Patent Grant
11656000
The disclosure relates to water heating systems.
Tank-type water heating systems which incorporate gas combustion as a heat source typically utilize a pilot flame issuing from a pilot burner to initiate combustion of a main gas flow. Combustion of the main gas flow initiates a flame at a main burner. The main burner flame typically heats a volume of water. A temperature sensing device in thermal communication with the volume of water may provide a temperature to a control system to serve as an indication of when pilot flame and main burner flame may be desired. The control system may initiate operations within the water heater system to initiate the pilot flame and the main burner flame by, for example, energizing valve actuators in order to establish the necessary gas flows to one or more dormant burners.
In general, the water heater control system disclosed provides for energy usage of components in a water heater system. For example, the water heater system includes a rechargeable and non-rechargeable power source. In one or more examples, a controller such as a microcontroller of the water heater system is configured to receive power from the non-rechargeable power source and does not receive power from the rechargeable power source. Various other components of the water heater system are configured to receive power from the rechargeable power source.
By separating out the power sources for the microcontroller and the other components, the microcontroller may be guaranteed to receive power on demand with a non-rechargeable power source that provides power for the lifetime of the water heater system. With the non-rechargeable power source, the other components of the water heater system have a reliable power source that can be recharged as needed. Since the other components (e.g., other than microprocessor) do not receive power from the non-rechargeable power source, there is sufficient power for the microcontroller, allowing for uninterrupted operation of the microcontroller, while not draining the non-rechargeable power source. The rechargeable power source can provide power to the other components as needed, and can be recharged. In this way, the disclosure describes for a water heater system with robust power delivery mechanism to ensure that power is available as needed.
In an example, the disclosure provides a water heater comprising a power source that is non-rechargeable, a controller configured to receive power from the power source, an energy storage system comprising a rechargeable power supply and configured to provide power to one or more components of the water heater, wherein the water heater is configured to prevent the controller from receiving power from the rechargeable power supply, and a thermoelectric device configured to provide power to recharge the rechargeable power supply, wherein the thermoelectric device is configured to generate power in response to a pilot flame in proximity to the thermoelectric device.
In an example, the disclosure provides a water heater system comprising a first valve operator, wherein the first valve operator initiates a first gas flow when energized, an energy storage system coupled to energize the first valve operator, a power source coupled to recharge the energy storage system, a pilot ignition circuit configured to cause a pilot spark ignitor to generate a pilot flame using the first gas flow, a second valve operator, wherein the second valve operator initiates a second gas flow when energized, wherein the second gas flow is greater than the first gas flow, and wherein the second valve operator cannot be energized from the energy storage system, and a thermoelectric device that converts thermal energy from the pilot flame into electrical energy, the thermoelectric device coupled to provide a first portion of the electrical energy to energize the second valve operator and the thermoelectric device coupled to provide a second portion of the electrical energy to the energy storage system.
In an example, the disclosure provides a method of generating a main burner flame comprising initiating a first gas flow using a first valve operator configured to initiate the first gas flow when energized by energizing the first valve operator using an energy storage system coupled to the first valve operator, thereby initiating the first gas flow, prompting a pilot ignition circuit to cause a pilot spark ignitor in thermal communication with the first gas flow to generate ignition energy, thereby generating a pilot flame, allowing a thermoelectric device in thermal communication with the pilot flame to convert thermal energy from the pilot flame to electrical energy, initiating a second gas flow using a second valve operator configured to initiate the second gas flow when energized by energizing the second valve operator using a first portion of the electrical energy, thereby initiating the second gas flow, providing a second portion of the electrical energy to the energy storage system, and porting the second gas flow to a burner configured to establish thermal communication between the second gas flow and the pilot flame, thereby generating the main burner flame.
The details of one or more examples are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.
The water heater control system includes an energy storage system and may operate in the absence of an external power supply, such as a line voltage provided by existing energy infrastructure to a residence or some other structure. The energy storage system may be electrically connected to a pilot valve operator which controls whether there is a pilot gas flow to a pilot gas burner. The energy storage system may comprise rechargeable energy storage system, non-rechargeable energy storage system, or both. For example, energization of the pilot valve operator may cause operation of a servo valve which initiates the pilot gas flow. The energy storage system may additionally be electrically connected to an ignition circuit causing a pilot spark ignitor to generate thermal energy. The pilot spark ignitor may be in close proximity to and/or in thermal communication with the pilot gas flow, initiating a pilot flame at the pilot burner.
A thermoelectric device is in thermal communication with the pilot flame. The thermoelectric device (e.g., a thermopile) converts some portion of the thermal energy received from the pilot flame into electrical energy. In accordance with one or more examples described in this disclosure, the thermoelectric device is electrically connected to a main valve operator, which controls whether there is a main gas flow to a main burner. For example, energization of the main valve operator may cause operation of a servo valve which initiates the main gas flow. The thermoelectric device may also provide power to the energy storage system and the pilot valve operator when the thermoelectric device is generating electrical power.
