A flashback resistant gas burner system and method of using the same

Abstract

The application discloses to the technical field of gas burners, and particularly relates to a backfire-preventing gas burner system and a use method thereof. First, the working condition of the burner is detected and pretreated in advance to obtain clean intake working condition parameters and output the same. Then, based on the clean intake working condition parameters, dynamic modulation of gas and air ratio is performed to output compliant mixed gas parameters. Subsequently, based on the compliant mixed gas parameters, the combustion mixed gas flow is controlled to limit the speed to generate real-time monitoring feedback data of the flame position. Based on the above, the application can not only actively intervene in the regulation at the budding stage when the flow rate deviates from the safety interval, but also ensure the continuous reliability of the regulation effect through steady-state calibration, so that the precise interruption of the physical conditions of the flame reverse is completed before backfire occurs, the time window of the accident intervention is greatly moved from the post-disposal to the proactive prevention, and the problem of serious lag in prevention and intervention is fundamentally solved.

Description

Technical Field

[0001] This invention relates to the field of gas burner technology, specifically to a backfire-proof gas burner system and its usage method. Background Technology

[0002] Gas burners are core heat exchange equipment in industrial kilns, commercial kitchens, residential heating, and thermal chemical industries. Their working principle involves premixing gaseous fuel with combustion air in a specific ratio, followed by stable combustion at the combustion end to release heat energy. Premixed gas burners, due to their advantages of complete combustion, high thermal efficiency, and low energy consumption, have become the mainstream in the market. However, these burners consistently face the high-risk safety hazard of "backfire" during operation. Backfire refers to the abnormal combustion phenomenon where the flame fails to remain stably stationary at the burner's ignition end and instead propagates backwards to the gas pipeline, premixing chamber, and air intake channel. Once backfire occurs, it can instantly burn out internal components, sensors, and pipelines of the burner. This can lead to equipment shutdown and damage, gas leaks, or even major safety accidents such as deflagration, fires, and personal injury, severely restricting the safe and stable operation of gas burners.

[0003] Currently, conventional backfire prevention methods mostly rely on passive protection modes such as static flame arrestor nets for physical isolation, fixed flow control valves for set flow control, and emergency gas shut-off after an incident. They lack a comprehensive, proactive prevention and control system encompassing "condition pre-inspection, dynamic mixing, real-time flow control, and closed-loop reset in case of anomalies." This extensive control mode suffers from inadequate airflow control and severely delayed accident intervention under complex and fluctuating actual operating conditions: existing technologies rely solely on a single fixed flow-limiting component to control the mixed airflow velocity, lacking both tiered, fine-grained control based on flow velocity changes and real-time monitoring of the flame front position. Its intervention in backfire is entirely a passive, reactive response. For example, when a household gas stove suddenly increases its heat, the intake airflow surges. If the flow-limiting measures cannot be adjusted in real time, the mixed airflow velocity will momentarily exceed the flame stabilization range, causing the flame front to rapidly reverse and form a backfire, damaging the stove's internal valve body and control circuitry. Summary of the Invention

[0004] To address the aforementioned technical problems of crude airflow control and severely delayed accident intervention, this invention provides the following technical solution:

[0005] A backfire-preventing gas burner system, comprising:

[0006] The pre-operating condition detection and pre-processing module performs pre-operating condition detection and pre-processing on the burner to obtain clean intake air operating condition parameters and output them.

[0007] The gas-air ratio dynamic modulation module dynamically modulates the gas-air ratio based on the clean air intake condition parameters output by the pre-processing module to output compliant mixed gas parameters.

[0008] The combustion mixed airflow limiting and velocity control module includes a real-time measurement unit for mixed airflow velocity, a multi-level flow limiting gradient control unit, a flow velocity steady-state verification and feedback unit, and an online monitoring unit for the flame front position;

[0009] The real-time mixed gas velocity measurement unit calculates the initial flow velocity of the mixed gas before entering the combustion zone in real time based on the compliant mixed gas parameters output by the gas and air ratio dynamic modulation module and the flow cross-sectional area of ​​the premixed cavity, and outputs the measured mixed gas velocity data.

[0010] The multi-level flow restriction gradient control unit compares the measured data of the mixed airflow velocity output by the real-time mixed airflow velocity value calculation unit with the preset multi-level backfire prevention safety flow velocity standard, matches and executes the corresponding multi-level flow restriction gradient control strategy according to the flow velocity deviation, and outputs the mixed airflow after one flow restriction control.

[0011] The flow velocity steady-state verification and feedback unit continuously monitors the flow velocity of the mixed airflow after the multi-level flow limiting gradient control unit outputs the flow limiting control once, performs closed-loop verification to check whether it stably converges to the backfire prevention safety range, and outputs steady-state qualified airflow condition data.

