Manufacturing method of cast aluminum electric heating device and control method of instantaneous electric water heater using cast aluminum electric heating device

Abstract

The invention discloses a cast aluminum electric heating device manufacturing method and an instantaneous electric water heater control method applying the cast aluminum electric heating device manufacturing method. A metal water pipe, an electric heating pipe and cast aluminum are included. The metal water pipe is wound into a spiral water pipe, a cavity is formed in the middle of the spiral water pipe, the electric heating pipe is placed in the cavity, the hot water end of the metal water pipe is wound back by 120-650 mm to be led out close to the cold water end of the metal water pipe, the metal water pipe and the electric heating pipe are combined together through cast aluminum, and the output water temperature is more stable. And hot water output is controlled through the intelligent constant-temperature control panel, and the constant-temperature hot water output time of the electric water heater is shorter.

Description

Technical Field

[0001] This invention relates to the field of cast aluminum electric heating device water heater technology, specifically to a method for manufacturing a cast aluminum electric heating device and a control method for a fast-heating electric water heater. Background Technology

[0002] Current cast aluminum electric heating devices, such as Figure 1 As shown in -4 and document CN211781915U, this technology is widely used in high-power instantaneous electric water heaters, especially those above 7KW. When the outlet pipe of the cast aluminum electric heating device is directly led to the outlet, due to the high heating power, if the water supply is interrupted during use and heating is briefly stopped, a large amount of residual heat will be generated when the water is turned on again, causing the outlet water temperature to rise instantly, resulting in a decrease in user comfort. Figure 5 As shown in document CN217685913U, electric water heater manufacturers install cooling buffer devices or constant temperature chambers at the hot water end of the metal water pipes in the cast aluminum heating element. This not only increases manufacturing costs but also increases the risk of water leakage at the connection ports due to the added water connection ports. Furthermore, existing intelligent constant temperature fast-heating electric water heaters using cast aluminum electric heating elements, such as... Figure 3 , Figure 4 As shown, not only does it take a long time for the hot water output to reach the set outlet temperature of the water heater to remain constant, but the water that has not reached a constant temperature is usually drained and used again after the outlet temperature has stabilized. Due to the large amount of water used, this also results in a significant waste of water and electricity resources. Summary of the Invention

[0003] The present invention provides a method for manufacturing a cast aluminum electric heating device and a control method for a fast-heating electric water heater, which can avoid the increase in manufacturing costs caused by setting a cooling buffer device or a constant temperature chamber at the outlet of the cast aluminum electric heating device to reduce the instantaneous excessively high temperature of the residual heat at the outlet of the fast-heating electric water heater. It also avoids the risk of water leakage caused by adding a cooling buffer device or a constant temperature chamber to the port of the cast aluminum electric heating device.

[0004] The first problem this invention solves is how to prevent high-power cast aluminum electric heating devices from generating excessive residual heat and causing the outlet water temperature to spike when the water supply is interrupted and heating is restarted due to excessive heating power. This is to avoid increasing the manufacturing cost of the electric water heater and the risk of leakage at the interface by adding a cooling buffer device or a constant temperature chamber to the metal water pipe output end of the cast aluminum electric heating device. To solve these problems, this invention winds the metal water pipe into a spiral shape with a cavity in the middle. An electric heating element is placed inside the cavity. The water end is looped back 120-650mm in length and led out close to the cold water end of the metal water pipe. Cast aluminum is used to combine the metal water pipe and the electric heating element together. Cast aluminum is used to die-cast the metal water pipe and the electric heating element. This invention transfers the high-temperature water flow from the hot water end of the metal water pipe to the low-temperature water flow in the cold water end of the metal water pipe through the heat transfer of the cast aluminum, thereby reducing the outlet water temperature. This eliminates the need for a cooling buffer device or a constant temperature chamber, which not only reduces the manufacturing cost of the electric water heater, but also avoids the risk of water leakage caused by the connection between the cooling buffer device or the constant temperature chamber and the water port of the cast aluminum electric heating device.

[0005] The second technical problem solved by this invention is how to address the long waiting time for the water heater to heat up and reach a constant temperature during initial startup in existing intelligent constant-temperature fast-heating water heaters using cast aluminum electric heating devices. To solve this problem, this invention combines the cast aluminum electric heating device with an intelligent constant-temperature control board. After the water heater starts, some of the hot water heat energy output from the hot water end of the metal water pipe on the cast aluminum electric heating device is transferred to the cold water end of the metal water pipe through the cast aluminum, thereby reducing the temperature of the hot water at the hot water end of the cast aluminum electric heating tube, resulting in a lower outlet water temperature detected by temperature sensor A. The intelligent constant-temperature control board controls the electric heating tube to increase its heating power or operate at full load, increasing the speed at which the water heater heats the water flow to a constant temperature output. Simultaneously, during the heating process, the cold water at the cold water end of the metal water pipe absorbs the heat energy of the hot water at the hot water end of the metal water pipe through the cast aluminum, increasing the input water temperature at the cold water end of the metal water pipe, thereby shortening the waiting time for the water outlet temperature to reach a constant temperature.

