Control method of gas water heater and gas water heater

Abstract

The present application relates to gas water heater technical field, specifically disclose a kind of control method and gas water heater of gas water heater, gas water heater includes main heat exchanger, condensing heat exchanger and atomizer, condensing heat exchanger has water collecting cavity, atomizer is used to atomize condensate, after obtaining the real-time liquid level of condensate in condensing heat exchanger, based on real-time liquid level, the atomization power of atomizer is adjusted, to make real-time liquid level be in the ideal working liquid level range of atomizer, both improve the atomization effect and atomization efficiency of atomizer, also make atomizer long-term be in the ideal working liquid level range operating condition operation, effectively delay the device consumption of atomizer, greatly extend service life, so that atomizer and gas water heater whole service life match.

Description

Technical Field

[0001] This invention relates to the field of water heater technology, and more particularly to a control method for a gas water heater and a gas water heater. Background Technology

[0002] Condensing gas water heaters improve thermal efficiency by recovering the latent heat of vaporization from flue gas through a condensing heat exchanger. In order to treat condensate, an atomizer is installed in the condensing gas heat exchanger to atomize the condensate before discharging it into the atmosphere.

[0003] Currently, ultrasonic atomizers are widely used in gas water heaters because their atomized particles are fine and do not easily re-agglomerate into water droplets when they encounter the flue. However, the control schemes for ultrasonic atomizers in existing gas water heaters are not perfect, which can easily lead to the atomizer being in abnormal working conditions for a long time, resulting in a service life of only 1,000 to 2,000 hours, far below the designed service life of the entire gas water heater. Summary of the Invention

[0004] One of the technical problems solved by this invention is to provide a control method for a gas water heater that enables the atomizer to operate within an ideal working liquid level range, thereby improving the atomization effect and efficiency while extending the service life of the atomizer, making the lifespan of the atomizer compatible with the overall lifespan of the gas water heater.

[0005] The second technical problem solved by this invention is to provide a gas water heater that enables the atomizer to operate within an ideal working liquid level range, thereby improving the atomization effect and efficiency while extending the service life of the atomizer, making the lifespan of the atomizer compatible with the overall lifespan of the gas water heater.

[0006] The first technical problem mentioned above is solved by the following technical solution:

[0007] A control method for a gas water heater, the gas water heater comprising a main heat exchanger, a condensing heat exchanger, and an atomizer, wherein the condensing heat exchanger has a water collection chamber for collecting condensate produced by the condensing heat exchanger, and the atomizer is used to atomize the condensate; the control method includes:

[0008] Obtain the real-time liquid level of condensate in the condenser heat exchanger;

[0009] Based on the real-time liquid level, the atomization power of the atomizer is adjusted so that the real-time liquid level is within the ideal working liquid level range of the atomizer. Specifically, the lower limit of the ideal working liquid level range is lower than the optimal working liquid level height of the atomizer, and the atomization volume per unit time corresponding to the lower limit is not less than 60% of the atomization volume per unit time corresponding to the optimal working liquid level height; the upper limit of the ideal working liquid level range is higher than the optimal working liquid level height, and the atomization volume per unit time corresponding to the upper limit is not less than 60% of the atomization volume per unit time corresponding to the optimal working liquid level height.

[0010] The control method for gas water heaters described in this invention has the following advantages compared to the prior art:

[0011] By monitoring the condensate level in real time, the atomization power of the atomizer is adjusted based on the real-time level to keep the real-time level within the ideal working range of the atomizer. On the one hand, controlling the real-time level within the ideal working range improves the atomization effect and efficiency of the atomizer. On the other hand, it allows the atomizer to operate under the ideal working range for a long time, effectively delaying component wear and significantly extending its service life, thus matching the service life of the atomizer with that of the gas water heater as a whole.

[0012] The second technical problem mentioned above is solved by the following technical solution:

[0013] A gas water heater includes a main heat exchanger, a condensing heat exchanger, an atomizer, and a controller. The condensing heat exchanger has a water collection chamber for collecting condensate produced by the condensing heat exchanger. The atomizer is electrically connected to the controller and is used to atomize the condensate. The controller is used to execute the control method of the gas water heater according to any one of the present invention.

[0014] Compared with the prior art, the gas water heater of the present invention has the following beneficial effects:

[0015] By monitoring the condensate level in real time, the atomization power of the atomizer is adjusted based on the real-time level to keep the real-time level within the ideal working range of the atomizer. On the one hand, controlling the real-time level within the ideal working range improves the atomization effect and efficiency of the atomizer. On the other hand, it allows the atomizer to operate under the ideal working range for a long time, effectively delaying component wear and significantly extending its service life, thus matching the service life of the atomizer with that of the gas water heater as a whole.

