Hot Water Recirculation Control Using External Flow Sensing
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Solution Overview
Problem
Existing hot water recirculation systems face inefficiencies due to unnecessary pump operation, energy wastage, and costly installation challenges, with existing solutions like timers and manual switches being inconvenient or ineffective.
Innovation Solution
A device comprising a flow sensor, booster pump, and controller that determines resting and in-use flow states to optimize pump operation based on user input, allowing for efficient control of pump duration and reducing energy consumption, with a non-invasive flow sensor installation method that doesn't require plumbing system disruption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pump is operated continuously to ensure hot water availability, then hot water delivery reliability is improved, but energy consumption increases
Solution Approach 1:
The pump operation transitions from static continuous operation to dynamic on-demand operation. The controller dynamically adjusts pump operation based on real-time flow sensor data, activating the pump only when actual water demand is detected through the plumbing system, thereby maintaining reliability while reducing energy consumption.
Solution Approach 2:
A feedback mechanism is implemented where the flow sensor continuously monitors water flow conditions and provides information to the controller. The controller uses this feedback to determine when hot water is actually needed and activates the pump accordingly, creating a closed-loop system that balances reliability and energy efficiency.
2Productivity
If plumbing changes are made to improve hot water recirculation system function, then system performance is improved, but installation cost increases
Solution Approach 1:
The system is segmented into independent functional modules: the pump, flow sensor, and controller can be installed and configured separately. This modular approach allows for incremental installation and reduces the need for extensive plumbing modifications, as components can be integrated into existing systems with minimal disruption.
Solution Approach 2:
The flow sensor and controller are designed to work with various pump types and existing plumbing configurations, providing universal compatibility. This multi-functionality allows the system to improve performance without requiring specific plumbing modifications, as the components can adapt to different installation scenarios.
Data Source
AI summary
Technologies for use with a hot water recirculation system containing a hot water source, a booster pump downstream from the sensor, a conduit connecting the booster pump and water source, a flow sensor external to the conduit for sensing water flow within the conduit, and a plumbing fixture downstream from the pump are provided. The technologies enable a controller to couple to the sensor and the pump, and operate in a calibration mode and a control mode. Such operations can increase energy efficiency of the pump and increase operational longevity of the pump.