Method and controller for operating a boiler appliance
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Solution Overview
Problem
Existing boiler appliances rely on inaccurate and unreliable feedback signals from the pump motor to determine water flow rates, which can lead to insufficient water circulation, potentially causing thermal shock to the heat exchanger, and require additional sensors like water pressure switches for reliable operation.
Innovation Solution
A method using both the pump motor's feedback signal and temperature sensor data to determine if the water flow rate is sufficient, allowing or denying combustion based on these thresholds, allowing for the potential removal of water pressure sensors and providing a reliable and cost-effective solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a water pressure switch or water pressure sensor is used to measure water flow rate, then the reliability of water flow measurement is improved, but the device complexity and cost increase
Solution Approach 1:
The patent extracts the water flow measurement function from dedicated sensors (water pressure switch/sensor) and implements it using the existing pump motor feedback signal and temperature sensor, which are already present in the boiler system for other purposes. This eliminates the need for additional measurement devices while maintaining measurement capability.
Solution Approach 2:
The pump motor feedback signal and temperature sensor, originally designed for motor control and temperature monitoring respectively, are repurposed to also determine water flow rate sufficiency. This multi-functional use of existing components avoids adding dedicated water flow measurement devices.
2Device complexity
If the pump motor feedback signal is used to determine water flow rate, then the device complexity is reduced, but the measurement precision deteriorates
Solution Approach 1:
The temperature sensor acts as an intermediary indicator to infer water flow rate conditions. Instead of directly measuring flow rate with imprecise motor feedback, the system monitors temperature changes in the water as an indirect but more reliable indicator of actual water flow through the heat exchanger.
Solution Approach 2:
The system uses feedback from both the pump motor and temperature sensor to continuously monitor and determine water flow sufficiency. The temperature feedback provides real-time information about actual heating performance, allowing the system to accurately assess whether sufficient water is flowing through the heat exchanger.
3Object-affected harmful factors
If a water pressure sensor is installed to ensure sufficient water flow, then the heat exchanger protection is improved, but the manufacturing cost increases
Solution Approach 1:
The patent removes the water pressure sensor from the system and extracts the water flow monitoring function to use existing components (pump motor feedback and temperature sensor). This eliminates the need for additional sensors while maintaining the protective function against thermal shock to the heat exchanger.
Solution Approach 2:
The system uses its own existing components (pump motor and temperature sensor) to perform the water flow monitoring and heat exchanger protection function that would otherwise require dedicated water pressure sensors. The boiler system monitors itself using components already present in the 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
Ensures sufficient water flow before ignition, minimizing thermal stress and avoiding damage to the heat exchanger, while eliminating the need for additional sensors, thus enhancing operational safety and reducing costs.
Implementation Method 1
A temperature sensor measures the temperature of the water heated within the heat exchanger
Implementation Method 2
thermal energy resulting from the combustion of the combustible within the combustion chamber is used to heat water flowing through the heat exchanger
Implementation Method 3
The water flow through the heat exchanger is provided by a pump, wherein the pump, namely a motor of the pump, is driven by a control variable
Data Source
Figure 1
Figure 2
AI summary
Method for operating a boiler appliance (10), the boiler appliance (10) comprising: a combustion chamber (11) for combusting a combustible; a heat exchanger (23) positioned within the combustion chamber (11), wherein thermal energy resulting from the combustion of the combustible within the combustion chamber (11) is used to heat water flowing through the heat exchanger (23); a pump (27) for pumping the water through the heat exchanger (23), wherein a motor (40) the pump (27) is driven by control variable (30) provided by a controller (20), and wherein the motor (40) of the pump (27) provides a feedback signal (31) that the motor (40) of the pump (27) is consuming electrical power to the controller (22); a temperature sensor (28) for measuring the temperature of the water heated within the heat exchanger (23), wherein the temperature sensor (28) provides by a temperature signal (29) to the controller (22). The feedback signal (31) provided by the motor (40) of the pump (27) and the temperature signal (29) provided by the temperature sensor (28) are both used to determine if the water flow rate through the heat exchanger (23) is sufficient or insufficient, wherein the combustion of the combustible is allowed when a sufficient water flow rate is determined and the combustion of the combustible is not allowed when an insufficient water flow rate is determined. (Figure 1)