Hybrid range and method of use thereof

An appliance includes an oven cavity; a gas burner disposed within the oven cavity; an electrical heating element disposed within the oven cavity; and a controller in operative communication with the gas burner and the electrical heating element, the controller being configured to receive a signal indicative of a current state of an associated utility, and to selectively activate at least one of the gas burner and the electrical heating element based upon the signal.

BACKGROUND

The present disclosure generally relates to energy management of household consumer appliances, and more particularly to energy management in hybrid cooking appliances.

Utilities typically charge a flat rate for energy consumption, but with the increasing cost of fuel prices and high energy usage at certain parts of the day, generally referred to herein as “peak demand” or “peak demand periods”, utilities have to buy more energy to supply customers during these peak demand periods. Consequently, utilities tend to charge higher rates during peak demand periods. If demand during peak periods can be lowered, then a potential cost savings can be achieved and the load that the utility has to accommodate during peak demand periods is lessened.

One proposed solution is to provide a system where a controller “switches” the actual energy supply to the appliance or control unit on and off. However, there is no active control beyond the mere on/off switching. Another method involves demand side management (DSM), where a control device in an electromechanical appliance can delay, adjust or disable power consuming features to reduce power consumption. However, such DSM devices simply switch off or reduce loads without any feedback regarding the loads in use.

Electrical utilities moving to an Advanced Metering Infrastructure (AMI) system will need to communicate to appliances, HVAC, water heaters, ranges, etc. in a home or office building. In these types of advanced systems, the utility can transmit a signal to appliances employing “smart” metering devices or systems to indicate periods of peak demand. These “smart” devices can then employ various load shedding processes to reduce the demand on the utility or grid.

As described above, various factors can influence the relative costs associated with use of different types of heating elements, such as electric or gas. It would be advantageous to be able to switch between different energy sources during peak demand periods or when one energy source is less costly than another. Accordingly, it would be desirable to provide a cooking appliance that overcomes at least some of the problems identified above.

BRIEF DESCRIPTION OF THE DISCLOSED EMBODIMENTS

As described herein, the exemplary embodiments overcome one or more of the above or other disadvantages known in the art.

One aspect of the disclosed embodiments relates to an appliance. The appliance includes a controller and an oven cavity with a gas burner and an electrical heating element mounted therein. The controller is in operative communication with the gas burner and the electrical heating element. The controller is configured to receive a signal indicative of a current state of an associated utility, and to selectively activate at least one of the gas burner and the electrical heating element based upon the signal.

Another aspect of the disclosed embodiments relates to an oven. The oven includes a controller and an oven cavity with a gas burner and an electrical heating element disposed therein. The controller is in operative communication with the gas burner and the electrical heating element. The controller is configured to calculate an energy supply factor, and to selectively activate at least one of the gas burner and the electrical heating element based upon the energy supply factor.

Another aspect of the disclosed embodiments relates to a method of operating an oven having a controller and an oven cavity with a gas burner and an electrical heating element mounted therein and in operative communication with the controller. The method includes calculating an energy supply factor at the controller, and in response to the calculated energy supply factor, selectively activating at least one of the gas burner and the electrical heating element.

These and other aspects and advantages of the exemplary embodiments will become apparent from the following detailed description considered in conjunction with the accompanying drawings. It is to be understood, however, that the drawings are designed solely for purposes of illustration and not as a definition of the limits of the invention, for which reference should be made to the appended claims. Moreover, the drawings are not necessarily drawn to scale and unless otherwise indicated, they are merely intended to conceptually illustrate the structures and procedures described herein. In addition, any suitable size, shape or type of elements or materials could be used.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS OF THE DISCLOSURE

