Modular Water Heater Control for Low-Cost Feature Upgrades
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Solution Overview
Problem
Conventional water heaters face challenges in efficiently providing different models with varying features and functionalities, leading to increased manufacturing costs and burdensome retrofitting processes, especially when upgrading controllers, which can be problematic for consumers and unskilled technicians.
Innovation Solution
A modular control system for water heaters, comprising a first control module providing basic functionality and a second control module that can be added to upgrade the system, allowing for different feature sets without removing the first module, using communication ports for interfacing and implementing algorithms for heating element control, usage tracking, and diagnostic functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different controllers are installed for different water heater models to provide varying features and functionalities, then the functionality and features of water heaters are improved, but manufacturing costs increase due to the need for multiple assembly lines with separate tooling equipment
Solution Approach 1:
The patent implements a universal controller design that can serve multiple water heater models with different feature requirements. The controller includes a base unit with core functionality and optional modular components that can be selectively activated or configured. This allows a single controller platform to provide basic functionality for standard models while supporting advanced features for premium models, eliminating the need for separate assembly lines for different controller types.
2Adaptability or versatility
If retrofitting is performed to upgrade controllers in existing water heaters, then the functionality and performance are improved, but the process becomes burdensome and problematic for consumers and unskilled technicians
Solution Approach 1:
The controller is divided into modular segments including a base controller unit and separate functional modules. For retrofitting, only the necessary modular components need to be added or replaced rather than replacing the entire controller. The modular design includes standardized connection interfaces that simplify installation. Documentation and labeling guide consumers through the upgrade process, making it accessible to unskilled technicians by breaking down the complex retrofitting task into simple, discrete steps.
3Adaptability or versatility
If a more sophisticated controller is installed to provide better functionality and features, then the performance is improved, but the device complexity and manufacturing costs increase
Solution Approach 1:
The controller employs dynamic configuration capabilities where the system can adapt its complexity based on detected usage patterns, environmental conditions, or user preferences. The controller includes a base level of sophistication that provides core functionality, with additional intelligent features that can be selectively enabled. This dynamic approach allows the controller to maintain simpler operation for basic needs while providing advanced functionality when required, optimizing the balance between performance and complexity.
Data Source
AI summary
A water heater has a modular control system. The water heater comprises a tank, a heating element, a first controller, and a second controller. The heating element is coupled to the tank. The first controller is mounted on the tank and has a first communication port. The second controller has a second communication port communicatively coupled to the first communication port of the first controller. The first controller is configured to control the heating element in accordance with any desired algorithm in an absence of the second controller, and the second controller is configured to perform at least one function in addition to or in lieu of the first controller.