A gas heater based on closed-loop control of a wide-range oxygen sensor

Abstract

The present invention discloses a gas heater based on closed-loop control of a wide-range oxygen sensor, which comprises a burner, and a mixing core and a mixing cylinder which are connected to each other are arranged in the burner; a fan assembly is installed at one end of the burner, the fan assembly comprises a fan motor, and an air-sweeping disc is arranged at the position where the output end of the fan motor is located inside the burner; a fuel injection rail assembly is arranged on the burner, and the fuel injection rail assembly comprises a gas nozzle; a flame ionization sensor and an ignition needle are arranged at the other end of the burner, and the ignition needle is connected to the output end of an ignition driver; one end of the burner where the ignition needle is located is fixedly connected to a water heat exchange jacket, an exhaust gas guide cylinder is arranged inside the water heat exchange jacket, an exhaust pipe penetrating through and extending to the outside is arranged on the side wall of the water heat exchange jacket, and a wide-range oxygen sensor is arranged on the exhaust pipe. The present invention can solve the problem of insufficient adjustability of automotive gas heating in the prior art, and has rapid adjustment, high automation degree and good combustion economy.

Description

Technical Field

[0001] The present invention relates to an automotive gas heater, and more particularly to a gas heater based on closed-loop control of a wide-range oxygen sensor. Background Art

[0002] As people pay more and more attention to environmental protection, higher requirements are also put forward for the exhaust emissions of heaters. Generally, when the heater burns with an equivalent ratio, the exhaust emissions are the lowest and the fuel is the most economical. The traditional control scheme of gas heaters is based on the Venturi mixing principle. The amount of gas supply depends on initial data such as the size parameters of the Venturi mixer, the air flow rate, the spring pressure of the pressure regulator, and the initial flow rate of the pressure regulator. It is difficult to maintain the equivalent combustion state when the fan speed, air density, or the spring pressure of the pressure regulator changes, resulting in the air-fuel ratio deviating from the ideal air-fuel ratio, thereby causing the deterioration of emissions.

[0003] At the same time, with the rapid development of electronic control technology, there are more and more electronic control units and various sensors on automobiles, and the information sharing of each electronic control unit has become an inevitable trend. The Controller Area Network bus, that is, the CAN bus, is becoming more and more popular in vehicles. However, the existing heaters are only independent heating devices and cannot communicate with other control units on the vehicle, and their adjustability is also seriously insufficient. Summary of the Invention

[0004] In view of the above deficiencies in the prior art, the present invention provides a gas heater based on closed-loop control of a wide-range oxygen sensor, which can solve the problem of insufficient adjustability of automotive gas heaters in the prior art.

[0005] To solve the above technical problems, the present invention adopts the following technical solutions:

[0006] There is provided a gas heater based on closed-loop control of a wide-range oxygen sensor, which includes a burner, in which a mixing core and a mixing cylinder are connected to each other; one end of the burner is equipped with a fan assembly, and the fan assembly includes a fan motor, and a wind-dispersing disc is arranged at the position where the output end of the fan motor is located inside the burner; a spray rail assembly is arranged on the burner, and the spray rail assembly includes a gas nozzle; the other end of the burner is provided with a flame ionization sensor and an ignition needle, and the ignition needle is connected to the output end of an ignition driver; the end of the burner where the ignition needle is located is fixedly connected to a heat exchange water jacket, an exhaust gas diversion cylinder is arranged inside the heat exchange water jacket, an exhaust pipe penetrating through to the outside is arranged on the side wall of the heat exchange water jacket, and a wide-range oxygen sensor is arranged on the exhaust pipe;

[0007] The hot water jacket includes an inlet and an outlet, and an inlet temperature sensor and an outlet temperature sensor are respectively arranged at adjacent positions of the inlet and the outlet; an ECU assembly is arranged outside the fan assembly, and the ECU assembly is electrically connected to the fan assembly, the fuel injection rail assembly, the ignition driver, the wide-band oxygen sensor, the flame ionization sensor, the inlet temperature sensor and the outlet temperature sensor through a wire harness assembly.

[0008] The main beneficial effects of the gas heater based on the closed-loop control of the wide-band oxygen sensor provided by the present invention are as follows:

[0009] The present invention realizes the closed-loop control with the set air-fuel ratio as the control target by the real-time feedback of the air-fuel ratio of the heater by the wide-band oxygen sensor and the precise control of the gas supply amount by the gas nozzle, so that the air-fuel ratio of the heater is always maintained around the ideal air-fuel ratio, realizes stoichiometric combustion, achieves the best emission, and improves fuel economy.