Referring toFIG. 1, an exemplary appliance, such as a free standing range, incorporating aspects of the disclosed embodiments, is generally designated by reference numeral100. The aspects of the disclosed embodiments are generally directed to selective activation of oven heating units, powered by different energy sources, to optimize oven performance and minimize energy usage during peak demand periods in a hybrid cooking appliance that incorporates both electric and gas powered heating assemblies. In a hybrid oven including both electric and gas powered heating assemblies, a normal state of the hybrid oven may be to operate using the electrical heating elements. However, in a period of peak demand, or when it is economically less efficient to utilize electrical power, the aspects of the disclosed embodiments will automatically switch the source of power to the hybrid oven from electric to gas, while maintaining the oven performance. Although the aspects of the disclosed embodiments will be described herein with respect to a range, the aspects of the disclosed embodiments can be generally applied to any appliance that is capable of utilizing multiple energy sources, such as refrigerators, air conditioning systems and hot water heaters, for example.

As is shown inFIG. 1, the range100includes a cabinet or housing2that has a front portion4, opposing side panels6, a base or bottom portion8, a top portion10, and a back panel12. In the embodiment shown inFIG. 1, the top portion10of the range100includes a cooktop20having one or more surface heating elements22. Heating elements22may be electrical or natural gas heating elements, as will be appreciated by one of skill in the art. In alternate embodiments, the range100does not include a cooktop20, such as in the case of a wall oven.

The range100also includes an oven unit24. Although the aspects of the disclosed embodiments are described herein with respect to the single oven configuration shown inFIG. 1, in alternate embodiments, the range100could comprise a multiple oven unit. As shown in the example ofFIG. 1, the range100includes an oven door26and a pullout drawer28, the operation of which is generally understood.

In one embodiment, the cabinet2of the range100includes a control surface30that supports one or more controls, generally referred to herein as burner control(s)32. The burner control(s) or control knob(s)32shown inFIG. 1are generally in the form of a knob style control that extends outwardly from and can be supported by the control surface30, which in one embodiment comprises a backsplash. In alternate embodiments, the knob(s)32can comprise any suitable switch or control device. In one embodiment, a control panel34includes a plurality of input selectors or switches36and a display38cooperating with control knob(s)32to form a user interface for selecting and displaying cooking cycles, warming cycles and/or other operating features, including selection of heating units within the oven unit24. In one embodiment, the input selectors or controls36can be in the form of push buttons or electronic switches.

In one embodiment, the range100includes a controller, such as controller40described herein. The controller40can be coupled to, or integrated within, the control panel34and configured to receive inputs and commands from, for example, the controls32and36, as well as external sources, and control the various operations and functions of the oven100, including the switching of the power source, as will be further described herein. In one embodiment, the controller40can include an electronic range control, and can be used to selectively activate heating elements within the oven unit24, based upon an energy supply factor characteristic of the utility state and/or supplied energy, e.g., electricity demand and/or availability, as is described herein.

FIG. 2is a schematic cross-sectional view of a portion of a dual fuel oven unit24that can be used with range100(shown inFIG. 1). Oven unit24includes an oven cavity42that is generally defined by a top wall44, a bottom wall46, two side walls48, and a back wall50. Front-opening access door26is hinged on one of side walls48and covers the front opening (not shown) of oven cavity42in the closed position.

In an exemplary embodiment, oven unit24includes a lower electrical heating element52, also referred to as a bake element, and a lower gas burner54, also referred to as a bake burner. The lower electrical heating element52and lower gas burner54are disposed in the lower portion of oven cavity42, typically attached to or above the bottom wall46. In one embodiment, the oven unit24can also include one or both of an upper electrical heating element56, also referred to as a broil element, and an upper gas burner58, also referred to as a broil burner. The upper electrical heating element56and upper gas burner58are disposed in an upper portion of oven cavity42, typically attached to or below the top wall44.

Oven unit24also includes a temperature sensor or probe60that extends at least partially into oven cavity42. The temperature sensor60is in signal communication with controller40in order to maintain a set temperature of the oven cavity42by modulating one or more of the heating elements52-58, as is generally understood in the art.

