WATER HEATER APPLIANCE WITH TANK CAPACITY CONTROL INTERFACE AND RELATED CONTROL METHODS

Abstract

In one aspect, a method for controlling the operation of a water heater appliance may generally include receiving a user input associated with a selection of a tank capacity setpoint for the water heater appliance, determining a tank temperature setpoint for water contained within a tank of the water heater appliance based on the user-selected tank capacity setpoint and controlling the operation of the water heater appliance based on the tank temperature setpoint.

Description

FIELD OF THE INVENTION

The present subject matter relates generally to water heater appliances and, more particularly, to a water heater appliance with a tank capacity control interface and related control methods that allow a user to interface with the water heater in terms of the desired tank capacity.

BACKGROUND OF THE INVENTION

Certain water heater appliances include a tank therein. Heating elements, such as gas burners, electric resistance elements, or induction elements, heat water within the tank during operation of such water heater appliances. In particular, the heating elements generally heat water within the tank to a predetermined temperature. The predetermined temperature is generally selected such that heated water within the tank is suitable for showering, washing hands, etc.

During operation, relatively cool water flows into the tank, and the heating elements operate to heat such water to the predetermined temperature. Thus, the volume of heated water available at the predetermined temperature is generally limited to the volume of the tank. According, water heater appliances are sold in various sizes to provide customers with a desired amount of heated water. However, large water heater appliances with large tanks occupy a large amount of space within a residence or business. In certain buildings, space is limited and/or expensive. Thus, utilizing large water heater appliances can be impractical and/or prohibitively expensive despite needing large volumes of heated water.

To provide relatively large volumes of heated water from relatively small tanks, certain water heater appliances utilize a mixing valve. The mixing valve permits water within the water heater's tank to be stored at relatively high temperatures. The mixing valve mixes such high temperature water with relatively cool water in order to bring the temperature of such water down to suitable and/or more usable temperatures. Thus, such water heater appliance can provide relatively large volumes of heated water without requiring a large tank.

Typically, a user is allowed to select the temperature to which the water within the tank will be heated. This user-selected tank temperature is then used to control the operation of the heating elements. Unfortunately, users often select tank temperature setpoints that do not provide that most efficient settings based on their particular hot water usage (e.g., based on their specific first hour delivery requirements). This is often particularly true for water heater appliances that incorporate a mixing valve given the increased temperatures to which the water within the tank may be heated.

Accordingly, a tank capacity control interface and/or a control method that allows a user to control the operation of his/her water heater appliance as a function of a desired tank capacity for the appliance would be welcomed in the technology.

BRIEF DESCRIPTION OF THE INVENTION

Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

In one aspect, the present subject matter is directed to a method for controlling the operation of a water heater appliance. The method may generally include receiving a user input associated with a selection of a tank capacity setpoint for the water heater appliance, determining a tank temperature setpoint for water contained within a tank of the water heater appliance based on the user-selected tank capacity setpoint and controlling the operation of the water heater appliance based on the tank temperature setpoint.

In another aspect, the present subject matter is directed to a method for controlling the operation of a water heater appliance, wherein the water heater appliance includes a mixing valve configured to mix non-heated water received from a non-heated water conduit and heated water received from a heated water conduit and supply the mixed non-heated and heated water to a mixed water conduit. The method may generally include receiving a user input associated with a selection of a tank capacity setpoint for the water heater appliance, receiving a second user input associated with a selection of a mixed water temperature setpoint for the mixed water supplied from the mixing valve to the mixed water conduit, determining a tank temperature setpoint for water contained within a tank of the water heater appliance based on the user-selected tank capacity setpoint, determining a valve control setpoint for the mixing valve based on the mixed water temperature setpoint and controlling the operation of the water heater appliance based on the tank temperature setpoint and the valve control setpoint.