[0010] Through the ECU assembly, the air-fuel ratio in the gas discharged from the burner is detected in real time by the wide-band oxygen sensor to adjust the injection time of the gas nozzle in real time, change the gas supply amount of the fuel injection rail assembly, and realize the closed-loop control of the air-fuel ratio, so as to ensure that the air-fuel ratio of the heater fluctuates within the set range of the ideal value and realize stoichiometric combustion. By setting the flame ionization sensor, the working state of the burner is detected in real time.

[0011] By respectively setting the inlet temperature sensor and the outlet temperature sensor, the temperature in the hot water jacket is detected in real time, and the working state of the fan assembly is adjusted according to the outlet temperature signal to change the air flow rate, so as to realize the stepless adjustment of the heat release power of the heater and greatly reduce the heating fluctuation of the vehicle. Through the double closed-loop control of the air-fuel ratio and the fan speed, the adjustable range of the heat release power of the heater is greatly improved, thus facilitating the power matching and selection of the vehicle heater. Description of the Drawings

[0012] Figure 1 is the front view of the present invention.

[0013] Figure 2 is the structural sectional view of the present invention.

[0014] Figure 3 is the side view of the burner of the present invention.

[0015] Among them, 1. Burner, 11. Burner base, 12. Mixing core, 13. Combustion net, 14. Wire harness assembly, 16. Mixing cylinder, 17. Flow guide cone, 18. Movable lug, 19. Wire passing hole, 2. Heat exchange water jacket, 21. Water inlet, 22. Water outlet, 3. Water pump assembly, 24. Inlet water temperature sensor, 25. Outlet water temperature sensor, 26. Wide-range oxygen sensor, 27. Outer sleeve, 28. Inner sleeve, 3. Fan assembly, 31. Fan motor, 32. Rotation speed sensor, 33. Motor mounting fixed plate, 34. Magnetic ring, 35. Wind hood, 36. Bush, 37. Wind throwing disc, 38. End cover, 4. Spray rail assembly, 41. Gas nozzle, 42. Gas joint, 43. Ignition needle, 44. Flame ionization sensor, 45. Ignition driver, 46. ECU mounting bracket, 47. Gas pipe, 5. ECU assembly, 6. Exhaust gas guide cylinder, 61. Heat exchange fin, 62. Exhaust pipe. Detailed implementation mode

[0016] The present invention will be further described below with reference to the accompanying drawings:

[0017] As Figure 1 shown, it is the front view of a gas heater based on closed-loop control of a wide-range oxygen sensor.

[0018] The gas heater based on closed-loop control of a wide-range oxygen sensor of the present invention includes a burner 1, and a mixing core 12 and a mixing cylinder 16 which are connected to each other are arranged inside the burner 1; a fan assembly 3 is installed at one end of the burner 1, and the fan assembly 3 includes a fan motor 31, and a wind throwing disc 37 is arranged at the position where the output end of the fan motor 31 is located inside the burner 1.

[0019] A spray rail assembly 4 is arranged on the burner 1, and the spray rail assembly 4 includes a gas nozzle 41; a mixing core 12 and a mixing cylinder 16 which are connected to each other are arranged inside the burner 1; a flame ionization sensor 44 and an ignition needle 43 are arranged at the other end of the burner 1, the ignition needle 43 is connected to the output end of an ignition driver 45, and the ignition driver 45 is arranged outside the fan assembly 3; one end of the burner 1 where the ignition needle 43 is located is fixedly connected to a heat exchange water jacket 2, an exhaust gas guide cylinder 6 is arranged inside the heat exchange water jacket 2, one side of the ignition needle 43 on the burner 1 is located on the side of the exhaust gas guide cylinder 6, and an exhaust pipe 62 penetrating through to the outside is arranged on the side wall of the heat exchange water jacket 2, and a wide-range oxygen sensor 26 is arranged on the exhaust pipe 62.

[0020] The hot water jacket 2 includes a water inlet 21 and a water outlet 22. An inlet water temperature sensor 24 and an outlet water temperature sensor 25 are respectively arranged at positions adjacent to the water inlet 21 and the water outlet 22. By respectively arranging the inlet water temperature sensor 24 and the outlet water temperature sensor 25, the temperature in the hot water jacket 2 is detected in real time, and the working state of the fan assembly 3 is adjusted according to the outlet water temperature, changing the air flow rate, realizing stepless adjustment of the heat release power of the heater, and greatly reducing the heating fluctuation of the vehicle. Through the double closed-loop control of the air-fuel ratio and the fan speed, the adjustable range of the heat release power of the heater is greatly improved, thus facilitating the power matching and selection of the vehicle heater.

