Modulating boiler system
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Solution Overview
Problem
Existing boiler systems face inefficiencies due to reliance on outdoor air sensors, which can provide erroneous measurements, fail to account for non-temperature related heat sources, and are not suitable for fixed set point boilers, limiting energy reduction and comfort.
Innovation Solution
A modulating boiler system that calculates energy input based on the moving average of the thermostat's on-time, eliminating the need for ambient air sensors and allowing direct adjustment of boiler energy to match heating needs, thereby optimizing efficiency and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If outdoor reset systems are used to reduce boiler set point in warmer weather, then energy consumption is reduced, but measurement accuracy deteriorates due to sensor errors from sun radiation, snow, ice, and calibration issues
Solution Approach 1:
The patent introduces an intermediary calculation method that uses the relationship between boiler runtime and outdoor temperature as a mediator to derive an effective outdoor temperature measurement. Instead of directly measuring outdoor temperature with a vulnerable sensor, the system uses the boiler's operational data and heat loss model to calculate an equivalent outdoor temperature that reflects actual heating needs, thereby avoiding the measurement errors of physical sensors.
Solution Approach 2:
The system implements feedback by continuously monitoring thermostat on-time and using it to adjust the calculated outdoor temperature and subsequent boiler set point. The moving average of thermostat on-time provides feedback about actual heating requirements, allowing the system to refine its energy consumption estimates and adjust operations accordingly, creating a closed-loop control that compensates for measurement uncertainties.
2Loss of energy
If outdoor reset systems are used to reduce energy input, then efficiency increases, but system complexity increases due to sensor installation, positioning, calibration, and reset ratio programming requirements
Solution Approach 1:
The system performs self-service by automatically calculating the effective outdoor temperature and adjusting the boiler set point without requiring external sensor installation or manual calibration. The controller uses internally available data (thermostat on-time, boiler runtime) and pre-programmed heat loss characteristics to autonomously determine optimal operating parameters, eliminating the need for complex sensor systems and their associated installation, positioning, and calibration procedures.
Solution Approach 2:
The patent makes the boiler controller universal by enabling it to perform multiple functions: it acts as both the primary control device and the outdoor temperature sensing device. The same controller that manages boiler operation also calculates effective outdoor temperature based on operational data, eliminating the need for separate dedicated outdoor sensors and reducing overall system complexity while maintaining the ability to adjust set points based on environmental conditions.
3Reliability
If conservative reset ratio is programmed to ensure sufficient heat availability, then comfort is maintained, but energy reduction effectiveness is severely limited
Solution Approach 1:
The system applies dynamics by making the reset ratio adaptive rather than fixed. Instead of programming a single conservative reset ratio that limits energy reduction, the system dynamically calculates the effective outdoor temperature and determines the appropriate set point adjustment in real-time based on actual heating需求的. The moving average of thermostat on-time allows the system to adapt to changing conditions and optimize the balance between comfort and energy reduction, enabling more aggressive energy savings while maintaining reliability.
Solution Approach 2:
The patent changes the parameter of reset ratio from a fixed conservative value to a dynamically adjusted value based on calculated effective outdoor temperature. By using the moving average of thermostat on-time to inform set point adjustments, the system can vary the effective reset ratio according to actual heating needs, allowing for greater energy reduction effectiveness while maintaining sufficient heat availability through data-driven parameter optimization rather than conservative fixed parameters.
4Loss of energy
If outdoor sensor is used for reset control, then energy consumption is reduced, but adaptability deteriorates because sources of heat gain or loss not related to outdoor air temperature are not captured
Solution Approach 1:
The system uses feedback from thermostat on-time to capture the effects of all heat gain and loss sources, not just outdoor air temperature. The moving average of thermostat on-time serves as feedback that reflects the net effect of all thermal influences including solar radiation, internal heat gains from occupants and appliances, window leakage, and insulation performance. This feedback mechanism allows the system to adapt to various heat gain/loss sources without requiring separate sensors for each factor.
Solution Approach 2:
The patent uses thermostat on-time as an intermediary that indirectly captures the combined effect of all heat gain and loss sources. Rather than directly measuring each individual heat transfer mechanism with specialized sensors, the system uses the thermostat's operational data as an intermediary indicator that reflects the overall thermal balance. This intermediary approach provides adaptability to various heat sources while simplifying the measurement system.
Data Source
AI summary
An increased efficiency boiler system includes a boiler, a thermostat in operative communication with the boiler and a controller. The controller is in communication with the boiler and the thermostat and selectively exchanges data with the boiler and the thermostat. The controller determines a proportional time period, reflecting how long the thermostat is requesting heat from the boiler within a predetermined time period, in dependence upon the exchange of data. The controller further determining a cycle frequency reflecting the number of times the thermostat is requesting heat from the boiler within the predetermined time period. The controller adjusts an energy input provided to the boiler in dependence upon the proportional time period and the cycle frequency.