In a further aspect, the present subject matter is directed to a water heater appliance. The water heater appliance may generally include a tank, a heating element associated with the tank, a non-heated water conduit for supplying non-heated water to the tank, a heated water conduit for receiving heated water from the tank and a mixing valve in fluid communication with the non-heated water conduit and the heated water conduit. The mixing valve may be configured to mix the non-heated water flowing through the non-heated water conduit with the heated water flowing through the heated water conduit to create a mixed water flow. The water heater appliance may also include a mixed water conduit for receiving the mixed water flow expelled from the mixing valve. In addition, the water heater appliance may include a controller communicatively coupled to the mixing valve. The controller may be configured to receive a user input associated with a selection of a tank capacity setpoint for the tank, determine a tank temperature setpoint for the water contained within the tank based on the user-selected tank capacity setpoint and control the operation of the heating element based on the tank temperature setpoint so as to maintain a water temperature of the water contained within the tank at the tank temperature setpoint.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

FIG. 1 illustrates a perspective view of one embodiment of a water heater appliance in accordance with aspects of the present subject matter;

FIG. 2 illustrates a schematic view of various components that may be included within the water heater appliance shown in FIG. 1; and

FIG. 3 illustrates a flow diagram of one embodiment of a method for controlling the operation of a water heater appliance in accordance with aspects of the present subject matter.

DETAILED DESCRIPTION OF THE INVENTION

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

In general, the present subject matter is directed to a tank capacity control interface and related control methods for a water heater appliance. Specifically, in several embodiments, a user of a water heater appliance may be provided with a suitable interface for providing user inputs associated with a desired tank capacity for the appliance. For instance, the user may provide such inputs via a control panel having suitable user interface elements communicatively coupled to a controller of the water heater appliance. Alternatively, the user inputs may be provided via a suitable application implemented on a separate computing device of the user (e.g., his/her smartphone, tablet, desktop, etc.) and subsequently communicated wirelessly to the appliance controller across a wireless network. Regardless, once the user input(s) associated with the desired tank capacity is received, the controller may be configured to determine a tank temperature setpoint corresponding to the user-selected tank capacity and control the operation of the water heater appliance to ensure that the water contained within the tank is maintained at the determined tank temperature setpoint. As such, the present subject matter may allow a user to control the operation of a water heater appliance based on a parameter that more closely relates to his/her actual hot water usage/requirements, thereby providing the user with a simpler means for selecting the most efficient operating setpoint(s) for his/her appliance.

Referring now to the drawings, FIG. 1 illustrates a perspective view of one embodiment of a water heater appliance 100 in accordance with aspects of the present subject matter. In general, the water heater appliance 100 may include a casing 102 forming the outer housing or compartment of the water heater 100. As will be described below, a tank 104 (FIG. 2) and one or more heating elements 106 (FIG. 2) may be positioned within the casing 102 for heating water contained therein. The heating element(s) 106 may generally correspond to a gas burner(s), a heat pump(s), an electric resistance element(s), a microwave element(s), an induction element(s) and/or any other suitable heating element(s) or combination thereof. As will be understood by those skilled in the art and as used herein, the term “water” includes purified water and solutions or mixtures containing water and, e.g., elements (such as calcium, chlorine, and fluorine), salts, bacteria, nitrates, organics, and other chemical compounds or substances.

Additionally, the water heater appliance 100 may also include a cold or non-heated water conduit 108 and a hot or heated water conduit 110 that are both configured to be in fluid communication with a chamber 112 (FIG. 2) defined by the tank 104. As an example, cold or non-heated water from a water source, e.g., a municipal water supply or a well, may enter the water heater appliance 100 through the non-heated water conduit 108 (shown schematically with arrow labeled F_cool in FIG. 2). From the non-heated water conduit 108, such non-heated water may enter the chamber 112 of the tank 104, wherein it is heated with the heating elements 106 to generate heated water. Such heated water may then exit the water heater appliance 100 via the heated water conduit 110 and, e.g., may be supplied to a bath, shower, sink, or any other suitable feature.

As shown in FIG. 1, the water heater appliance 100 generally extends longitudinally between a top portion 114 and a bottom portion 116 along a vertical direction V. Thus, the water heater appliance 100 is generally vertically oriented. The water heater appliance 100 may also be leveled, e.g., such that the casing 102 is plumb in the vertical direction V, in order to facilitate proper operation of the water heater. A drain pan 118 may be positioned at the bottom portion 116 of the water heater appliance 100 such that the tank 102 sits on the drain pan 110. As is generally understood, the drain pan 110 may sit beneath the water heater appliance 100 along the vertical direction V, e.g., to collect water that leaks from the appliance 100 or water that condenses on an evaporator (not shown) of the appliance 100.