[0021] A wind hood 35 is arranged outside the fan assembly 3. An ECU mounting bracket 46 is arranged on the wind hood 35. An ECU assembly 5 is mounted on the ECU mounting bracket 46. The ECU assembly 5 is electrically connected to the fan assembly 3, the fuel injection rail assembly 4, the ignition driver 45, the wide-range oxygen sensor 26, the flame ionization sensor 44, the inlet water temperature sensor 24 and the outlet water temperature sensor 25 through a wire harness assembly 14.

[0022] By arranging the ECU assembly 5, the air-fuel ratio in the gas discharged from the burner 1 is detected in real time by using the wide-range oxygen sensor 26, so as to adjust the injection time of the gas nozzle 41 in real time, change the gas supply amount of the fuel injection rail assembly 4, realize the closed-loop control of the air-fuel ratio, and thus ensure that the air-fuel ratio of the heater fluctuates within the set range of the ideal value, realizing stoichiometric combustion. By arranging the flame ionization sensor 44, the working state of the burner 1 is detected in real time.

[0023] Specifically, the burner 1 includes a burner base 11. Inside the burner base 11 is a mixing core 12. The gas nozzle 41 is connected to the burner base 11. The air deflector 37 is installed at the output end of the fan motor 31 through a bushing 36. The flame ionization sensor 44 and the ignition needle 43 are arranged on one side of the burner base 11 deviating from the fan motor 31.

[0024] One side of the burner base 11 deviating from the fan motor 31 is fixedly connected to the mixing cylinder 16. A flow guide cone 17 is arranged at the end of the mixing cylinder 16. A combustion net 13 is installed at the front end of the flow guide cone 17. The bottom ends of the ignition needle 43 and the flame ionization sensor 44 are respectively mounted on the burner base 11, and the upper ends are both located at positions adjacent to the combustion net 13.

[0025] The burner base 11 is provided with wire passing holes 19 respectively connected to the wires of the flame ionization sensor 44 and the ignition needle 43. The fuel injection rail assembly 4 includes a gas connector 42 fixedly arranged on the burner base 11 and connected to the gas nozzle 41. The gas nozzle 41 is connected to the mixing core 12 through the gas connector 42 and the gas pipe 47 in sequence.

[0026] The mixing core 12 is provided with an annular groove, and a number of small holes are opened on the annular groove. One end of the gas pipe 47 is connected to the gas joint 42, and the other end is connected to the annular groove around the mixing core 12.

[0027] The gas ejected from the gas nozzle 41 enters the annular groove through the gas pipe 47, and then disperses into the mixing core 12 from the small holes on the annular groove. The air agitated by the fan assembly 3 axially passes through the middle of the mixing core 12. The gas ejected from the gas nozzle 41 contacts and mixes with the air agitated by the fan assembly 3 at the outlet of the mixing core 12, and then enters the mixing cylinder 16 and is fully mixed, and is dispersed through the combustion net 13 to ensure the combustion effect; by arranging the flame ion sensor 44 at a position adjacent to the combustion net 13, the detection effect of the working state of the burner 1 is ensured.

[0028] Preferably, a motor mounting fixed plate 33 is erected on one side of the burner 1 adjacent to the fan motor 31. The lower end of the motor fixed mounting plate 33 is installed on the end cover 38, and the end cover 38 is installed at the end of the burner seat 11. The fan motor 31 is arranged on the motor mounting fixed plate 33. In this way, the fan motor 31 is arranged at a position adjacent to the burner 1, and the volume of the burner 1 can be prevented from being too large.

[0029] A magnetic ring 34 is fixedly sleeved on the output shaft of the fan motor 31, and a speed sensor 32 is fixedly arranged at a position adjacent to the magnetic ring 34 on the motor mounting fixed plate 33. The speed sensor 32 obtains the rotation speed of the fan motor 31 by detecting the rotation condition of the magnetic ring 34. By arranging the speed sensor 32, real-time feedback adjustment of the fan motor 31 can be performed.

[0030] Optionally, the fan motor 31 is electrically connected to the wire harness assembly 14 through a Hall signal output interface. By arranging a fan that can output Hall signals by itself, the magnetic ring 34 and the speed sensor 32 can be replaced, and real-time monitoring of the fan speed can be realized.

[0031] A water pump assembly 23 is arranged outside the water heat exchange jacket 2. The water outlet of the water pump assembly 23 is connected to the water inlet 21 of the water heat exchange jacket 2 through a rubber hose; through the water pump assembly 26, the water circulation flow of the pipeline system connected to the heater is realized.

