Heating System Flow Control Using Balancing Valve and Single Sensor
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Solution Overview
Problem
Existing hydraulically non-decoupled heating systems with two heating circuits face challenges in ensuring precise and energy-efficient operation without hydraulic decoupling, often requiring complex and inaccurate methods for setting overflow valves and lacking feedback for optimal heat distribution.
Innovation Solution
A procedure for operating a heating system that uses a heat generator circuit with a circulation pump and volume flow sensor, connected to two heating circuits, where a 3-way mixing valve and strand regulating valve allow for precise control of volume flows without an overflow valve, enabling operation with a single volume flow sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If hydraulic decoupling is implemented to independently control flow rates in each heating circuit, then flow rate control precision is improved, but device complexity increases due to requiring hydraulic separators, multiple circulation pumps, and flow rate sensors
Solution Approach 1:
The patent extracts and eliminates the hydraulic separator component from the system by implementing direct hydraulic coupling between the heat generator circuit and heating circuits. This allows independent flow rate control to be achieved through electronic regulation of circulation pumps rather than through complex hydraulic separation, thereby reducing device complexity while maintaining control precision
Solution Approach 2:
The patent replaces the mechanical hydraulic decoupling system with an electronic control system. Instead of using hydraulic separators and mechanical flow control devices, the system uses electronically controlled circulation pumps with integrated flow rate sensors and control units that can independently regulate flow rates in each heating circuit, substituting mechanical complexity with electronic control
2Device complexity
If overflow valve is used for hydraulic balancing in non-decoupled systems, then device complexity is reduced, but manufacturing precision deteriorates because the valve cannot be adjusted based on measured values and requires time-consuming trial and error
Solution Approach 1:
The patent implements feedback control by equipping each heating circuit with a flow rate sensor that continuously measures the actual flow rate. The control unit receives this feedback information and automatically adjusts the circulation pump settings to achieve the desired flow distribution, eliminating the need for manual trial and error adjustment of overflow valves while maintaining system simplicity
Solution Approach 2:
The system performs self-balancing through automated control. The control unit automatically calculates the required flow distribution based on system parameters and adjusts the circulation pumps accordingly, eliminating the need for manual intervention by installers to adjust overflow valves, thereby achieving both simplicity and precision
3Device complexity
If overflow valve is manually adjusted for heat distribution, then device complexity is reduced, but loss of time increases due to time-consuming installation and adjustment processes
Solution Approach 1:
The system performs preliminary automated balancing calculations and adjustments during the commissioning phase. The control unit stores the optimal flow distribution parameters and automatically implements them during operation, eliminating the need for repeated manual adjustments by installers and significantly reducing installation and commissioning time while maintaining system simplicity
4Device complexity
If overflow valve is used for flow rate control, then device complexity is reduced, but adaptability deteriorates because the mechanical valve cannot respond to dynamic, variable heat demand
Solution Approach 1:
The patent implements dynamic control by equipping each heating circuit with an electronically controlled circulation pump that can continuously adjust its operating speed. The control unit receives real-time information about heat demand from temperature sensors and other system components, and dynamically adjusts the pump speeds to match varying heat requirements, replacing static mechanical valve control with dynamic electronic control while maintaining system simplicity
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 solution allows for precise and energy-efficient operation of the heating system, ensuring optimal heat distribution between the two heating circuits, reducing maintenance costs, and simplifying installation processes.
Implementation Method 1
a volume flow sensor (5) for determining the volume flow delivered by the first circulation pump (8)
Implementation Method 2
a heat generator (2) having a heat generator circuit (13)
Implementation Method 3
a first circulation pump (8) arranged in the heat generator circuit (13)
Data Source
Figure 1~2
Figure 3
AI summary
A method for operating a heating system (1) is proposed.The heating system (1) has a heat generator circuit (13) with a first circulation pump (8) and a flow sensor (5), wherein the heat generator circuit (13) is hydraulically connected to a first heating circuit (10) and a second heating circuit (11), and in the second heating circuit (11) a second circulation pump (19) and a 3-way mixing valve (17) which can allow flow through a bypass (18) between the flow and return of the second heating circuit (11), as well as a balancing valve (16) are arranged, and the method comprises at least the following steps: a) determining a necessary first differential pressure (27) to operate the first heating circuit (10) in the design state, and b) adjusting a second predetermined target flow rate (24) in the heat generator circuit (13) and adjusting the first differential pressure (27) determined in step a) with the actuating position (25) of the balancing valve. (16) as an actuator.