Mixer Valve Flow Restriction Detection for Digital Showers
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Solution Overview
Problem
Digital shower/tap systems experience performance loss due to restricted water flow caused by blockages or retro-fitted flow restrictors, leading to incorrect temperature control and reduced functionality.
Innovation Solution
A control system for ablutionary devices that includes a mixer valve and a controller to compare current operating signals with historical signals, generating a diagnostic signal for flow restrictions, allowing for adjustments to maintain optimal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If flow restrictors or outlet diverters are retro-fitted to the ablutionary device, then energy efficiency is improved, but water flow rate is reduced
Solution Approach 1:
The system performs preliminary calibration to establish baseline flow rate data before any restrictions are applied. This historical data is stored and used for future comparisons to detect when flow restrictions have been retro-fitted, allowing the system to distinguish between intentional energy-saving restrictions and problematic blockages.
Solution Approach 2:
The system continuously monitors flow rate and compares it against the calibrated baseline, providing feedback when deviations are detected. This allows the system to identify when flow restrictions are present and adjust operation accordingly, or alert the user to potential problems.
2Duration of action of stationary object
If outlet holes or filters become blocked with deposits over time, then manufacturing durability is improved, but water flow rate is reduced
Solution Approach 1:
The system establishes a baseline flow rate during initial calibration before any deposits can accumulate. This historical data serves as a reference point to detect gradual flow degradation over time, allowing the system to monitor the development of blockages throughout the service life of the device.
Solution Approach 2:
The system continuously compares current flow rate measurements against the calibrated baseline, providing feedback when gradual reductions are detected. This enables the system to identify when deposits are accumulating and affecting performance, even though the device is still functioning.
3Measurement precision
If flow rate is reduced due to blockages or restrictors, then temperature control precision is improved, but system performance is degraded
Solution Approach 1:
The system uses feedback from flow rate sensors to detect when flow restrictions are present, comparing current flow against calibrated baseline data. This feedback allows the system to identify when performance degradation is occurring due to blockages or restrictions.
Solution Approach 2:
The system changes operational parameters based on detected flow conditions. When flow restrictions are detected, the system can adjust valve positions, pump speeds, or heating power to compensate for the reduced flow, thereby maintaining temperature control precision despite the flow limitation.
Data Source
AI summary
A control system for one or more ablutionary devices includes a mixer valve having a first inlet and a second inlet configured to receive a supply of hot and cold water, and an outlet configured to output cold water, hot water or a mixture thereof as an output stream for supplying water to the one or more ablutionary devices downstream of the mixer valve; and a controller. The controller is configured obtain one or more current operating signals related to the flow rate of the output stream produced by the mixer valve and compare each of the one or more current operating signals to a corresponding historical operating signal, the historical operating signal being an operating signal previously obtained by the controller, and to generate a diagnostic signal based on the comparison.