Additionally, as shown in FIG. 2, the water heater appliance 100 may also include a control panel 120 providing a plurality of user interface elements 122 (e.g., buttons, knobs, a keypad, switches, etc.). The user interface elements 122 may generally allow a user of the water heater appliance 100 to interface with a controller 124 of the appliance 100. Specifically, in several embodiments, the user interface elements 122 may provide a means for the user to provide user inputs to the controller 124 associated with adjusting the operational settings of the appliance 100. For instance, as will be described below, the user interface elements 122 may allow a user to provide a user input associated with a desired tank capacity setpoint for the water heater appliance 100. The controller 124 may then determine the proper tank temperature setpoint for the water heater appliance 100 based on the particular tank capacity setpoint selected by the user.

It should be appreciated that the water heater appliance 100 shown in FIG. 1 is simply provided as one example of a suitable water heater configuration with which the present subject matter may be used. In general, it should be appreciated that the present subject matter may be used with any suitable water heater appliance have any suitable configuration.

Referring now to FIG. 2, a schematic view of one embodiment of various components that may be included within the water heater appliance 100 shown in FIG. 1 is illustrated in accordance with aspects of the present subject matter. As shown in FIG. 2, the water heater appliance 100 may include a mixing valve 126 (e.g., an electronically controlled mixing valve) and a mixed water conduit 128. The mixing valve 126 may be in fluid communication with the non-heated water conduit 108, the heated water conduit 110, and the mixed water conduit 128. As discussed in greater detail below, the mixing valve 126 may be configured for selectively directing water from the non-heated water conduit 108 and the heated water conduit 110 into the mixed water conduit 128 in order to regulate a temperature of the water supplied to the mixed water conduit 128. In several embodiments the mixing valve 126 may be positioned or disposed within the casing 102 of the water heater appliance 100, e.g., such that mixing valve 126 is integrated within the appliance 100.

As an example, the mixing valve 126 may be configured to be actuated or moved to a plurality of different valve positions for controlling the ratio of the non-heated and heated water supplied to the mixed water conduit 128. Specifically, by controlling the valve position of the mixing valve 126, the particular amounts of the non-heated and heated water supplied from the non-heated and heated water conduits 108, 110, respectively, to the mixed water conduit 128 may be carefully regulated. As such, the water supplied to the mixed water conduit 128 (shown schematically with arrow labeled F_mixed in FIG. 2) may generally have any suitable temperature ranging between the temperature of the non-heated water supplied through the non-heated water conduit 108 and the temperature of the heated water supplied through the heated water conduit 110.

The water heater appliance 100 may also include a position sensor 130 configured for determining the valve position of the mixing valve 126. Specifically, the position sensor 130 may monitor the valve position of the mixing valve 126 in order to assist in regulating the temperature of the water supplied to the mixed water conduit 128. For example, position measurements provided by the position sensor 130 may be transmitted to the controller 124, which may use the position measurements to determine the current valve position of the mixing valve 126 in order to ensure that the valve 126 is properly or suitably positioned to allow the water supplied to the mixed water conduit 128 to be at the desired or selected temperature. Thus, the position sensor 130 may provide feedback to the controller 124 regarding the status or position of the mixing valve 126.

It should be appreciated that the position sensor 130 may generally be any suitable type of sensor. For example, in one embodiment, the position sensor 130 may be a physical sensor, such as an optical sensor, Hall-effect sensor, etc. Alternatively, the water heater appliance 100 need not include a position sensor 130. In such an embodiment, the controller 124 may be configured to determine or measure the valve position of the mixing valve 126 based on the previously commanded position of the valve 126. For instance, controller 124 may determine that the current valve position of the mixing valve 126 corresponds to the latest position that the controller 124 commanded for the mixing valve 126 in a previous iteration.