The electrically operated lower element52and upper element56are typically coupled to an electrical power supply62, such as a 120 volt power supply or a 240 volt power supply, for example, in a suitable fashion. The gas operated lower burner54and upper burner58are coupled to a gas supply64, also in a fashion that is generally understood.

In one embodiment, each of the electrical power supply62and the gas supply64are communicatively coupled to the controller40. The controller40is configured to regulate the supply of, to switch between, the gas or electrical power to respective electrical heating elements52,56and gas burners54,58in the oven unit24in a manner as described herein. The electrical supply62will include suitable relays, switches or other controls for controlling the supply of electrical power to the elements52,56, as will be understood in the art, while the gas supply64will include suitable valves and switches for controlling the gas flow to the burners54,58, as will be understood in the art.

Referring toFIG. 3, the aspects of the disclosed embodiments allow the use of an advanced system300to handle energy management between the utility302and the homeowner's appliances320, also referred to herein as “smart” or “intelligent” appliances. In one embodiment, the system300can include one or more of a controller310, utility meter304, communication network328, intelligent appliances320, and a home network330. Less advanced systems may allow for direct communication between the appliances320and the utility meter304, or mesh the network328through a DSMM (Demand Side Management Module). In one embodiment, the controller310is a DSM Module, which receives information from either the utility302via a smart meter or the internet or a home pc via home router314.

The home network330is generally a computer system that is coupled to the utility302, either through the meter304or via an Internet connection318, for example, that allows the utility to notify the controller310when the utility is in peak demand. In the embodiment shown inFIG. 3, the home network330includes a computer312coupled to the Internet318via a router314and modem316. In alternate embodiments, the home network330can be configured to receive information from the utility302in any suitable manner over any suitable communication network, including for example, a telecommunication network.

In one embodiment, the utility302provides the controller310with a signal106that is indicative of the occurrence of peak demand, also herein referred to as an energy supply factor. In one embodiment, the signal106is generated by the utility302to indicate a period of peak demand. Additionally, the homeowner can select a power source based on the rate the utility is charging, for example, at different times of the day. The controller310can also evaluate the energy consumption used by the home via the utility meter304at a specific point in time and determine if the home is exceeding a demand limit that is set by the utility or homeowner. If the demand limit is exceeded, the controller310can control the appliances320in a suitable manner.

As shown inFIG. 3, each intelligent appliance320has or is coupled to a communication interface326that is communicatively linked to the controller310via the network328, or other suitable communication means. Although the communication interface326is shown as a separate device for each intelligent appliance320, in one embodiment, the communication interface326is a single unit shared by the different appliances321-324. The communication interface326can be a power-line carrier receptive of data via electrical power transmission lines, a wireless device, and/or a wired communication interface that allows the transfer and exchange of data and information between each of the intelligent appliances320and the controller310. The controller310will communicate with, and control, the lighting321, appliances322, and thermostat323(for HVAC324), to execute the user's preferences/settings. In one embodiment, the user inputs the settings and preferences via the user interface325. The user interface325can comprise, be part of, or communicatively coupled to the user interface34described with respect toFIG. 1. The appliances322shown inFIG. 3can generally include the appliance100illustrated inFIG. 1.

In the system300ofFIG. 3, the intelligent appliances320respond to, or are controlled by, the signal106from the utility meter304to lower the peak load on the utility302and reduce the amount of energy that the consumer uses during peak energy demand periods. The signal106may generated by the utility provider302, such as a power company, and can be transmitted via a power transmission line, as a radio frequency signal, or by any other means for transmitting a signal when the utility provider302desires to reduce demand for its resources. Other suitable methods are described in U.S. patent application Ser. No. 12/559, 597.

