the technology the limitless switch is in-line with the element in the circuit of the element, and if the element or the pan gets too hot, it shuts the switch off. With the present technology as disclosed and claimed, it does not rely upon the temperature being sensed of the element or the pan necessarily. The present technology as disclosed and claimed modifies the cam to control and limit the frequency of the limitless switch going on and off, and thereby it limits how hot element or the pan can get. The apparatus and method varies from the traditional methodology of using a limitless switch that is controlled and regulated by a temperature sensor.

[0050] The technology as disclosed and claim utilizes an optimal point where the duty cycle is at about approximate 50% on and 50% off time and the cam us uses such that when the control knob is rotated past a certain point the switch doesn't continue to increase past the desire duty cycle. The cycle of 50% on and 50% off can vary by plus or minus 10 percent, for example 58% on and 42% off. Through tests it is determined how hot the element and pan could get without exceeding the temperature, but still allows for sufficient cooking temperatures. The same function can be accomplished as the first two methods and apparatus which uses a physical detent but with the limitless switch and a specially configured cam instead of with stop plate or indents in the stop plate.

[0051] The cam 1102 as illustrate in FIG. 11 within the switch applies pressure within the switch on a heated a bi-metal and such that when the heated bi-metal gets enough current flowing through it, it heats up and the bi-metal becomes more flexible bends and breaks the contact thereby shutting off the switch. The cam configuration is designed to apply the desired varying pressure to shut off the switch or cycle the switch off at the desired point in order to achieve the 50% on and 50% off result. The cam configuration provide a varying pressure against the arm and holds that arm in so it takes more heating or more current flowing through it to pop it open and disrupt the contact. The cam is configured to apply the necessary pressure corresponding to a defined rotation point of the knob to shut of the limitless switch by disrupting contact. With a traditional switch, which had not been configured to the achieve the desired duty cycle, that cam would have allowed the limitless switch to stay on full time and then the frequency would have been much greater as you ramp down through the selected temperatures. The cam ramps up or down depending on the rotation of the switch.

[0052] On implementation of a current limiting device for an electric cooking range as disclosed and claimed herein includes a mechanical stop detent member 402 extending from a mounting bracket 400 where the mounting bracket has a central through hole 404. The device includes a rotary switch having a shaft mounted to control the rotational position of the rotary switch and said shaft extends from said rotary switch and through the central through hole of the mounting bracket as illustrated in FIGS. 2, 4, 5 and 6. A control knob 700 as illustrated in FIGS. 1, 3 and 7 having a rear cavity and a shaft collar extending from the rear cavity is mounted on said shaft and further having a knob stop plate pin 706 extending from the cavity and said stop plate pin positioned to engage the mechanical stop detent when the control knob rotates the shaft and rotary switch to its maximum setting. For one implementation of the device the maximum setting of the rotary switch is rotated about approximately 227, plus or minus 5, degrees from an off position.

[0053] One implementation of a current limiting device for an electric cooking range as disclosed and claimed herein includes a rotary switch as illustrated in FIG. 8A and 8D having a shaft mounted to control the rotational position of the rotary switch and said shaft extends from said rotary switch. The device further includes a detent mounted on the rotary switch and position to engage and stop rotation of the shaft and the rotary switch at its maximum setting. For one implementation the maximum setting of the rotary switch is about approximately 227, plus or minus 5, degrees from an off position. One implementation includes a control knob having a rear cavity and a shaft collar extending from the rear cavity and mounted on said shaft.

