Continuous-Flow Heater Flow Meter Insertion for Leak-Safe Assembly
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Solution Overview
Problem
Existing electric instantaneous water heaters face challenges with the arrangement of flow meters, requiring complex sealing and assembly processes, leading to increased susceptibility to faults and high assembly costs, as well as difficulties in replacing or cleaning the flow meters.
Innovation Solution
The flow meter is designed as a slide-in part with a dedicated insertion space in the end channels, allowing for easy insertion and removal without additional sealing measures, utilizing existing sealing surfaces on the water heater for secure attachment, and can be replaced with inexpensive mass-produced components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flow meter is installed in the water path of a continuous-flow heater using conventional sealing methods, then the flow meter can detect water flow rate, but the assembly becomes complex with multiple sealing surfaces and increased susceptibility to leakage
Solution Approach 1:
The flow meter is integrated into the end channel such that the flow meter housing and the end channel form a unified structure. The sealing surface of the flow meter is merged with the sealing surface of the end channel, eliminating the need for separate sealing connections. This merging reduces the number of sealing surfaces from multiple to a single integrated sealing interface, thereby reducing complexity while maintaining sealing reliability.
Solution Approach 2:
The end channel is designed to serve multiple functions: it guides water flow, provides structural support, and integrates the flow meter mounting function. The flow meter is not just an add-on component but is incorporated into the multi-functional end channel structure, which already exists for water guidance. This eliminates the need for separate mounting structures and their associated sealing requirements.
2Reliability
If special sealing surfaces and seals are provided for the flow meter, then the flow meter can be sealed against water and pressure, but assembly work and costs increase
Solution Approach 1:
The sealing function is merged into the existing end channel structure. The flow meter utilizes the same sealing surface that is already part of the end channel's water guidance function. This eliminates the need for separate sealing surfaces and reduces the number of sealing components required, thereby lowering assembly costs while maintaining pressure tightness.
Solution Approach 2:
The end channel's existing sealing surface serves the dual purpose of sealing both the water flow path and the flow meter installation. The structure is designed to seal itself without requiring additional sealing components specifically for the flow meter, reducing manufacturing and assembly costs.
3Reliability
If multiple seals are arranged in the flow meter installation, then sealing against water and pressure is achieved, but susceptibility to wear and leakage increases with service life
Solution Approach 1:
Multiple sealing surfaces are merged into a single integrated sealing interface between the flow meter and the end channel. This reduces the number of seals from multiple to one, minimizing the points of potential wear and failure. The single sealing interface is designed to withstand both water flow and pressure throughout the service life of the heater.
4Reliability
If the flow meter is installed with sealed flange or flange/connector connections, then the flow meter can be securely attached, but the installation and replacement require significant assembly work
Solution Approach 1:
The flow meter attachment is merged with the end channel structure. The flow meter is installed directly into the end channel using the existing sealing surface, eliminating the need for separate flange or connector assemblies. This simplifies the installation process while maintaining secure attachment, as the flow meter becomes an integral part of the end channel assembly.
5Ease of manufacture
If existing seals are used for flow meter installation, then assembly is simplified, but the seals cannot be reused and must be replaced
Solution Approach 1:
The flow meter is designed as a separable component that can be independently removed from the end channel. The sealing interface is designed such that the seal remains with the end channel while the flow meter can be detached and replaced. This segmentation allows the flow meter to be replaced without replacing the seal, facilitating easier repair and maintenance.
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
This design simplifies the assembly and maintenance of the flow meter, reducing assembly costs and fault susceptibility, while allowing for space-saving and time-effective installation and replacement, eliminating the need for special seals and reducing the complexity of sealing connections.
Implementation Method 1
an electrical heating device arranged to heat water flowing through the channel arrangement
Implementation Method 2
a flow measuring device, which detects the amount of water supplied to the heating device and applies a flow control signal to the electrical control device, which is effected in accordance with the flow rate
Data Source
AI summary
The heater has a channel arrangement (4) comprising water-guiding channels (41-43) formed between inner channel ends (22, 32) of end channels (2, 3). An electrical heating device (5) heats water flowing through the arrangement. An electronic control device controls temperature of the device. A flow rate measuring device (7) has a flowmeter (71) designed as a flowmeter-insertion part (711) that is guided into one of the end channels and removably arranged in a flowmeter-insertion area (23) in series with a conducting connection piece (24) removed from an outer channel opening (211).