Additionally, the water heater appliance 100 may also include a mixed water conduit temperature sensor or first temperature sensor 132 and a non-heated water conduit temperature sensor or second temperature sensor 134. The first temperature sensor 132 may be positioned on or proximate to the mixed water conduit 128 and may be configured for measuring the temperature of the water supplied through the mixed water conduit 126. As such, it should be appreciated that the first temperature sensor 132 may be positioned downstream of the mixing valve 126. The second temperature sensor 134 may be positioned on or proximate to the non-heated water conduit 108 and may be configured for measuring the temperature of the water supplied through the non-heated water conduit 110. As such, it should be appreciated that the second temperature sensor 134 may be positioned upstream of the mixing valve 126. In certain embodiments, the first temperature sensor 132 and/or the second temperature sensor 135 may be positioned proximate or adjacent to the mixing valve 126.

The water heater appliance 100 may also include a tank temperature sensor 136 that is configured for measuring the temperature of the water contained within the tank chamber 112. In general, the tank temperature sensor 136 may be positioned at any suitable location within the water heater appliance 100. For example, the tank temperature sensor 136 may be positioned within the chamber 112 of the tank 102 or may be mounted to the tank 102 outside of the chamber 112. It should be appreciated that, when mounted to the tank 102 outside of the chamber 112, the tank temperature sensor 136 may be configured for indirectly measuring the temperature of the water contained within the chamber 112. For example, the tank temperature sensor 136 may measure the temperature of the tank 102 and correlate such temperature to the temperature of the water contained within the chamber 112. It should also be appreciated that the tank temperature sensor 136 may generally correspond to any suitable temperature sensor. For example, in one embodiment, the tank temperature sensor 136 may be a thermocouple or a thermistor.

As indicated above, the water heater appliance 100 may also include a controller 124 configured for regulating the operation of the water heater appliance 100. Thus, in several embodiments, the controller 124 may be provided in operative communication with the heating elements 106, the mixing valve 126, the position sensor 130, the first and second temperature sensors 132, 134 and the tank temperature sensor 136. In such embodiments, the controller 124 may be configured to selectively activate the heating elements 106 in order to heat the water contained within the chamber 112 of the tank 102. Similarly, the controller 124 may be configured to selectively operate the mixing valve 126 in order to adjust the position of the valve 126, thereby allowing the controller 124 to automatically regulate the temperature of the water supplied to the mixed water conduit 128.

It should be appreciated that the controller 124 may generally correspond to any suitable processor-based device and/or combination of processor-based devices. Thus, in several embodiments, the controller 124 may include one or more processor(s) 138 and associated memory device(s) 140 configured to perform a variety of computer-implemented functions (e.g., performing the methods, steps, calculations and the like disclosed herein). As used herein, the term “processor” refers not only to integrated circuits referred to in the art as being included in a computer, but also refers to a controller, a microcontroller, a microcomputer, a programmable logic controller (PLC), an application specific integrated circuit, and other programmable circuits. Additionally, the memory device(s) 140 may generally comprise memory element(s) including, but not limited to, computer readable medium (e.g., random access memory (RAM)), computer readable non-volatile medium (e.g., a flash memory), a floppy disk, a compact disc-read only memory (CD-ROM), a magneto-optical disk (MOD), a digital versatile disc (DVD) and/or other suitable memory elements. Such memory device(s) 140 may generally be configured to store suitable computer-readable instructions that, when implemented by the processor(s) 138, configure the controller 124 to perform various functions including, but not limited to, the control method 200 described below with reference to FIG. 3.

Additionally, the controller 124 may also include a communications module 142 to facilitate communications between the controller 124 and the various components of the water heater appliance 100. For instance, the communications module 142 may include a sensor interface (e.g., one or more analog-to-digital converters) to permit the signals transmitted by the various sensor(s) 130, 132, 134, 136 of the water heater appliance 100 to be converted into signals that can be understood and processed by the processors 138.