The main valve operator may be electrically isolated from the energy storage system by, for example, a unidirectional power convertor or some other component. In some examples, the main valve operator has a high electrical resistance such that electrical energy provided by the energy storage system is insufficient to operate the main valve operator. This prevents the energy storage system from providing sufficient power to operate the main valve operator. The main valve operator which initiates main gas flow may only be sufficiently energized by the thermoelectric device, which only generates sufficient electrical energy once the pilot flame has been established. This safeguards against initiation of a main gas flow prior to establishment of an active pilot flame and avoids discharges of uncombusted fuel into enclosed spaces or other environments.
The water heater control system may include a power source, such as one or more batteries and/or capacitors. The power source may be electrically connected to the energy storage system, in order to recharge the energy storage system when necessary. In general, the thermoelectric device generates the power that recharges the energy storage system, but in some instances, power from the power source may be needed to recharge the energy storage system to cause the pilot flame to ignite. The power source may be pre-charged and intended to last all or some significant portion of the life of the associated water heater. The power source may be replaceable and may be rechargeable.
The water heater control system may include a controller such as a microcontroller configured to establish electrical communication between the thermoelectric device and the energy storage system, the pilot valve operator, and the main valve operator. The microcontroller may be configured to create and/or initiate a call for main burner operation, and in response, establish the electrical communication. The microcontroller may also be configured to check an available voltage of the energy storage system against a setpoint. Based on the available voltage, the microcontroller may establish electrical connection between the power source and the energy storage system, in order to maintain the stored energy system in a condition necessary to initiate the pilot gas flow when called for. The microcontroller may be powered by the thermoelectric device when the thermoelectric device is generating electrical power. The microcontroller may also be powered by the power source. In some examples, the microcontroller being powered by the power source allows the microcontroller to periodically conduct checks throughout the system. This may be particularly advantageous when the water heater control system operates in the absence of an external power supply such as a line voltage provided by a separate infrastructure.
There may be a thermoelectric device 66 such as a thermopile connected by an electrical line 52 to control system 71. There may be a pilot spark ignitor 56 for igniting a pilot gas flow discharging from pilot burner 41. Pilot spark ignitor 56 may be connected via electrical line 60 to control system 71. Thermoelectric device 66 may be in thermal communication with pilot flame generated at pilot burner 41, and may convert some portion of a heat flux emitted by the pilot flame into electrical energy. A temperature sensing device 62 may be connected to control system 71 and situated in a water tank 64, or otherwise be configured to be in thermal communication with a volume of water in water tank 64. Control system 71 may incorporate a controller such as a microcontroller configured to establish electrical or data communication with one or more of main valve 44, the pilot valve, and other components.
Control system 71 may include a pilot valve operator configured to actuate the pilot valve of system 70, and may include a main valve operator configured to actuate main valve 44. Control system 71 may also establish an electrical connection between thermoelectric device 66 and the main valve operator, such that the main valve operator can be powered by thermoelectric device 66. Control system 71 may also include an energy storage system in electrical connection with the pilot valve operator.
In an intermittent pilot light system, when main burner 48 operation is called for, an operating sequence in system 70 might initially actuate the pilot valve and establish a pilot flame at pilot burner 41 prior to commencing main valve 44 operations. For example, control system 71 might initially actuate the pilot valve and pilot spark ignitor 56 using an energy storage system in order to establish the pilot flame at pilot burner 41. Subsequently, once the pilot flame is established, the operating sequence might actuate main valve 44 using power delivered by thermoelectric device 66. In this manner, main fuel flow to main burner 48 may be established and the pilot flame may generate combustion of the main fuel flow. A sequence ensuring that the pilot flame is established prior to initiating main fuel flow to the burner avoids situations leading to discharges of uncombusted main fuel into surrounding environments.
Valve body 120 also has diaphragm 142, and servo valve 152 having disc 154. Diaphragm 142 is in a closed position isolating intermediate pressure chamber 130 (comprising 130a, 130b, and 130c) and outlet 148 at least at position 160 (outlet 148 comprises and extends across 148a, 148b, and 148c). Outlet 148 may be in fluid communication with a main burner. Diaphragm 142 is acted on by spring member 144, and diaphragm 124 is maintained in the closed position at least by spring member 144. The pressure of chamber 146 is equalized with outlet 148 through conduit 162.
A pilot valve operator may be configured to cause servo valve 134 to reposition disc 136. In an example, control system 71 may be configured to energize the pilot valve operator using a stored energy system. For example,
With fuel supplied to the pilot burner, such as pilot burner 41, an ignitor such as ignitor 56 may establish a pilot flame at pilot burner 41 (
A main valve operator may be configured to cause servo valve 152 to reposition disc 154. In an example, control system 71 may be configured to energize the main valve operator using electrical power from a thermoelectric device such as thermoelectric device 66. For example,
With fuel supplied to the main burner and the pilot flame established, a main flame may be generated at the main burner. In examples where control system 71 uses a stored energy system to energize the pilot valve, and utilizes electrical energy generated through thermal communication with an established pilot flame to energize a main valve, control system 71 provides a safeguard against discharges of uncombusted fuel into enclosed spaces or other environments. This may be particularly advantageous in water heater systems such as water heater system 70, where a main gas flow to main burner 41 is intended to be significantly greater than the pilot gas flow provided to pilot burner 41.
