Abstract:
Appliances, such as hot water heaters, hot water heater controllers, and methods of operating such hot water heaters, that take into consideration the availability and capacity of alternative energy sources so that additional efficiencies can be realized by sensing the availability of an alternative energy source and adjusting the control algorithms used to control the use of the available electric power is provided.

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATION 
       [0001]    This patent application claims the benefit of U.S. Provisional Patent Application No. 62/247,635, filed Oct. 28, 2015, the entire teachings and disclosure of which are incorporated herein by reference thereto. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention generally relates to heating controls for consumer and commercial appliances, and more particularly to heating controls for hot water heaters. 
       BACKGROUND OF THE INVENTION 
       [0003]    It has now been recognized that the world&#39;s environment is suffering too much from global warming caused by greenhouse gas exposure in the atmosphere. To address this problem governments are now starting to adopt targets for reducing the emission of greenhouse gases to the environment and play their part to address this problem for future generations. While some countries have not adopted a firm goal, other countries, for example Australia, have adopted a policy for the reducing greenhouse gases by 20% by the year 2020. 
         [0004]    Greenhouse gases can be emitted from cars, industry, farming, and households to name a few. While certainly not as apparent as a large factory with tall smokestacks, within a normal household the gas burning appliances, such as furnaces, water heaters, etc., all release such greenhouse gases as a by-product of the combustion process itself. While the appliance industry has taken a leading role in energy efficiency and environmental concern, further improvement is always foremost in mind of the appliance design engineer. 
         [0005]    With such further improvement in mind, especially with the increased awareness of global climate change and changing governmental regulations, it is noted that hot water heaters can be one of the more fairly inefficient appliances in energy conservation, and therefore require the burning of additional fuel or the converting of more electricity to heat to maintain the set point temperature. This, of course, results in the additional production of greenhouse gas directly from the appliance beyond that which a more efficient appliance would produce. 
         [0006]    Recognizing the issue of greenhouse gas, many consumers have moved from gas burning appliances to electric appliances. A typical electric water heater includes one or two electric heating elements to heat water within a water holding tank. Particularly, when the water within the holding tank drops below a predetermined temperature, there is a call for heat and the heating elements are energized to raise the temperature of the water. Once the temperature of the water is raised to a predetermined or user determined set temperature the heating elements are deactivated. 
         [0007]    Typically, in water heaters having two heating elements, the heating elements are spaced vertically apart from one another. Further, when there is a call for heat, the heating elements can be controlled by a controller such that they can be energized simultaneously, or independent of one another to provide the most efficient heating of the water, depending on operating conditions and inputs by the operator. 
         [0008]    To determine the temperature of the water within the holding tank, the water heaters include temperature sensors. Typically, a temperature sensor is placed above and proximate to each heating element. Thus, the individual temperature sensors can determine the localized temperature of the water proximate the individual heating elements. This allows for localized heating of the water in the water heater to, again, improve efficiency. 
         [0009]    In addition to the movement from gas burning to electric appliances, many consumers have installed alternative energy sources of electricity, such as wind turbines, solar panels, etc. to further reduce the production of greenhouse gases. While such alternative energy sources can have a great impact in this regard, their availability and capacity can be limited compared to electric power from the grid. Unfortunately, current appliances are not designed in any way to recognize this limitation, and instead continue to operate as if the availability of electric power is limitless. 
         [0010]    What is needed are appliances, appliance controllers, and methods of operating such appliances to take into consideration the availability and capacity of alternative energy sources so that additional efficiencies can be had. The invention provides such appliances, appliance controllers, and methods of operating such appliances. These and other advantages of the invention, as well as additional inventive features, will be apparent from the description of the embodiments of the present invention provided herein. 
       BRIEF SUMMARY OF THE INVENTION 
       [0011]    In one aspect, embodiments of the present invention provide appliances, appliance controllers, and methods of operating such appliances that take into consideration the availability and capacity of alternative energy sources so that additional efficiencies can be realized. 
         [0012]    In another aspect, embodiments of the present invention provide appliances, appliance controllers, and methods of operating such appliances that take into consideration the availability and capacity of alternative energy sources so that additional efficiencies can be realized by sensing the availability of an alternative energy source and adjusting the control algorithms used to control the use of the available electric power. 