Moreover, in several embodiments, the communications module 142 may include suitable components for allowing the controller 124 to communicate wirelessly with one or more separate devices. For instance, in one embodiment, the communications module 142 may include or may be coupled to a wireless communications device 144 (e.g., a wireless receiver) for providing wireless communications between controller 124 and a separate computing device 145 (e.g., a smartphone, tablet, desktop, etc.) via any suitable wireless communications protocol, such as Bluetooth, WiFi, near field communication (NFC) and/or the like. In such an embodiment, the controller 124 may be configured to receive user inputs wirelessly from a remote computing device 145 associated with controlling the operation of the water heater appliance 100 (e.g., user inputs associated with a desired tank capacity setpoint for the appliance 100).

It should also be appreciated that the controller 124 may be positioned at any suitable location. For instance, as shown in FIG. 1, the controller 124 is positioned within the water heater appliance 100, e.g., as an integral component of the appliance 100. In alternative embodiments, the controller 124 may be positioned separate from the water heater appliance 100. In such embodiments, the controller 124 may be configured to communicate with the water heater appliance 100 over a wireless connection or any other suitable connection, such as a wired connection.

As indicated above, the controller 124 may be configured to operate the heating elements 106 so as to heat the water contained within the tank chamber 112. For instance, as will be described below, the controller 124 may, in one embodiment, be configured to calculate or determine a tank temperature setpoint for the water contained within the chamber 112 based on a tank capacity setpoint selected by the user of the water heater appliance 100. In such an embodiment, based on the tank temperature setpoint, the controller 124 may be configured to selectively activate the heating elements 106 in order to maintain the temperature of the water within the chamber 112 at the tank temperature setpoint (or within a given threshold of such temperature). It should be appreciated that the tank temperature setpoint may generally correspond to any suitable temperature. For example, in one embodiment, the tank temperature setpoint may range from about one hundred and ten degrees Fahrenheit to about one hundred and eighty-degrees Fahrenheit.

Additionally, as indicated above, the controller 124 may also be configured to operate the mixing valve 126 so as to regulate the temperature of the water supplied to the mixed water conduit 128. For example, the controller 124 may be configured to transmit suitable control signals (e.g., current signals) to the mixing valve 126 so as to adjust its position, thereby allowing the temperature of the water within the mixed water conduit 128 to be automatically regulated. As will be described below, a user may, in one embodiment, select or establish a mixed water temperature setpoint for the mixing valve 126. In such an embodiment, based on the mixed water temperature setpoint, the controller 124 may adjust the position of the mixing valve 126 in order to change or tweak the ratio of the amount of non-heated water flowing into the mixed water conduit 126 from the non-heated water conduit 108 to the amount of heated water flowing into the mixed water conduit 128 from the heated water conduit 108. In such manner, the controller 124 may regulate the temperature of the water supplied to the mixed water conduit 128.

It should be appreciated that the mixed water temperature setpoint for the mixing valve 126 may correspond to any suitable temperature. For example, in one embodiment, the mixed water temperature setpoint for the mixing valve 126 may range from about one hundred degrees Fahrenheit to about one hundred and twenty degrees Fahrenheit. It should also be appreciated that, in general, the mixed temperature setpoint may be selected so that the setpoint is less than the tank temperature setpoint for the water contained within the tank chamber 112. In such a manner, the mixing valve 126 may utilize water from both the non-heated water conduit 108 and the heated water conduit 110 to regulate the temperature of the water supplied to the mixed water conduit 128.

Referring now to FIG. 3, a flow diagram of one embodiment of a method 200 for controlling the operation of a water heater appliance is illustrated in accordance with aspects of the present subject matter. In general, the method 200 will be described herein with reference to the water heater appliance 100 described above with reference to FIGS. 1 and 2. However, it should be appreciated by those of ordinary skill in the art that the disclosed method 200 may be implemented with any other suitable water heater appliance. In addition, although FIG. 3 depicts steps performed in a particular order for purposes of illustration and discussion, the methods discussed herein are not limited to any particular order or arrangement. One skilled in the art, using the disclosures provided herein, will appreciate that various steps of the methods disclosed herein can be omitted, rearranged, combined, and/or adapted in various ways without deviating from the scope of the present disclosure.