[0032] The water heat exchange jacket 2 includes an outer sleeve 27 and an inner sleeve 28 which are sleeved with each other. One end of the outer sleeve 27 and the inner sleeve 28 deviating from the burner 1 is closed, and the position between the other end of the outer sleeve 27 and the inner sleeve 28 is closed, so that the water heat exchange jacket 2 forms a structure with a closed interior except for the water inlet 21 and the water outlet 22.

[0033] The exhaust gas guide cylinder 6 is arranged inside the inner sleeve 28, and the exhaust pipe 62 penetrates through the inner sleeve 28 and the outer sleeve 27. Heat exchange fins 61 are fixedly arranged on the inner side wall of the inner sleeve 28, and the contact area between the high-temperature gas after combustion and the heat exchange water jacket 2 is increased through the heat exchange fins 61 to fully conduct heat exchange.

[0034] Preferably, a gas leakage sensor is arranged at a position adjacent to the heater, and the gas leakage sensor is electrically connected to the ECU assembly 5 to prevent the gas in the heater from leaking and ensure the overall safety of the equipment.

[0035] The ECU assembly 5 includes a CAN processing module communicatively connected to the vehicle CAN communication system. By using CAN communication, the operation data of the heater can be shared in the vehicle network, the relevant parameters of the heater can be conveniently set through the main controller of the vehicle, and the operation state of the heater can also be controlled through the main controller, so that automatic control can be conveniently realized on the vehicle.

[0036] The following is the working principle of this solution:

[0037] After the gas is decompressed by the pressure reducer in the vehicle, it enters the fuel injection rail assembly 4 through the external gas hose, and enters the gas pipe 47, the mixing core 12, and the mixing cylinder 16 through the gas nozzle 41 in sequence. The gas supply amount is controlled by the ECU assembly 5 to control the injection duration of the gas nozzle 41 within a unit time period.

[0038] The fan motor 31 drives the air deflector 37 to rotate to generate pressure, so that fresh air flows from the fan motor 31 towards the combustion net 13 and mixes with the gas in the mixing core 12 and the mixing cylinder 16. The rotation speed of the fan motor 31 is controlled by the ECU assembly 5 through the pulse width modulation method, that is, the PWM method. The higher the rotation speed of the fan motor 31, the greater the air flow. After the fresh air is mixed with the gas sprayed by the gas nozzle 41 in the mixing cylinder 16, it burns outside the combustion net 13, and the exhaust gas generated after combustion is discharged through the exhaust pipe 62.

[0039] When the fan motor 31 rotates, the magnetic ring 34 rotates together with the output shaft, and the rotation speed sensor 32 outputs a pulse signal. The ECU assembly 5 calculates the current fan rotation speed according to the frequency of this pulse signal.

[0040] Furthermore, the ECU assembly 5 calculates the current air-fuel ratio of the heater according to the signal output by the wide-range oxygen sensor 26. When the heater works, the ECU assembly 5 sets the target air-fuel ratio to the ideal air-fuel ratio, that is, the best air-fuel ratio with an excess air coefficient of 1, that is, the stoichiometric combustion air-fuel ratio. Through the signal fed back by the wide-range oxygen sensor 26, the ECU assembly 5 can grasp the air-fuel ratio of the heater in real time.

[0041] When the actual air-fuel ratio of the heater deviates from the set target air-fuel ratio or has a tendency to deviate, the ECU assembly 5 adjusts the continuous injection time of the gas nozzle 41 in a timely manner through the PID algorithm, changes the supply amount of the gas, so that the actual air-fuel ratio during the operation of the heater always remains around the set target air-fuel ratio.

[0042] The ECU assembly 5 grasps the actual speed of the blower motor 31 in real time according to the pulse signal fed back by the speed sensor 32, and determines the target speed of the blower motor 31 according to the operating state of the heater or the control requirements of the vehicle. When the actual speed of the blower motor 31 deviates from the target speed or has a tendency to deviate, the ECU assembly 5 adjusts the PWM pulse width of the blower motor 31 in a timely manner through the PID algorithm, so that the speed of the blower motor 31 always remains around the set target speed. Thus, equivalent combustion is achieved, the best emission is achieved, and the fuel economy is improved.

[0043] The specific implementation manners of the present invention are described above to facilitate the understanding of the present invention by those skilled in the art. However, it should be clear that the present invention is not limited to the scope of the specific implementation manners. For those of ordinary skill in the art, as long as various changes are within the spirit and scope of the present invention defined and determined by the appended claims, these changes are obvious, and all inventions created using the concept of the present invention are within the scope of protection.