[0016] It should be understood that the description in this section is not intended to identify key or essential features of the embodiments of the present invention, nor is it intended to limit the scope of the invention. Other features of the invention will become readily apparent from the following description. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a flowchart of a control method for a gas water heater provided in Embodiment 1 of the present invention;

[0019] Figure 2 This is a structural diagram of a gas water heater;

[0020] Figure 3 It is a curve showing the change in atomization amount as a function of condensate level;

[0021] Figure 4 This is a flowchart of a control method for a gas water heater provided in Embodiment 2 of the present invention;

[0022] Figure 5 This is a schematic diagram of a level gauge with a probe structure;

[0023] Figure 6 This is a flowchart of a control method for a gas water heater provided in Embodiment 3 of the present invention;

[0024] Figure 7 This is a schematic diagram of a guide rod type float leveling device. Detailed Implementation

[0025] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0026] Example 1

[0027] Figure 1 A flowchart of a control method for a gas water heater provided in Embodiment 1 of the present invention is shown below. Figure 1 As shown, the control method of this gas water heater includes:

[0028] S101. Obtain the real-time liquid level of condensate in the condenser heat exchanger.

[0029] The gas water heater in this embodiment is a water heater with a condensing heat exchanger, which recovers heat from the flue gas generated by gas combustion. Figure 2 As shown, the gas water heater includes a main heat exchanger 1, a condenser heat exchanger 2, and an atomizer 3. The condenser heat exchanger 2 has a water collection chamber 20 for collecting the condensate produced by the condenser heat exchanger 2, and the atomizer 3 is used to atomize the condensate.

[0030] The main heat exchanger 1 is the main component used to realize combustion and heat exchange. The flue gas generated by combustion in the main heat exchanger 1 enters the condenser heat exchanger 2 through the flue. The flue gas exchanges heat with the heat exchange tubes in the condenser heat exchanger 2 to realize the recovery of flue gas heat. At the same time, condensate is generated and collected by the water collection chamber 20 in the condenser heat exchanger 2. The atomizer 3 atomizes the condensate in the water collection chamber 20 and discharges it into the atmosphere. The cold water flowing into the condenser heat exchanger 2 increases in temperature after completing heat exchange and then flows into the main heat exchanger 1.

[0031] After the gas water heater is working, the real-time liquid level of the condensate in the water collection chamber 20 can be detected by a liquid level gauge. The liquid level gauge can be of various forms, such as a liquid level probe, a guide rod float liquid level device, etc. This embodiment does not limit the liquid level gauge.

[0032] S102. Based on the real-time liquid level, adjust the atomization power of the atomizer so that the real-time liquid level is within the ideal working liquid level range of the atomizer.

[0033] In this embodiment, the atomizer can be an ultrasonic atomizer, which uses the high-frequency resonance of the piezoelectric ceramic transducer to atomize liquid water into tiny particles. The atomization efficiency and service life of the ultrasonic atomizer are related to the condensate level in the water collection chamber 20: when the level is too low, the transducer is prone to no-load resonance, which leads to a sharp increase in its surface temperature and increased oscillator loss, resulting in a significant reduction in service life. When the level is too high, the water pressure above the transducer is too high, which will suppress its vibration amplitude, resulting in a significant reduction in atomization or even failure to atomize normally. Therefore, the atomizer 3 has an ideal working liquid level range (such as a vertical distance of 40mm from the upper plane of the atomizer to the water surface). Within this ideal working liquid level range, the atomization efficiency is the highest and the device loss is the lowest.

[0034] like Figure 3 The graph shows the atomization rate curves of the atomizer at different working liquid levels. The horizontal axis represents the liquid level L, and the vertical axis represents the atomization rate V per unit time. Each atomizer has an optimal working liquid level Lc. When the condensate level is at this optimal working liquid level Lc, the atomization rate per unit time is the maximum. If the liquid level is lower or higher than the optimal working liquid level Lc, the atomization rate per unit time decreases. Based on this, an ideal working liquid level range is set. For example, the lower limit of the ideal working liquid level range is lower than the optimal working liquid level height of the atomizer, and the atomization rate per unit time corresponding to the lower limit liquid level is not less than 60% of the atomization rate per unit time corresponding to the optimal working liquid level height. Figure 3The atomization rate per unit time at the lower limit liquid level La is equal to 60% of the atomization rate per unit time at the optimal working liquid level Lc. Similarly, the upper limit liquid level of the ideal working liquid level range is higher than the optimal working liquid level height, and the atomization rate per unit time corresponding to the upper limit liquid level is not less than 60% of the atomization rate per unit time corresponding to the optimal working liquid level height. Figure 3 The atomization rate per unit time at the upper limit liquid level Lb is equal to 60% of the atomization rate per unit time corresponding to the optimal working liquid level height. The range between the lower limit liquid level La and the upper limit liquid level Lb is the ideal working liquid level range of the atomizer.

[0035] After detecting the real-time liquid level of the condensate, if the real-time liquid level is outside the ideal working liquid level range, the atomization power of the atomizer needs to be adjusted. For example, when the real-time liquid level is lower than the lower limit of the ideal working liquid level range, the atomization power of the atomizer can be reduced, or even the atomizer can be turned off, so that the atomization rate of the condensate is less than the generation rate of the condensate, and the condensate rises back to the ideal working liquid level range. When the real-time liquid level is higher than the upper limit of the ideal working liquid level range, the atomization power of the atomizer can be increased, so that the atomization rate of the condensate is greater than the generation rate of the condensate, and the condensate drops back to the ideal working liquid level range. The atomization power of the atomizer 3 can be adjusted by directly reducing the atomization power of the atomizer 3. When the atomizer 3 has two or more atomizing heads, the atomization power can be reduced by decreasing the number of working atomizing heads, and the atomization power can be increased by increasing the number of working atomizing heads. Alternatively, the atomization power of the atomizing head can be adjusted, and the number of working atomizing heads can be increased or decreased in combination. This embodiment does not limit the method of adjusting the atomization power of the atomizing head.

