Retrofittable Boiler Thermostat Control With Wireless Programmer Bypass
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Solution Overview
Problem
Existing boiler-based heating systems face inefficiencies in energy management due to the bifurcation of control functions between programmers and thermostats, leading to wasted energy when schedules change and requiring high-voltage wire connections, which are hazardous and difficult to install.
Innovation Solution
An intelligent thermostat system with a modular design, comprising a head unit, backplate, and base unit, that communicates wirelessly and can bypass existing programmers, allowing for advanced scheduling and energy control without the need for new wiring, using dual-mode communication and power conversion to safely handle high AC voltages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-voltage wire connections are used to connect thermostat to boiler system, then reliable power delivery is achieved, but installation becomes hazardous and difficult
Solution Approach 1:
The patent replaces the mechanical/electrical high-voltage wiring system with a wireless communication system. The thermostat and boiler controller communicate control signals and power data wirelessly, eliminating the need for physical high-voltage wire connections between the thermostat and boiler system, thereby making installation safer and easier while maintaining reliable power delivery through dedicated power wiring.
2Ease of operation
If control functions are bifurcated between programmers and thermostats, then specialized control is achieved, but energy waste occurs when schedules change
Solution Approach 1:
The patent merges the scheduling control functions from the external programmer into the thermostat itself. The thermostat now contains both temperature control and scheduling capabilities in a single device, allowing it to autonomously manage heating schedules without requiring separate programmer hardware. This integration eliminates energy waste associated with schedule changes while maintaining specialized control functionality.
Solution Approach 2:
The thermostat is designed as a multi-functional device that performs both traditional temperature regulation and advanced scheduling operations. By incorporating programmable timing and control features directly into the thermostat, the system achieves universal control capabilities that eliminate the need for separate programmer devices and prevent energy waste during schedule transitions.
3Device complexity
If wireless communication is implemented for thermostat control, then installation complexity is reduced, but data transmission reliability may be compromised
Solution Approach 1:
The patent segments the communication system into two distinct wireless channels: one dedicated to control signal transmission between thermostat and boiler controller, and another for power management data exchange. This segmentation allows each wireless communication stream to be optimized for its specific function, ensuring reliable control signaling while separately managing power coordination, thereby maintaining communication reliability while eliminating wiring complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient energy management by allowing users to control boiler-based heating systems without adjusting programmers, reducing energy waste and installation risks through safe, low-voltage connections and advanced scheduling algorithms.
Implementation Method 1
power conversion circuitry for converting a relatively large AC voltage received from the third wiring terminals to a relatively low DC voltage
Implementation Method 2
thermostats generally use a bimetallic strip to sense temperature and respond to temperature changes in the room
Data Source
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AI summary
A control system may include a thermostat device and boiler control device. The thermostat device may be configured to receive electrical power from second wiring terminals and provide control signals to boiler control device using a second radio when wires are not present in first wiring terminals. The thermostat device may also be configured to receive electrical power from the first wiring terminals and provide the coded control signals to the boiler control device through the first wiring terminals when wires are present in the first wiring terminals. The boiler control device may be configured to receive the control signals from the thermostat device using a third radio and selectively couple the third wiring terminals to fifth wiring terminals to selectively control activation of the boiler-based heating system when wires are not present in fourth wiring terminals.