[0006] This invention discloses a method for manufacturing a cast aluminum electric heating device and a control method for a fast-heating electric water heater, comprising a metal water pipe, an electric heating element, and cast aluminum; the metal water pipe is wound into a spiral shape with a cavity in the middle, and the electric heating element is placed inside the cavity; the hot water end of the metal water pipe is wound back 120-650mm and led out close to the cold water end of the metal water pipe; the cast aluminum connects the metal water pipe and the electric heating element together; the manufacturing method is as follows: Step 1: Wind the metal water pipe into a spiral shape, with a cavity in the middle of the spiral water pipe; Step 2: The hot water end of the metal water pipe is looped back to the cold water end of the metal water pipe, and a length of 120-650mm is set to be led out parallel to the cold water end of the metal water pipe. Step 3: Place an electric heating element inside the cavity; Step 4: Use cast aluminum to die-cast and bond the metal water pipes and electric heating tubes together.

[0007] The hot water end of the metal water pipe is wound 1-2 times and brought close to the cold water end of the metal water pipe before being led out.

[0008] It is equipped with an intelligent constant temperature control board. The water outlet end of the metal water pipe is connected to the water outlet, and the water inlet end of the metal water pipe is connected to the water inlet. A temperature sensor A is installed at the water outlet end. The electric heating tube, temperature sensor A and intelligent constant temperature control board are electrically connected.

[0009] The system is equipped with an intelligent thermostatic control board. The outlet end of the metal water pipe is connected to the water outlet, and the inlet end is connected to the water inlet. Temperature sensor A is installed at the outlet end, and temperature sensor B is installed at the inlet end. Temperature sensors A and B are electrically connected to the intelligent thermostatic control board. The control method is as follows: Step 1: The intelligent constant temperature control board automatically controls the heating power of the electric heating tube based on the outlet water temperature detected by temperature sensor A; the lower the outlet water temperature detected by temperature sensor A is compared to the set outlet water temperature, the greater the heating power of the electric heating tube; the closer the outlet water temperature detected by temperature sensor A is to the set outlet water temperature, the smaller the heating power of the electric heating tube. Step 2: When the water heater is initially started, the hot water heat energy output from the hot water end of the metal water pipe of the cast aluminum electric heating device is conducted to the cold water end of the metal water pipe through the cast aluminum, which reduces the water temperature detected by the water outlet temperature sensor A, while increasing the inlet water temperature at the cold water end of the metal water pipe. The intelligent thermostatic control board controls the increase of the heating power of the electric heating tube, or the electric heating tube to work at full load, to reduce heat energy waste and quickly heat up and maintain the temperature to the set outlet water temperature of the water heater.

[0010] As can be seen from the above technical solutions, the present invention provides a method for manufacturing a cast aluminum electric heating device and a control method for a fast-heating electric water heater, comprising a metal water pipe, an electric heating element, and cast aluminum; the metal water pipe is wound into a spiral shape with a cavity in the middle, and the electric heating element is placed inside the cavity; the hot water end of the metal water pipe is wound back 120-650mm in length and led out close to the cold water end of the metal water pipe; the cast aluminum combines the metal water pipe and the electric heating element together, resulting in a more stable output water temperature; and the output hot water is controlled by an intelligent thermostatic control board, resulting in a shorter time for the electric water heater to output hot water at a constant temperature. Attached Figure Description

[0011] Figure 1 This is a schematic diagram of the metal water pipe structure of an existing cast aluminum electric heating device.

[0012] Figure 2 This is a schematic diagram of the existing cast aluminum electric heating device, where the electric heating element is placed inside a cavity formed by a metal water pipe. Figure 1 .

[0013] Figure 3 This is a schematic diagram of the existing cast aluminum electric heating device, where the electric heating element is placed inside a cavity formed by a metal water pipe. Figure 2 .

[0014] Figure 4 This is a schematic diagram of the existing cast aluminum electric heating device.

[0015] Figure 5 This is a schematic diagram of the structure of an existing cast aluminum electric heating device with a cooling buffer device installed at the water outlet.