Claims

1. A gas heater based on closed-loop control of a wide-range oxygen sensor, characterized in that, it includes a burner, in which a mixing core and a mixing cylinder are connected to each other; a gas nozzle is connected through a gas joint and a gas pipe in sequence and penetrates through the mixing core; an annular groove is formed in the mixing core, and a number of small holes are formed in the annular groove; one end of the gas pipe is connected to the gas joint, and the other end is connected to the annular groove around the mixing core; a fan assembly is installed at one end of the burner, and the fan assembly includes a fan motor, and a wind-dispersing disc is arranged at the position where the output end of the fan motor is located inside the burner; a spray rail assembly is arranged on the burner, and the spray rail assembly includes a gas nozzle; a flame ionization sensor and an ignition needle are arranged at the other end of the burner, and the ignition needle is connected to the output end of the ignition driver; the end of the burner where the ignition needle is located is fixedly connected to a heat exchange water jacket, an exhaust gas guide cylinder is arranged in the heat exchange water jacket, an exhaust pipe penetrating through to the outside is arranged on the side wall of the heat exchange water jacket, and a wide-range oxygen sensor is arranged on the exhaust pipe; the heat exchange water jacket includes a water inlet and a water outlet, and a water inlet temperature sensor and a water outlet temperature sensor are respectively arranged at positions adjacent to the water inlet and the water outlet; an ECU assembly is arranged outside the fan assembly, and the ECU assembly is electrically connected to the fan assembly, the spray rail assembly, the ignition driver, the wide-range oxygen sensor, the flame ionization sensor, the water inlet temperature sensor and the water outlet temperature sensor through a wire harness assembly.

2. The gas heater based on closed-loop control of a wide-range oxygen sensor according to claim 1, characterized in that, the burner includes a burner base, the gas nozzle is connected to the burner base, the wind-dispersing disc is installed on the output end of the fan motor through a shaft sleeve, and the flame ionization sensor and the ignition assembly are arranged on the side of the burner base deviating from the fan motor.

3. The gas heater based on closed-loop control of a wide-range oxygen sensor according to claim 2, characterized in that, the side of the burner base deviating from the fan motor is fixedly connected to the mixing cylinder, a flow guide cone is arranged at the end of the mixing cylinder, a combustion net is installed at the front end of the flow guide cone, and the ignition needle, the flame ionization sensor and the ignition driver are respectively arranged at positions adjacent to the combustion net.

4. The gas heater based on closed-loop control of a wide-range oxygen sensor according to claim 3, characterized in that, threading holes respectively connected to the flame ionization sensor and the ignition needle wires are arranged on the burner base, and the spray rail assembly includes a gas joint fixedly arranged on the burner base and connected to the gas nozzle.

5. The gas heater based on closed-loop control of a wide-range oxygen sensor according to claim 2, characterized in that, a motor installation fixing plate is erected on the side of the burner adjacent to the fan motor, the lower end of the motor installation fixing plate is connected to the end cover at the end of the burner base, and the fan motor is arranged on the motor installation fixing plate.

6. The gas heater based on closed-loop control of a wide-range oxygen sensor according to claim 5, characterized in that, a magnetic ring is fixedly sleeved on the output shaft of the fan motor, and a rotational speed sensor is fixedly arranged on the motor installation fixing plate at a position adjacent to the magnetic ring.

7. The gas heater based on closed-loop control of a wide-range oxygen sensor according to claim 5, characterized in that, the fan motor is electrically connected to the wire harness assembly through a Hall signal output interface.

8. The gas heater based on closed-loop control of a wide-range oxygen sensor according to claim 1, characterized in that, a water pump assembly is arranged outside the water heat exchange jacket, and the water outlet of the water pump assembly is connected to the water inlet of the water heat exchange jacket through a rubber hose; the water heat exchange jacket includes an inner sleeve and an outer sleeve that are sleeved with each other, one end of the inner sleeve and the outer sleeve deviating from the burner is closed, and the position between the other end of the outer sleeve and the inner sleeve is closed.

9. The gas heater based on closed-loop control of a wide-range oxygen sensor according to claim 8, characterized in that, the exhaust gas guide cylinder is arranged inside the inner sleeve, the exhaust pipe penetrates through the inner sleeve and the outer sleeve, and heat exchange fins are fixedly arranged on the inner side wall of the inner sleeve.

10. The gas heater based on closed-loop control of a wide-range oxygen sensor according to claim 1, characterized in that, the ECU assembly includes a CAN processing module communicatively connected to the vehicle CAN communication system.

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