Flow through electrical heat controller having asymptotic temperature control arrangement to avoid overshoot

• US 5,390,277 A
• Filed: 03/27/1992
• Issued: 02/14/1995
• Est. Priority Date: 03/27/1992
• Status: Expired due to Fees

• Current Assignee: Andermac, Inc.
• Original Assignee: Andermac, Inc.
• Inventors: Stapleton, John, Hay, Mohammed R., Van Wagner, Mark, Byers, Allan W.
• Primary Examiner(s): Paschall, Mark H.
• Application Number:
  US07/858,164
• Time in Patent Office: 1,054 Days
• Field of Search: 392/480-493, 392/465, 219/485, 219/497, 4/420.1, 4/420.2, 4/443
• US Class Current: 392/485
• CPC Class Codes: F24H 15/174 Supplying heated water with desired temperature or desired range of temperature
• CPC Class Codes: F24H 15/215 before heating
• CPC Class Codes: F24H 15/219 after heating
• CPC Class Codes: F24H 15/238 Flow rate
• CPC Class Codes: F24H 15/37 of electric heaters
• CPC Class Codes: F24H 15/395 Information to users, e.g. alarms
• CPC Class Codes: F24H 15/407 using electrical switching, e.g. TRIAC
• CPC Class Codes: F24H 15/414 using electronic processing, e.g. computer-based
• CPC Class Codes: F24H 9/2028 Continuous-flow heaters
• CPC Class Codes: G05D 23/1917 using digital means
• CPC Class Codes: G05D 23/24 the sensing element having a resistance varying with temperature, e.g. a thermistor

Abstract

This invention relates to the control of the temperature of heated fluid flow through a so-called single pass electrical heater. Specifically, a controller and accompanying flow circuit including a flow through single pass electrical heater is disclosed which provides for heating of water upon initiation of flow. A two stage control protocol is utilized for routing current under precise control to the heater element. In the first protocol utilized at start up to a control temperature limit slightly below the temperature set point, phase angle of current turn on with zero crossing current turn off control a 220 volt current to the single pass heater element. Once the control temperature is achieved, incremental adjustment of phase angle thereafter occurs with rapid asymptotical approach of the output temperature of the flowing water to a preselected temperature "set point" occurs. Problems relating to thermally inefficient storage of water as well as overshoot of the desired water output temperature are held to a minimum. Preferred use of the heating system in combination with a female hygiene douche is disclosed.

Claims

1. A controller and single pass electrical fluid heater in combination operated from an alternating current source in which heated fluid asymptotically approaches a temperature "set point" without the danger of appreciable overshoot and with minimum undershoot comprising in combination:

a single pass electrical fluid heater placed in series between a fluid source and an outlet;

an electrical heating element in said fluid heater having electrical connection for imparting heat to fluid flowing in a single pass through said heater;

at least one flow throttling aperture;

a first temperature sensor for measuring the water outflow temperature from said heater;

a second temperature sensor for measuring the water inflow temperature to said heater;

a connected controller for setting the desired set 18 point temperature of said outflow from said heater;

means for establishing a control point temperature at level below said set point temperature as a function of said set point temperature;

means for comparing the first temperature sensor for measuring the water outflow from said heater with said control point temperature;

current control means connected between said alternating current source and said heater element operatively connected to said first temperature sensor, said second temperature sensor, said current control means having first and second current control protocols, said first current control protocol Operative when said water outflow temperature from said heater is below said control point temperature permitting computation of phase angle of said alternating current as a function of said heater input temperature, heater output temperature, and desired control point temperature;

said second control protocol operative when said water temperature is between said control point and said set point to incrementally change current as a function of heater output temperature and said set point temperature whereby said heater asmpytotically equilibrates to said set point.

2. The invention of claim 1 and including:

a flow control valve in series with said heater for enabling flow through said heater.

3. The invention of claim 1 and including:

means for measuring flow of fluid through said single pass heater; and

,

means for inhibiting current to said heater element in response to the absence of measured flow at said means for measuring flow.