[0012] The flame front position online monitoring unit, based on the steady-state compliant airflow condition data output by the flow velocity steady-state verification and feedback unit, uses a flame sensor for real-time monitoring and outputs real-time flame position monitoring feedback data.

[0013] The backfire anomaly closed-loop reset module performs a backfire anomaly closed-loop reset based on the real-time flame position monitoring feedback data output by the combustion mixture flow limiting and speed control module, so as to complete the safety blocking, hazard elimination and automatic restart when backfire occurs.

[0014] As a preferred embodiment of the anti-backfire gas burner system described in this invention, the pre-condition detection and pre-processing module includes:

[0015] The pipeline pressure real-time acquisition unit collects the gas pressure value inside the gas transmission and distribution pipeline in real time and outputs the raw gas pressure data.

[0016] The cavity temperature synchronous detection unit determines the corresponding safe operating temperature threshold range based on the raw gas pressure data output by the pipeline pressure real-time acquisition unit, synchronously and in real-time detects the working temperature in the burner premix cavity, and outputs the actual measured data of temperature and pressure linkage operation.

[0017] The intake impurity filtration pretreatment unit, based on the raw gas pressure data output by the pipeline pressure real-time acquisition unit and the temperature and pressure linkage measured data output by the cavity temperature synchronous detection unit, combined with the preset pipeline health assessment model, comprehensively judges the impurity blockage risk level, and matches and activates the corresponding filtration and purification strategy according to the impurity blockage risk level, outputting clean intake air condition parameters.

[0018] As a preferred embodiment of the anti-backfire gas burner system described in this invention, the pre-condition detection and pre-processing module includes:

[0019] The safety ratio threshold precision calibration unit, based on the clean intake air condition parameters output by the pre-operating condition detection and pre-treatment module, combined with the inherent properties of the burner, calibrates the theoretical safety ratio threshold range under different operating load segments and outputs it.

[0020] The dynamic deviation correction unit for operating conditions, based on the theoretical safe ratio threshold range output by the precise calibration unit for safe ratio thresholds, introduces measured data of temperature and pressure linkage operating conditions and clean air intake operating parameters to quantitatively correct the deviation between theoretical and actual operating conditions and output adaptive precise ratio control commands.

[0021] The gas intake flow adaptive control unit executes the adaptive precise proportioning control command output by the working condition dynamic deviation correction unit, adaptively adjusts the opening of the gas intake proportional valve, and outputs a stable gas supply flow value.

[0022] The combustion air distribution adaptation and adjustment unit uses the stable gas supply flow value output by the gas intake flow adaptive control unit as a benchmark, and synchronously matches and adjusts the combustion fan speed and damper opening degree according to the dynamic safety ratio value in the adaptive precise ratio control command, so as to output compliant mixed gas parameters.

[0023] As a preferred embodiment of the anti-backfire gas burner system described in this invention, the backfire anomaly closed-loop reset module includes:

[0024] The real-time backfire anomaly detection unit compares the real-time flame position monitoring feedback data output by the combustion mixture flow limiting and speed control module with the preset safe combustion reference position. When the flame front is detected to deviate in the opposite direction and cross the warning boundary, it is determined to be a backfire anomaly and outputs a backfire detection result signal.

[0025] After receiving the backfire judgment result signal output by the backfire anomaly real-time judgment unit, the emergency gas cut-off valve of the main gas line is closed and the backflow prevention barrier is activated, and the emergency gas cut-off barrier completion signal is output.

[0026] The forced air cooling extinguishing and cooling unit, based on the emergency gas cut-off and backflow isolation completion signal output by the emergency gas cut-off and backflow isolation unit, starts the forced air cooling purging program, extinguishes the residual flame in the cavity and forcibly reduces the cavity temperature to a safe range, and outputs a safe no-residual-flame working condition signal.

[0027] The fault parameter tracing and calibration unit, based on the safe and flameless operating condition signal output by the forced air cooling extinguishing and cooling unit, reads historical operating data to trace the cause of backfire, performs targeted calibration of control parameters, and outputs a fault calibration completion signal.

[0028] The system full self-test and compliance reset unit initiates a full system safety and compliance self-test based on the fault calibration completion signal output by the fault parameter tracing calibration unit. After the self-test is passed, a compliance reset operation is performed to restore the burner to normal operation.