FIG. 4is a schematic illustration of the demand managed cooking appliance100shown inFIG. 1. As noted, the appliance100includes one or more power consuming features/functions, such as the surface heating elements22, electric oven heating elements52,56and oven gas burners54,58. The controller40, which in one embodiment is part of, or communicatively coupled to the controller310ofFIG. 3, is operatively connected to each of the heating elements22, the lower and upper electrical heating elements52,56and the lower and upper gas burners54,58. The controller40can also be coupled to a memory unit402and the user interface325ofFIG. 3. In one embodiment, the controller40includes a microcomputer(s) or processor(s) on a printed circuit board which is programmed to selectively control the source of power to the oven unit24in accordance with the aspects of the disclosed embodiments described herein.

In the embodiment ofFIG. 4, the controller40is configured to receive and process the signal106. The signal106is received from the utility meter304. Alternatively, the signal106can be received directly from the utility302. The signal106can be indicative of the state of the demand, or a supply factor, for the utility's energy. For example, a relatively high price may be associated with a peak demand state or period, and a relative low price or cost is typically associated with an off-peak demand state or period.

The controller40can operate the appliance100in one of a plurality of operating modes, including a normal operating mode and an energy savings mode. In one embodiment, the controller40can switch between the normal operating mode and the energy savings mode in response to the received signal106. Specifically, the appliance100can be switched to operate in the energy savings mode in response to a state of signal106that indicates a peak demand state or period. For purposes of the description herein, the energy savings mode is a mode where the source of energy being used to power the oven cavity24is switched from an energy source that is subject to peak demand, such as electrical power, to an energy source that is not subject to peak demand constraints, such as natural gas. As will be discussed in greater detail below, the controller40is configured to selectively switch between the consumption of electrical energy or gas to reduce consumption of peak demand power by the cooking appliance100in the energy savings mode.

The controller40is responsive to the utility state to selectively activate operational aspects of the appliance100. For example, in one scenario during a peak demand period, the controller40will receive a signal106from the utility302, home network330, or user interface325that indicates the appliance100or system300has exceeded a demand limit. Responsive to the signal106, the controller40allocates, or switches the power source to appliance100based on two factors. A priority dictates which appliances321-324have higher priority to be in full energy mode than other appliances. Energy need dictates how much energy is required in a certain time period in order for each appliance to function properly. If an appliance's energy need to function properly exceeds the energy available in the energy saving mode, the appliance moves to a normal mode. The energy saving mode is typically a lower energy usage mode for the appliance such as shutdowns of compressors and motors, delayed cycles, higher operating temperatures in summer, lower operating temperatures in winter until the peak demand period is over, or use of an alternate available energy source. Once the demand limit is reached, the appliances will begin to transition into energy saving mode based on the priority and energy need level. The controller40receives periodic status updates from the utility302and appliances321-324in order to determine the appropriate mode of operation and if priorities need to change to maintain operation of the system300beneath the demand limit.

If the controller40receives and processes signal106indicative of a peak demand period or that the peak demand limit has been exceeded, the controller40determines whether one or more of the power consuming features/functions should be operated in the energy savings mode and if so, it signals the appropriate features/functions of the appliance100to begin operating in the energy savings mode to reduce the instantaneous peak energy demand by the appliance. For example, it has been observed that use of electrical power to heat an oven, such as oven cavity42of range100provides generally preferred temperature control. Accordingly, in one embodiment, the range100may operate in the normal mode using electrical heating elements52,56and transition to use of gas burners54,58in the energy savings mode.

In response to determination of a peak energy demand or that a peak demand limit has been exceeded, the controller40may transition the oven from normal to energy savings mode. In an exemplary embodiment, the controller40is responsive to the signal106to determine that the peak demand limit has been reached and selectively activates the gas burners54,48to initiate a transition from use of the electric heating elements52,56to gas burners54,58to heat the oven cavity42. The transition from the use of electric heating elements52,56to gas burners54,58is temperature based, and therefore controlled in a manner to maintain an appropriate cooking temperature within oven cavity42.