         [0013]    In yet another aspect, embodiments of the present invention provide hot water heaters, hot water heater controllers, and methods of operating such hot water heater that take into consideration the availability and capacity of alternative energy sources so that additional efficiencies can be realized by sensing the availability of an alternative energy source and adjusting the control algorithms used to control the use of the available electric power. 
         [0014]    Other aspects, objectives and advantages of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]    The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings: 
           [0016]      FIG. 1  is an isometric view of an embodiment of a single element hot water electronic controller constructed in accordance with the teachings of the present invention; 
           [0017]      FIG. 2  is an isometric view of the embodiment of the single element hot water electronic controller of  FIG. 1  rotated 90°; 
           [0018]      FIG. 3  is an isometric view of an embodiment of a dual element hot water electronic controller constructed in accordance with the teachings of the present invention; 
           [0019]      FIG. 4  is an isometric view of the embodiment of a dual element hot water electronic controller of  FIG. 3  showing the opposite side thereof; 
           [0020]      FIG. 5  is a simplified block diagram of the embodiment of a dual element hot water electronic controller of  FIG. 3 ; 
           [0021]      FIG. 6  is a partial isometric illustration of an embodiment of the hot water controller of the present invention installed on a hot water heater appliance within the same footprint as prior electromechanical controls; 
           [0022]      FIG. 7  is a simplified process control flow diagram for an embodiment of the present invention illustrating control of a two element hot water heater utilizing grid power; 
           [0023]      FIG. 8  is a simplified process control flow diagram for an embodiment of the present invention illustrating control of a two element hot water heater utilizing an alternative energy source; and 
           [0024]      FIG. 9  is a screen shot illustration of an embodiment of a thermostat configuration tool user interface for use with embodiments of the appliance controllers of the present invention. 
       
    
    
       [0025]    While the invention will be described in connection with certain preferred embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications and equivalents as included within the spirit and scope of the invention as defined by the appended claims. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0026]    Turning now to the Drawings, there are illustrated various embodiments of electronic controllers, exemplary appliances, and control methods in accordance with the teachings of the present invention. While such embodiments will be described herein, those skilled in the art will recognize that such embodiments are provided by way of example and not by way of limitation. Indeed, other embodiments of the present invention will become apparent to those skilled in the art from the following description and attached figures, and all rights are reserved therein. 
         [0027]      FIG. 1  illustrates one embodiment of an electronic controller  100  that is particularly well adapted for use with a single element hot water heater (not shown). This controller  100  has a modular design that locates the control and power switching elements in different portions of the housing. In the control section  102  the controller electronics are housed and insulated from the relays and power switching elements contained in the power section  104  of controller  100 . 
         [0028]    In the embodiment illustrated in  FIG. 1 , a user temperature adjustment interface  106  is provided to allow the user to adjust the temperature set point for the hot water heater. This control section  102  also includes an interface for external communication via, e.g., an RS485 port  108  as may best be seen in  FIG. 2 . Also visible in this  FIG. 2  is the integrated temperature probe  110  that provides temperature sensing, in some embodiments, of the water storage tank on which it is mounted. 
         [0029]    Returning again to  FIG. 1 , the power switching section  104  of controller  100  includes a bi-metal high temperature limit device  112  that ensures that power is cut off to the heating element in the event of a system failure that could cause excessive heating of the water in the storage tank. Once activated, the user would need to push the high limit reset button  114  in order to reset the bi-metal high limit device  112  to allow for continued operation. 
         [0030]      FIG. 3  and  FIG. 4  illustrate an embodiment of the electronic controller of the present invention particularly adapted to a dual element hot water heater having an upper heating element and a lower heating element (not shown). It is noted that similar components in this embodiment utilize the same numerical designation with an appended apostrophe in this embodiment. For example, the controller is now designated in this embodiment as  100 ′. 