[0016] Figure 6 This is a schematic diagram of the internal structure of the cavity formed by the electric heating tube and the metal water pipe of the cast aluminum electric heating device of the present invention.

[0017] Figure 7 This is a schematic diagram of the structure of the cast aluminum electric heating device of the present invention, in which the electric heating tube is placed inside a cavity formed by a metal water pipe. Figure 1 .

[0018] Figure 8 This is a schematic diagram of the structure of the cast aluminum electric heating device of the present invention, in which the electric heating tube is placed inside a cavity formed by a metal water pipe. Figure 2 .

[0019] Figure 9 This is a schematic structural diagram of the cast aluminum electric heating device of the present invention.

[0020] Figure 10 This is a schematic diagram of the intelligent constant temperature control board structure of the cast aluminum electric heating device of the present invention.

[0021] Figure 11 This invention relates to the working principle of the intelligent constant temperature control board. Figure 1 .

[0022] Figure 12 This invention relates to the working principle of the intelligent constant temperature control board. Figure 2 . Detailed Implementation

[0023] The technical solutions in the embodiments of the present invention will be further described below with reference to the accompanying drawings: This invention discloses a method for manufacturing a cast aluminum electric heating device and a control method for a fast-heating electric water heater, such as... Figure 6As shown in Figure 9, the device includes a metal water pipe 1, an electric heating element 2, and a cast aluminum tube 3. The metal water pipe 1 is wound into a spiral shape with a cavity 103 in the middle. The electric heating element 2 is placed inside the cavity 103. The hot water end 102 of the metal water pipe is wound back 120-650mm and led out close to the cold water end 101 of the metal water pipe. The cast aluminum tube 3 connects the metal water pipe 1 and the electric heating element 2 together. The spiral shape of the metal water pipe 1 can be square, circular, or other shapes. In this embodiment, it is square. The cold water end 101 of the metal water pipe is the length after the cold water enters the cast aluminum tube and the electric heating element. The hot water end 102 of the metal water pipe is the length before the hot water flows out of the cast aluminum tube and the electric heating element.

[0024] like Figure 5 , Figure 7 As shown, the present invention transfers the high-temperature water flow from the hot water end 102 of the metal water pipe to the low-temperature water flow from the cold water end 101 of the metal water pipe through the heat transfer of the cast aluminum 3, thereby reducing the outlet water temperature. This eliminates the need for the existing cast aluminum electric heating device to have a cooling buffer device or a constant temperature chamber 4. It reduces the manufacturing cost of the water heater and avoids the risk of water leakage caused by the connection between the cooling buffer device or the constant temperature chamber 4 and the port of the metal water pipe 1.

[0025] like Figure 7 , Figure 8 As shown, the hot water end 102 of the metal water pipe of the present invention is wound into 1-2 turns and led out in parallel with the cold water end 101 of the metal water pipe; in the embodiment of the present invention, it is set to one turn, which can be applied to electric water heaters with adjustable heating levels, and can also be used in electric water heaters with constant temperature control.

[0026] like Figure 9 , Figure 10 , Figure 11 As shown, an intelligent constant temperature control board 5 is provided. The water outlet 12 of the metal water pipe 1 is connected to the water outlet 42, and the water inlet 11 of the metal water pipe 1 is connected to the water inlet 41. A temperature sensor A421 is provided at the water outlet 42. The electric heating tube 2, the temperature sensor A421 and the intelligent constant temperature control board 5 are electrically connected.

[0027] like Figure 9 , Figure 10 , Figure 12 As shown, an intelligent thermostatic control board 5 is provided. The outlet 12 of the metal water pipe 1 is connected to the outlet 42, and the inlet 11 of the metal water pipe 1 is connected to the inlet 41. A temperature sensor A421 is provided at the outlet 42, and a temperature sensor B411 is provided at the inlet 41. Temperature sensors A421 and B411 are electrically connected to the intelligent thermostatic control board 5. The control method is as follows: Step 1: The intelligent constant temperature control board 5 automatically controls the heating power of the electric heating tube 2 based on the outlet water temperature detected by the temperature sensor A421; the lower the outlet water temperature detected by the temperature sensor A421 is compared to the set outlet water temperature, the greater the heating power of the electric heating tube 2; the closer the outlet water temperature detected by the temperature sensor A421 is to the set outlet water temperature, the smaller the heating power of the electric heating tube 2. Step 2: When the water heater is initially started, the hot water heat energy output from the hot water end 102 of the metal water pipe of the cast aluminum electric heating device is conducted to the cold water end 101 of the metal water pipe through the cast aluminum 3, which reduces the water temperature detected by the temperature sensor A421 at the water outlet 42, and at the same time increases the inlet water temperature of the cold water end 101 of the metal water pipe. The intelligent thermostatic control board 5 controls the increase of the heating power of the electric heating tube 2, or the electric heating tube 2 to work at full load, reducing heat energy waste, and quickly heating up and maintaining the temperature to the set outlet water temperature of the water heater.