The controller40is responsive to determination that the peak demand limit has been exceeded during a cooking operation to regulate a decrease in electricity, via electrical supply62to the electrical heating elements52,56and an increase in natural gas, via supply64to the gas burners54,58. Heat to maintain the desired temperature in the oven is supplied by duty cycle control of the heat source. In one embodiment the transition from electricity to gas involves simply switching from duty cycling the electric element or elements to duty cycling the gas burner or burners, as necessary to maintain the desired oven temperature. It is also contemplated that the temperature based transition may include a temporary overlap of energy supply from both electrical and gas energy via supplies62,64. For example, the electrical heating elements52,54may initially operate at reduced power while the gas burners54,58begin to affect the heating of the oven cavity42. As the gas burners54,58increase their contribution of heating the oven cavity42; the electrical heating elements52,54may be turned off to reduce power consumption beneath the peak demand limit. In this manner, the temperature based transition maintains proper cooking temperature within the oven cavity42during the transition from normal (electric) to energy savings (natural gas) mode. In some embodiments, the power consumption may be reduced beneath the peak demand limit by increasing the energy provided by gas supply64and reducing the electrical supply62without necessarily fully deactivating the electrical heating elements52,54.

As described above with reference toFIGS. 1 through 3, the controller310receives periodic status updates from the utility302and appliances, such as range100. The controller310determines the present operational mode, and if operation of the system300is beneath the demand limit, the controller310may require (or allow) a change in operational mode of the appliances. For example, the controller310is responsive to a determination that operation of the oven24at a desired temperature does not exceed the demand limit to transition to use of electrical power, via energy supplies62,64to heat the oven. As described above, the transition may be temperature based, and thereby maintain a desired cooking temperature within the oven cavity42.

In view of the foregoing, the controller40facilitates a method of operating an oven24.FIG. 5depicts a flowchart500of exemplary process steps of operating an oven, such as oven24. At process step504, the controller40calculates an energy supply factor, such as to compare a present electricity demand to a peak electrical demand limit. At process step508, based upon the energy supply factor calculated at step504, the controller40selectively activates one or more of the gas burners54,58, one or more of the electrical heating elements52,56, or a combination thereof.

In an embodiment, the process step504of calculating the energy supply factor may be based upon various inputs, including without limitation, time of day, season of year, geographic location, and relative present demand of natural gas and electricity. In an embodiment, the process step508may include selectively activating elements using only one energy source, such as gas burners54,58or electrical heating elements52,56.

Embodiments of the process may also include receiving, at the controller40, data such as from the Internet318. Some embodiments may include a wireless connection to the Internet. Some embodiments may include receiving the data via the electrical power supply62, shown inFIG. 2.

While embodiments of the disclosure have been described as a dual-fuel oven, it will be appreciated that the scope of the disclosure is not so limited and may apply to ranges with other arrangements of heating sources, such as dual-fuel surface heating elements, for example.

As disclosed, some embodiments of the disclosure may include some of the following advantages: an ability to specify an energy supply source used to heat an oven; an ability to calculate an energy supply factor; and an ability to reduce peak energy usage.

An embodiment of the disclosure may be embodied in the form of computer-implemented processes and apparatuses for practicing those processes. Embodiments of the present disclosure may also be embodied in the form of a computer program product having computer program code containing instructions embodied in tangible media, such as floppy diskettes, CD-ROMs, hard drives, USB (universal serial bus) drives, or any other computer readable storage medium, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus for practicing the invention. Embodiments of the disclosure also may be embodied in the form of computer program code, for example, whether stored in a storage medium, loaded into and/or executed by a computer, or transmitted over some transmission medium, such as over electrical wiring or cabling, through fiber optics, or via electromagnetic radiation, wherein when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus for practicing aspects of the disclosure. When implemented on a general-purpose microprocessor, the computer program code segments configure the microprocessor to create specific logic circuits. A technical effect of the executable instructions is to calculate an energy supply factor and select an available energy supply source based upon a desired criterion.