[0036] By monitoring the condensate level in real time, the atomization power of the atomizer is adjusted based on the real-time level to keep the real-time level within the ideal working range of the atomizer. On the one hand, controlling the real-time level within the ideal working range improves the atomization effect and efficiency of the atomizer. On the other hand, it allows the atomizer to operate under the ideal working range for a long time, effectively delaying component wear and significantly extending its service life, thus matching the service life of the atomizer with that of the gas water heater as a whole.

[0037] Example 2

[0038] Figure 4 A flowchart of a control method for a gas water heater provided in Embodiment 2 of the present invention is shown below. Figure 4 As shown, the control method of this gas water heater includes:

[0039] S401. Obtain the real-time liquid level of condensate in the condenser heat exchanger.

[0040] like Figure 5The diagram shows a level gauge for detecting condensate level in this embodiment. The level gauge adopts a level probe structure, which includes a first level probe 21, a second level probe 22, a third level probe 23, a fourth level probe 24, and a common electrode 25 that extend into the water collection cavity 20. The distance from the end of the fourth level probe 24, the second level probe 22, the first level probe 21, the third level probe 23, and the common electrode 25 extending into the water collection cavity 20 to the bottom of the water collection cavity 20 decreases sequentially. The fourth level probe 24, the second level probe 22, the first level probe 21, and the third level probe 23 are used to detect the fourth level L4, the second level L2, the first level L1, and the third level L3, respectively, that is, the heights of the fourth level L4, the second level L2, the first level L1, and the third level L3 decrease sequentially.

[0041] When the condensate water submerges the level probe, the condensate water acts as a conductive medium, causing the level probe and the common electrode 25 to form an electrical circuit. The level probe submerged in the condensate water outputs a level signal. Based on the signal output status of each level probe, the real-time level height of the condensate water can be determined.

[0042] It should be noted that when using level probes to detect real-time liquid levels, the level probe corresponding to a high liquid level will output a liquid level signal, and the level probe corresponding to a low liquid level will also output a liquid level signal. The level probe corresponding to a low liquid level will stop outputting a liquid level signal, and the level probe corresponding to a high liquid level will also stop outputting a liquid level signal. For example, when the first level probe 21 outputs a liquid level signal, it means that the condensate level has reached or is higher than the first liquid level L1, and the condensate must also submerge the third level probe 23, causing the third level probe 23 to also output a liquid level signal. When the first level probe 21 stops outputting a liquid level signal, it means that the condensate level has fallen below the first liquid level L1, and the condensate must not have submerged the second level probe 22 and the fourth level probe 24, causing the second level probe 22 and the fourth level probe 24 to stop outputting liquid level signals.

[0043] S402. If the real-time liquid level is determined to be lower than the first liquid level when the first liquid level probe does not output a signal, the atomization power of the atomizer is reduced.

[0044] Atomizer 3 has an ideal working liquid level range (e.g., the vertical distance from the upper surface of the atomizer to the water surface is 40mm). Within this ideal working liquid level range, the atomization efficiency is the highest and the device loss is the lowest. Figure 3 As shown, in this embodiment, the ideal working liquid level range of the atomizer is the range formed by liquid level La and liquid level Lb. The ideal working liquid level range varies for different gas water heaters and different atomizers. Figure 5As shown, the first liquid level and the second liquid level are within the ideal working liquid level range, and the first liquid level L1 is lower than the second liquid level L2. For example, the first liquid level L1 is greater than and close to the lower limit liquid level La of the ideal working liquid level range, and the second liquid level L2 is less than and close to the upper limit liquid level Lb of the ideal working liquid level range.

[0045] If the first liquid level probe 21 does not output a signal, it can be determined that the real-time liquid level of the condensate is lower than the first liquid level L1, and is close to the lower limit of the ideal working liquid level range. If the liquid level of the condensate continues to drop, it will exceed the ideal working liquid level range. Therefore, the atomization rate of the condensate should be controlled to be less than the generation rate of the condensate, so that the liquid level of the condensate rises and remains within the ideal working liquid level range. The method for determining the rise of the condensate liquid level is as follows: if the first liquid level probe 21 outputs a liquid level signal within a preset time after reducing the atomization power of the atomizer, then it is determined that the liquid level of the condensate has risen. The reduction of the atomization power can include the following two methods:

[0046] Method 1: Reduce the atomization power of at least one atomizing head until the condensate level rises.

[0047] Specifically, the atomizer may include at least two atomizing heads, and the atomization power of at least one atomizing head may be reduced step by step. If the liquid level of the condensate does not rise after each reduction in atomization power, the atomization power of the atomizing head may be reduced further until the liquid level of the condensate rises. Here, step by step reduction may refer to reducing the atomization power according to a preset step size (such as 20% of the maximum power).