As shown in FIG. 3, at (202), the method 200 includes receiving a user input associated with a selection of a tank capacity setpoint for the water heater appliance 100. Specifically, in several embodiments, a user of the water heater appliance 100 may be allowed to provide a user input associated with the selection of a tank capacity setpoint to be used in controlling the operation of the water heater appliance 100. As will be described below, the controller 124 may then, in one embodiment, be configured to determine a proper tank temperature setpoint for the water heater appliance 100 based on the user-selected tank capacity setpoint.

It should be appreciated that, in several embodiments, the tank capacity setpoint may be selected by the user from a set of predetermined tank capacity setpoints. For instance, in one embodiment, the user may be provided the option of selecting from a “LOW” tank capacity setpoint, a “MED” tank capacity setpoint or a “HIGH” capacity setpoint. In such an embodiment, the “LOW” tank capacity setpoint may correspond to a relatively low capacity setpoint for the water heater appliance 100 (e.g., a first hour delivery capacity of 20 gallons), the “HIGH” capacity setpoint may correspond to a relatively high capacity setpoint for the water heater appliance 100 (e.g., a first hour delivery capacity of 80 gallons) and the “MED” tank capacity setpoint may correspond to a capacity setpoint defined between the “LOW” and “HIGH” capacity setpoints (e.g., a first hour delivery capacity of 50 gallons). In another embodiment, the user may be provided the option of selecting from any other suitable number of predetermined tank capacity setpoints, such as by providing the user less than three predetermined tank capacity setpoints to choose from or more than three predetermined tank capacity setpoints to choose from. Alternatively, the user may be allowed to input a specific tank capacity setpoint, such as by allowing the user to input a tank capacity setpoint ranging from a capacity of about 20 gallons to a capacity of about 80 gallons.

It should also be appreciated that the controller 124 may be configured to receive the user input associated with the selection of a tank capacity setpoint for the water heater appliance 100 via any suitable input means. For instance, as indicated above, the water heater appliance 100 may include a control panel 120 having suitable user interface elements 112 that allow the user to provide inputs to the controller 124. Thus, in several embodiments, a user may input his/her selected tank capacity setpoint using the user interface elements 122, such as by selecting a button corresponding to the desired tank capacity setpoint or turning a knob to the desired tank capacity setpoint or by inputting the desired tank capacity setpoint into a keypad provided on the control panel 122.

Alternatively, the user input associated with the selection of a tank capacity setpoint may be communicated wirelessly to the controller 124 from a separate computing device (e.g., the remote device 145 shown in FIG. 2). For instance, the user may have a smartphone, tablet or other computing device that is configured to execute a suitable application that provides the user with a user interface for inputting a tank capacity setpoint. In such an embodiment, when the user inputs a desired tank capacity setpoint via the interface provided on his/her separate computing device, the tank capacity setpoint may then be transmitted wirelessly to the controller 124 (e.g., via the controller's wireless communications device 144) and stored in the controller's memory 140.

As shown in FIG. 3, at (204), the method 200 includes receiving a user input associated with a selection of a mixed water temperature setpoint for the water heater appliance 100. Specifically, in several embodiments, a user of the water heater appliance 100 may be allowed to provide a user input associated with the selection of a mixed water temperature setpoint to be used in controlling the operation of the water heater appliance 100. As will be described below, the controller 124 may then, in one embodiment, be configured to utilize the user-selected mixed temperature setpoint for determining a proper valve control setpoint for controlling the mixing valve 126.

It should be appreciated that, similar to the user input described above with reference to method element (202), the controller 124 may be configured to receive the user input associated with the selection of the mixed water temperature setpoint via any suitable input means. For instance, the user may input or select the mixed water temperature setpoint via the user interface elements 122 provided on the control panel 120. Alternatively, the user may input or select the mixed temperature setpoint via a suitable computer application implemented on his/her separate computing device, which may then be transmitted wirelessly to the controller 124.

Referring still to FIG. 3, at (206), the method 200 may include determining a tank temperature setpoint for the water heater appliance based on the user-selected tank capacity setpoint. Specifically, in several embodiments, upon the receipt of the desired tank capacity setpoint, the controller 124 may be configured to calculate or look-up a corresponding tank temperature setpoint for the water heater appliance 100. As will be described below, the operation of the water heater appliance 100 may then be controlled to ensure that the temperature of the water contained within the tank chamber 112 is maintained at the determined tank temperature setpoint.

