Claims:WE CLAIM:
1. A liquid heating system (100) comprising:
• a liquid bath (105) having a liquid storage compartment (125) configured to store a liquid therewithin;
• at least one burner compartment (130) configured within said bath (105);
• a heat conductive partition (135) configured within said bath (105) to separate said liquid storage compartment (125) and said burner compartment (130);
• at least one burner (140) disposed within said burner compartment (130);
• a fuel source coupled to said burner (140);
• a solenoid valve (145) configured to couple said fuel source to said burner (140);
• at least one first sensor (150) disposed within said liquid storage compartment (125), said first sensor (150) configured to periodically sense the temperature of said liquid and generate at least one sensed signal corresponding to said sensed temperature; and
• a temperature control unit (155) configured to receive said sensed signal, and generate a valve control signal based on said sensed signal, said solenoid valve (145) configured to receive said valve control signal, and further configured to control fuel flow from said fuel source to said burner (140) based on said valve control signal.
2. The system (100) as claimed in claim 1, wherein said temperature control unit (155) comprises:
a converter (160) configured to receive said sensed signal and convert said sensed signal into a digital value;
a memory (165) configured to store a predetermined first threshold value of temperature of said liquid;
a computation unit (170) cooperating with said memory (165), and is configured to compute a second threshold value based on said first threshold value; and
a controller (180) configured to cooperate with said computation unit (170) and said converter (160), said controller (180) is further configured to generate said valve control signal:
• for activating said solenoid valve (145), when said digital value is less than the second threshold value; or
• for deactivating said solenoid valve (145), when said digital value is greater than the first threshold value.
3. The system (100) as claimed in claim 2, wherein said computation unit (170) is configured to generate the second threshold value which is less than the first threshold value by a predetermined delta value.
4. The system (100) as claimed in claim 1, wherein said system (100) includes:
a spark generation unit (190) disposed proximal to said burner (140), said spark generation unit (190) configured to generate a spark; and
a second sensor (195) disposed in said burner compartment (130) proximal to said burner (140), said second sensor (195) configured to sense flame generated by said burner (140) and generate a second sensed signal;
wherein said temperature control unit (155) is configured to cooperate with said spark generation unit (190), and is further configured to control spark generation process based on said second sensed signal.
5. The system (100) as claimed in claim 2, wherein said solenoid valve (145) is configured to allow fuel flow to said burner (140) when activated by said valve control signal, and is further configured to restrict the fuel flow to said burner (140) when deactivated by said valve control signal.
6. The system (100) as claimed in claim 4, wherein said spark generation unit (190) includes at least two electrodes.
7. The system (100) as claimed in claim 1, wherein an inner wall (105a) of said liquid bath (105) is of stainless steel, an outer wall (105b) of said liquid bath (105) is of galvanized iron, and an insulating material (118) is disposed between said inner wall (105a) and said outer wall (105b) of said liquid bath (105).
8. The system (100) as claimed in claim 1, wherein said first sensor (150) is a temperature sensor selected from the group consisting of a thermocouple, a thermistor, a Resistance Temperature Detector (RTD), and a thermostat.
9. The system (100) as claimed in claim 4, wherein said second sensor (195) is a flame sensor.
10. The system (100) as claimed in claim 1, wherein said fuel source is a liquid petroleum gas (LPG).
11. The system (100) as claimed in claim 1, wherein said system includes an air control unit configured to control flow of air in said burner compartment (130).
12. The system as claimed in claim 1, wherein said system (100) comprises a plurality of baffles (138) disposed in said burner compartment (130).
13. The system as claimed in claim 1, wherein said liquid bath (105) is insulated.
, Description:FIELD
The present disclosure relates to the field of liquid heating systems.