[0029] A method of using a backfire-prevention gas burner system includes the following steps:

[0030] S1, Pre-operating condition detection and pre-processing: Perform pre-operating condition detection and pre-processing on the burner to obtain clean intake air operating condition parameters and output them;

[0031] S2, Dynamic modulation of gas and air ratio: Based on the clean air intake condition parameters output by S1, the gas and air ratio is dynamically modulated to output compliant mixed gas parameters;

[0032] S3, combustion mixture flow rate control:

[0033] S31, Real-time Calculation of Mixed Gas Flow Rate: Based on the compliant mixed gas parameters output by S2, combined with the flow cross-sectional area of ​​the premixed cavity, the initial flow rate of the mixed gas before entering the combustion zone is calculated in real time, and the measured data of the mixed gas flow rate is output.

[0034] S32, Multi-level flow restriction gradient control: The measured mixed airflow velocity data output by S31 is compared with the preset multi-level backfire prevention safety flow velocity standard. Based on the flow velocity deviation, the corresponding multi-level flow restriction gradient control strategy is matched and executed, and the mixed airflow after one flow restriction regulation is output.

[0035] S33, Flow velocity steady-state verification and feedback: After the mixed airflow is output by S32 once for flow restriction and control, its flow velocity is continuously monitored, and closed-loop verification is performed to check whether it has stably converged to the backfire prevention safety range, and output steady-state qualified airflow condition data.

[0036] S34, Online monitoring of flame front position: Based on the steady-state compliant airflow condition data output by S33, the flame sensor is used for real-time monitoring and outputs real-time flame position monitoring feedback data;

[0037] S4, Backfire Anomaly Closed-Loop Reset: Based on the real-time flame position monitoring feedback data output by S3, a backfire anomaly closed-loop reset is performed to complete safety blocking, hazard elimination, and automatic restart when backfire occurs.

[0038] As a preferred embodiment of the method of using the anti-backfire gas burner system described in this invention, the specific steps of S1 are as follows:

[0039] S11, Real-time pipeline pressure acquisition: Real-time acquisition of gas pressure values ​​inside gas transmission and distribution pipelines, outputting raw gas pressure data;

[0040] S12, Synchronous detection of cavity temperature: Based on the raw gas pressure data collected by S11, determine the corresponding safe operating temperature threshold range, synchronously and in real time detect the working temperature in the burner premixing cavity, and output the actual measured data of temperature and pressure linkage.

[0041] S13, Intake air impurity filtration pretreatment: Based on the raw gas pressure data collected by S11 and the measured temperature and pressure linkage operating conditions data output by S12, combined with the preset pipeline health assessment model, the impurity blockage risk level is comprehensively judged, and the corresponding filtration and purification strategy is activated according to the impurity blockage risk level, and clean intake air operating condition parameters are output.

[0042] As a preferred embodiment of the method of using the anti-backfire gas burner system described in this invention, the specific steps of S2 are as follows:

[0043] S21, Precise Calibration of Safety Ratio Threshold: Based on the clean air intake condition parameters output by S1, combined with the inherent properties of the burner, the theoretical safety ratio threshold range under different operating load segments is calibrated and output;

[0044] S22, Dynamic Deviation Correction of Operating Conditions: Based on the theoretical safe ratio threshold range output by S21, the measured data of temperature and pressure linkage operating conditions and clean air intake operating parameters are introduced to quantitatively correct the deviation between theoretical and actual operating conditions and output adaptive precise ratio control commands.

[0045] S23, Adaptive control of gas intake flow: Executes the adaptive precise proportioning control command output by S22, adaptively adjusts the opening of the gas intake proportional valve, and outputs a stable gas supply flow value.

[0046] S24, Combustion-Assisted Air Distribution Adaptation and Adjustment: Based on the stable gas supply flow value output by S23, and according to the dynamic safety ratio value in the adaptive precise ratio control command, the combustion-assisted fan speed and damper opening degree are synchronously matched and adjusted to output compliant mixed gas parameters.

[0047] As a preferred embodiment of the method of using the anti-backfire gas burner system described in this invention, the specific steps of S4 are as follows:

[0048] S41, Real-time backfire anomaly detection: The real-time flame position monitoring feedback data output by S3 is compared with the preset safe combustion reference position. When the flame front is detected to deviate in the opposite direction and cross the warning boundary, it is determined to be a backfire anomaly, and the backfire detection result signal is output.

[0049] S42, Emergency Gas Cut-off and Backflow Isolation: After receiving the backfire judgment result signal output by S41, execute the operation of closing the emergency shut-off valve of the main gas line and starting the backflow isolation, and output the emergency gas cut-off isolation completion signal.

[0050] S43, Forced air cooling extinguishes residual flame and reduces temperature: Based on the emergency gas cut-off isolation completion signal output by S42, the forced air cooling purging procedure is started to extinguish the residual flame in the cavity and force the cavity temperature to be reduced to a safe range, and outputs a safe no-residual-flame condition signal.