4. The invention of claim 1 and wherein:

said first control protocol computes phase angle as a function of the slowest flow rate of fluid through said heater.

5. The invention of claim 1 and wherein said second control protocol includes:

means for incrementally reducing said current in response to output temperature over said set point at a faster rate than incrementally increasing current in response to output temperature under said set point.

6. The invention of claim 1 and wherein said control point is 5°

below said set point.

7. A process of controlling a single pass electrical fluid heater operated from an alternating current source in which heated fluid asymptotically approaches a temperature "set point" without the danger of appreciable overshoot and with minimum undershoot comprising in combination:

providing a single pass electrical fluid heater placed in series between a fluid source and an outlet;

providing an electrical heating element in said fluid heater having electrical connection for imparting heat to fluid flowing through said heater;

starting said flow through said heater;

throttling said flow through said heater;

measuring at a first temperature sensor the outflow temperature from said heater;

measuring at a second temperature sensor the inflow temperature to said heater;

providing a connected controller for setting the desired set point temperature of said outflow from said heater;

setting the desired temperature of said outflow to said provided connected controller;

computing as a function of said set point temperature a control point temperature, said control point temperature being less than said set point temperature;

providing current control means connected between said alternating current source and said heater element operatively connected to said first temperature sensor, said second temperature sensor, and said connected controller having first and second control protocols, said first current control protocol operative when said water outflow temperature from said heater is below said control point temperature permitting computation of phase angle of said alternating current as a function of said heater input temperature, heater output temperature, and desired control point temperature, said second control protocol operative when said water temperature is between said control point and said set point to incrementally change current as a function of heater output temperature and said set point temperature whereby said heater asmpytotically equilibrates to said set point;

utilizing said first control protocol when said output temperature of said heater is below said control point temperature;

utilizing said second control protocol when said output temperature is between said control point temperature and said set point temperature.

8. The process of claim 7 and including the step of:

monitoring the presence of fluid flow within said heater; and

enabling said current control means responsive to said measured flow.

9. The process of claim 7 and including the step of:

utilizing said first control protocol and a minimum flow rate through said throttled flow to compute said phase angle.

10. The process of claim 7 and including:

providing a pressure reducing valve in series with said fluid flow through said heater; and

controlling said pressure to adjust said flow rate through said heater.

11. The process of claim 7 and wherein said fluid is water.

12. A controller and single pass electrical fluid heater having an output in series connection with a female hygiene douche operated from an alternating current source in which heated fluid asymptotically approaches a temperature "set point" without the danger of appreciable overshoot and with minimum undershoot comprising in combination:

a female hygiene douche;

a single pass electrical fluid heater placed in series between a fluid source and an outlet to said douche;

an electrical heating element in said fluid heater having electrical connection for imparting heat to fluid flowing in a single pass through said heater;

at least one flow throttling aperture between said fluid source and said douche;

a first temperature sensor for measuring the outflow temperature from said heater;

a second temperature sensor for measuring the inflow temperature to said heater;

means for establishing a control point temperature at level below said set point temperature as a function of said set point temperature;

means for comparing the first temperature sensor for measuring the water outflow from said heater with said control point temperature;

current control means connected between said alternating current source and said heater element operatively connected to said first temperature sensor, said second temperature sensor, said current control means having first and second current control protocols, said first current control protocol operative said water outflow temperature from said heater is below said control point temperature permitting computation of phase angle of said alternating current as a function of said heater input temperature, heater output temperature, and desired control point temperature;

said second control protocol operative when said water temperature is between said control point and said set point to incrementally change current as a function of heater output temperature and said set point temperature whereby said heater asmpytotically equilibrates to said set point.

13. The invention of claim 12 and including:

means for providing a default temperature setting to said connected controller.

14. The invention of claim 12 and including:

a vacuum interrupter between said female hygiene douche and said outlet of said heater.