[0054] One implementation current limiting device for an electric cooking range includes a limitless rotary switch 1000 having a shaft 1002 mounted to control the rotational position of the limitless rotary switch, where the rotation of the shaft varies the flow of current through a circuit to a load element as illustrated in FIG. 11, where the rotary switch cycles current flow through the circuit on and off at a frequency which depends upon the rotational position of the shaft as illustrated in FIG. 10C. For one implementation of the technology, a cam 1102 attached to the shaft 1002 where rotation of the shaft effects rotation of the cam where the cam is configured to vary the circuit operation to thereby vary the on and off cycle of the current flow such that the frequency of the on and off cycle doesn't allow the load element to exceed a specified temperature. For one implementation of the technology, the cam applies a varying pressure against a heated bi-metal where when the heated bi-metal gets enough current flowing heats up and the bi-metal becomes more flexible thereby bending under varying pressure of the rotating cam to thereby break a contact in the limitless switch thereby causing an on and off cycles of the switch based on the varying pressure of the cam. For one implementation, the cam configuration is designed to apply the desired varying pressure to cycle the switch off at the desired point in order to achieve an about approximately 50% on and 50% off result.

[0055] One implementation of a method to current limit an electric cooking range as disclosed and claimed herein includes, rotating a control knob having a rear cavity and a shaft collar extending from the rear cavity and mounted on a shaft extending from a rotary switch and where said control knob further having a knob stop plate pin extending from the cavity and said stop plate pin is positioned to engage a mechanical stop detent when the control knob rotates the shaft and the rotary switch to its maximum setting. For one implementation the method further includes rotating the shaft mounted to the rotary switch with the control knob thereby controlling the rotational position of the rotary switch; and controlling a current applied to a top burner element of an electric cooking range by rotating the control knob to thereby rotate the stop plate pin to engage a mechanical stop detent.

[0056] One implementation of a method to current limit an electric cooking range includes rotating a control knob having a rear cavity and a shaft collar extending from the rear cavity and mounted on a shaft extending from a rotary switch and rotating the shaft mounted to the rotary switch with the control knob thereby controlling the rotational position of the rotary switch. The method further includes controlling a current applied to a top burner element of an electric cooking range by rotating the control knob to thereby rotate the shaft to engage a mechanical stop detent of the rotary switch when the rotary switch is at its maximum setting.

[0057] One implementation of a method to current limit an electric cooking range include rotating a limitless rotary switch having a shaft mounted to control the rotational position of the limitless rotary switch, where the rotation of the shaft varies the flow of current through a circuit to a load element, where the rotary switch cycles current flow through the circuit on and off at a frequency which depends upon the rotational position of the shaft. The method further includes rotating a cam attached to the shaft where rotation of the shaft effects rotation of the cam where the cam is configured to vary the circuit operation to thereby vary the on and off cycle of the current flow such that the frequency of the on and off cycle doesn't allow the load element to exceed a specified temperature. For one implementation rotating the cam applies a varying pressure against a heated bi-metal where when the heated bi-metal gets enough current flowing heats up and the bi-metal becomes more flexible thereby bending under varying pressure of the rotating cam to thereby break a contact in the limitless switch thereby causing an on and off cycles of the switch based on the varying pressure of the cam.

[0058] A detailed view of the cam configuration is provided in FIGS. 13, 14 and 15. As can be seen in FIG. 15, rotation of the cam about an axis of rotation identified by the arrow will cause the cam to apply a varying pressure against a heated bi-metal, because of the position of the axis of rotation, where when the heated bi-metal gets enough current flowing heats up and the bi-metal becomes more flexible thereby bending under varying pressure of the rotating cam to thereby break a contact in the limitless switch thereby causing an on and off cycles of the switch based on the increase pressure of the cam at given current flow, which causes the bi-metal to be more flexible.

[0059] The various current limiting examples shown above illustrate an apparatus and method for limiting the electrical current provided to a top burner element of an electric cooking range. A user of the present technology as disclosed may choose any of the above implementations, or an equivalent thereof, depending upon the desired application. In this regard, it is recognized that various forms of the subject current limiting device could be utilized without departing from the scope of the present invention.

[0060] As is evident from the foregoing description, certain aspects of the present technology as disclosed are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. It is accordingly intended that the claims shall cover all such modifications and applications that do not depart from the scope of the present technology as disclosed and claimed.

[0061] Other aspects, objects and advantages of the present technology as disclosed can be obtained from a study of the drawings, the disclosure and the appended claims.