         [0031]    While the function of these similar components is the same, and therefore a discussion thereof will be avoided in the interest of brevity, there are additional components and features provided in this embodiment to accommodate the dual heating elements and dual temperature sensing accommodated thereby. For example,  FIG. 3  illustrates the power connections  116 ,  118  that are connected to the top and bottom heating elements of the hot water heater.  FIG. 4  also illustrates the connector  120  for the top temperature sensor of the hot water tank in addition to the integrated temperature probe  110 ′ that serves as the temperature sensor for the bottom of the hot water tank based upon the typical installation location of the electronic controller on such an appliance. 
         [0032]      FIG. 5  illustrates a simplified block diagram of the dual element electronic controller  100 ′ in order to provide additional information on the internal components and partitions between the control section  102 ′ and the power switching section  104 ′, and the external connections to other system elements. As may be seen from this block diagram, the power switching section  104 ′ includes the high temp limit switch, e.g. the bi-metal high limit  112 ′ that serves to break both the power lines L 1 , L 2  so as to disconnect power from the heating elements  122 ,  124 . In the control section  102 ′, the low voltage isolated control circuitry is segregated from the switching relays  126 ,  128  that provide the controlled power to the heating elements  122 ,  124 . As may be seen from this  FIG. 5 , in addition to the upper temperature sensor  130  and the lower temperature sensor  110 ′, in one embodiment an additional board ambient temperature sensor  132  is provided in order to sense PCB temperature, correct for thermal drift of the temperature sensing circuitry, for diagnostics, etc. as is known in the art. 
         [0033]    In preferred embodiments, the physical layout and configuration of the controller  100 ,  100 ′ are such that they are line replaceable for conventional electronic or electromechanical controllers in field installed appliances in order to allow them to take advantage of the control algorithms of the present invention to accommodate the use of alternative energy sources. Such an exemplary installation is illustrated in  FIG. 6  wherein the controller  100 ,  100 ′ has been installed in a hot water heater  134 . 
         [0034]    With an understanding of the physical configuration of the embodiments discussed above, attention is now directed to the control flow diagrams of  FIG. 7  and  FIG. 8  so that operation of the controller that enables the environmental utilization of the alternative power source may be understood. Such operation prioritizes the use of the alternative energy source and provides it with additional time to accomplish the heating of the water so as to not tax the capacity of the source. Within the control flow diagrams of  FIG. 7  and  FIG. 8 , the abbreviations of “TS” refer to the top temperature sensor; “BS” refers to the bottom, also known as, the lower temperature sensor; “SP” refers to set point; “TE” refers to a top element; and “BE” refers to a bottom element. 
         [0035]    Beginning with  FIG. 7 , the system first checks the PCB ambient temperature to ensure that it is within operating temperature parameters at decision block  140 . Specifically, this step  140  determines whether the ambient temperature is greater than 70° C. If the PCB temperature is greater than 70° C., step  142  powers off the elements and returns to decision block  140 . If, however, the PCB temp is less than 70° C., the system next checks to see whether an alternative heat source is available at decision block  144 . If an alternative energy source is available, then it is prioritized and the control of the system is transitioned to the flow diagram of  FIG. 8 , which will be discussed more fully below, at step  146 . 
         [0036]    However, if no alternative source of energy is available, i.e. the system will operate off of grid power, the system next checks to determine whether the top temperature sensor is less than the set point by 10° F. or more at step  148 . If step  148  is affirmative, then the system powers the top heating element at step  150 . Thereafter, the system will check to determine whether the temperature as read by the top temperature sensor is within 5° F. of the set point temperature with a rise of greater than a predetermined ramp rate of, e.g. 2° F. per second at step  152 . If this condition is true, then the controller may remove power from the top heating element because with such a rate of rise within range of the set point, the thermal inertia of the system will likely result in the temperature reaching the set point. However, if step  152  is negative, then the system will check to see if the temperature sensed by the top temperature sensor is greater than or equal to the set point at step  154 . If this condition is true the system may then de-energize the heating element as the desired condition is then met. However, if this decision at step  154  is also negative, the system will continue to monitor the temperature sensor in steps  152  and  154  until one of these conditions is met. 