[0028] Implementation process of Example 1; as follows Figure 2 , Figure 3 , Figure 4 As shown, existing cast aluminum electric heating devices: 1. Cold water enters from the inlet 11, passes through the cold water end 101 of the metal water pipe, is heated by the electric heater 2, flows through the hot water end 102 of the metal water pipe, and is output from the outlet 12.

[0029] 2. At this time, the electric heater 2 heats the cast aluminum 3, and the cast aluminum 3 transfers the heat energy to the water in the metal water pipe 1, and the hot water end 102 of the metal water pipe outputs hot water.

[0030] 3. When cold water stops flowing in for a short time, such as 3-10 seconds, due to the high heating power of electric heating element 2, no cold water flows into the cast aluminum electric heating device to cool it down. The high-temperature residual heat on electric heating element 2 and cast aluminum 3 continues to be conducted to metal water pipe 1, causing the water temperature at the hot water end 102 of the metal water pipe to continue to rise. When electric heating element 2 restarts heating, the water temperature at the hot water end 102 of the metal water pipe of the cast aluminum electric heating device will be too high for a moment, affecting the comfort of bathing. As a result, water heater manufacturers need to install a cooling buffer device after the hot water end 102 of the metal water pipe of the cast aluminum electric heating device, which increases manufacturing costs and causes the risk of water leakage when the cooling buffer device is connected to the port of the cast aluminum electric heating device.

[0031] 4. For example Figure 8 , Figure 9As shown, the cast aluminum electric heating device of the present invention has the hot water end 102 of the metal water pipe wrapped around the cold water end 101 of the metal water pipe in parallel for one turn, so that the residual heat during the heating process is dissipated to the water inlet end of the cast aluminum electric heating device. The temperature is reduced by the low temperature cast aluminum 1, thereby reducing the instantaneous high temperature residual hot water flow output of the hot water end 102 of the metal water pipe of the cast aluminum electric heating device. This eliminates the need for a cooling buffer device at the hot water end of the metal water pipe, which would increase manufacturing costs and reduce the risk of water leakage when the cooling buffer device is connected to the port of the cast aluminum electric heating device.

[0032] Implementation process of Example 2; as follows Figure 3 , Figure 4 , Figure 10 As shown: 1. Cold water enters from the cold water end 101 of the metal water pipe, is heated by the electric heater 2, and is then output from the hot water end 102 of the metal water pipe.

[0033] 2. At this time, the electric heater 2 heats the cast aluminum 3, and the cast aluminum 3 transfers the heat energy to the water in the metal water pipe 1, and the hot water end 102 of the metal water pipe outputs hot water.

[0034] 3. At room temperature, when the cast aluminum intelligent constant temperature fast-heating electric water heater is initially started, the electric heater 2 adjusts the heating power of the electric heating tube 2 according to the temperature detected by the temperature sensor B421 at the outlet 42. For the same water flow, the closer the outlet water temperature is to the set temperature, the lower the heating power of the electric heating tube 2; the greater the difference between the outlet water temperature and the set temperature, the greater the heating power of the electric heating tube 2, thus achieving rapid constant temperature. Since the water heated by the cast aluminum electric heating device is directly led out from the outlet 12 to the outlet 42, the temperature sensor B421 on the outlet 42 can only receive the outlet water temperature during the normal heating and continuous temperature rise until the outlet water temperature reaches the set outlet water temperature, resulting in a long heating and constant temperature time.

[0035] 4. For example Figure 9 , Figure 10 , Figure 12As shown, the intelligent constant-temperature fast-heating electric water heater of the present invention, using cast aluminum electric heating device, adjusts its heating power according to the outlet water temperature during initial startup at room temperature. With the same water flow rate, the closer the outlet water temperature is to the set temperature, the lower the heating power; conversely, the greater the difference between the outlet water temperature and the set temperature, the higher the heating power, thus achieving rapid temperature control. Due to the technical feature that the heat energy on the hot water end 102 of the metal water pipe of the cast aluminum electric heating device can be absorbed by the cast aluminum 3 and transferred to the cold water end 101 of the metal water pipe, the heat generated by the cast aluminum electric heating device is effectively transferred to the cold water end 101 of the metal water pipe. Some of the heat energy from the hot water is absorbed by the water flow at the cold water end 101 of the metal water pipe, thereby increasing the inlet water temperature of the cold water end 101 of the cast aluminum electric heating device. At this time, the temperature sensor B421 at the outlet 42 will detect a water temperature lower than that of conventionally heated water, and will not be affected by the temperature sensor A411 at the inlet 41. This achieves full-load power heating of the electric heating tube 2. The present invention has a faster heating and constant temperature effect, and also reduces the waste of water and electricity during the heating and constant temperature waiting process of the water heater when bathing.

