Programmable Water Heater Output Limiting for Model Customization
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Solution Overview
Problem
Manufacturers face the challenge of maintaining a large inventory of water heaters with different models to cater to various heating requirements, leading to increased costs and storage needs, as existing water heaters are not easily customizable to generate specific heating outputs.
Innovation Solution
A water heater system featuring a controller that can be programmed to limit the heating output of an electric resistance heating element to a defined maximum, allowing for customization and reduction in the number of end models by enabling the generation of a predetermined heating output tailored to specific applications, thereby reducing inventory needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manufacturers produce multiple water heater models with different heating outputs to cater to various heating requirements, then customer needs are met, but inventory costs and storage needs increase
Solution Approach 1:
The patent applies universality by designing a single water heater model that can perform multiple heating output functions through software configuration. The controller is programmed to limit the heating element output to different predefined levels, allowing one physical device to serve multiple application needs without requiring separate hardware variants for each heating capacity.
Solution Approach 2:
The patent implements parameter changes by modifying the operational parameters of the heating element through controller programming rather than changing physical hardware parameters. The controller can be configured with different maximum heating output limits, effectively changing the heating capacity parameter software-based, which reduces the need to manufacture and store multiple physical models with different heating element specifications.
2Adaptability or versatility
If manufacturers maintain a large inventory of different water heater models, then various heating requirements are satisfied, but manufacturing and storage costs increase
Solution Approach 1:
The patent applies universality by designing a single water heater model that can perform multiple heating output functions through software configuration. The controller is programmed to limit the heating element output to different predefined levels, allowing one physical device to serve multiple application needs without requiring separate hardware variants for each heating capacity.
Solution Approach 2:
The patent implements copying by using software copies of heating output profiles rather than physical copies of different hardware models. The controller contains programmed limitations that replicate the functional characteristics of different water heater models, allowing the same physical unit to be configured to match various model specifications through software copying of operational parameters.
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 allows for the reduction of inventory by enabling generic water heaters to be customized electronically, reducing the need for multiple models and enabling efficient management of heating output, thus optimizing storage and manufacturing processes.
Implementation Method 1
a heating fixture having a rated maximum heating output
Data Source
AI summary
A water heater including a vessel, a heating fixture (e.g., an electric-resistance heating element, a gas burner) having a rated maximum heating output, and a controller. The controller includes an interface and a temperature sensor. The controller can control the heating output of the heating element based on a sensed temperature of the temperature sensors. The heating output is a defined maximum heating output for the heating fixture. Also disclosed are methods of defining the capabilities of a water hater heater and methods of operating a water heater.