Air Handler Auxiliary Heat Cycling for Element Wear Balancing
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Solution Overview
Problem
The limited lifespan and frequent activation of heat elements in auxiliary electric heat systems used in conjunction with heat pumps, particularly during cold weather and defrost cycles, necessitate improvements in performance and durability to reduce operational frequency.
Innovation Solution
An air handler system with a controller that implements a wear-leveling algorithm to distribute the usage of heat elements evenly by selecting the least-used heat elements for activation and a fault-handling mechanism to manage faulty elements, ensuring extended lifespan and efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If auxiliary electric heat is activated frequently to maintain heating performance, then heating effectiveness is improved, but the lifespan of heat elements and relays deteriorates
Solution Approach 1:
The auxiliary heat source is divided into multiple independent heat elements (first heat element, second heat element, etc.) with separate relays. Instead of using a single heat element continuously, the system segments the heating function across multiple elements that can be independently controlled and cycled.
Solution Approach 2:
The control system implements periodic cycling of heat elements based on wear-tracking information. Each heat element is energized for a certain number of cycles, then cycled off while another element takes over. This periodic on/off action based on wear tracking extends the overall system lifespan while maintaining continuous heating capability.
2Duration of action of stationary object
If the number of heat elements is increased to extend lifespan through wear-leveling, then component durability is improved, but device complexity increases
Solution Approach 1:
Multiple heat elements serve universal heating functions with identical operational characteristics. Each element can replace any other element in the heating process, making them interchangeable. This multi-functionality allows the system to achieve wear-leveling without requiring complex differential control of each element's specific role.
Solution Approach 2:
The control system incorporates wear-tracking information that monitors the operational cycle count of each heat element and relay. This feedback mechanism automatically determines which element should be activated next based on accumulated wear, creating a self-regulating system that extends component lifespan without requiring complex manual intervention or monitoring.
3Duration of action of stationary object
If wear-tracking information is implemented to distribute usage evenly, then component lifespan is extended, but measurement and control complexity increases
Solution Approach 1:
The control system automatically tracks and manages the wear of each heat element and relay through integrated wear-tracking information. The system serves itself by autonomously determining which component should be activated based on accumulated cycle counts, eliminating the need for external monitoring or manual tracking of component usage.
Solution Approach 2:
The patent replaces physical wear indicators or manual tracking mechanisms with electronic wear-tracking information stored and processed by the control system. This substitution of mechanical tracking with digital monitoring simplifies the measurement process and enables automated wear-leveling control.
Data Source
AI summary
In at least some embodiments, an air handler includes a coil and a fan. The air handler also includes an auxiliary heat source having a plurality of heat elements. The auxiliary heat source implements a wear-leveling algorithm to cycle use of the heat elements over multiple auxiliary heat cycles.