[0048] Taking atomizer 3, which includes atomizing head A and atomizing head B, as an example, if both atomizing head A and atomizing head B are currently operating at 100% power, and the first liquid level probe 21 does not output a signal, the atomization power of the atomizer can be reduced in the following way:

[0049] The atomization power of atomizing head A is gradually reduced. For example, the power of atomizing head A is first reduced to 80%. After waiting for a preset time (e.g., 5 seconds), if the first liquid level probe still does not output a signal, it means that the liquid level has not risen back to the first liquid level. Then the power of atomizing head A is reduced to 60% until the first liquid level probe outputs a signal, indicating that the liquid level has risen back to the first liquid level, and the power reduction operation is stopped.

[0050] The atomization power of atomizing head A and atomizing head B is gradually reduced. For example, the power of atomizing head A and atomizing head B is first reduced to 80%. After waiting for a preset time (e.g., 5 seconds), if the first liquid level probe still does not output a signal, it means that the liquid level has not risen back to the first liquid level. Then the power of atomizing head A and atomizing head B is reduced to 60% until the first liquid level probe outputs a signal, indicating that the liquid level has risen back to the first liquid level, and the power reduction operation is stopped.

[0051] By gradually reducing the atomization power of at least one atomizing head, the atomization speed of the condensate can be reduced in preset steps to a level lower than the condensate generation speed under the current gas water heater load. This avoids a sharp rise in liquid level due to a sudden drop in atomization power, keeping the liquid level within the ideal working range. In addition, gradually reducing the atomization power avoids current surges to the atomizer when the atomization power is reduced significantly, thus extending the atomizer's lifespan.

[0052] Method 2: Control at least one atomizing head that is in the open state to close until the condensate level rises.

[0053] Specifically, the working time of each atomizing head can be obtained, and the atomizing heads can be sorted in descending order of working time. The working time is either continuous working time or total working time. The atomizing heads that are in the open state are turned off one by one according to the sorting. If the liquid level of the condensate does not rise after each atomizing head is turned off, the next atomizing head that is in the open state is turned off until the liquid level of the condensate rises.

[0054] For example, suppose the atomizer includes atomizing head A, atomizing head B, and atomizing head C, and all of them are currently on. Atomizing head A has been working continuously for 100 hours, atomizing head B for 60 hours, and atomizing head C for 50 hours. The order of working time from longest to shortest is: atomizing head A (100h) > atomizing head B (60h) > atomizing head C (50h). When it is necessary to turn off the atomizing head to reduce the atomization power, atomizing head A is turned off first, so that the atomizing head with the longer working time can rest first. If the liquid level does not rise after turning off atomizing head A, then atomizing head B is turned off, and so on.

[0055] By sequentially shutting down the atomizing heads according to their working duration, prioritizing the head with the longest continuous working time, a dynamic balance of wear and tear on each atomizing head is achieved. This prevents premature failure of a single atomizing head due to overuse, effectively extending the overall lifespan of the atomizer. Furthermore, by combining sequential shutdown with liquid level rise detection, the simultaneous shutdown of multiple atomizing heads can prevent a sudden surge in liquid level, ensuring that the condensate level accurately recovers and remains within the ideal working range.

[0056] S403. If the third liquid level probe does not output a signal, and it is determined that the real-time liquid level is lower than the third liquid level, the atomizer is controlled to stop working.

[0057] like Figure 5 As shown, the gas water heater also includes a third liquid level probe 23 for detecting a third liquid level L3, which is lower than the first liquid level L1. The third liquid level L3 can be a liquid level outside the ideal working liquid level range, for example, the third liquid level L3 is less than the lower limit liquid level La of the ideal working liquid level range. The third liquid level L3 is the liquid level used to trigger the atomizer to shut down.

[0058] After executing step S402 to reduce the atomization power of the atomizer, if the third liquid level probe 23 does not output a signal, it indicates that the real-time liquid level is lower than the third liquid level L3. For example, when the gas water heater is operating at a very low load (such as supplying only a small amount of hot water), the condensate is generated very slowly. Even if the atomizer is operating at the lowest power, the real-time liquid level continues to drop below the third liquid level L3. The third liquid level probe does not output a signal, so the power supply to the atomizer can be cut off to stop the atomizer from working, so as to avoid the atomizer being damaged by dry burning due to the liquid level being too low.

[0059] S404. If the first liquid level probe outputs a signal, control the atomizer to start working.

[0060] After step S403 detects that the real-time liquid level is lower than the third liquid level L3 and controls the atomizer to stop working, if subsequent condensate continues to be generated and the liquid level rises back to the first liquid level, the first liquid level probe outputs a signal indicating that the condensate liquid level has risen back to the ideal working liquid level range, and the atomizer can be controlled to start working again.

[0061] Specifically, the atomizer has N atomizing heads, where N≥2. When the atomizer starts working, the total working time of each atomizing head in the off state is obtained, and the atomizing heads in the off state are sorted in ascending order of total working time. The first n atomizing heads in the sorted order are turned on, where N>n≥1. This allows the atomizing heads with shorter total working time to be put into operation first, thus balancing the overall wear and tear of each atomizing head.