BACKGROUND
Hot water is used in a variety of residential and industrial applications. In one of the applications, the hot water is used for improving the strength and shine of a textile product. For example yarn or packing straps are dipped in the hot water to improve the strength and shine thereof. Conventionally, the hot water is obtained either by using a wood fired boiler or an electric water heater. In the wood fired boiler, the wooden logs are burnt to generate heat. The wooden logs are required to be cut in particular sizes before feeding to the boiler which is a cumbersome task. Use of wooden logs creates a tremendous amount of ash, which needs to be cleaned. Further, burning of wooden logs creates air pollution. Furthermore, there is no control on the amount of wood fed to the boiler which leads to an excessive heating of water. Such boilers are also not properly insulated. The electric water heater includes an electric coil which produces heat upon receiving an electric current. However, the electric water heater consumes a lot of electricity, thereby increasing the operational cost.
Therefore, there is felt a need of a liquid heating system that alleviates the aforementioned drawbacks of conventional heating systems.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
An object of the present disclosure is to provide a liquid heating system for providing hot liquid in which yarn and packing straps are dipped.
Yet another object of the present disclosure is to provide a liquid heating system that is environment friendly.
Another object of the present disclosure is to provide a liquid heating system that is energy efficient.
Yet another object of the present disclosure is to provide a liquid heating system that is cost effective.
Yet another object of the present disclosure is to provide a liquid heating system that is reliable, and user friendly.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure envisages a liquid heating system. The system comprises a liquid bath, at least one burner, a solenoid valve, at least one first sensor, and a temperature control unit. The liquid bath has a liquid storage compartment configured to store a liquid therewithin. At least one burner compartment is configured within the liquid bath. A heat conductive partition is configured within the liquid bath to separate the liquid storage compartment and the at least one burner compartment.
In an embodiment, the liquid bath is insulated.
The at least one burner is disposed within the burner compartment. A fuel source is coupled to the burner.
The solenoid valve is configured to couple the fuel source to the burner.
The at least one first sensor is disposed in the liquid storage compartment. The first sensor is configured to periodically sense the temperature of the liquid and is further configured to generate at least one sensed signal corresponding to the sensed temperature.
The temperature control unit is configured to receive the sensed signal, and generate a valve control signal based on the sensed signal. The solenoid valve is configured to receive the valve control signal and is further configured to control fuel flow from the source to the burner based on the valve control signal.
The temperature control unit comprises a converter, a memory, a computation unit, and a controller. The converter is configured to receive the sensed signal and is further configured to convert the sensed signal into a digital value. The memory is configured to store a predetermined first threshold value of temperature of the liquid. The computation unit cooperates with the memory, and is configured to compute a second threshold value based on the first threshold value. The controller is configured to cooperate with the computation unit and the converter, and is further configured to generate the valve control signal for activating the solenoid valve, when the digital value is less than the second threshold value, or for deactivating the solenoid valve, when the digital value is greater than the first threshold value.
In an embodiment, the computation unit is configured to generate the second threshold value which is less than the first threshold value by a predetermined delta value.
The system further comprises a spark generation unit and a second sensor. The spark generation unit is disposed proximal to the burner. The spark generation unit is configured to generate a spark. In an embodiment, the spark generation unit includes at least two electrodes.
The second sensor is disposed in the burner compartment proximal to the burner. The second sensor is configured to sense flame generated by the burner and further configured to generate a second sensed signal. Further, the temperature control unit is configured to cooperate with the spark generation unit, and is further configured to control spark generation process based on the second sensed signal.
In an embodiment, the solenoid valve is configured to allow fuel flow to the burner when activated by the valve control signal, and is further configured to restrict the fuel flow to the burner when deactivated by the valve control signal.
In an embodiment, an inner wall of the liquid bath is of stainless steel. An outer wall of the liquid bath is of galvanized iron or stainless steel as per requirement, and an insulating material is disposed between the inner wall and the outer wall of the liquid bath.
The system includes an air control unit configured to control flow of air in the burner compartment.