[0051] S44, Fault Parameter Tracing and Calibration: Based on the safe backfire-free operating condition signal output by S43, historical operating data is read to trace the cause of backfire, and the control parameters are calibrated accordingly, and a fault calibration completion signal is output.

[0052] S45, System Full Self-Check and Compliance Reset: Based on the fault calibration completion signal output by S44, a full system safety and compliance self-check is initiated. After the self-check is passed, a compliance reset operation is performed to restore the burner to normal operation.

[0053] Compared with existing technologies:

[0054] 1. By comparing the deviation between measured mixed airflow velocity data and preset multi-level safe flow velocity standards, graded flow restriction gradient control is implemented, and closed-loop steady-state verification of the mixed airflow after flow restriction is carried out. Finally, real-time online monitoring of the flame front position is performed under highly stable airflow conditions, realizing a leap from coarse fixed-value flow restriction to a refined, multi-level, and closed-loop active velocity control mode. This invention can not only proactively intervene and control the flow velocity at the initial stage of deviation from the safe range, but also ensure the continuous reliability of the control effect through steady-state verification. Thus, it can accurately block the physical conditions for flame reversal before backfire occurs, significantly shifting the time window for accident intervention from reactive post-accident handling to proactive pre-accident prevention, fundamentally solving the problem of serious lag in prevention and control intervention.

[0055] 2. By introducing real-time temperature and pressure linkage data and clean air intake parameters to dynamically correct the deviation of the theoretical ratio threshold, and accordingly to synchronously and adaptively adjust the gas flow and combustion air distribution, the air-fuel mixture ratio and the real-time operating conditions of the burner are accurately and dynamically matched, eliminating the risk of lean or rich combustion backfire caused by the imbalance of the ratio. Attached Figure Description

[0056] Figure 1 This is a schematic diagram of the overall framework of the present invention;

[0057] Figure 2 This is a schematic diagram of the pre-processing and detection module framework of the present invention.

[0058] Figure 3 This is a schematic diagram of the gas-air ratio dynamic modulation module framework of the present invention;

[0059] Figure 4 This is a schematic diagram of the combustion mixture flow limiting and speed control module frame of the present invention;

[0060] Figure 5 This is a schematic diagram of the frame of the tempering anomaly closed-loop reset module of the present invention. Detailed Implementation

[0061] To make the objectives, technical solutions, and advantages of the present invention clearer, the embodiments of the present invention will be described in further detail below with reference to the accompanying drawings.

[0062] This invention provides a backfire-preventing gas burner system; please refer to [link / reference]. Figure 1 ,include:

[0063] The pre-operating condition detection and pre-processing module performs pre-operating condition detection and pre-processing on the burner to obtain clean intake air operating condition parameters and output them.

[0064] The gas-air ratio dynamic modulation module dynamically modulates the gas-air ratio based on the clean air intake condition parameters output by the pre-processing module to output compliant mixed gas parameters.

[0065] The combustion mixture flow limiting and speed control module, based on the compliant mixed gas parameters output by the gas and air ratio dynamic modulation module, performs combustion mixture flow limiting and speed control to generate real-time flame position monitoring feedback data and output it.

[0066] The backfire anomaly closed-loop reset module performs a backfire anomaly closed-loop reset based on the real-time flame position monitoring feedback data output by the combustion mixture flow limiting and speed control module, so as to complete the safety blocking, hazard elimination and automatic restart when backfire occurs.

[0067] The pre-processing module for operating conditions includes:

[0068] The pipeline pressure real-time acquisition unit collects the gas pressure value inside the gas transmission and distribution pipeline in real time, generates and outputs the raw gas pressure data, and provides basic support for subsequent operating condition analysis.

[0069] The cavity temperature synchronous detection unit determines the corresponding safe operating temperature threshold range based on the raw gas pressure data output by the pipeline pressure real-time acquisition unit; it synchronously and in real-time detects the working temperature in the burner premix cavity, generates and outputs temperature-pressure linkage working condition measured data containing the pressure-temperature linkage relationship;

[0070] The intake air impurity filtration pretreatment unit, based on the raw gas pressure data output by the pipeline pressure real-time acquisition unit and the temperature and pressure linkage measured data output by the cavity temperature synchronous detection unit, combined with the preset pipeline health assessment model, comprehensively judges the impurity blockage risk level of intake air impurity accumulation and blockage, and matches and activates the corresponding filtration and purification strategy according to the judged impurity blockage risk level to pretreat the gas and combustion air, and outputs clean intake air operating parameters.

