Integrated device and method for enhancing heater life and performance

1. A control system for controlling an operation of a resistive heater, the control system comprising:

a dielectric parameter determination module for determining a material property of a dielectric material of the resistive heater when the resistive heater is in an active mode;

a prediction module for predicting a life expectancy of the resistive heater based on the material property of the dielectric material; and

a heater operation control module for changing operation of the resistive heater based on the material property and the life expectancy.

2. The control system according to claim 1 , wherein the material property of the dielectric material is dielectric strength of the dielectric material when the resistive heater is in the active mode.

3. The control system according to claim 1 , wherein the dielectric parameter determination module further determines a change in the material property of the dielectric material.

4. The control system according to claim 3 , wherein the dielectric parameter determination module further includes a monitoring module including a transducer for monitoring a leakage current through the dielectric material of the resistive heater.

5. The control system according to claim 4 , wherein the dielectric parameter determination determines the change in the material property based on the leakage current through the dielectric material of the resistive heater.

6. The control system according to claim 5 , further comprising a diagnostic module that determines performance of the resistive heater based on a comparison of the leakage current and a threshold leakage current.

7. The control system according to claim 6 , wherein the diagnostic module further includes a fault detection control module that generates a warning signal when the leakage current reaches the threshold leakage current.

8. The control system according to claim 1 , wherein the prediction module includes correlations among the material property, the life expectancy, and an operating temperature of the resistive heater.

9. The control system according to claim 1 , wherein the prediction module determines a constant factor (K) based on the material property of the dielectric material.

10. The control system according to claim 1 , wherein the heater operation control module operates the resistive heater based on the material property of the dielectric material by changing at least one of operating temperature, ramp up speed and ramp down speed.

11. A method for controlling a resistive heater, comprising:

determining a material property of a dielectric material of the resistive heater when the resistive heater is in an active mode;

predicting a life expectancy of the resistive heater based on the material property of the dielectric material; and

controlling the resistive heater based on the material property and the life expectancy.

12. The method according to claim 11 , wherein the material property is dielectric strength of the dielectric material when the resistive heater is in the active mode.

13. The method according to claim 12 , further comprising determining the dielectric strength based on a leakage current through the dielectric material.

14. The method according to claim 13 , further comprising establishing a threshold leakage current, and determining a heater failure when the leakage current reaches the threshold leakage current.

15. The method according to claim 11 , further comprising predetermining correlations among the material property of the dielectric material, an operating temperature of the resistive heater and operating time.

16. The method according to claim 11 , further comprising controlling the resistive heater based on the material property by changing at least one of operating temperature, ramp up speed and ramp down speed.

17. The method according to claim 11 , further comprising defining and calculating a constant factor (K).

18. The method according to claim 17 , further comprising predicting the life expectancy of the resistive heater based on the constant factor.

19. The method according to claim 11 , further comprising setting up mathematical formula or algorithm into a prediction module to dynamically predict the life expectancy of the resistive heater at a given temperature and time.

20. The method according to claim 11 , further comprising providing dielectric parameter changes and correlation factor as a feedback for diagnostic and fault detection control (FDC).