[0062] For example, the atomizer has three atomizing heads. Atomizing head A has worked for a total of 200 hours, atomizing head B for a total of 150 hours, and atomizing head C for a total of 80 hours, all of which are currently off. After the liquid level rises back to the first level, the atomizing heads are sorted by total working time from shortest to longest as follows: atomizing head C (80 hours) < atomizing head B (150 hours) < atomizing head A (200 hours). The two atomizing heads with the shortest total working time are prioritized for operation, namely atomizing head C and atomizing head B.

[0063] S405. When the second liquid level probe outputs a signal, if it is determined that the real-time liquid level is higher than the second liquid level, the atomization power of the atomizer is increased.

[0064] In this embodiment, after detecting the real-time liquid level in step S401, if the second liquid level probe 22 outputs a signal, it can be determined that the real-time liquid level of the condensate is higher than the second liquid level L2, and the liquid level of the condensate is close to the upper limit of the ideal working liquid level range. If the liquid level of the condensate continues to rise, it will exceed the ideal working liquid level range. Therefore, the atomization speed of the condensate should be controlled to be greater than the generation speed of the condensate, so that the liquid level of the condensate drops and remains within the ideal working liquid level range. The method for determining the drop in the liquid level of the condensate is as follows: if the second liquid level probe 22 stops outputting a liquid level signal within a preset time after increasing the atomization power of the atomizer, it is determined that the liquid level of the condensate has dropped. Increasing the atomization power can include the following two methods:

[0065] Method 1: Increase the atomization power of at least one atomizing head until the condensate level drops.

[0066] Specifically, the atomizer 3 may include at least two atomizing heads, and the atomization power of at least one atomizing head may be increased step by step. If the liquid level of the condensate does not drop after each increase in atomization power, the atomization power of the atomizing head may be increased further until the liquid level of the condensate drops. Here, "step by step" may refer to increasing the atomization power in preset increments (such as 20% of the maximum power).

[0067] by Figure 5 Taking atomizer 3, which includes atomizing head A and atomizing head B, as an example, atomizing head A is currently operating at 20% power. When the real-time liquid level is higher than the second liquid level, the power of atomizing head A is increased to 40%, and a preset time (e.g., 5 seconds) is waited. If the second liquid level probe still outputs a signal, the power is increased to 60%, and so on, until the second liquid level probe stops outputting a signal. If the power of atomizing head A is increased to 100%, and the second liquid level probe still outputs a signal, the power of atomizing head B is increased step by step.

[0068] Of course, the atomization power of atomizing head A and atomizing head B can also be increased step by step at the same time. For example, the power of atomizing head A and atomizing head B can be increased to 40% first. After waiting for a preset time (such as 5 seconds), if the second liquid level probe still outputs a signal, it means that the liquid level has not dropped to the second liquid level. Then the power of atomizing head A and atomizing head B can be increased to 60% until the second liquid level probe stops outputting a signal. It is determined that the liquid level has dropped below the second liquid level, and the operation of increasing the atomization power is stopped.

[0069] By progressively increasing the atomization power of at least one atomizing head, the atomization speed of the condensate can be increased in preset steps to a level greater than the condensate generation speed under the current gas water heater load. This avoids a sharp drop in liquid level due to a sudden increase in atomization power, ensuring that the liquid level drops precisely within the ideal working range. In addition, progressively increasing the atomization power avoids current surges to the atomizer when the atomization power is increased significantly, thus extending the atomizer's lifespan.

[0070] Method 2: Control at least one atomizing head that is in the off state to turn on until the liquid level of the condensate drops.

[0071] Specifically, the atomizing heads are sorted in descending order of working time, and the atomizing heads that are in the closed state are turned on one by one in reverse order of the sorting. If the liquid level of the condensate does not drop after each atomizing head is turned on, the next atomizing head that is in the closed state is turned on, until the liquid level of the condensate drops.

[0072] For example, suppose the atomizer includes atomizing head A, atomizing head B, and atomizing head C, wherein atomizing head A is in the open state, and atomizing heads B and C are in the closed state. Atomizing head A has been working continuously for 100 hours, atomizing head B has been working continuously for 60 hours, and atomizing head C has been working continuously for 50 hours. The order of working time from longest to shortest is: atomizing head A (100h) > atomizing head B (60h) > atomizing head C (50h). When it is necessary to turn on the atomizing head to increase the atomization power, atomizing head C is turned on first, so that the atomizing head with the shorter working time is turned on first. If the liquid level does not drop after turning on atomizing head C, then atomizing head B is turned on, and so on.

[0073] By activating the atomizing heads one by one according to their working time, and prioritizing the atomizing head with the shortest total working time, a dynamic balance of wear and tear on each atomizing head is achieved, preventing premature failure of a single atomizing head due to overuse, thus effectively extending the overall lifespan of the atomizer. On the other hand, by activating them one by one in conjunction with the determination of liquid level drop, the simultaneous activation of multiple atomizing heads can prevent a sudden drop in liquid level and overshoot, ensuring that the condensate liquid level drops precisely and remains within the ideal working liquid level range.

[0074] S406. When the fourth liquid level probe outputs a signal, if the real-time liquid level is determined to be higher than the fourth liquid level, control the gas water heater to stop working.

