Real-time heated water supply measurement systems for water heaters and methods thereto
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Solution Overview
Problem
Storage-type water heaters face challenges in accurately determining the amount of heated water available in real-time, especially when multiple processes demand hot water simultaneously, leading to inefficiencies and potential shortages, and increasing the number of temperature sensors complicates the system and increases costs.
Innovation Solution
A water heating system with a controller that uses two or more temperature sensors, strategically placed at the top and bottom ends of the tank, to measure water temperatures and determine the amount of heated water using algorithms, allowing for granular temperature data and triggering corrective actions such as heating additional water or agitating the tank to distribute heat uniformly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple temperature sensors are installed throughout the tank to accurately measure water temperature at different locations, then measurement precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The tank is divided into multiple vertical zones (top, middle, bottom sections) with each zone monitored by temperature sensors positioned at strategic locations. This segmentation allows accurate temperature profiling of different water layers without requiring sensors at every possible location, balancing measurement precision with system simplicity.
Solution Approach 2:
The system transitions from measuring only vertical temperature gradients to incorporating horizontal position data through multiple sensors at different radial positions. This dimensional expansion enables three-dimensional temperature mapping of the tank, providing comprehensive hot water availability assessment without requiring excessive sensor density.
2Reliability
If temperature sensors are installed throughout the tank to determine hot water availability, then reliability is improved, but device complexity increases
Solution Approach 1:
The monitoring system is segmented into critical zones (top, middle, bottom) with sensors positioned to detect temperature changes in each segment. This zone-based approach ensures reliable detection of hot water depletion while maintaining a manageable sensor count that avoids system over-complication.
Solution Approach 2:
The system continuously monitors temperature at multiple locations and provides real-time feedback to the control algorithm, which adjusts heating element operation accordingly. This feedback mechanism ensures reliable hot water supply by proactively responding to temperature changes before complete depletion occurs, maintaining reliability without requiring excessive sensors.
3Productivity
If real-time temperature monitoring at multiple locations is implemented, then productivity is improved, but use of energy increases
Solution Approach 1:
The system performs preliminary temperature assessment by monitoring multiple locations simultaneously, allowing the control algorithm to predict hot water depletion before it occurs. This advance detection enables proactive heating element activation, ensuring hot water availability without continuous high-energy operation, thus improving productivity while managing energy consumption.
Solution Approach 2:
The system uses a limited number of temperature sensors positioned at critical locations rather than comprehensive coverage. This partial monitoring approach provides sufficient data for the control algorithm to make informed decisions about heating operation, achieving good productivity without the excessive energy consumption that would result from full-tank sensor deployment.
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 provides accurate and granular data on hot water availability, enabling timely corrective actions to ensure sufficient hot water supply, reducing the need for multiple sensors and maintaining system simplicity while improving efficiency and user experience.
Implementation Method 1
a first temperature sensor disposed toward a top end of the tank, where the first temperature sensor measures a first temperature of water toward the top end of the tank
Implementation Method 2
The one or more algorithms can be used to solve for at least one calculated temperature for at least one point between a first location of the first temperature sensor and a second location of the second temperature sensor along a height of the tank
Data Source
AI summary
Disclosed herein is a water heating system including a water heater having a tank, and a first temperature sensor disposed toward a top end of the tank to measure a first temperature and a second temperature sensor disposed toward a bottom end of the tank to measure a second temperature. The water heating system can further include a controller communicably coupled to the first temperature sensor and the second temperature sensor, where the controller determines an amount of heated water in the tank based on one or more algorithms and measurements made by the first and second temperature sensors.