System and method for control of electric water heater
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Solution Overview
Problem
Conventional electric water heaters consume energy based on water temperature or peak demand, leading to high costs during peak hours and inefficient energy usage, requiring costly upgrades to operate during off-peak hours.
Innovation Solution
A water heater system with a controller and control circuit that receives temperature and grid information signals, selectively energizing the heating element based on both temperature and grid demand data to optimize energy usage during off-peak hours, using a relay and microprocessor to manage energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If water heaters operate during peak hours to meet temperature demands, then water temperature setpoints are maintained, but energy costs increase significantly
Solution Approach 1:
The water heater system performs preliminary heating actions during off-peak hours when electricity rates are lower. The controller receives electrical grid information and proactively heats water in advance of peak demand periods, storing thermal energy in the water tank insulation system. This eliminates the need to operate heating elements during expensive peak hours while still maintaining adequate hot water availability.
Solution Approach 2:
The system implements a feedback mechanism where the controller continuously monitors both water temperature levels and electrical grid conditions (peak/off-peak status). Based on this dual feedback, the controller dynamically adjusts heating element operation to maintain temperature setpoints during off-peak hours while avoiding operation during peak hours, thereby optimizing the trade-off between temperature maintenance and energy cost reduction.
2Use of energy by moving object
If water heaters are upgraded with new control systems to operate during off-peak hours, then energy costs decrease, but manufacturing and installation costs increase
Solution Approach 1:
The control circuit is designed to perform multiple functions: it monitors water temperature, receives and processes electrical grid information signals, determines peak/off-peak status, and controls heating element operation. By consolidating these functions into a single multi-functional control unit, the system achieves off-peak operation capability without requiring multiple separate components, thereby reducing manufacturing complexity and cost.
Solution Approach 2:
The patent combines the temperature control function with the grid-aware scheduling function into a unified control system. The controller integrates temperature sensing, grid information processing, and heating element control into one cohesive unit, eliminating the need for separate control systems and reducing overall manufacturing and installation costs while achieving off-peak operation.
3Device complexity
If water heaters use traditional control methods based solely on temperature, then system complexity remains low, but energy efficiency during peak/off-peak hours cannot be optimized
Solution Approach 1:
The control circuit acts as an intermediary between the temperature control system and the heating element. It receives both temperature signals and electrical grid information, processes this information through a microprocessor, and generates appropriate control signals. This intermediary layer adds minimal complexity while enabling sophisticated energy efficiency optimization by mediating between simple sensors and the heating element based on multiple input factors.
Solution Approach 2:
The patent replaces traditional mechanical or simple thermal control mechanisms with an electronic control system that processes digital signals from temperature sensors and grid information receivers. The microprocessor-based control circuit substitutes complex mechanical timing and control mechanisms with software-based decision logic, achieving high energy efficiency with relatively simple hardware components.
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 reduces energy costs by aligning water heating with off-peak electrical rates, ensuring efficient energy use while maintaining water temperature setpoints, thereby lowering operational expenses for users and manufacturers.
Implementation Method 1
a heating element, a relay configured to provide power to the heating element
Data Source
AI summary
System and methods of operating a water heater receiving power from an electrical grid. The water heater includes a heating element, a controller, and a first control circuit. The first control circuit including an energizing terminal and a microprocessor. The method includes connecting an energizing terminal of the first control circuit between a power output terminal of the controller and the heating element, receiving driving power from the controller based on a temperature signal. The method also includes receiving control signals from the controller based on electrical grid information, and selectively energizing the heating element, by the microprocessor of the first control circuit and through the energizing terminal of the first control circuit based on the control signals.