[0075] like Figure 5 As shown, in this embodiment, the gas water heater also includes a fourth liquid level probe 24 for detecting the fourth liquid level L4. The fourth liquid level L4 is higher than the second liquid level L2. The fourth liquid level L4 is outside the ideal working liquid level range. The fourth liquid level L4 is the liquid level used to trigger the gas water heater shutdown protection.

[0076] After executing step S405 to increase the atomization power, when the fourth liquid level probe 24 outputs a signal, it indicates that the real-time liquid level is higher than the fourth liquid level L4. This means that even if the atomizer is working at its highest power, the atomization speed of the condensate is still less than the condensate generation speed. For example, when the gas water heater is running at its maximum load, the condensate generation speed is extremely fast. All atomizing heads of the atomizer are turned on and working at full power, but the liquid level still continues to rise above the fourth liquid level L4. The fourth liquid level probe 24 outputs a signal, indicating that there is a risk of condensate overflow. The gas water heater is then controlled to report a fault and stop working. For example, the gas valve can be shut off and all components such as the fan and water pump can be stopped. At the same time, a fault alarm can be issued through the display screen or buzzer to prevent condensate overflow from damaging the machine or causing safety hazards.

[0077] This embodiment uses multiple liquid level probes to accurately detect the condensate level and dynamically adjusts the atomizer's power or increases / decreases the number of atomizing heads in the active state based on the output signals of each probe. This ensures the atomizer operates within the ideal liquid level range, significantly improving atomization effect and efficiency. Furthermore, by prioritizing the shutdown of atomizing heads with longer operating times and prioritizing the activation of atomizing heads with the shortest total operating time, the atomizer rotates its operation, balancing wear and tear and effectively extending the overall lifespan of the atomizer. Additionally, a third liquid level trigger to stop the atomizer prevents dry burning due to low liquid levels, and a fourth liquid level trigger to shut down the gas water heater prevents condensate from overflowing even when the atomizer is operating at maximum power, thus improving the overall safety of the gas water heater.

[0078] Example 3

[0079] Figure 6 A flowchart of a control method for a gas water heater provided in Embodiment 3 of the present invention is shown below. Figure 6 As shown, the control method of this gas water heater includes:

[0080] S601. Obtain the real-time liquid level of condensate in the condenser heat exchanger.

[0081] like Figure 7As shown, the gas water heater also includes a guide rod type float level device for detecting the real-time liquid level. The guide rod type float level device includes a guide rod 30, a float 31 passing through the guide rod 30, and a first signal triggering component 26, a second signal triggering component 27, a third signal triggering component 28, and a fourth signal triggering component 29 located on the guide rod 30. The first signal triggering component 26 is at the same height as the first liquid level L1, the second signal triggering component 27 is at the same height as the second liquid level L2, the third signal triggering component 28 is at the same height as the third liquid level L3, and the fourth signal triggering component 29 is at the same height as the fourth liquid level L4. 4. When the float 31 is at the same height, it outputs liquid level signals representing the fourth liquid level L4, the second liquid level L2, the first liquid level L1, and the third liquid level L3 respectively when it passes the fourth signal triggering component 29, the second signal triggering component 27, the first signal triggering component 26, and the third signal triggering component 28. Each signal triggering component can be an electromagnetic induction switch or a mechanical switch. The float 31 has a magnet or a triggering structure that triggers the mechanical switch. When the float 31 rises or falls with the liquid level and passes the signal triggering component, the corresponding signal triggering component outputs a liquid level signal representing the corresponding liquid level.

[0082] S602. When the real-time liquid level drops to the first liquid level, reduce the atomization power of at least one atomizing head until the liquid level of the condensate rises; or, control at least one atomizing head that is in the open state to close until the liquid level of the condensate rises.

[0083] Since the float 31 only outputs a liquid level signal when it passes the corresponding liquid level, the controller of the gas water heater can cache the liquid level previously detected by the float 31 and determine the liquid level change trend by comparing the current and previous detected liquid levels. When the float 31 detects the first liquid level L1, it indicates that the condensate liquid level is at the first liquid level. If the float 31 previously detected the second liquid level, it indicates that the condensate has dropped to the first liquid level L1, which is close to the lower limit of the ideal working liquid level range. If the condensate continues to drop, it will cause the condensate liquid level to exceed the ideal working liquid level range of the atomizer. The atomization speed of the condensate should be controlled to be less than the condensate generation speed so that the condensate liquid level rises and remains within the ideal working liquid level range. This can be achieved by reducing the atomization power of at least one atomizing head until the condensate liquid level rises; or by controlling at least one atomizing head that is in the open state to close until the condensate liquid level rises.

[0084] Specifically, when reducing the atomization power of at least one atomizing head, the atomization power of at least one atomizing head can be reduced step by step. If the liquid level of the condensate does not rise after each reduction in atomization power, the atomization power of the atomizing head is further reduced until the liquid level of the condensate rises. When controlling at least one atomizing head that is in the open state to be turned off, the working time of each atomizing head can be obtained, and the atomizing heads can be sorted in descending order of working time. The working time is either the continuous working time or the total working time. According to the sorting, the atomizing heads that are in the open state are turned off one by one. If the liquid level of the condensate does not rise after each atomizing head is turned off, the next atomizing head that is in the open state is turned off until the liquid level of the condensate rises.