It should be appreciated that the controller 124 may be configured to determine a tank temperature setpoint for the water heater appliance 100 based on the user-selected tank capacity setpoint using any suitable means. For instance, in one embodiment, the controller 124 may include a look-up table stored within its memory 140 that relates each tank capacity setpoint to a corresponding tank temperature setpoint. In such an embodiment, upon the receipt of a user input associated with a selected tank capacity setpoint, the controller 124 may simply reference the look-up table to determine the corresponding tank temperature setpoint. Alternatively, the controller 124 may determine the tank temperature setpoint using any other suitable means. For instance, in another embodiment, a suitable mathematical equation or function may be stored within the controller's memory 140 that correlates the user-selected tank capacity setpoint to a corresponding tank temperature setpoint. In such an embodiment, upon the receipt of a user input associated with a selected tank capacity setpoint, the controller 124 may calculate the corresponding tank temperature setpoint using the stored mathematical equation/function.

It should also be appreciated that the tank temperature setpoint may generally vary based on variations in the desired tank capacity setpoint. Specifically, in several embodiments, as the tank capacity setpoint is decreased, the corresponding tank temperature setpoint may be increased to allow a larger volume of mixed water to be output from the mixing valve 126 at the desired mixed water temperature setpoint given the smaller tank capacity setpoint.

Additionally, at (208), the method 200 may include determining a valve control setpoint for controlling the operation of the mixing valve based on the user-selected mixed water temperature setpoint. Specifically, in several embodiments, the controller 124 may be configured to determine a suitable output signal (e.g., a given current signal) for adjusting the position of the mixing valve 126 in a manner that allows the temperature of the water supplied to the mixed water conduit 128 to be at the mixed temperature setpoint. For instance, the controller 124 may include a suitable look-up table and/or mathematical equation/function that relates the mixed water temperature setpoint to the control signal(s) that must be transmitted to the mixing valve 126 to allow the valve 126 to be properly positioned for supplying water into the mixed water conduit 128 at the mixed water temperature setpoint.

Moreover, at (210), the method 200 may include controlling the operation of the water heater appliance based on the tank temperature setpoint and/or the valve control setpoint. For instance, as indicated above, the controller 124 may be configured to automatically control the operation of the heating elements 106 such that the water contained within the tank chamber 112 is maintained at or around the desired tank temperature setpoint. Similarly, the controller 124 may be configured to automatically control the operation of the mixing valve 124 via the determined valve control setpoint in order to achieve the desired mixed water temperature for the water supplied to the mixed water conduit 128.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

1. A method for controlling the operation of a water heater appliance, the method comprising:

receiving, by a controller, a user input associated with a selection of a tank capacity setpoint for the water heater appliance;

determining, by the controller, a tank temperature setpoint for water contained within a tank of the water heater appliance based on the user-selected tank capacity setpoint; and

controlling, by the controller, the operation of the water heater appliance based on the tank temperature setpoint.

2. The method of claim 1, wherein the tank temperature setpoint is varied with variations of the user-selected tank capacity setpoint.

3. The method of claim 1, wherein receiving the user input associated with the selection of the tank capacity setpoint comprises receiving the user input via a control panel of the water heater appliance.

4. The method of claim 1, wherein receiving the user input associated with the selection of the tank capacity setpoint comprises receiving the user input wirelessly from a separate computing device.

5. The method of claim 1, wherein determining the tank temperature setpoint for the water contained within the tank of the water heater appliance based on the user-selected tank capacity setpoint comprises determining the tank temperature setpoint based on a look-up table stored within memory of the controller that relates the tank temperature setpoint to the user-selected tank capacity setpoint.

6. The method of claim 1, controlling the operation of the water heater appliance based on the tank temperature setpoint comprises controlling the operation of one or more heating elements of the water heater appliance in order to maintain a water temperature of the water contained within the tank at the tank temperature setpoint.