System 10 is an electric circuit configured to receive power from a thermoelectric device 16. Thermoelectric device 16 is a component configured to convert thermal energy into electrical power, such as a thermopile. System 10 additionally comprises pilot valve operator 12 and main valve operator 14, as well as convertor 18. As illustrated, thermoelectric device 16 may provide power to main valve operator 14 through electrical line 34, and to convertor 18 through electrical connection 36. Convertor 18 may forward the generated power through electrical line 39 to energy storage system 20 through electrical connection 40, and to pilot valve operator 12 through electrical connection 38. Energy storage system 20 may also provide power to pilot valve operator 12 through electrical connection 40 and electrical connection 38. Energy storage system 20 may thus provide the capability to store some portion of the electrical power generated by thermoelectric device 16, and also provides for powering of pilot valve operator 12 when thermoelectric device 16 is not generating. For example, thermoelectric device 16 may be configured to be in thermal communication with a heat source intended to operate intermittently, such as an intermittent pilot flame in a water heater, and power from thermoelectric device 16 to pilot valve operator 12 may not always be available. In such cases, energy storage system 20 may provide power to pilot valve operator 12, among other components. Energy storage system 20 may power pilot valve operator 12 using rechargeable and/or non-rechargeable storage components. Energy storage system 20 may also power an ignition circuit 24 using a rechargeable and/or non-rechargeable storage components via electrical connection 40, electrical line 39, and electrical connection 51.
System 10 further comprises a power source 31, such as a battery or capacitor. The power source may be a non-rechargeable battery or pre-charged capacitor intended to last all or some significant portion of the life of the associated water heater. Power source 31 may be replaceable and may be rechargeable. Power source 31 is configured to provide recharging power to energy storage system 20 through electrical connection 33. System 10 may further comprise a controller such as microcontroller 22 configured to receive electrical power from power source 31, or thermoelectric device 16 via converter 45. System 10 may further comprise one or more electronic devices, such as first electronic device 26 between electrical line 39 and pilot valve operator 12, second electronic device 28 between electrical line 34 and main valve operator 14, third electronic device 30 between power source 31 and energy storage system 20, fourth electronic device 47 between power source 31 and energy storage system 20, and fifth electronic device 49 between electrical line 39 and ignition circuit 24. Microcontroller 22 be configured to control first electronic device 26, second electronic device 28, third electronic device 30, fourth electronic device 49, and fifth electronic device 49 to carry out various operations of system 10, as will be discussed. System 10 may be contained either wholly or in part within a control module casing 11. Although not illustrated in
System 10 is configured to limit power flow from node 35 to energy storage system 20 to a single direction, so that while energy storage system 20 may receive power from thermoelectric device 16 via node 35 and converter 18, power flow cannot occur from energy storage system 20 to any components where node 35 is in the electrical path, such as main valve operator 14. In some examples, convertor 18 is a unidirectional device such as a unidirectional DC-DC-convertor which limits power flow from node 35 through electrical line 39 to the single direction. The unidirectional flow of power from node 35 results in an arrangement whereby, when thermoelectric device 16 is receiving thermal energy and generating power, thermoelectric device 16 may deliver power to main valve operator 14 and converter 18, and converter 18 may deliver power to pilot valve operator 12 and energy storage system 20. However, when thermoelectric device 16 is not generating electrical power, energy storage system 20 may deliver power to pilot valve operator 12, but not to main valve operator 14. System 10 is thereby configured such that main valve operator 14 can only receive power when thermoelectric device 16 is generating power, whereas pilot valve operator 12 may receive power from thermoelectric device 16 (when thermoelectric device 16 is generating) or energy storage system 20 (when thermoelectric device 16 is not generating). System 10 is additionally configured so that energy storage system 20 may not provide power to microcontroller 22.
Using a unidirectional DC-DC convertor for convertor 18 is one example way to ensure that energy storage system 20 does not deliver power to activate main valve operator 14. However, the example techniques are not so limited and other techniques to ensure that energy storage system 20 does not deliver sufficient power may be possible. For example, components such as diodes, switches, etc. At 36 or 39 may be used to ensure that energy storage system 20 does not provide sufficient power to activate main valve operator 14. Also, the above approaches provide example manners in which to ensure that main valve operator 14 receives sufficient power only from thermoelectric device 16. However, these examples are not intended to be exhaustive, and system 10 may utilize any configuration which allows thermoelectric device 16 to provide sufficient activation power to main valve operator 14 while preventing energy storage system 20 from providing the sufficient activation power.
In some examples, during an initial startup, energy storage system 20 may not store any power. In this case, power source 31 may output power to energy storage system 20 to charge energy storage system 20 to such a level that energy storage system 20 can deliver sufficient power to ignition circuit 24 to cause ignition circuitry 24 to deliver power to ignitor 32 to start the pilot flame. In response to the pilot flame, thermoelectric device 16 may generate power that recharges energy storage system 20.
