Systems and methods for controlling water heaters

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Solution Overview

Problem

Water heaters experience temperature stratification, known as stacking, when subjected to repeated short draws of hot water, leading to uneven heating and complaints of cold water, while large temperature differentials reduce energy efficiency and frequent heater activation.

Innovation Solution

A processor-controlled system that initiates a call for heat when the water temperature reaches a trigger temperature below the set-point, calculates a reduced activation time based on repeated calls within a predetermined period, and controls the burner accordingly to prevent excessive heating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If a large temperature differential setting is implemented to reduce stacking, then temperature stratification is reduced, but the water heater may fail to maintain comfortable hot water temperature after extended inactivity

Engineering Contradiction:

Improvetemperature uniformityVSAvoidhot water temperature availability

Core Design Contradiction:

Stability of the object's compositionVSTemperature

Solution Approach 1:

The system dynamically adjusts the trigger temperature based on the calculated reduced activation time. When repeated short draws are detected, the trigger temperature is lowered to prevent stacking; when inactivity is detected, the trigger temperature is raised to maintain hot water availability. This dynamic adjustment resolves the contradiction between preventing stacking and maintaining temperature availability.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the trigger temperature parameter based on usage patterns. By calculating reduced activation time from sensor data and adjusting the trigger temperature accordingly, the system adapts to different operational conditions, resolving the contradiction between temperature uniformity and hot water availability.

Inventive Principle:

Principle #35Parameter changes

2Temperature

If a narrow differential setting is used to maintain hot water temperature, then hot water availability is improved, but energy efficiency decreases and stacking occurs

Engineering Contradiction:

Improvehot water temperature availabilityVSAvoidenergy efficiency

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The system dynamically adjusts the trigger temperature based on calculated reduced activation time. During periods of repeated short draws, the trigger temperature is lowered to reduce heating cycles and improve energy efficiency. During inactivity, the trigger temperature is raised to maintain hot water availability, thus resolving the contradiction between energy efficiency and temperature availability.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The trigger temperature parameter is adjusted based on usage patterns and reduced activation time calculations. This parameter change allows the system to optimize between energy efficiency and hot water availability depending on operational conditions, resolving the identified contradiction.

Inventive Principle:

Principle #35Parameter changes

3Temperature

If the water heater activates frequently to maintain temperature, then hot water availability is maintained, but energy consumption increases

Engineering Contradiction:

Improvehot water temperature maintenanceVSAvoidenergy consumption

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The system uses sensor data to calculate reduced activation time and provides feedback to adjust the trigger temperature. This feedback mechanism allows the system to learn from usage patterns and adjust heating behavior accordingly, reducing unnecessary heating cycles and energy consumption while maintaining hot water availability when needed.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The trigger temperature parameter is dynamically changed based on feedback from usage pattern analysis. By adjusting this parameter according to reduced activation time calculations, the system optimizes the balance between maintaining hot water temperature and minimizing energy consumption.

Inventive Principle:

Principle #35Parameter changes

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 approach reduces temperature stratification, maintains a comfortable hot water temperature, and enhances energy efficiency by adjusting the heating duration based on usage patterns, preventing stacking and ensuring consistent water temperature.

Implementation Method 1

a burner configured to heat the water in the storage tank

Methodology Applied

Scientific EffectCombustion: Combustion

Implementation Method 2

a sensor configured to measure a temperature of water in the storage tank

Methodology Applied

Scientific EffectThermal detection: Thermistor

Data Source

PatentUS9829897B2Systems and methods for controlling water heaters

Publication Date: 2017.11.28 COPELAND COMFORT CONTROL LP

AI summary

A water heater includes a storage tank, a sensor configured to measure a temperature of water in the storage tank, a burner configured to heat the water in the storage tank, and a controller communicatively coupled to the sensor and the burner. The controller is configured to initiate a call for heat when the measured temperature reaches a trigger temperature, wherein the trigger temperature is a differential amount less than a set-point temperature, calculate a reduced activation time when the call for heat results in a predetermined number of calls for heat occurring within a predetermined time period, and control the burner based on the reduced activation time.