Networked boiler system and method
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Solution Overview
Problem
Existing boiler systems face inefficiencies and high installation costs due to the need for separate wiring between each boiler and a centralized control, limiting the ability to maximize individual and overall system efficiency.
Innovation Solution
A networked boiler system with a modular boiler control that allows a master boiler to function as a centralized external control, eliminating the need for separate wiring by using a control algorithm in software to regulate slave boilers and internal sub-boilers, enabling hierarchical control and efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a centralized external control is used to control multiple boilers, then control functionality is provided, but installation costs increase due to separate wiring requirements
Solution Approach 1:
The patent combines the external control functionality into the master boiler's controller, eliminating the need for a separate centralized control device. The master boiler controller performs both internal boiler control and external system control functions, reducing wiring requirements and installation costs while maintaining full control capability over the boiler system.
Solution Approach 2:
The master boiler controller is designed to perform multiple functions: controlling the master boiler's operation, monitoring system temperature, managing slave boiler sequencing, and providing outdoor reset functionality. This multi-functional controller eliminates the need for separate dedicated control devices for each boiler.
2Reliability
If separate wiring is run between each boiler and centralized control, then control signaling is reliable, but device complexity increases
Solution Approach 1:
The patent merges all control signaling into a single network communication bus that connects the master boiler controller with slave boiler controllers. This eliminates the need for separate control wiring to each individual boiler, reducing wiring complexity while maintaining reliable communication through the network protocol.
3Ease of manufacture
If a master boiler controls slave boilers without separate wiring, then installation costs are reduced, but control precision may be compromised
Solution Approach 1:
The system implements feedback control where the master boiler controller receives temperature signals from the heat exchanger and system temperature sensors, processes this information through control algorithms, and adjusts slave boiler operation accordingly. This closed-loop feedback ensures precise temperature control despite the simplified wiring architecture.
Solution Approach 2:
The patent segments control functions between the master boiler controller (handling system-level control, outdoor reset, and sequencing) and individual slave boiler controllers (handling local boiler operation). This segmentation allows precise local control at each boiler while maintaining system-wide coordination through the network communication.
Data Source
AI summary
A networked boiler system includes a first boiler, at least one secondary boiler in operative connection with the first boiler and having a plurality of internal sub boilers, a boiler control connected to one of the first or secondary boilers, and an external control connected to one of the first or secondary boilers. The boiler control enables the first boiler to control a boiler parameter of the first boiler, the at least one secondary boiler, and the plurality of internal sub boilers of the at least one secondary boiler. A method of operating a networked boiler system includes the steps of connecting a first boiler to at least one secondary boiler, the secondary boiler including a plurality of nested sub boilers; connecting the first boiler to an external control; and with a boiler control connected to one of said first boiler and said at least one secondary boiler, controlling a boiler parameter of said first boiler, said at least one secondary boiler, and said plurality of nested sub boilers of said at least one secondary boiler.