System 400 is configured to receive power from thermoelectric device 16, and comprises pilot valve operator 12 and main valve operator 414. System 400 also comprises convertor 418. Thermoelectric device 16 may provide power to electrical line 436 and energy storage system 20 through electrical connection 40 and pilot valve operator 12 through electrical connection 38. Thermoelectric device 16 may provide power to convertor 418 through electrical line 436 and electrical connection 439. Convertor 418 may forward the generated power through electrical line 434 to main valve operator 414. Energy storage system 20 may also provide power to pilot valve operator 12 through electrical connection 40 and electrical connection 38. Energy storage system 20 may also power an ignition circuit 24. System 400 further comprises power source 31 configured to provide recharging power to energy storage system 20 through electrical connection 33. System 400 may further comprise a controller such as microcontroller 22 configured to receive electrical power from power source 31 via electrical line 37 and from thermoelectric device 16 via converter 445. Microcontroller 22 may be configured to control first electronic device 26, second electronic device 28, third electronic device 30, fourth electronic device 47, and fifth electronic device 49 to carry out various operations of system 400, as will be discussed. System 400 may be contained either wholly or in part within control module casing 411.
In system 400, main valve operator 414 is configured to have a high electrical resistance such that main valve operator 414 cannot actuate a valve (such as servo valve 152) when supplied with a voltage typical of the output voltage produced by thermoelectric device 16. The electrical resistance of main valve 414 is such that main valve 414 may only be sufficiently energized to actuate the necessary valve when thermoelectric device 16 is generating a voltage (i.e., the pilot flame is lit) and converter 418 is stepping up the voltage from the generated level to a level sufficient to cause main valve operator 44 to actuate. This provides an arrangement whereby, when thermoelectric device 16 is receiving thermal energy and generating power, thermoelectric device 16 may deliver power to energy storage system 20, pilot valve operator 12, and converter 418, and converter 418 may deliver a stepped up voltage to main valve operator 414. However, when thermoelectric device 16 is not generating electrical power, energy storage system 20 may deliver power and cause operation of pilot valve operator 12, but cannot provide sufficient power to cause converter 418 to deliver power sufficient to operate main valve operator 14. System 400 is thereby configured such that main valve operator 414 can only operate when thermoelectric device 16 is generating power, whereas pilot valve operator 12 may receive power from thermoelectric device 16 (when thermoelectric device 16 is generating) or energy storage system 20 (when thermoelectric device 16 is not generating). System 400 may be additionally configured such that, when thermoelectric device 16 is not generating electrical power, energy storage system 20 cannot provide sufficient power to cause converter 445 to deliver power to microcontroller 22.
In an example, thermoelectric device 16 generates a first amount of electrical energy and operation of main valve operator 414 requires a second amount of electrical energy, and the second amount of energy is greater than the first amount of energy. Thermoelectric device 16 may generate the first amount of electrical energy when thermoelectric device 16 is in thermal communication with a pilot flame from a pilot burner, such as pilot burner 41 (
System 10 and system 400 may provide advantage in an apparatus where a first gas flow sustains a first flame generating a heat flux, and some portion of the heat flux impinges on some portion of a second gas flow in order to generate a second flame. In such devices, it may be advantageous to ensure the first flame is operating before commencing the second gas flow, in order to avoid discharges of uncombusted fuel into enclosed spaces or other environments, or for other reasons. This may be particularly advantageous when the second gas flow is significantly larger than the first gas flow (e.g., the second gas flow has a greater mass flow rate than the first gas flow). For example, it may be advantageous in water heater systems where a smaller pilot gas flow sustains a pilot flame at a pilot burner, and the pilot flame is in thermal communication with a larger main gas flow to generate a flame at a main burner. In
Control system 10 and control system 400 may be utilized in an intermittent pilot light system to effectively ensure that a pilot flame is established prior to initiating main fuel flow to a main burner. Pilot valve operator 12 may be configured to actuate a pilot valve such as the pilot valve of system 70 (
When main burner operation is called for in the intermittent pilot light system, pilot valve operator 12 is in a state such as de-energized where fuel flow through the pilot valve is secured (e.g., blocked), and the pilot flame is dormant. With the pilot flame dormant, thermoelectric device 16 is generating insufficient electrical power to cause valve operation through main valve operator 14. As previously discussed, systems 10 and 400 are configured so that energy storage system 20 may deliver power sufficient to operate pilot valve operator 12, but not sufficient to operate main valve operator 14. Main valve operator 14 can only receive sufficient power for operation from thermoelectric device 16.
System 10 and system 400 may initiate establishment of the dormant pilot flame by energizing pilot valve operator 12 using stored energy system 20, and thereby initiating a pilot gas flow to a pilot burner such as pilot burner 41 (
Acting in this manner, system 10 and system 400 may ensure that a pilot flame is established prior to initiating main fuel flow to a main burner. Ensuring that the pilot flame is established prior to initiating main fuel flow to the burner avoids situations leading to discharges of uncombusted main fuel into surrounding environments.
Further, while main burner operation is required and the pilot flame remains established, system 10 may be configured to allow thermoelectric device 16 to provide power to pilot valve operator 12 through convertor 18, electrical line 39, and electrical connection 38. System 10 may also be configured to allow thermoelectric device 16 to provide power to stored energy system 20 through converter 18, electrical line 39, and electrical connection 40, replenishing the stored energy utilized to initially open the pilot valve. In examples, system 10 may be configured to allow thermoelectric device 16 to provide power to one or more of ignition circuit 24, pilot spark ignitor 32, and microcontroller 22. Additionally, while main burner operation is required and the pilot flame remains established, system 400 (
Additionally, system 10 and system 400 may be configured such that thermoelectric device 16 and power source 31 are the sole sources of power input for one or more of convertor 18 or converter 418, microcontroller 22, energy storage system 20, pilot valve operator 12, main valve operator 14 or 414, ignition circuit 24, or pilot spark ignitor 32. This configuration may be advantageous in a water heater system where an additional source of power is unavailable due to, for example, a water heater location removed from a line power source, or some other reason.
