Boiler control system

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Solution Overview

Problem

Existing boiler control systems rely heavily on microcontrollers, which are inflexible and require costly certification processes for software updates, even for non-safety critical functions, limiting the ability to modify or update systems without recertification.

Innovation Solution

A boiler control system that combines a microcontroller for safety-critical functions with a microcomputer for more flexible and adaptable operating controls, allowing for updates to be made without recertification through external interfaces like USB, SD cards, and wireless networks, enabling easier modification and enhancement of non-safety critical functions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a microcontroller is used for boiler control, then safety critical functions are reliably controlled, but flexibility and adaptability are reduced

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 critical operating controls. This segmentation allows each component to have optimized characteristics - the microcontroller ensures reliability for safety functions while the microcomputer provides flexibility for operating controls, resolving the contradiction between reliability and adaptability.

Inventive Principle:

Principle #1Segmentation

2Reliability

If a microcontroller is used for boiler control, then safety critical functions are tightly controlled, but software update cost and complexity increase due to recertification requirements

Engineering Contradiction:

Improvesafety critical function controlVSAvoidsoftware update cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

By separating safety-critical control (microcontroller) from operating control (microcomputer), the system allows software updates to the microcomputer without triggering recertification processes. The microcontroller remains certified and unchanged, while the microcomputer can be updated freely, significantly reducing update costs and complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The microcontroller acts as an intermediary that maintains safety-critical control while allowing the microcomputer to handle flexible operating controls. This intermediary relationship enables the microcomputer to be updated without affecting the certified safety functions, thus avoiding recertification costs.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If external interfaces are added to the microcomputer, then system flexibility and update capability are improved, but device complexity increases

Engineering Contradiction:

Improvesoftware update capabilityVSAvoidinterface port quantity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The microcomputer is designed with multiple external interfaces (USB, SD card, wireless networks) that serve universal purposes: software updates, configuration, and monitoring. These multi-functional interfaces provide versatile update capabilities while being integrated into a single control unit, managing complexity through consolidation rather than proliferation of separate systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS10533756B2Boiler control system

Publication Date: 2020.01.14 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.