System and approach for water heater comfort and efficiency improvement
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Solution Overview
Problem
Residential and commercial water heaters often experience temperature stratification, leading to unsafe and uncomfortable hot water temperatures and excessive energy consumption, as the top of the tank can reach temperatures beyond 150°F due to inefficient temperature control during multiple draws.
Innovation Solution
A water heater control system that tracks burner history and limits the return to the setpoint temperature only during excess demand cycles, reducing the setpoint by up to 10°F during the third reheat cycle within an hour, and maintains this reduced setpoint for up to four hours to prevent overheating and ensure consistent hot water supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the water heater maintains a high setpoint temperature to ensure sufficient hot water supply, then hot water availability is improved, but temperature stratification causes unsafe temperatures at the top of the tank and excessive energy consumption
Solution Approach 1:
The system dynamically adjusts the setpoint temperature based on detected draw patterns. When multiple draws are detected within a time period, the setpoint is temporarily reduced from the normal high temperature to a lower temperature, preventing excessive heating while ensuring adequate hot water supply during demand periods.
Solution Approach 2:
The controller changes the temperature parameter (setpoint) based on operational conditions. During excess demand cycles, the setpoint is reduced by a predetermined amount (e.g., 10-20°F) compared to the normal setpoint, allowing the system to maintain hot water availability while preventing temperature stratification and energy waste.
2Productivity
If the water heater returns to the setpoint temperature after multiple draws, then hot water regeneration is improved, but temperature overshoot occurs causing unsafe temperatures and energy waste
Solution Approach 1:
The system applies a preliminary restriction on the return to setpoint temperature when excess demand is detected. By limiting the temperature increase during recovery cycles, the system prevents the harmful effect of temperature overshoot before it occurs, ensuring safe temperatures while maintaining adequate hot water supply.
Solution Approach 2:
The controller monitors draw patterns and burner cycle history, using this feedback to determine when to limit the return to setpoint. When multiple draws are detected within a time period, the feedback mechanism triggers a modified recovery mode that prevents overshooting while ensuring hot water regeneration.
3Stability of the object's composition
If the water heater operates with frequent burn cycles to maintain setpoint temperature, then temperature consistency is improved, but energy consumption increases
Solution Approach 1:
Instead of fully returning to the high setpoint temperature during recovery cycles, the system applies partial heating by limiting the temperature increase to a predetermined amount below the normal setpoint. This reduces energy consumption while maintaining sufficient hot water temperature for user needs.
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 effectively prevents overheating, ensures safe and comfortable hot water temperatures, and reduces energy consumption by limiting temperature overshoot and maintaining sufficient hot water regeneration without excessive energy use.
Implementation Method 1
a temperature sensor situated in a tank of a water heater and connected to the processor
Implementation Method 2
a heater connected to a valve or switch... a gas burner which can use electricity, gas or a combination to create heat for increasing a temperature of water in tank 32
Implementation Method 3
Around tank 32 may be an insulating layer 34
Data Source
AI summary
A system for heating water to improve safety and efficiency. The system may have normal operation measured in time. After a time of normal operation, a water temperature setpoint may be checked. If the setpoint is not at a certain level, normal operation may continue. If the setpoint is within the certain level, water temperature may be measured. If the water temperature is less than a desired level, one or more draws of water may be measured for a preset temperature drop. If the draws do not meet the temperature drop, a return to check the setpoint may be made. If the draws meet the temperature drop, the setpoint may be reduced and a time of normal operation may be measured to determine whether a burn cycle occurs within the time. If not, normal operation may continue; but if so, a return to check the setpoint may be made.