In examples, pilot valve operator 12 may operate a pilot servo valve. The pilot servo valve may be configured to control a pressure of a fluid acting on a fluid actuated valve operator, with the fluid valve operator isolating a fuel supply from the pilot burner. When the pilot servo valve acts to increase or decrease a pressure of the fluid, the fluid actuated valve operator may establish fluid communication between the fuel supply and the pilot burner, establishing the pilot gas flow. Similarly, in examples main valve operator 14 (
For example, Pilot valve operator 12 may be configured to cause operation of servo valve 134 (
In examples, when a flame such as the pilot flame is in thermal communication with a gas flow, or a gas flow is in thermal communication with a flame, this means the flame generates a heat flux and the heat flux impinges on some portion of the gas flow. In examples, the heat flux of the flame is sufficient to generate combustion within the portion of the gas flow. In examples, when the pilot spark ignitor is in thermal communication with a gas flow, this means that when the pilot spark ignitor generates an igniting energy such as a heat flux or electrical discharge, and some portion of the igniting energy impinges on some portion of the gas flow. In examples, the igniting energy of the pilot spark ignitor is sufficient to generate combustion within the portion of the gas flow. In examples, when thermoelectric device 16 is in thermal communication with a flame, the flame generates a heat flux and some portion of the heat flux impinges on some part of thermoelectric device 16. In examples, the heat flux of the flame is sufficient to cause thermoelectric device 16 to convert some portion of the heat flux into electrical energy. In examples, when a temperature sensing device is in thermal communication with a body of water, this means a change in the temperature of the body of water affects the operating behavior of the temperature sensing device.
As discussed, system 10 and system 400 may comprise microcontroller 22. Microcontroller 22 may comprise a processor, memory and input/output (I/O) peripherals. In examples, microcontroller 22 is configured to establish electrical contact between energy storage system 20 and pilot valve operator 12. In an example, the first electronic device 26 is configured to establish electrical contact between energy storage system 20 and pilot valve operator 12, and microcontroller 22 is configured to utilize first electronic device 26 to establish the electrical contact. In some examples, microcontroller 22 is configured to terminate electrical contact between energy storage system 20 and pilot valve operator 12. In an example, first electronic device 26 may be likewise configured to terminate electrical contact between energy storage system 20 and pilot valve operator 12, and microcontroller 22 may be configured to utilize first electronic device 26 to terminate the electrical contact. First electronic device 26 may be similarly configured to maintain or terminate electrical contact between thermoelectric device 16 and pilot valve operator 12, and microcontroller 22 may be configured to utilize first electronic device 26 to maintain or terminate the electrical contact.
Microcontroller 22 may be is configured to establish electrical contact between thermoelectric device 16 and main valve operator 14 (
In some examples, microcontroller 22 is configured to establish electrical contact between power source 31 and energy storage system 20. In an example, the third electronic device 30 is configured to establish electrical contact between power source 31 and energy storage system 20, and microcontroller 22 is configured to utilize third electronic device 30 to establish the electrical contact. Microcontroller 22 may be configured to terminate electrical contact between power source 31 and energy storage system 20. In an example, third electronic device 30 is likewise configured to terminate electrical contact between power source 31 and energy storage system 20, and microcontroller 22 is configured to utilize third electronic device 30 to terminate the electrical contact.
In some examples, microcontroller 22 is configured to establish electrical contact between power source 31 and microcontroller 22. In an example, the fourth electronic device 47 is configured to establish electrical contact between power source 31 and microcontroller 22, and microcontroller 22 is configured to utilize fourth electronic device 47 to establish the electrical contact. Microcontroller 22 may be configured to terminate electrical contact between power source 31 and microcontroller 22. In an example, fourth electronic device 47 is likewise configured to terminate electrical contact between power source 31 and microcontroller 22, and microcontroller 22 is configured to utilize fourth electronic device 47 to terminate the electrical contact.
In some examples, microcontroller 22 is configured to establish electrical contact between ignition circuit 24 and energy storage system 20. In an example, a fifth electronic device 49 is configured to establish electrical contact between ignition circuit 24 and energy storage system 20, and microcontroller 22 is configured to utilize fifth electronic device 49 to establish the electrical contact. Microcontroller 22 may be configured to terminate electrical contact between ignition circuit 24 and energy storage system 20. In an example, fifth electronic device 49 is likewise configured to terminate electrical contact between ignition circuit 24 and energy storage system 20, and microcontroller 22 is configured to utilize fifth electronic device 49 to terminate the electrical contact. First electronic device 26 may be similarly configured to maintain or terminate electrical contact between thermoelectric device 16 and ignition circuit 24, and microcontroller 22 may be configured to utilize first electronic device 26 to maintain or terminate the electrical contact.
