Modular Water Heater Controller for Low-Cost Feature Upgrades
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Solution Overview
Problem
Conventional water heaters face challenges in cost-effectively providing different models with varying features due to the complexity of upgrading controllers, which can be burdensome and often requires significant reconfiguration, especially for consumers or unskilled technicians.
Innovation Solution
A modular control system for water heaters, where a first control module provides basic functionality, and a second control module can be added to upgrade the system, allowing for enhanced features without removing the first module, using a communication port for interfacing and implementing control logic in software or hardware, enabling efficient upgrading and feature enhancement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a more sophisticated controller is installed to provide additional features and better performance, then the water heater functionality is improved, but the manufacturing cost increases and assembly line complexity increases
Solution Approach 1:
The controller is divided into a base controller providing essential functionality and optional upgrade modules that can be selectively added. This segmentation allows manufacturers to produce a standardized base unit on a single assembly line, then offer optional sophistication through add-on modules, thereby maintaining manufacturing efficiency while providing adaptability for different market segments.
Solution Approach 2:
The base controller is designed with universal interfaces and capabilities that can support multiple levels of functionality. The same fundamental hardware platform can serve both standard and premium models, with the ability to accommodate additional features through software updates or optional module attachments, eliminating the need for separate assembly lines.
2Adaptability or versatility
If different assembly lines are created for different water heater models, then model-specific features are achieved, but manufacturing cost significantly increases
Solution Approach 1:
A universal controller platform is designed that can accommodate multiple water heater models through software configuration and optional module attachments. This single platform approach allows one assembly line to produce controllers for various models, eliminating the need for multiple dedicated assembly lines while maintaining model-specific capabilities.
Solution Approach 2:
The controller system incorporates dynamic configurability through software updates and modular attachments, allowing the same hardware platform to adapt to different model requirements. This dynamic adaptability replaces the static approach of dedicated assembly lines, enabling flexible production on a single line.
3Adaptability or versatility
If a controller is retrofitted after manufacturing to upgrade features, then water heater functionality is enhanced, but the retrofitting process becomes burdensome and problematic
Solution Approach 1:
The controller is designed with modular components and standardized interfaces that can be easily attached or upgraded without complete replacement. The segmentation of control functions into core capabilities and optional modules allows for simple retrofitting where users can add upgrade modules to existing controllers without complex reconfiguration or specialized technical knowledge.
Solution Approach 2:
Upgrade modules are designed to nest within or attach to the existing controller structure, with the new functionality embedded within the framework of the original controller. This nesting approach allows upgrades to be integrated seamlessly into the existing device without requiring complete disassembly or complex installation procedures.
4Reliability
If a new controller is replaced without damaging other portions of the water heater, then system integrity is maintained, but the replacement process becomes more difficult
Solution Approach 1:
The controller system is segmented into a removable module that can be independently replaced without affecting the water tank, heating elements, or other system components. The standardized interface and modular design allow the controller to be detached and replaced as a complete unit, maintaining system integrity while simplifying the replacement process to a straightforward module swap.
Data Source
AI summary
A water heater having a modular control system. The water heater includes a tank, a heating element, a first controller, and a second controller. The heating element is coupled to the tank. The first controller is supported by the tank and includes a housing, a first communication port, a processor, and a first memory storing executable instructions that are executed by the processor. The first controller determines whether the first controller is connected to the second controller through the communication port. The first controller controls an operation of the water heater according to a first algorithm when the first controller is not connected to the second controller. The operation of the water heater is controlled based on an algorithm stored on the second controller when the first controller is connected to the second controller.