[0071] For example, when the controller detects that the rate of decrease in gas intake pressure per unit time exceeds a preset threshold, and the premixing chamber temperature shows an abnormal rise that is not corresponding to the load, it is determined to be a high-impurity blockage risk level. At this time, the system automatically switches the intake passage to the high-efficiency filter branch, or starts the self-cleaning filter for backflushing to restore the cleanliness of the intake air.

[0072] The gas-air ratio dynamic modulation module includes:

[0073] The safety ratio threshold calibration unit, based on the clean air intake condition parameters output by the pre-operating condition detection and pre-processing module, combined with the inherent attributes of the burner such as rated power and model, accurately calibrates and outputs the theoretical safe ratio threshold range of gas and combustion air that can ensure stable combustion under different operating load segments;

[0074] The dynamic deviation correction unit for operating conditions, based on the theoretical safe ratio threshold range output by the accurate calibration unit for safe ratio threshold, introduces measured data of temperature and pressure linkage operating conditions and clean air intake operating parameters to establish a dynamic correction model, quantitatively corrects the deviation between theoretical and actual operating conditions, and outputs a set of adaptive and accurate ratio control instructions that are adapted to the current real-time state.

[0075] For example, if the theoretical optimal air-fuel ratio is 10:1 at 50% load, but the premix chamber temperature is detected to be too high, indicating that the combustion tends to drift towards a richer fuel mixture, this ratio instruction will be dynamically corrected, for example, by adjusting it to 10.2:1 to maintain flame stability.

[0076] The gas intake flow adaptive control unit executes the adaptive and precise proportioning control command output by the working condition dynamic deviation correction unit, and adaptively adjusts the opening of the gas intake proportional valve through a closed-loop control algorithm to precisely control the real-time gas intake flow and output a stable gas supply flow value.

[0077] The combustion air distribution adaptation and adjustment unit uses the stable gas supply flow value output by the gas intake flow adaptive control unit as a benchmark. Based on the dynamic safety ratio value in the adaptive precise ratio control command, it synchronously matches and adjusts the speed of the combustion air blower and the opening and closing degree of the damper to achieve adaptive adaptation and control of the combustion air flow. Finally, it outputs compliant mixed gas parameters that are fully mixed and accurately proportioned.

[0078] The combustion mixture flow limiting and speed control module includes:

[0079] The real-time mixed gas velocity measurement unit, based on the compliant mixed gas parameters output by the gas and air ratio dynamic modulation module and combined with the known flow cross-sectional area of ​​the premixed cavity, accurately calculates the initial flow velocity of the mixed gas before entering the combustion zone in real time, generates and outputs the measured mixed gas velocity data;

[0080] The multi-level flow restriction gradient control unit compares the measured data of the mixed airflow velocity output by the real-time mixed airflow velocity value calculation unit with the preset multi-level backfire prevention safety flow velocity standard. Based on the magnitude and direction of the flow velocity deviation, it matches and executes the corresponding multi-level flow restriction gradient control strategy to implement fine-grained pressure stabilization and velocity limiting control of the mixed airflow and outputs the mixed airflow after one flow restriction control.

[0081] For example, three flow velocity standards are preset: safe range (3-5 m / s), warning range (2-3 m / s or 5-6 m / s), and danger range (<2 m / s or >6 m / s). When the flow velocity enters the warning range, the controller outputs a first-level control signal to cause an electric regulating valve to close / open by a certain step; if the flow velocity deteriorates and enters the danger range, a second-level control signal is output to shut off the main flow and open the bypass flow-limiting orifice plate branch, forcefully pulling the flow velocity back to the safe range.

[0082] The flow velocity steady-state verification and feedback unit continuously monitors the real-time flow velocity of the mixed airflow after the multi-level flow limiting gradient control unit outputs the mixed airflow after one flow limiting control. It performs closed-loop verification to check whether the mixed airflow has been stably converged to the center region of the backfire prevention safety zone, eliminates the hidden danger of flow velocity fluctuation caused by factors such as control overshoot and external disturbances, and outputs steady-state qualified airflow condition data.

[0083] For example, after the flow restriction operation is performed, a short high-frequency detection cycle is entered. If it is found that the flow velocity has returned to the safe range but is still oscillating at the boundary, a fine-tuning command will be generated and fed back to the regulating valve until the flow velocity curve tends to be flat and stable. Finally, the steady-state qualified airflow condition data is confirmed and output.

[0084] The flame front position online monitoring unit, based on the steady-state compliant airflow condition data output by the flow velocity steady-state verification and feedback unit, uses a flame ionization probe or ultraviolet sensor to monitor the actual position of the flame front at the burner's nozzle end face in real time and generates continuous real-time flame position monitoring feedback data.