[0036] The above description further illustrates the manufacturing method of a cast aluminum electric heating device and its application in the control method of a fast-heating electric water heater according to embodiments of the present invention. Specific examples have been used to illustrate the principles and implementation methods of the present invention. The description of the above embodiments is only for the purpose of helping to understand the core ideas of the present invention. For those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of the present invention. Therefore, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. A method for manufacturing a cast aluminum electric heating device and a control method for a fast-heating electric water heater thereof, comprising a metal water pipe (1), an electric heating element (2), and cast aluminum (3); characterized in that: A metal water pipe (1) is wound into a spiral shape, with a cavity (103) in the middle. An electric heating tube (2) is placed inside the cavity (103). The hot water end (102) of the metal water pipe is wound back to a length of 120-650 mm and led out close to the cold water end (101) of the metal water pipe. Cast aluminum (3) is used to connect the metal water pipe (1) and the electric heating tube (2). The manufacturing method is as follows: Step 1: Wind the metal water pipe (1) into a spiral water pipe, with a cavity (103) in the middle of the spiral water pipe; Step 2: The hot water end (102) of the metal water pipe (1) is looped back to the cold water end (101) of the metal water pipe, and a length of 120-650mm is set to be close to and parallel to the cold water end (101) of the metal water pipe. Step 3: Place an electric heating tube (2) inside the cavity (103); Step 4: Use cast aluminum (3) to die-cast and combine the metal water pipe (1) and the electric heating tube (2) together.

2. The manufacturing method of the cast aluminum electric heating device according to claim 1 and the control method of the instantaneous electric water heater thereof, characterized in that: The hot water end (102) of the metal water pipe is wound into 1-2 turns and led out close to the cold water end (101) of the metal water pipe.

3. The manufacturing method of a cast aluminum electric heating device according to claim 1 or 2 and the control method of a fast-heating electric water heater thereof, characterized in that: An intelligent constant temperature control board (5) is provided. The outlet end (12) of the metal water pipe (1) is connected to the outlet (42), and the inlet end (11) of the metal water pipe (1) is connected to the inlet (41). A temperature sensor A (421) is provided at the outlet (42). The electric heating tube (2), the temperature sensor A (421) and the intelligent constant temperature control board (5) are electrically connected.

4. The manufacturing method of a cast aluminum electric heating device according to claim 1 or 2 and the control method of a fast-heating electric water heater thereof, characterized in that: An intelligent thermostatic control board (5) is provided. The outlet (12) of the metal water pipe (1) is connected to the outlet (42), and the inlet (11) of the metal water pipe (1) is connected to the inlet (41). A temperature sensor A (421) is provided at the outlet (42), and a temperature sensor B (411) is provided at the inlet (41). Temperature sensors A (421) and B (411) are electrically connected to the intelligent thermostatic control board (5). The control method is as follows: Step 1: The intelligent constant temperature control board (5) automatically controls the heating power of the electric heating tube (2) based on the outlet water temperature detected by the temperature sensor A (421); the lower the outlet water temperature detected by the temperature sensor A (421) is compared to the set outlet water temperature, the greater the heating power of the electric heating tube (2); the closer the outlet water temperature detected by the temperature sensor A (421) is compared to the set outlet water temperature, the smaller the heating power of the electric heating tube (2). Step 2: When the water heater is initially started, the hot water heat energy output by the hot water end (102) of the metal water pipe of the cast aluminum electric heating device is conducted to the cold water end (101) of the metal water pipe through the cast aluminum (3), which reduces the water temperature detected by the temperature sensor A (421) at the water outlet (42) and at the same time increases the inlet water temperature of the cold water end (101) of the metal water pipe. The intelligent constant temperature control board (5) controls the increase of the heating power of the electric heating tube (2) or the electric heating tube (2) to work at full load, reducing heat energy waste and quickly heating up and maintaining the temperature to the set outlet water temperature of the water heater.

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