The system further includes a plurality of baffles disposed in the at least one burner compartment.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
A liquid heating system, of the present disclosure, will now be described with the help of the accompanying drawing, in which:
Figure 1 illustrates a schematic front view of a liquid heating system, in accordance with an embodiment of the present disclosure;
Figure 2 illustrates a schematic side view of a liquid bath of the liquid heating system of Figure 1;
Figure 3 illustrates a schematic view depicting arrangement of a burner and a fuel supply to the burner of the liquid heating system of the present disclosure;
Figure 4 illustrates another schematic view of the liquid heating system, in accordance with an embodiment of the present disclosure;
Figure 5 illustrates a block diagram of a control unit of the liquid heating system of the present disclosure; and
Figure 6 illustrates a schematic view of the liquid heating system, in accordance with another embodiment of the present disclosure.
LIST OF REFERENCE NUMERALS
100 – System
105 – Liquid bath
105a – Inner wall
105b – Outer wall
110 – Base portion
115 – Side walls
118 – Insulating material
120 – Top cover
125 – Liquid storage compartment
130 – Burner compartment
133 – Provision
135 – Partition
138 – Baffles
140 – Burner
145 – Solenoid valve
150 – First sensor
155 – Temperature control unit
160 – Converter
165 – Memory
170 – Computation unit
180 – Controller
185 – User input module
190 – Spark generation unit
195 – Second sensor
200 – Control unit
205, 210 – Regulator
215 – LPG cylinder
220 – Supply pipe
225, 230, 235 – Pressure gauge
240 – Needle valve
245 – Gas valve
DETAILED DESCRIPTION
The present disclosure envisages a liquid heating system that used a liquefied petroleum gas (LPG) and is environment friendly.
The liquid heating system (hereinafter referred to as system) is now described with reference to Figure 1 through Figure 6. Figure 1 illustrates a schematic front view of a system 100, in accordance with an embodiment of the present disclosure.
The system 100 comprises a liquid bath 105. In an embodiment, the liquid bath 105 is insulated.
The liquid bath 105 has a base portion 110, a plurality of side walls 115 extending from the base portion 110, and a top cover 120. The liquid bath 105 has a liquid storage compartment 125 configured to store a liquid therewithin. At least one burner compartment 130 is configured within the insulated liquid bath 105. Further, the burner compartment 130 is provided with a provision 133 to facilitate hot air to escape from the burner compartment 130. In an embodiment, the provision 133 is in the form of a chimney.
In an embodiment, the system 100 comprises a plurality of the burner compartments having configuration similar to the burner compartment 130. Various arrangements and configurations of the plurality of burner compartments in the liquid bath 105 are well within the scope and ambit of the present disclosure. The total number of the burner compartments is determined as per requirement of the application for which the system 100 is to be used.
In an embodiment, the liquid is water stored in the liquid storage compartment 125.
A heat conductive partition 135 is configured within the insulated liquid bath 105 to separate the liquid storage compartment 125 and the at least one burner compartment 130 from each other. In an embodiment, the heat conductive partition 135 is made of stainless steel.
In an embodiment, the system 100 comprises a plurality of partitions 135, each of which is configured to separate each of the burner compartments 130 from the liquid storage compartment 125.
In an embodiment, the liquid storage compartment 125 is arranged such that liquid storage compartment 125 at least partially circumscribes the burner compartment 130.
Referring to Figure 2, the liquid bath 105 is a double walled liquid bath having an insulating material 118 disposed in the space between the walls. In an embodiment, an inner wall 105a of the liquid bath 105 is of stainless steel, and an outer wall 105b of the liquid bath 105 is of galvanized iron or of stainless steel as per requirement. The insulating material 118 is disposed between the inner wall 105a and the outer wall 105b of the liquid bath 105.
The system 100 further comprises at least one burner 140 disposed in the at least one burner compartment 130. The burner 140 is configured to generate heat in the burner compartment 130. The heat is transferred to the liquid storage compartment 125 by conduction and convection mechanisms to heat the liquid. A fuel source is coupled to the burner 140.
In an embodiment, a single burner 140 is provided in each of the burner compartments. In another embodiment, a plurality of burners 140 is disposed in each of the burner compartments.
In an embodiment, the burner 140 is a naturally aspirated burner.
In an embodiment, the fuel source is a liquefied petroleum gas (LPG).