[0085] The tempering anomaly closed-loop reset module includes:

[0086] The real-time backfire anomaly detection unit continuously compares the flame position monitoring feedback data obtained by the combustion mixture flow limiting and speed control module with the preset safe combustion reference position. Once it detects that the flame front continuously deviates in the reverse direction and crosses the preset warning boundary, it is determined that a backfire anomaly has occurred, and the backfire detection result signal is immediately output.

[0087] Upon receiving the flashback detection result signal from the real-time flashback detection unit, the emergency gas cut-off and backflow isolation unit immediately triggers a dual blocking action: first, it drives the emergency shut-off valve on the main gas pipeline to close quickly; second, it simultaneously activates the anti-backflow isolation device to physically and quickly block the reverse propagation path of the flame and outputs an emergency gas cut-off isolation completion signal.

[0088] The forced air cooling extinguishing and cooling unit, based on the emergency gas cut-off and backflow isolation completion signal output by the emergency gas cut-off and backflow isolation unit, immediately starts the forced air cooling purging program, blows a large amount of cooling air into the premixed chamber and combustion area to purge and extinguish the residual fire in the chamber, and quickly forces the chamber temperature down to the safe operating range, effectively eliminating the risk of secondary reignition caused by high temperature walls or carbon deposits, and outputs a safe no-residual-fire condition signal.

[0089] The fault parameter tracing and calibration unit, based on the safe, flameless operating condition signal output by the forced air-cooled flameout and cooling unit, reads historical operating data and systematically analyzes the core causes leading to this backfire event. Based on the analysis results, it automatically performs targeted calibration, repair, or compensation for key control parameters such as mixing ratio parameters, current limiting thresholds, and drift of temperature / pressure sensors, fundamentally eliminating identified potential faults and outputting a fault calibration completion signal.

[0090] For example, the system checks the operating data tens of seconds before the fault occurs and finds that the temperature sensor reading has risen abnormally and triggered backfire, but the temperature rise rate does not match the load change. The system determines that the temperature sensor may have zero drift and compares it with the built-in redundant sensor or historical calibration data, automatically calculates and writes a new compensation coefficient, and eliminates the root cause of the fault.

[0091] The system full-scale self-check and compliance reset unit, based on the fault calibration completion signal output by the fault parameter traceability and calibration unit, starts the safety compliance self-check program for the entire burner system, including pipeline airtightness testing, sensor circuit integrity inspection, actuator action zero / full-scale calibration, etc. After all self-check items are judged to be qualified, the system performs a compliance reset operation and gradually restores the normal combustion state of the burner according to the preset safe start curve to complete a safe restart.

[0092] A usage method of an anti-flashback gas burner system includes the following steps:

[0093] S1, pre-condition detection and pre-treatment of working conditions:

[0094] S11, real-time acquisition of pipeline pressure: Real-time acquisition of the gas pressure value inside the gas transmission and distribution pipeline, generation and output of the original gas pressure acquisition data, providing a basic support for subsequent working condition analysis;

[0095] S12, synchronous detection of cavity temperature: Based on the original gas pressure acquisition data output by S11, determine the corresponding safe operating temperature threshold range; synchronously and real-time detect the working temperature inside the burner premixing cavity, generate and output the measured temperature-pressure linkage working condition data including the pressure-temperature linkage relationship;

[0096] S13, pre-treatment of intake impurities filtration: Based on the original gas pressure acquisition data output by S11 and the measured temperature-pressure linkage working condition data output by S12, combined with the preset pipeline health assessment model, comprehensively judge the impurity blockage risk level of intake impurity accumulation and blockage, and according to the judged impurity blockage risk level, match and start the corresponding filtration and purification strategy to pre-treat the gas and combustion-supporting air, and output the clean intake working condition parameters.

[0097] For example, when the controller monitors that the decline rate of the gas intake pressure within a unit time exceeds the preset threshold and the temperature of the premixing cavity shows an abnormal temperature rise not corresponding to the load, it is judged as a high impurity blockage risk level. At this time, the system automatically switches the intake passage to the high-efficiency filtration branch or starts the self-cleaning filter for reverse purging to restore the intake cleanliness.

[0098] S2: Dynamic modulation of gas and air ratio:

[0099] S21, accurate calibration of safety ratio threshold: Based on the clean intake working condition parameters output by S1, combined with the inherent attributes such as the rated power and model of the burner, accurately calibrate the theoretical safety ratio threshold range of gas and combustion-supporting air that can ensure stable combustion in different operating load segments and output;

[0100] S22, Dynamic Deviation Correction of Operating Conditions: Based on the theoretical safe ratio threshold range output by S21, the measured data of temperature and pressure linkage operating conditions and clean air intake operating parameters are introduced to establish a dynamic correction model, which quantitatively corrects the deviation between theoretical and actual operating conditions and outputs a set of adaptive and precise ratio control instructions that are adapted to the current real-time state.