First electronic device 26, second electronic device 28, third electronic device 30, fourth electronic device 47, and fifth electronic device 49 may each be an apparatus sufficient to establish, maintain, and terminate electrical contact between two portions of an electrical system in response to a signal from microcontroller 22. For example, first electronic device 26, second electronic device 28, and/or third electronic device 30 may comprise a field effect transistor (FET), a relay, a separate switching circuit, or any other device capable of establishing and terminating electrical contact in response to a signal.
In an example, microcontroller 22 is configured to recognize a requirement for main burner operation and in response, establish electrical contact between energy storage system 20 and pilot valve operator 12, and establish electrical contact between thermoelectric device 16 and main valve operator 14 (
When microcontroller 22 recognizes the requirement for main burner operation, microcontroller 22 may be configured to initially utilize electrical power from power source 31 to establish the electrical connections necessary to establish a pilot flame. As thermoelectric device 16 begins generating electrical energy in response to the pilot flame, microcontroller 22 may be configured to shift its power supply from power source 31 to electrical energy provided by thermoelectric device 16 and delivered via, for example, converter 45. Microcontroller 22 may be configured to terminate an electrical connection between microcontroller 22 and power source 31 using fourth electronic device 47 while thermoelectric device 16 generates and provides electrical energy through converter 45.
While the main burner requirement is ongoing, microcontroller 22 may be configured to maintain the electrical connection between thermoelectric device 16 and pilot valve operator 12 using first electronic device 26, in order that thermoelectric device 16 may provide the electrical power necessary to maintain pilot valve operator 12 energized. Similarly, while the main burner requirement is ongoing, microcontroller 22 may be configured to maintain the electrical connection between thermoelectric device 16 and ignition circuit 24 using fifth electronic device 49, in order that thermoelectric device 16 may provide the igniting energy to ignition circuit 24.
In an example, microcontroller 22 is similarly programmed to recognize a requirement to secure the main burner, and in response, terminate electrical contact between thermoelectric device 16 (and energy storage system 20) and pilot valve operator 12, and terminate electrical contact between thermoelectric device 16 and main valve operator 14 (
In some examples, microcontroller 22 is configured to periodically wake and monitor a status of system 10 (
In examples, one or more of pilot valve operator 12, main valve operator 14, or main valve operator 414 are millivoltage automatic valve operators. In examples, one or more of pilot valve operator 12 or main valve operator 14 are configured to alter the position of a valve when thermoelectric device 16 generates electrical power at a voltage of 800 mV or less (e.g., a voltage in a range of 800 mV to 400 mV). In examples, one or more of pilot valve operator 12 or main valve operator 14 are configured to alter the position of a valve when pilot valve operator 12 or main valve operator 14 receives a current of 50 mA or less (e.g., a current in a range of 25 mA to 50 mA). The electrical resistance of main valve operator 414 is such that main valve operator 414 may only be sufficiently energized to actuate the necessary valve when thermoelectric device 16 is generating a voltage (i.e., the pilot flame is lit) and converter 418 is stepping up the voltage from the generated level to a level sufficient to cause main valve operator 414 to actuate. In examples, one or more of pilot valve operator 12, main valve operator 14, or main valve operator 414 cause the opening of a valve when in the energized state. In some examples, one or more of pilot valve operator 12, main valve operator 14, or main valve operator 414 cause the closing of a valve when in the de-energized state. In some examples, one or more of pilot valve operator 12, main valve operator 14, or main valve operator 414 control the energizing of an electromechanical device such as a solenoid valve.
Power source 31 may be one or more devices capable of storing electrical energy, such as a battery, a capacitor, one or more series connected batteries and/or another device capable of storing electrical energy. Power source 31 may comprise a lithium battery Power source 31 may comprise a supercapacitor. Power source 31 may comprise an electrochemical double-layer capacitor (EDLC) Power source 31 may comprise one or more of a double-layer capacitor, a pseudocapacitor, or a hybrid capacitor. In examples, power source 31 may comprise an initial energy storing component which may be removed from a water heater control system and replaced in the water heater control system with a subsequent energy storing component. The energy storing component may be rechargeable. Power source 31 may be charged to a specified voltage prior to installation of the associated water heater.
In examples, convertor 18 and convertor 418 may be a power convertor which receives electrical power is a first form and converts the electrical power to another form. Converter 18 and convertor 418 may be an electronic circuit, electronic device, or electromechanical device. In examples, converter 18 receives a first voltage received from thermoelectric device 16 and provides a second voltage to electrical line 39. In examples, converter 418 receives a first voltage received from thermoelectric device 16 and provides a second voltage to electrical line 434. In examples, the second voltage is greater than the first voltage. Converter 418 may be configured to generate a voltage greater than that generated by thermoelectric device 16. In examples, converter 418 may be configured to generate a voltage in a range of 3 VDC-6 VDC, or some other voltage greater than that produced by thermoelectric device 16. For example, convertor 18 or convertor 418 might receive a first voltage of about 0.7 VDC (700 mV) from thermoelectric device 16 and provide a voltage of about 3.3 VDC to electrical line 39 or electrical line 434 respectively. In examples, convertor 18 or convertor 418 is a DC step-up convertor.