         [0037]    Returning to step  148 , if this decision is negative, then the system checks to determine whether the temperature sensed by the bottom temperature sensor is less than the set point by 10° F. or more at step  156 . If not, then no heating is required and the system will simply continue to monitor the previous decision steps as shown in  FIG. 8 . However, if the temperature sensed by the bottom sensor is less than the set point by 10° F. or more, then step  158  will energize the bottom heating element. Once power has been applied to the bottom heating element at step  158 , the bottom temperature sensor will be monitored to determine whether it is within 5° F. of the set point with a temperature rise rate of 2° F. per second or more at step  160 . If this check is positive, then the heating element may be de-energized as the continued temperature rise will likely reach the set point temperature without further heating. If, however, step  160  is negative, then the temperature sensed by the bottom sensor will be monitored to determine if it is greater than or equal to the set point temperature at step  162 . If this decision is positive, the heating element may be de-energized as the set point temperature has been reached. However, if this condition is negative at step  162 , the system will continue to monitor the temperature sensed by the bottom temperature sensor until one of these two conditions is met and the bottom heating element may be de-energized. 
         [0038]    As discussed above, if an alternative source of energy is available, the system will prioritize its use and alter its operating algorithms to utilize this alternative source of power recognizing that the capacity of such sources may be limited. Such operation is illustrated in the flow diagram of  FIG. 8 . As with the operation with grid power, the system first checks to determine if the PCB temperature is greater than 70° C. at step  164 . If this check is positive, then the elements are powered off as illustrated in step  166 . If, however, the PCB temp is not greater than 70° C., then the system checks to verify that the alternative source of energy is available at step  168 . If an alternative source is not available, then the system will return to the operation as illustrated in  FIG. 7  at step  170 . 
         [0039]    However, if the alternative energy source check at step  168  is positive, then the system checks the temperature monitored by the top temperature sensor to determine whether it is lower than the set point by 20° F. or more at step  172 . This additional temperature difference allows for a wider variation in the sensed temperature from the set point recognizing that the capacity of the alternative energy source may be lower than the grid power and therefore should be utilized sparingly so as to not deplete the source unnecessarily. If this decision at step  172  is positive, then the top heating element is energized at step  174 . 
         [0040]    Once energized, the temperature monitored by the top temperature sensor is monitored to determine whether it is within 10° F. of the set point with a temperature rise differential greater than 2° F. per second at step  176 . If it is, then the heating element may be de-energized as it is likely that the temperature will continue to rise to meet the set point without further utilization of the alternative power source. If, however, this condition is not met at step  176 , then the temperature monitored by the top temperature sensor is checked to determine whether it is greater than or equal to the actual set point temperature at step  178 . If not, the system continues to monitor these parameters in order to determine when the energization of the heating element may be discontinued. If, however, this condition is met at step  178 , the system de-energizes the heating element as the set point temperature has been reached. 
         [0041]    Returning to decision block  172 , if this condition is not met then the temperature monitored by the bottom temperature sensor is checked to determine whether it is less than 20° or more from the set point temperature at step  180 . If this condition is not met, the system continues to monitor the temperature sensors as illustrated in  FIG. 8 . If, however, the determination at step  180  is positive, then the bottom heating element is energized at step  182 . Once energized, the system then monitors the temperature of the bottom temperature sensor to determine whether it is within 10° F. of the set point with a temperature rise differential of greater than 2° F. per second as illustrated at decision block  184 . If this determination is negative, then the system checks to see whether the temperature monitored by the bottom temperature sensor is equal to or greater than the set point at step  186 . If not, the system will continue to monitor the temperature sensed by the bottom temperature sensor until one of these two conditions is reached at which point the bottom heating element is de-energized. 
         [0042]    While the preceding discussion of the operation illustrated in  FIGS. 7 and 8  utilize particular parameters, such parameters are not limiting but instead merely discuss one embodiment of the enhanced control enabled by the present invention. Indeed, as illustrated in  FIG. 9 , a configuration user interface may be provided that allows these various parameters to be modified to fine tune operation of the system based on the particular type of alternative energy source and capacity available in a particular installation, or use with a particular model. Such reprogramming of the controller  100 ,  100 ′ may be accomplished via the RS485 network illustrated in the above-described embodiments, or may be wirelessly transmitted to the controller in embodiments utilizing such wireless interface. 
         [0043]    All references, including publications, patent applications, and patents cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein. 
         [0044]    The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention. 
         [0045]    Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.