The arrangement of the burner 140 and a fuel supply to the burner 140 is shown in Figure 2. The burner 140 is in fluid communication with a plurality of LPG cylinders 215 via a supply pipe 220. The supply pipe 220 is provided with pressure gauges 225, 230, 235 at desired locations. Two pressure regulators 205, 210 are provided on the supply pipe 220 to regulate the pressure of the LPG in the supply pipe 220. In an embodiment, the pressure at the regulator 210 is set at 1.5 kg/cm2, and the pressure at the regulator 205, which is proximal to the burner 140, is set at 0.25 kg/cm2 to 0.5 kg/cm2. Furthermore, a gas valve 245 is provided on the supply pipe 220. The gas valve 245, when activated, allows the flow of LPG from the cylinders 215 to the regulator 210 when activated. A needle valve 240 is provided on the supply pipe 220 between the burner 140 and a solenoid valve 145.
Further, the supply pipe is provided a gas valve 245 that allows the flow of LPG from the cylinders 215
The system 100 includes an air control unit (not specifically shown in figures) configured to control flow of air in the burner compartment 130.
Referring to Figure 4 and Figure 5, the system 100 comprises a control unit 200 configured to control the operation of the burner 140. The control unit includes at least one first sensor 150, the solenoid valve 145, a temperature control unit 155, a spark generation unit 190, and a second sensor 195.
The at least one first sensor 150 is disposed in the liquid storage compartment 125. The first sensor 150 is configured to periodically sense the temperature of the liquid, and generate at least one sensed signal corresponding to the sensed temperature.
In an embodiment, the system 100 includes a plurality of first sensors 150 disposed in the liquid storage compartment 125 to periodically sense the temperature of the liquid.
In another embodiment, the first sensor 150 is a temperature sensor selected from the group consisting of a thermocouple, a thermistor, a Resistance Temperature Detector (RTD), and a thermostat.
The temperature control unit 155 is configured to receive the sensed signal, and generate a valve control signal based on the sensed signal. Further, the solenoid valve 145 is configured to couple the fuel source to the burner 140. The solenoid valve 145 is configured to receive the valve control signal, and is further configured to control fuel flow from the fuel source to the burner 140 based on the valve control signal.
The temperature control unit 155 includes a converter 160, a memory 165, a computation unit 170, and a controller 180. The converter 160 is configured to receive the sensed signal and is further configured to convert the sensed signal into a digital value. The memory 165 is configured to store a predetermined first threshold value of temperature of liquid. In an embodiment, the first threshold value corresponds to the value of desired temperature of liquid for a particular application in which the system 100 is used.
In an embodiment, the temperature control unit 155 includes a user input module 185 configured to receive the first threshold value from a user.
Further, the computation unit 170 cooperates with the memory 165, and is configured to compute a second threshold value based on the first threshold value. In an embodiment, the second threshold value is the value of the minimum allowable temperature of liquid.
In an embodiment, the computation unit 170 is configured to generate the second threshold value which is less than the first threshold value by a predetermined delta value. The predetermined delta value can be in the percentage form. For example, if the delta value is 3%, and the first threshold value is 60º Celsius, the computation unit 170 computes the second threshold value which is 3% less than the first threshold value.
The controller 180 is configured to cooperate with the computation unit 170 and the converter 160, and is further configured to generate the valve control signal for activating the solenoid valve 145, when the digital value is less than the second threshold value, or for deactivating the solenoid valve 145, when the digital value is greater than the first threshold value. In an embodiment, the controller 180 is a sequential controller.
In an embodiment, the solenoid valve 145 is a normally closed solenoid valve. The solenoid valve 145 is configured to allow fuel flow to the burner 140 when activated by the valve control signal. The solenoid valve 145 is further configured to restrict the fuel flow to the burner 140 when deactivated by the valve control signal. Although the system 100 is described with reference to normally closed solenoid valve, a normally open solenoid valve is also well within the scope an ambit of the present disclosure.