In examples, thermoelectric device 16 comprises one or more components which generate an output voltage proportional to a local temperature difference or temperature gradient, such as a thermopile, thermocouple, or other thermoelectric generator. Thermoelectric device 16 may comprise a thermoelectric material. Thermoelectric device 16 may comprise a plurality of thermocouples connected in series or in parallel. Thermoelectric device 16 may comprise one or more thermocouple pairs. In examples, a heat flux from a pilot flame generates a temperature gradient, and thermoelectric device 16 generates a DC voltage in response to the temperature gradient.
In examples, energy storage system 20 comprises one or more of a capacitor, a battery, or a capacitor and a battery. Energy storage system 20 may comprise a supercapacitor. Energy storage system 20 may comprise an electrochemical double-layer capacitor (EDLC). Energy storage system 20 may comprise one or more of a double-layer capacitor, a pseudocapacitor, or a hybrid capacitor. Energy storage system 20 may comprise a lithium battery. In examples, the energy storage system 20 may comprise an energy storage component which may be removed from water heater control system 10 and replaced in water heater control system 10 with a subsequent energy storage component. The energy storage component may be rechargeable such that the energy storage component is configured to have its stored electrical energy restored through a permanent or temporary connection to a power supply, for example thermoelectric device 16 or some other power supply. The energy storage component may be non-rechargeable.
In examples, microcontroller 22 may include any one or more of a microcontroller (MCU), e.g. a computer on a single integrated circuit containing a processor core, memory, and programmable input/output peripherals, a microcontroller (μP), e.g. a central processing unit (CPU) on a single integrated circuit (IC), a controller, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field-programmable gate array (FPGA), a system on chip (SoC) or equivalent discrete or integrated logic circuitry. A processor may be integrated circuitry, i.e., integrated processing circuitry, and that the integrated processing circuitry may be realized as fixed hardware processing circuitry, programmable processing circuitry and/or a combination of both fixed and programmable processing circuitry.
Example techniques of generating a main burner flame is illustrated at
The technique may include allowing a device to convert thermal energy from the pilot flame into electrical energy (174). In examples, the technique allows thermoelectric device 16 in thermal communication with the pilot flame to generate electrical energy from some portion of the thermal energy received from the pilot flame. The technique may include initiating a second gas flow using a first portion of the electrical energy (176). In examples, the technique initiates a main gas flow by energizing main valve operator 14 using a first portion of the electrical energy. The technique may include storing a second portion of the electrical energy. In examples, the technique provides a second portion of the electrical energy to energy storage system 20.
The technique may include porting the second gas flow to a burner in thermal communication with the pilot flame (168). In examples, the technique ports the main gas flow to main burner 48, which is configured to establish thermal communication between the main gas flow and the pilot flame, thereby generating the main burner flame.
In examples, the technique may include recognizing a temperature signal using a microcontroller, and responding to the temperature signal by utilizing the microcontroller to establish electrical communication between the energy storage system and the first valve operator. The technique may include reacting to the temperature signal by utilizing the microcontroller to prompt the pilot ignition circuit to cause the pilot spark ignitor to generate the pilot flame. In examples, the technique may include acknowledging the temperature signal by utilizing the microcontroller to establish electrical contact between the device and the second valve operator.
In one or more examples, functions described herein may be implemented in hardware, software, firmware, or any combination thereof. For example, the various components and functions of
Instructions may be executed by one or more processors, such as one or more DSPs, general purpose microcontrollers, ASICs, FPGAs, or other equivalent integrated or discrete logic circuitry. Accordingly, the term “processor,” as used herein, such as may refer to any of the foregoing structure or any other structure suitable for implementation of the techniques described herein. Also, the techniques could be fully implemented in one or more circuits or logic elements.
The techniques of this disclosure may be implemented in a wide variety of devices or apparatuses, including a wireless handset, an integrated circuit (IC) or a set of ICs (e.g., a chip set). Various components, modules, or units are described in this disclosure to emphasize functional aspects of devices configured to perform the disclosed techniques, but do not necessarily require realization by different hardware units. Rather, as described above, various units may be combined in a hardware unit or provided by a collection of interoperative hardware units, including one or more processors as described.
The present disclosure includes the following examples:
A water heater comprising: a power source that is non-rechargeable; a controller configured to receive power from the power source; an energy storage system comprising a rechargeable power supply and configured to provide power to one or more components of the water heater, wherein the water heater is configured to prevent the controller from receiving power from the rechargeable power supply; and a thermoelectric device configured to provide power to recharge the rechargeable power supply, wherein the thermoelectric device is configured to generate power in response to a pilot flame in proximity to the thermoelectric device.
The water heater of example 1, wherein the rechargeable power supply is configured to receive power for recharging from the power supply in instances when there is no pilot flame and a power level of the rechargeable power supply is less than a threshold.
The water heater of example 1 or 2, wherein the controller is configured to selectively receive power from at least one of the power source or the thermoelectric device.
The water heater of any of examples 1-3, further comprising: a first valve operator configured to cause a first gas flow, wherein the first valve operator is coupled to receive power from the energy storage system, the power source, or both the energy storage system and the power source when the thermoelectric device is not generating power and coupled to receive power generated by the thermoelectric device when the thermoelectric device is generating power; an ignition circuit is configured to cause the pilot flame using the first gas flow; a second valve operator coupled to receive power generated by the thermoelectric device, wherein the second valve operator is configured to cause a second gas flow; and a burner configured to generate a main burner flame using the pilot flame and the second amount of gas flow.
