Modular Water Heater Control Using Add-On Second Controllers
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Solution Overview
Problem
Conventional water heaters require separate assembly lines and costly equipment for different models, and retrofitting with advanced controllers is cumbersome and often damaging, especially for consumers or unskilled technicians.
Innovation Solution
A modular control system that allows for the addition of a second control module to upgrade water heaters, enabling different feature sets without removing the existing controller, using a communication port for interfacing and implementing control logic in software or hardware to manage heating elements based on user-defined or usage history algorithms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different controllers are installed for different water heater models to provide different features, then functionality and performance are improved, but manufacturing costs increase due to separate assembly lines
Solution Approach 1:
The patent implements a universal controller design that can serve multiple water heater models through software configuration rather than hardware differentiation. The controller includes a processor that can be programmed with different algorithms and features depending on the model requirements, allowing a single physical controller to provide basic functionality for standard models and advanced features for premium models without requiring separate assembly lines
2Adaptability or versatility
If retrofitting is performed to upgrade water heaters with better controllers, then functionality is improved, but the process becomes burdensome and problematic for consumers
Solution Approach 1:
The patent segments the controller functionality into modular software components that can be independently updated or configured. The controller is designed with a standardized interface and communication protocol that allows firmware updates to be performed without physical disassembly or complex reconfiguration, enabling consumers to upgrade functionality through simple software installation rather than complex hardware retrofitting
Solution Approach 2:
The patent introduces a standardized communication interface and protocol as an intermediary between the controller and the water heater system. This standardized interface allows different software versions and feature sets to be installed on the same hardware platform without requiring physical modifications to the water heater tank or heating elements, simplifying the upgrade process for consumers
3Adaptability or versatility
If a more sophisticated controller is installed to provide additional features, then performance is improved, but the controller complexity increases
Solution Approach 1:
The patent implements dynamic complexity management where the controller's operational complexity is adjusted based on the installed software configuration rather than fixed hardware architecture. The processor can execute different algorithms and activate different features depending on the software package installed, allowing the same physical controller to operate with varying levels of complexity suitable for different model requirements without increasing the base hardware 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 a first algorithm in an absence of the second controller, and the second controller is configured to control the heating element in accordance with a second algorithm.