[0085] S603. When the real-time liquid level rises to the second liquid level, increase the atomization power of at least one atomizing head until the liquid level of the condensate drops; or, control at least one atomizing head that is in the off state to open until the liquid level of the condensate drops.

[0086] When the float 31 detects the second liquid level L2, it indicates that the condensate level is at the second liquid level L2. If the float 31 previously detected the first liquid level L1, it indicates that the condensate has risen to the second liquid level L2, which is close to the upper limit of the ideal working liquid level range. If the condensate continues to rise, the condensate level will exceed the ideal working liquid level range of the atomizer. The atomization rate of the condensate should be controlled to be greater than the condensate generation rate so that the condensate level drops within the ideal working liquid level range. This can be achieved by increasing the atomization power of at least one atomizing head until the condensate level drops; or by controlling at least one atomizing head that is in the off state to open until the condensate level drops.

[0087] Specifically, when increasing the atomization power of at least one atomizing head, the atomization power of at least one atomizing head can be increased step by step. If the liquid level of the condensate does not drop after each increase in atomization power, the atomization power of the atomizing head can be increased until the liquid level of the condensate drops.

[0088] When controlling at least one atomizing head that is in the closed state to be turned on, the atomizing heads are sorted in descending order of working time, and the atomizing heads that are in the closed state are turned on one by one in reverse order of sorting. If the liquid level of condensate does not drop after each atomizing head is turned on, the next atomizing head that is in the closed state is turned on, until the liquid level of condensate drops.

[0089] This embodiment uses a guide rod type float level device to accurately detect the condensate level and adjust the atomization power or the number of atomizing heads opened in a timely manner according to the rise and fall of the level, ensuring that the condensate level is within the ideal working level range of the atomizer. On the one hand, controlling the real-time level within the ideal working level range improves the atomization effect and efficiency of the atomizer. On the other hand, it allows the atomizer to operate under the ideal working level range for a long time, effectively delaying the wear and tear of the atomizer components and significantly extending its service life, so that the service life of the atomizer matches that of the entire gas water heater.

[0090] Example 4

[0091] Figure 2 This is a schematic diagram of the structure of a gas water heater provided in Embodiment 4 of the present invention. Figure 2 As shown, the gas water heater includes a main heat exchanger 1, a condenser heat exchanger 2, an atomizer 3, and a controller 4. The condenser heat exchanger 2 has a water collection chamber 20 for collecting the condensate produced by the condenser heat exchanger 2. The atomizer 3 is electrically connected to the controller 4 and is used to atomize the condensate. The controller 4 is used to execute the control method of the gas water heater according to any one of the present invention.

[0092] In an alternative embodiment, the atomizer 3 is provided with at least two atomizing heads.

[0093] Of course, gas water heaters can also include various types of level gauges, such as... Figure 5 The liquid level probe type liquid level gauge shown, such as Figure 7 The guide rod type float level device is shown.

[0094] Controller 4 can be a variety of general-purpose and / or dedicated processing components with processing and computing capabilities. Some examples of controller 4 include, but are not limited to, a central processing unit (CPU), a graphics processing unit (GPU), various dedicated artificial intelligence (AI) computing chips, various processors running machine learning model algorithms, digital signal processors (DSPs), and any suitable processor, microcontroller, etc. Controller 4 performs the various methods and processes described above, such as the control methods for a gas water heater.

[0095] In some embodiments, the control method for the gas water heater may be implemented as a computer program tangibly contained in a computer-readable storage medium, which, when loaded and executed by the controller 4, can perform one or more steps of the control method for the gas water heater described above. Alternatively, in other embodiments, the controller 4 may be configured to perform the control method for the gas water heater by any other suitable means (e.g., by means of firmware).

[0096] The gas water heater in this embodiment detects the condensate level in real time and adjusts the atomization power of the atomizer based on the real-time level to keep the real-time level within the ideal working range of the atomizer. On the one hand, controlling the real-time level within the ideal working range ensures the atomization effect and efficiency of the atomizer. On the other hand, it allows the atomizer to operate under reasonable liquid level conditions for a long time, effectively delaying the wear and tear of the atomizer components and significantly extending its service life, so that the service life of the atomizer matches that of the entire gas water heater.

[0097] It should be understood that the various forms of processes shown above can be used to reorder, add, or delete steps. For example, the steps described in this invention can be executed in parallel, sequentially, or in different orders, as long as the desired result of the technical solution of this invention can be achieved, and this invention does not impose any limitations on them.

[0098] The specific embodiments described above do not constitute a limitation on the scope of protection of this invention. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this invention should be included within the scope of protection of this invention.

