One-pipe hydronic heating control device
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Solution Overview
Problem
Existing heat exchanger control systems are inefficient due to reliance on flow meters, which increase costs and have narrow operational ranges, and lack precise temperature measurements, leading to inaccurate heat output control and diagnostics.
Innovation Solution
A one-pipe heating connection system with integrated temperature sensors and a pump that controls flow rate from nearly zero to maximum, using the secondary circuit's constant hydraulic resistance and pump pressure characteristics to estimate and control absolute heat flow, eliminating the need for flow meters and reducing mechanical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a flow meter is used to measure the flow rate, then the heat output control precision is improved, but the device cost and complexity significantly increase
Solution Approach 1:
The patent extracts the flow measurement function from a dedicated flow meter and integrates it into the pump assembly. The pump housing incorporates temperature sensors and flow path measurements, eliminating the need for a separate flow meter while maintaining measurement capability for heat output calculation.
Solution Approach 2:
The patent merges multiple functions into the pump assembly: pumping function, temperature measurement (via integrated sensors), and flow rate determination (via dimensional data). This combination reduces the number of separate components while achieving the same measurement precision for heat output control.
2Measurement precision
If a valve actuator is used to change the flow rate, then the heat output control is improved, but the operational range and reliability are reduced
Solution Approach 1:
The patent replaces the static valve actuation system with a dynamic pump speed control system. The pump can continuously adjust its flow rate across a wide operational range by varying motor speed, providing better adaptability and reliability compared to on/off valve actuation with limited modulation capability.
Solution Approach 2:
The patent substitutes the mechanical valve actuation system with an electronically controlled pump speed regulation system. This replacement eliminates the mechanical wear and limited range issues of valve actuators while providing continuous, precise flow rate control through electronic motor speed adjustment.
3Measurement precision
If temperature sensors are integrated into the pump assembly, then the measurement accuracy is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent combines temperature sensing functionality directly into the pump housing structure. By integrating the sensors during pump manufacturing rather than as separate installation steps, the system achieves accurate temperature measurement while streamlining the overall manufacturing process through component consolidation.
4Reliability
If multiple separate components are used for heating control, then the system reliability is improved, but the installation complexity and risk increase
Solution Approach 1:
The patent merges the pump, temperature sensors, and flow measurement capabilities into a single integrated assembly. This consolidation reduces the number of separate components that need to be installed and connected, thereby reducing installation complexity and potential failure points while maintaining system reliability through integrated design.
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
This solution provides precise heat flow control and diagnostics, reducing installation risks and simplifying design, while allowing control of a wide range of heat exchangers with improved accuracy and reduced costs.
Implementation Method 1
The pump impeller (3) is connected, with the right orientation, anywhere into the secondary circuit formed by the device secondary supply pipe (13), heat exchanger supply pipe (16), heat exchanger return pipe (17), and device secondary return pipe (19)
Implementation Method 2
The secondary supply temperature sensor (20) is placed so that it can sense the temperature of the heat-transfer medium entering the heat exchanger (2), and the secondary return temperature sensor (22) is placed so that it can sense the temperature of the heat-transfer medium leaving the heat exchanger (2)
Implementation Method 3
heat from a heat source is transported via a distribution network to end heat exchangers. Then, the control of heat exchanger power is an important tool to control the temperature in associated processes or rooms
Data Source
AI summary
Heat exchanger output control device in a one-pipe heating network characterized in that a first T-branch, which is connected to a second T-branch interconnected to a primary outlet pipe connection of a primary outlet pipe to a heat source through a primary outlet, is connected to the primary inlet pipe connection through a primary inlet. The first T-branch is connected to a secondary supply pipe connection through a secondary supply pipe with a secondary supply temperature sensor, and the second T-branch is connected to a secondary return pipe connection through a secondary return pipe with an additional secondary return temperature sensor. An impeller of a pump is connected to a secondary circuit to pump the heat-transfer medium from the first T-branch through a heat exchanger back to the second T-branch, and to connected to a electrical motor provided with a control unit connected to secondary supply and return temperature sensors.