Water heater control system with powered anode rod
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Solution Overview
Problem
Existing water heater control systems require multiple accesses into the tank and have a large physical footprint, making them less efficient and harder to manufacture, and they struggle to effectively control temperature and corrosion in water heaters of varying volumes and geometries.
Innovation Solution
A water heater control system that includes a temperature sensor, an anode rod, and a controller, all supported by a mounting bracket that forms a water-tight seal through a single opening in the tank, allowing the controller to be compactly housed and reducing the number of required accesses, while also applying voltage or current to the anode rod for corrosion protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple accesses into the tank are used for control systems, then temperature control and corrosion protection functions can be provided, but the physical footprint increases and manufacturability decreases
Solution Approach 1:
The patent combines the temperature sensor and anode rod into a single integrated assembly that accesses the water tank through one opening. The mounting bracket holds both components in close proximity, allowing them to share a common access point and eliminating the need for separate openings for each function.
Solution Approach 2:
The single access opening serves multiple functions by accommodating both the temperature sensor for thermal monitoring and the anode rod for corrosion protection. The mounting bracket structure enables this multi-functionality by providing a unified interface that supports both components simultaneously.
2Adaptability or versatility
If multiple accesses into the tank are used for control systems, then temperature control and corrosion protection functions can be provided, but manufacturing complexity increases
Solution Approach 1:
The temperature sensor and anode rod are merged into a single assembly unit mounted on a common bracket, which simplifies the installation process. Instead of requiring separate mounting operations for each component, the integrated assembly can be installed through a single opening in one operation.
Solution Approach 2:
The control system is segmented into a modular assembly that can be pre-assembled and tested outside the tank, then installed as a complete unit. The mounting bracket serves as a standardized interface that facilitates this modular approach to manufacturing and installation.
3Area of stationary object
If the controller is compactly housed, then the physical footprint is reduced, but the mounting and sealing complexity may increase
Solution Approach 1:
The mounting bracket integrates multiple functions into a single component: it provides mechanical support for the temperature sensor and anode rod, creates the seal against the tank opening, and establishes electrical connections. This consolidation reduces the number of separate parts and assembly steps required.
Solution Approach 2:
The mounting bracket acts as an intermediary element between the control system components and the water tank. It provides a standardized interface that simplifies both the mechanical mounting and the sealing requirements, while also facilitating electrical connections to the immersed 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 configuration reduces the physical footprint, enhances manufacturability, and allows effective operation in water heaters of varying sizes, while providing efficient temperature control and corrosion protection by maintaining a voltage difference between the anode and the tank wall.
Implementation Method 1
A powered anode rod may be immersed in the water tank to reduce corrosion of the water tank
Implementation Method 2
A temperature sensor in thermal communication with the water in the water tank provides an indication of the temperature of the water in the tank
Data Source
AI summary
A water heater control system comprising a temperature sensor, an anode rod, and a controller. The controller is configured to receive a signal indicative of a temperature from the temperature sensor and apply a voltage and/or current to the anode rod. A mounting bracket mates with a spud of a water heater and provides a conduit space for conductors providing connectivity among the controller, temperature sensor, and anode rod. The mounting bracket may provide mechanical support for the anode rod and the temperature sensor. The mounting bracket may comprise a housing mechanically supporting and surrounding the controller.