Claims

1. A control method for a gas water heater, characterized in that, The gas water heater includes a main heat exchanger (1), a condensing heat exchanger (2), and an atomizer (3). The condensing heat exchanger (2) has a water collection chamber (20) for collecting the condensate produced by the condensing heat exchanger (2). The atomizer (3) is used to atomize the condensate. The control method includes: Obtain the real-time liquid level of condensate in the condenser heat exchanger; Based on the real-time liquid level, the atomization power of the atomizer is adjusted so that the real-time liquid level is within the ideal working liquid level range of the atomizer; wherein, the lower limit of the ideal working liquid level range is lower than the optimal working liquid level height of the atomizer, and the atomization volume per unit time corresponding to the lower limit liquid level is not less than 60% of the atomization volume per unit time corresponding to the optimal working liquid level height; the upper limit of the ideal working liquid level range is higher than the optimal working liquid level height, and the atomization volume per unit time corresponding to the upper limit liquid level is not less than 60% of the atomization volume per unit time corresponding to the optimal working liquid level height. The gas water heater further includes a first liquid level probe for detecting a first liquid level, a second liquid level probe for detecting a second liquid level, and a third liquid level probe for detecting a third liquid level, wherein the second liquid level is higher than the first liquid level, the first liquid level and the second liquid level are within the ideal working liquid level range, the third liquid level is lower than the first liquid level, and the first liquid level and the second liquid level are within the ideal working liquid level range. Adjusting the atomization power of the atomizer based on the real-time liquid level includes: If the real-time liquid level is determined to be lower than the first liquid level when the first liquid level probe does not output a signal, the atomization power of the atomizer is reduced. After reducing the atomization power of the atomizer, if the third liquid level probe does not output a signal, it is determined that the real-time liquid level is lower than the third liquid level, and the atomizer is controlled to stop working. After the atomizer is stopped, if the first liquid level probe outputs a signal, the atomizer is started to work again. When the second liquid level probe outputs a signal, if it is determined that the real-time liquid level is higher than the second liquid level, then the atomization power of the atomizer is increased.

2. The control method according to claim 1, characterized in that, The atomizer has at least two atomizing heads, and reducing the atomization power of the atomizer includes: Reduce the atomization power of at least one of the atomizing heads until the condensate level rises; or, control at least one atomizing head that is in the open state to close until the condensate level rises. The improvement of the atomization power of the atomizer includes: Increase the atomization power of at least one of the atomizing heads until the condensate level drops; or, control at least one atomizing head that is in the off state to turn on until the condensate level drops.

3. The control method according to claim 2, characterized in that, The method for determining the rise in the condensate level is as follows: If the first liquid level probe outputs a liquid level signal within a preset time after the atomization power of the atomizer is reduced, it is determined that the liquid level of the condensate has risen. The method for determining the drop in the condensate level is as follows: If the second liquid level probe stops outputting a liquid level signal within a preset time period after the atomization power of the atomizer is increased, it is determined that the liquid level of the condensate has dropped.

4. The control method according to claim 2, characterized in that, Reducing the atomization power of at least one of the atomizing heads until the condensate level rises includes: The atomization power of at least one of the atomizing heads is gradually reduced. If the liquid level of the condensate does not rise after each reduction in atomization power, the atomization power of the atomizing head is further reduced until the liquid level of the condensate rises. Increasing the atomization power of at least one of the atomizing heads until the condensate level drops includes: The atomization power of at least one of the atomizing heads is increased step by step. If the liquid level of the condensate does not drop after each increase in atomization power, the atomization power of the atomizing head is increased again until the liquid level of the condensate drops.

5. The control method according to claim 2, characterized in that, The control method further includes: The working time of each atomizing head is obtained, and the atomizing heads in the on state are sorted in descending order of the working time; the working time is the continuous working time or the total working time. Controlling at least one atomizing head that is in the open state to shut off until the condensate level rises includes: According to the order, the atomizing heads that are in the open state are turned off one by one. If the liquid level of the condensate does not rise after each atomizing head is turned off, the next atomizing head that is in the open state is turned off until the liquid level of the condensate rises. Controlling at least one atomizing head that is currently closed to open until the condensate level drops includes: The atomizing heads that are in the closed state are turned on one by one in reverse order according to the sorting. If the liquid level of the condensate does not drop after each atomizing head is turned on, the next atomizing head that is in the closed state is turned on, until the liquid level of the condensate drops.

6. The control method according to claim 1, characterized in that, The atomizer has N atomizing heads, where N≥2. Controlling the atomizer to start operating includes: Obtain the total working time of each atomizing head in the off state, and sort the atomizing heads in the off state in ascending order of the total working time; Control the activation of the first n atomizing heads in the sequence, where N > n ≥ 1.

7. The control method according to any one of claims 1-5, characterized in that, The gas water heater also includes a fourth liquid level probe for detecting a fourth liquid level, which is higher than the second liquid level. After increasing the atomization power of the atomizer, it also includes: When the fourth liquid level probe outputs a signal, it is determined that the real-time liquid level is higher than the fourth liquid level, and the gas water heater is controlled to stop working.

8. A gas water heater, characterized in that, The device includes a main heat exchanger (1), a condenser heat exchanger (2), an atomizer (3), and a controller (4). The condenser heat exchanger (2) has a water collection chamber (20) for collecting the condensate produced by the condenser heat exchanger (2). The atomizer (3) is electrically connected to the controller (4) and is used to atomize the condensate. The controller (4) is used to execute the control method of the gas water heater according to any one of claims 1-7.

9. The gas water heater according to claim 8, characterized in that, The atomizer (3) is provided with at least two atomizing heads.

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