7. The method of claim 1, wherein the water heater appliance further comprises a mixing valve configured to mix non-heated water received from a non-heated water conduit and heated water received from a heated water conduit and supply the mixed non-heated and heated water to a mixed water conduit, the method further comprising receiving a second user input associated with a selection of a mixed water temperature setpoint for the mixed non-heated and heated water supplied from the mixing valve to the mixed water conduit.

8. The method of claim 7, further comprising determining a valve control setpoint for the mixing valve based on the mixed water temperature setpoint.

9. The method of claim 8, further comprising controlling the operation of the mixing valve based on the valve control setpoint such that a water temperature of the mixed non-heated and heated water supplied to the mixed water conduit corresponds to the mixed water temperature setpoint.

10. The method of claim 9, wherein controlling the operation of the mixing valve comprises adjusting a valve position of the mixing valve based on the valve control setpoint in order to regulate an amount of the non-heated water and an amount of the heated water supplied to the mixed water conduit.

11. A method for controlling the operation of a water heater appliance, the water heater appliance comprising a mixing valve configured to mix non-heated water received from a non-heated water conduit and heated water received from a heated water conduit and supply the mixed non-heated and heated water to a mixed water conduit, the method comprising:

receiving, by a controller, a user input associated with a selection of a tank capacity setpoint for the water heater appliance;

receiving, by the controller, a second user input associated with a selection of a mixed water temperature setpoint for the mixed water supplied from the mixing valve to the mixed water conduit;

determining, by the controller, a tank temperature setpoint for water contained within a tank of the water heater appliance based on the user-selected tank capacity setpoint;

determining, by the controller, a valve control setpoint for the mixing valve based on the mixed water temperature setpoint; and

controlling, by the controller, the operation of the water heater appliance based on the tank temperature setpoint and the valve control setpoint.

12. A water heater appliance, comprising:

a tank;

a heating element associated with the tank;

a non-heated water conduit for supplying non-heated water to the tank;

a heated water conduit for receiving heated water from the tank;

a mixing valve in fluid communication with the non-heated water conduit and the heated water conduit, the mixing valve being configured to mix the non-heated water flowing through the non-heated water conduit with the heated water flowing through the heated water conduit to create a mixed water flow;

a mixed water conduit for receiving the mixed water flow expelled from the mixing valve; and

a controller communicatively coupled to the mixing valve, the controller being configured to: receive a user input associated with a selection of a tank capacity setpoint for the tank; determine a tank temperature setpoint for the water contained within the tank based on the user-selected tank capacity setpoint; and control the operation of the heating element based on the tank temperature setpoint so as to maintain a water temperature of the water contained within the tank at the tank temperature setpoint.

13. The water heater appliance of claim 12, wherein the controller is configured to vary the tank temperature setpoint with variations in the user-selected tank capacity setpoint.

14. The water heater appliance of claim 12, further comprising a control panel having one or more user interface elements, wherein the controller is configured to receive the user input via the one or more user interface elements of the control panel.

15. The water heater appliance of claim 12, wherein the controller is configured to receive the user input wirelessly from a separate computing device.

16. The water heater appliance of claim 12, wherein the controller is configured to determine the tank temperature setpoint based on a look-up table stored within memory of the controller that relates the tank temperature setpoint to the user-selected tank capacity setpoint.

17. The water heater appliance of claim 13, wherein the controller is further configured to receive a second user input associated with a selection of a mixed water temperature setpoint for the mixing valve.

18. The water heater appliance of claim 17, wherein the controller is further configured to determine a valve control setpoint for the mixing valve based on the mixed water temperature setpoint.

19. The water heater appliance of claim 18, wherein the controller is configured to control the operation of the mixing valve based on the valve control setpoint such that a water temperature of the mixed water flow supplied to the mixed water conduit corresponds to the mixed water temperature setpoint.

20. The water heater appliance of claim 18, wherein the controller is configured to control the operation of the mixing valve by adjusting a valve position of the mixing valve based on the valve control setpoint in order to regulate an amount of the non-heated water and an amount of the heated water supplied to the mixed water conduit.