Boiler control system

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Solution Overview

Problem

Existing boiler control systems rely on inflexible microcontrollers, which require lengthy and expensive certification processes for software updates, even for non-safety critical functions, limiting their adaptability and efficiency.

Innovation Solution

A boiler control system that combines a microcontroller for safety-critical functions with a microcomputer for operating controls, allowing for flexible software updates and configuration changes without recertification, using a touchscreen interface and external ports for connectivity and data exchange.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a microcontroller is used for boiler control, then safety-critical functions are reliably controlled, but software updates require lengthy and expensive recertification

Engineering Contradiction:

Improvesafety-critical function controlVSAvoidsoftware update flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The control system is divided into two distinct parts: a microcontroller dedicated to safety-critical functions (flame safeguard operations) and a microcomputer for non-safety operating controls. This segmentation allows the microcontroller to maintain certification while the microcomputer can be updated flexibly without recertification requirements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The microcontroller acts as an intermediary between safety-critical operations and the microcomputer. It receives commands from the microcomputer but maintains independent control over safety functions, ensuring that software updates to the microcomputer do not compromise safety-critical operations.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a microcontroller is used for boiler control, then specialized functions are tightly controlled, but operational flexibility and adaptability are reduced

Engineering Contradiction:

Improvespecialized function controlVSAvoidoperational flexibility

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The system separates specialized safety functions (handled by the certified microcontroller) from general operating functions (handled by the flexible microcomputer). This allows each component to be optimized for its specific purpose while working together as an integrated system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The microcomputer provides universal control capabilities for various operating functions including temperature controls, pump controls, and peripheral controls. It can be programmed to handle diverse operational scenarios while the microcontroller ensures safety constraints are met.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If a microcontroller is used for boiler control, then certification is obtained, but updating non-safety critical functions requires recertification

Engineering Contradiction:

Improvecertified safety controlVSAvoidrecertification time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

By segmenting the control system into safety-critical (microcontroller) and non-safety (microcomputer) components, updates to the microcomputer do not affect the certified safety functions. This eliminates the need for recertification when updating operating controls, touchscreen interfaces, or communication protocols.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The non-safety critical functions are extracted from the certified microcontroller and placed in the uncertified microcomputer. This extraction allows independent updating of operating functions without involving the certification authority, saving significant time and resources.

Inventive Principle:

Principle #2Taking out (Extraction)

4Volume of moving object

If a microcontroller is used for boiler control, then system size is reduced, but functionality and connectivity are limited

Engineering Contradiction:

Improvecontroller sizeVSAvoidfunctionality and connectivity

Core Design Contradiction:

Volume of moving objectVSAdaptability or versatility

Solution Approach 1:

The system merges a compact microcontroller with a more capable microcomputer into an integrated control unit. The microcontroller handles safety functions with minimal size, while the microcomputer adds extensive functionality including touchscreen interface, multiple communication protocols (WiFi, Ethernet, Bluetooth), and advanced control algorithms without significantly increasing overall system footprint.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The microcomputer component provides universal connectivity options including WiFi, Ethernet, and Bluetooth interfaces, enabling the system to communicate with various devices and platforms. It also supports multiple programming languages and can be configured for different operational scenarios, greatly expanding system versatility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS9822986B2Boiler control system

Publication Date: 2017.11.21 THE MARLEY COMPANY

AI summary

A system and method for controlling a boiler comprising a microcomputer operatively connected to a microcontroller wherein the microcontroller is configured to provide flame safeguard operations and the microcomputer is configured to provide operating control instructions to the microcontroller. The boiler control system may operate either in a stand-alone, cascade master or cascade slave configuration.