Control-by-Wire Architecture for Gas Grill Burner Valve Actuation

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Solution Overview

Problem

Conventional gas grills rely on mechanical control architectures that require direct mechanical connections between control knobs and burner valves, which can be cumbersome and prone to interference, limiting the flexibility and efficiency of fuel control.

Innovation Solution

Implementing a 'control-by-wire' architecture that uses a rotary encoder, controller, and solenoid valves to electronically control the burner valves, eliminating mechanical connections and allowing for more precise and flexible fuel management, while also reducing electrical noise interference through differential signaling and daisy-chained user-interface assemblies.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If mechanical control architecture is used with direct mechanical connections between control knobs and burner valves, then the system is simple and reliable, but the flexibility and precision of fuel control are limited

Engineering Contradiction:

Improveflexibility of fuel controlVSAvoidcontrol architecture complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical control system with an electronic control system. Control knobs are decoupled from burner valves and instead connect to a controller via wiring harnesses. The controller receives user input from the control knobs and actuates the burner valves electronically, eliminating the need for direct mechanical connections and enabling flexible, precise fuel control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a controller as an intermediary between the control knobs and burner valves. This controller processes user inputs and manages the actuation of multiple burner valves, allowing for sophisticated control logic and flexibility without requiring complex mechanical linkages between each control knob and burner valve.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If mechanical connections are used between control knobs and burner valves, then the control system is straightforward, but electrical noise interference increases and wiring becomes complex

Engineering Contradiction:

Improvecontrol signal transmissionVSAvoidelectrical noise interference

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces mechanical signal transmission with electrical signaling through a controlled architecture. Control signals are transmitted electronically from control knobs to the controller and then to burner valves, allowing for noise filtering, signal conditioning, and reliable transmission without the interference issues associated with direct mechanical connections in electrically noisy environments.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If direct mechanical connections are used for control, then installation is simple, but precision and flexibility of fuel management are reduced

Engineering Contradiction:

Improvefuel flow control precisionVSAvoidcontrol system architecture

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent employs an electronic control system where the controller precisely manages burner valve actuation based on user inputs from control knobs. This electronic architecture enables precise fuel flow control through controlled opening/closing of valves, far exceeding the precision achievable with mechanical linkages, while the modular design keeps system complexity manageable.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

The solution enables more precise control over fuel flow and combustion rates, reduces electrical noise interference, and simplifies wiring, resulting in a more efficient and flexible grill control system with improved user interface and remote monitoring capabilities.

Implementation Method 1

a rotary encoder configured to detect a rotational position of the control knob

Methodology Applied

Scientific EffectRotational encoding:

Implementation Method 2

a solenoid valve configured to open or close a fuel passage between the manifold and the burner in response to signals from the controller

Methodology Applied

Scientific EffectSolenoid actuation: Solenoid

Implementation Method 3

reducing electrical noise interference through differential signaling

Methodology Applied

Scientific EffectDifferential signaling:

Data Source

PatentUS20230258338A1Methods and apparatus for communicating control signals in a grill

Publication Date: 2023.08.17 WEBER-STEPHEN PRODUCTS

AI summary

Example methods and apparatus for communicating control signals in a gas grill are disclosed herein. An example user-interface assembly for use in a grill includes control knob, knob sensor to detect a user interaction with the control knob, lighting circuitry including a plurality of light emitting diodes, and user-interface controller circuitry to identify an addressing block connected via an input wiring harness, the knob controller to select an address to be used to communicate with a central controller of the gas grill.