[0101] For example, if the theoretical optimal air-fuel ratio is 10:1 at 50% load, but the premix chamber temperature is detected to be too high, indicating that the combustion tends to drift towards a richer fuel mixture, this ratio instruction will be dynamically corrected, for example, by adjusting it to 10.2:1 to maintain flame stability.

[0102] S23, Adaptive control of gas intake flow: Executes the adaptive precise proportioning control command output by S22, and adaptively adjusts the opening of the gas intake proportional valve through a closed-loop control algorithm to precisely control the real-time gas intake flow and output a stable gas supply flow value.

[0103] S24, Combustion-supporting air distribution adaptation and adjustment: Based on the stable gas supply flow value output by S23, and according to the dynamic safety ratio value in the adaptive precise ratio control command, the speed of the combustion-supporting fan and the opening degree of the damper are synchronously matched and adjusted to achieve adaptive adaptation and control of the combustion-supporting air flow, and finally output compliant mixed gas parameters with sufficient mixing and precise ratio.

[0104] S3, combustion mixture flow rate control:

[0105] S31, Real-time Calculation of Mixed Gas Flow Rate: Based on the compliant mixed gas parameters output by S2, combined with the known flow cross-sectional area of ​​the premixed cavity, the initial flow rate of the mixed gas before entering the combustion zone is calculated in real time and accurately, generating and outputting the measured mixed gas flow rate data;

[0106] S32, Multi-level flow restriction gradient control: The measured mixed airflow velocity data output by S31 is compared with the preset multi-level backfire prevention safety flow velocity standard. Based on the magnitude and direction of the flow velocity deviation, the corresponding multi-level flow restriction gradient control strategy is matched and executed to implement fine-grained pressure stabilization and velocity limiting control of the mixed airflow, and the mixed airflow after one flow restriction control is output.

[0107] For example, three flow velocity standards are preset: safe range (3-5 m / s), warning range (2-3 m / s or 5-6 m / s), and danger range (<2 m / s or >6 m / s). When the flow velocity enters the warning range, the controller outputs a first-level control signal to cause an electric regulating valve to close / open by a certain step; if the flow velocity deteriorates and enters the danger range, a second-level control signal is output to shut off the main flow and open the bypass flow-limiting orifice plate branch, forcefully pulling the flow velocity back to the safe range.

[0108] S33, Flow velocity steady-state verification and feedback: After the mixed airflow is output by S32 once for flow restriction and control, the real-time flow velocity of the mixed airflow is continuously monitored, and the closed-loop verification is performed to check whether it has been stably converged to the center area of ​​the backfire prevention safety range, eliminating the hidden danger of flow velocity fluctuation caused by factors such as control overshoot and external disturbances, and outputting steady-state qualified airflow condition data.

[0109] For example, after the flow restriction operation is performed, a short high-frequency detection cycle is entered. If it is found that the flow velocity has returned to the safe range but is still oscillating at the boundary, a fine-tuning command will be generated and fed back to the regulating valve until the flow velocity curve tends to be flat and stable. Finally, the steady-state qualified airflow condition data is confirmed and output.

[0110] S34, Online monitoring of flame front position: Based on the steady-state compliant airflow condition data output by S33, the actual position of the flame front on the burner's jet end face is monitored in real time using a flame ionization probe or ultraviolet sensor, and continuous real-time flame position monitoring feedback data is generated.

[0111] S4, Reset of Tempering Anomaly Closed-Loop:

[0112] S41, Real-time backfire anomaly detection: The real-time monitoring feedback data of the flame position obtained by S3 is continuously compared with the preset safe combustion reference position. Once the flame front is detected to continuously deviate in the reverse direction and cross the preset warning boundary, it is determined that a backfire anomaly has occurred, and the backfire detection result signal is immediately output.

[0113] S42, Emergency Gas Cut-off and Backflow Blocking: Upon receiving the backfire judgment result signal output by S41, it immediately triggers the execution of dual blocking actions: First, it drives the emergency shut-off valve on the main gas pipeline to close quickly; second, it simultaneously activates the anti-backflow blocking device to physically and quickly block the reverse propagation path of the flame and outputs an emergency gas cut-off blocking completion signal.