The water heater of example 4, wherein the ignition circuit is coupled to receive power from the energy storage system, the power source, or both the energy storage system and the power source when the thermoelectric device is not generating power and coupled to receive power generated by the thermoelectric device when the thermoelectric device is generating power.
The water heater of examples 4 or 5, wherein the water heater is configured to prevent the second valve operator from receiving power from the energy storage system.
The water heater of any of examples 4-6, wherein: the first valve operator requires a first voltage to cause the first gas flow, the second valve operator requires a second voltage to cause the second gas flow, the first voltage is less than the second voltage, and the thermoelectric device is configured to provide power at a voltage greater than or equal to the first voltage and less than the second voltage.
The water heater of any of examples 1-7, wherein the controller is configured to establish electrical contact between the power source and the energy storage system to provide a recharging power from the power source to the energy storage system.
The water heater of any of examples 1-8, wherein the controller is configured to receive power from the thermoelectric device when the thermoelectric device is generating power.
The water heater of any of examples 1-9, wherein the controller is configured to: receive a signal indicative of a temperature; establish, in response to the signal indicative of the temperature, electrical contact between the energy storage system and a first valve operator, wherein the first valve operator is configured to cause a first gas flow control; and initiate, in response to the signal indicative of the temperature, electrical contact between the thermoelectric device and a second valve operator, wherein the second valve operator is configured to cause a second gas flow, wherein a mass flow rate of the second gas flow is greater than a mass flow rate of the first gas flow.
The water heater of example 10, further comprising: a first electronic device configured to establish electrical contact between the energy storage system and the first valve operator; and a second electronic device configured to establish electrical contact between the thermoelectric device and the second valve operator, wherein the microcontroller is configured to utilize the first electronic device to establish electrical contact between the energy storage system and the first valve operator in response to the signal indicative of the temperature, and wherein the microcontroller is configured to utilize the second electronic device to initiate electrical contact between the thermoelectric device and the second valve operator in response to the signal indicative of the temperature.
The water heater of any of examples 1-11, wherein the controller is configured to: determine an available voltage level in the energy storage system; determine whether the energy storage system requires additional charge based on the available voltage level; and establish, based on the energy system requiring additional charge, electrical contact between the power source and the energy storage system to provide the recharging power.
The water heater of example 12, further comprising an electronic device configured to establish electrical contact between the power source and the energy storage system, wherein the microcontroller is configured to utilize the electronic device to establish electrical contact between the power source and the energy storage system to provide the recharging power.
The water heater of any of examples 1-13, wherein the water heater controller is configured to prevent the controller from receiving power from the energy storage system.
A water heater system comprising: a first valve operator, wherein the first valve operator initiates a first gas flow when energized; an energy storage system coupled to energize the first valve operator; a power source coupled to recharge the energy storage system; a pilot ignition circuit configured to cause a pilot spark ignitor to generate a pilot flame using the first gas flow; a second valve operator, wherein the second valve operator initiates a second gas flow when energized, wherein the second gas flow is greater than the first gas flow, and wherein the second valve operator cannot be energized from the energy storage system; and a thermoelectric device that converts thermal energy from the pilot flame into electrical energy, the thermoelectric device coupled to provide a first portion of the electrical energy to energize the second valve operator and the thermoelectric device coupled to provide a second portion of the electrical energy to the energy storage system.
The water heater of example 15, further comprising a controller, wherein the water heater system is configured to provide electrical power from the power source to the controller when the thermoelectric device is not generating the electrical energy, and wherein the water heater system is configured to provide electrical power from the thermoelectric device to the microcontroller when the thermoelectric device is generating the electrical energy.
The water heater of example 15 or 16, wherein the controller is configured to: receive a signal indicative of a temperature; establish, in response to the signal indicative of the temperature, electrical contact between the energy storage system and the first valve operator; prompt, in response to the signal indicative of the temperature, the pilot ignition circuit to cause the pilot spark ignitor to generate the pilot flame using the first gas flow; and initiate, in response to the signal indicative of the temperature, electrical contact between the thermoelectric device and the second valve operator.
The water heater of any of examples 15-17, further comprising a controller configured to: determine an available voltage level in the energy storage system; determine if the energy storage system requires additional charge based on the available voltage; and establish, based on the energy system requiring additional charge, electrical contact between the energy storage system and the power source.
A method comprising: providing power to one or more components of the water heater using an energy storage system comprising a rechargeable power supply; recharging the rechargeable power supply using a thermoelectric device configured to generate power from a pilot flame; preventing a controller from receiving power from the energy storage system; and providing power to the controller using a non-rechargeable power source.
The method of example 19, further comprising: determining, using the controller, a voltage level of the energy storage system while the thermoelectric device is not generating power from the pilot flame; and recharging, based on the determined voltage level, the energy storage system by establishing an electrical connection between the energy storage system and the non-rechargeable power source.
Various examples have been described. These and other examples are within the scope of the following claims.
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/886,773 (filed Aug. 14, 2019), which is entitled, “BURNER CONTROL SYSTEM” and incorporated by reference herein in its entirety.
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