Ignition system having control circuit with learning capabilities and devices and methods related thereto

Abstract

Featured is an ignition system using miniaturized hot surface igniters of various types, configurations, and material systems. The ignition system includes an electronic microprocessor on which a software program is executed so as to control the operation of an igniter and all functions of the ignition system. The software program evaluates performance characteristics relating to operation of the igniter. Additionally, the software program determines operation parameters and characteristics for energizing the igniter when it determines that the operation parameters and characteristics for energizing should be updated or revised.

Description

[0001]The present application is a continuation application of U.S. patent application Ser. No. 13 / 092,839, filed on Apr. 22, 2011, which claims the benefit of U.S. Provisional Patent Application No. 61 / 327,649, filed on Apr. 23, 2010, both applications of which are incorporated herein by reference in their entireties.FIELD OF INVENTION[0002]The present invention relates to control systems for fuel burner igniters and more particularly to control systems for electrical resistance-type igniters for fuel burners and methods for determining and controlling the voltage to, and the “on time” duration for, such electrical resistance-type igniters.BACKGROUND OF THE INVENTION[0003]There are a number of appliances such as cooking ranges and clothes dryers, and heating apparatuses such as boilers and furnaces in which a combustible material, such as a combustible hydrocarbon (e.g., propane, natural gas, oil) is mixed with air (i.e., oxygen) and continuously combusted within the appliance or h...

AI Technical Summary

Benefits of technology

[0019]Such an ignition system further includes a flame sensing means for continuously sensing the presence or absence of a burner flame by any of a number of techniques known to those skilled in the art, including the flame rectification technique, a UV sensing technique, and a temperature measurement technique. In more particular embodiments, the flame rectification circuit design is established to eliminate the need for earthing or a ground, by the use of a comparator circuit actuated by a burner flame present between the igniter element and igniter assembly shielding.

[0028]In another illustrative embodiment, another mode of operation involves turning the igniter off or reducing the supply voltage to the igniter after ignition has been determined to occur (i.e., sensing the presence of a flame). This process minimizes, if not removes, the potential for the igniter overheating as well as limiting the time at which the igniter is at its operating temperature.

[0029]After igniter activation and after determining that ignition has occurred, the microcontroller continuously monitors the burner flame. In the event of a loss of burner flame, the microcontroller powers the igniter for a defined igniter activation period to attempt to re-light the burner. In further embodiments, multiple trials for ignition are programmed into the microcontroller. The microcontroller also is operated so that there is near instantaneous shut down of the gas valve by the flame sensing circuit thereby essentially eliminating the possible flow of raw un-lit gas to the appliance.

[0033]In yet further embodiments, the microcontroller is configured to check the flame sensing signal at the end of burner operation. In the event that the microcontroller detects that a flame is still present after the end of a burning operation, potentially indicating that the closure of the gas valve has failed to have properly occurred, the microcontroller is configured to reactivate the valve opening and closure sequence as an attempt to properly close the gas valve. A number of opening and closing sequences can be conducted as required. The microcontroller also is configurable to cause an auditory and / or a visual signal to be outputted or communicated to the user to identify the faulted condition. In this way, an indication is provided to the user to allow him or her to determine the reason for the fault, to correct the fault, and / or to have the appliance serviced.

Problems solved by technology

Problems with spark-type igniters, however, include, among other things, the electronic and physical noise produced by the spark.

Known ignition modules for gas-fired burners, however, are susceptible to malfunctions in use.

In addition, the modules are often sensitive to voltage on the neutral conductor which desensitizes the flame detection circuit and can lead to continuously generated sparks despite the presence of a flame on a burner.

If the electrical junction box is not properly wired, the ignition module will continuously spark.

Unnecessary sparking of the ignition module reduces energy efficiency and also shortens a useable life of the ignition module.

Hot surface-type igniters, however, can require significant ignition / warm-up time to resistively heat the resistance igniter sufficiently to a temperature that will ignite the fuel-air mixture (e.g., gas-air).

While certain of these efforts have been successful, other factors work so as to limit the usable service life of an igniter.

These two factors work to limit igniter usable life.

A delay is provided when recycling occurs during which the burner and related system is purged of unburned fuel or products of combustion.

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