The system 100 further includes the spark generation unit 190 and the second sensor 195. The second sensor 195 is disposed in the burner compartment 130 proximal to the burner 140. The second sensor 195 is configured to sense flame generated by the burner 140, and is further configured to generate a second sensed signal.
In an embodiment, the second sensor 195 is a flame sensor.
The spark generation unit 190 is disposed proximal to the burner 140. The spark generation unit 190 is configured to generate a spark when activated to facilitate ignition of the fuel exiting through the burner 140. In an embodiment, the spark generation unit 190 includes at least to electrodes configured to generate an electric spark.
The temperature control unit 155 is configured to cooperate with the spark generation unit 190, and is further configured to control spark generation process based on the second sensed signal. The temperature control unit 155 is configured to simultaneously activate the solenoid valve 145 and actuate the spark generation unit 190. Once the flame is established at the burner 140, the temperature control unit 155 is configured to deactivate the spark generation unit 190.
The working of the system 100 is now described in subsequent paragraphs.
Initially, the system 100 is switched on by a user. The user sets the first threshold value, for example 60º C. The computation unit 170 computes the second threshold value. If the predetermined delta value is 3%, then the second threshold value is 58.2º C. As the temperature of the liquid is below the second threshold value, the controller 180 actuates the spark generation unit 190 to initiate burning of the fuel, i.e., LPG, at the burner 140. As soon as the temperature of the liquid exceeds the first threshold value, the controller 180 deactivates the solenoid valve 145 to restrict the fuel flow to the burner 140, thereby shutting off the burner 140. Further, as soon as the temperature of the liquid falls below the second threshold value, the controller 180 activates the solenoid valve 145 and activates the spark generation unit 190 to initiate the burning of the fuel, i.e., LPG, at the burner 140 to heat the liquid.
The system 100 is described in previous paragraphs with reference to a single burner compartment 130 and a single burner 140. Similar arrangement of the temperature control unit 155, the spark generation unit 190, and second sensor 195 is possible for multiple burner compartments and multiple burners. Such arrangement is well within the scope of the present disclosure, and is not described again with reference to multiple burner compartments and multiple burners for the sake of the brevity of the present disclosure.
Figure 6 illustrates a schematic view of the liquid heating system 100, in accordance with another embodiment of the present disclosure.
In an embodiment, the system 100 comprises a plurality of baffles 138 disposed in the at least one burner compartment 130. The baffles 138 increase heat transfer between the burner compartment 130 and the liquid storage compartment 125, and optimally utilize the amount of heat in the hot air before escaping to the atmosphere. In case of the plurality of burner compartments, a plurality of baffles is disposed in each of the burner compartments.
The number and dimensions of the baffles 138 are determined according to the application, heat transfer requirement, and dimensions of the burner compartment 130. In an embodiment, the number of the baffles ranges from 3 to 6.
In an embodiment, the system 100 can be used to obtain hot water for any suitable application. For example the system 100 can be used in the process industry to obtain hot water in which yarn or packing straps are dipped to improve the strength and shine thereof. Initially, yarn extruded from an extruder is dipped in cold water. Further, the yarn is dipped in the hot water stored in the liquid bath 105 to improve the strength and shine thereof.
The system 100 of the present disclosure automatically shuts off and restarts based on the temperature of liquid. Thus, the user only needs to switch on the system 100.
The system 100 can be used instead of conventional wood fired boilers and electric water heaters. The system 100 uses LPG as fuel which is clean in nature and does not cause any air pollution.
Further, as the system 100 optimally burns LPG, the operational cost of the system 100 is lesser than the conventional wood fired boilers. The system 100 is also reliable as compared to the wood fired boilers. Furthermore, the system 100 occupies less space and eliminates need of separate piping to convey hot water which is required in the wood fired boilers. There is no ash generation in the system 100.
It was observed that the operational cost of the system 100 is 40% lesser than a conventional electric water heater system.
TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a liquid heating system that:
• is environment friendly;
• is energy efficient;
• is cost effective; and
• is reliable and user friendly.
The foregoing disclosure has been described with reference to the accompanying embodiments which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.