Steam Generator Water Level Detection Without Additional Sensors
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Solution Overview
Problem
Steam generators in household appliances face issues with calcification leading to clogged pipes, inefficient steam delivery, and steam concentration in unwanted areas, increasing production and assembly costs due to the need for additional sensors and components.
Innovation Solution
A steam generator with a control unit that monitors the cut-in and cut-off temperature time period to detect the water level, a channel extending below the minimum water level to prevent steam discharge from the inlet, and a thermal fuse to ensure safe operation, along with a helical heater configuration for faster heating and reduced contact area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a steam generator uses a conventional water level detection method with additional sensors, then the water level can be accurately monitored, but the production and assembly costs increase
Solution Approach 1:
The heater serves dual functions: heating water and detecting water level. The control unit monitors the heater's power consumption and temperature to infer water level, eliminating the need for separate level sensors. This self-service approach reduces component count while maintaining detection accuracy
Solution Approach 2:
The heater is designed to perform multiple functions: primary heating, water level detection through electrical parameters monitoring, and temperature regulation. This multi-functionality consolidates what would traditionally require separate components into a single element, reducing overall system complexity
2Productivity
If steam is discharged from the inlet opening, then steam can be delivered to the tub, but steam concentrates in unwanted areas and water condensation occurs in electronic components
Solution Approach 1:
The inlet opening is positioned and oriented to direct steam flow specifically toward the tub area. The channel geometry and opening placement create localized steam delivery zones, ensuring steam reaches the intended area while avoiding sensitive electronic components mounted in other locations
Solution Approach 2:
A channel structure serves as an intermediary pathway between the water reservoir and the tub. This channel controls and directs steam flow, acting as a mediator that guides steam to the desired location while preventing direct discharge into areas with electronic components
3Use of energy by moving object
If the heater contact area with water is increased, then heating efficiency improves, but the heating speed decreases
Solution Approach 1:
The heater operates in periodic cycles with alternating high-power and low-power phases. During high-power phases, the heater provides intensive heating; during low-power phases, it maintains temperature. This periodic operation allows the heater to achieve both fast heating responses and sustained energy efficiency
Solution Approach 2:
The heater's operational parameters are dynamically adjusted based on real-time feedback from temperature sensors and power consumption monitoring. The system varies heating intensity and duration to optimize both heating speed and efficiency depending on the current water level and temperature conditions
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 enhances steam efficiency, prevents water condensation in electronic components, reduces production costs by eliminating the need for extra sensors, and ensures safe operation by controlling the heater and monitoring temperature changes.
Implementation Method 1
a heater (5) that heats the water inside the reservoir (2)
Implementation Method 2
the temperature is measured by NTC sensors
Implementation Method 3
a thermal fuse is used in order to cut off the current supplied to the heater in case of any problems
Implementation Method 4
the generated steam leaving from the steam outlet opening
Data Source
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AI summary
The present invention relates to a household appliance comprising a steam generator (1) having a reservoir (2) wherein water is stored, at least one inlet opening (3) and at least one outlet opening (4) arranged on the reservoir (2), a heater (5) that heats the water inside the reservoir (2) and a temperature sensor (6) that measures the temperature of the heater (5).