Gas Boiler Heating-Time Diagnostics for Early Fault Detection
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Solution Overview
Problem
Existing methods for detecting malfunctions in combustion appliances, particularly three-way mixing valves in gas boilers, are inefficient and require time-consuming manual inspections after failures occur, lacking timely detection capabilities.
Innovation Solution
A method that measures the duration of a heating up process and compares it to an expected duration, using time deviation to detect errors in the operation of a combustion appliance, such as a gas boiler, by calculating time deviation based on target temperature, power, and heat capacity, without requiring hardware modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection of all boiler components is performed to determine the cause of malfunction symptoms, then diagnostic accuracy is improved, but time consumption and operational complexity increase significantly
Solution Approach 1:
The patent extracts the diagnostic function from manual inspection by implementing an automated control unit that monitors boiler parameters. The system extracts key operational data (temperature, pressure, flow rates) and automatically analyzes them to detect malfunctions, eliminating the need for time-consuming manual component-by-component inspection while maintaining diagnostic accuracy.
Solution Approach 2:
The boiler system performs self-diagnosis through the control unit that continuously monitors its own operational parameters. The system automatically detects deviations from normal operation and identifies potential malfunctions without requiring external manual inspection, enabling the system to service itself diagnostically.
2Reliability
If traditional malfunction detection methods are used waiting for component failure, then system simplicity is maintained, but reliability and timely detection capability deteriorate
Solution Approach 1:
The control unit performs preliminary detection of malfunctions by continuously monitoring operational parameters before actual component failure occurs. The system identifies early signs of malfunction through parameter deviations and alerts operators in advance, enabling preventive maintenance before critical failures happen, thus improving reliability without requiring overly complex additional hardware.
3Measurement precision
If extensive manual inspection of all components is conducted to identify malfunction causes, then diagnostic completeness is improved, but ease of operation and maintenance simplicity deteriorate
Solution Approach 1:
The patent replaces the mechanical manual inspection process with an automated electronic monitoring system. The control unit electronically collects, processes, and analyzes operational parameters to identify malfunction causes, substituting the manual mechanical inspection of components with an automated digital diagnostic system that provides complete diagnostic information more simply and efficiently.
Data Source
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Figure 3A~3B
AI summary
Method (100) for controlling the operation of a combustion appliance (1), in particular a gas boiler and more particularly a combi gas boiler, during a heating up process, the method (100) comprising measuring (S101) a time duration (Δt) of the heating up process until a target temperature (Ts) is achieved, determining (S102) an expected time duration (Δt*) of the heating up process based on said target temperature (Ts), determining (S103) a time deviation (TD), the time deviation (TD) being the difference between the measured time duration (Δt) and the expected time duration (Δt*), and determining (S104) the presence of an error in the operation of the combustion appliance (1), if the time deviation (TD) is greater than at least a time error value (ɛ1, ɛ2).