[0114] S43, Forced air cooling to extinguish residual flames and reduce temperature: Based on the emergency gas cut-off isolation completion signal output by S42, the forced air cooling purging procedure is immediately started, and a large amount of cooling air is blown into the premixed chamber and combustion area to purge and extinguish the residual flames in the chamber, and quickly force the chamber temperature to be reduced to a safe operating range, effectively eliminating the risk of secondary reignition caused by high temperature walls or carbon deposits, and outputting a safe no-residual-flame operating condition signal.

[0115] S44, Fault Parameter Tracing and Calibration: Based on the safe backfire-free operating condition signal output by S43, historical operating data is read to systematically trace and analyze the core causes leading to this backfire event. Based on the analysis results, key control parameters such as mixing ratio parameters, current limit threshold, and drift of temperature / pressure sensors are automatically calibrated, repaired, or compensated to fundamentally eliminate identified potential faults and output a fault calibration completion signal.

[0116] For example, the system checks the operation data in the tens of seconds before the fault occurs, and finds that the tempering is triggered after the reading of the temperature sensor increases abnormally, but shows that its heating rate does not match the load change. The system determines that there may be a zero drift in the temperature sensor, and compares it with the built-in redundant sensor or historical calibration data, automatically calculates and writes a new compensation coefficient to eliminate the root cause of this fault;

[0117] S45, system full-scale self-check and compliance reset: Based on the fault calibration completion signal output by S44, start the safety compliance self-check program of the entire burner system, including pipeline airtightness test, sensor circuit integrity check, actuator action zero / full scale calibration, etc. After all self-check items are determined to be qualified, the system performs a compliance reset operation, and gradually restores the normal combustion state of the burner according to the preset safe start curve to complete a safe restart.

[0118] Although the present invention has been described above with reference to the embodiments, various improvements can be made to it and its components can be replaced with equivalents without departing from the scope of the present invention. In particular, as long as there is no structural conflict, the various features in the disclosed embodiments of the present invention can be combined with each other in any way, and the exhaustive description of these combinations is not given in this specification only for the consideration of saving space and resources. Therefore, the present invention is not limited to the specific embodiments disclosed in the text, but includes all technical solutions falling within the scope of the claims.

Claims

1. A backfire-preventing gas burner system, characterized in that, include: The pre-operating condition detection and pre-processing module performs pre-operating condition detection and pre-processing on the burner to obtain clean intake air operating condition parameters and output them. The gas-air ratio dynamic modulation module dynamically modulates the gas-air ratio based on the clean air intake condition parameters output by the pre-processing module to output compliant mixed gas parameters. The combustion mixed airflow limiting and velocity control module includes a real-time measurement unit for mixed airflow velocity, a multi-level flow limiting gradient control unit, a flow velocity steady-state verification and feedback unit, and an online monitoring unit for the flame front position; The real-time mixed gas velocity measurement unit calculates the initial flow velocity of the mixed gas before entering the combustion zone in real time based on the compliant mixed gas parameters output by the gas and air ratio dynamic modulation module and the flow cross-sectional area of ​​the premixed cavity, and outputs the measured mixed gas velocity data. The multi-level flow restriction gradient control unit compares the measured data of the mixed airflow velocity output by the real-time mixed airflow velocity value calculation unit with the preset multi-level backfire prevention safety flow velocity standard, matches and executes the corresponding multi-level flow restriction gradient control strategy according to the flow velocity deviation, and outputs the mixed airflow after one flow restriction control. The flow velocity steady-state verification and feedback unit continuously monitors the flow velocity of the mixed airflow after the multi-level flow limiting gradient control unit outputs the flow limiting control once, performs closed-loop verification to check whether it stably converges to the backfire prevention safety range, and outputs steady-state qualified airflow condition data. The flame front position online monitoring unit, based on the steady-state compliant airflow condition data output by the flow velocity steady-state verification and feedback unit, uses a flame sensor for real-time monitoring and outputs real-time flame position monitoring feedback data. The backfire anomaly closed-loop reset module performs a backfire anomaly closed-loop reset based on the real-time flame position monitoring feedback data output by the combustion mixture flow limiting and speed control module, so as to complete the safety blocking, hazard elimination and automatic restart when backfire occurs.

2. The backfire prevention gas burner system according to claim 1, characterized in that, The pre-processing module for operating conditions includes: The pipeline pressure real-time acquisition unit collects the gas pressure value inside the gas transmission and distribution pipeline in real time and outputs the raw gas pressure data. The cavity temperature synchronous detection unit determines the corresponding safe operating temperature threshold range based on the raw gas pressure data output by the pipeline pressure real-time acquisition unit, synchronously and in real-time detects the working temperature in the burner premix cavity, and outputs the actual measured data of temperature and pressure linkage operation. The intake impurity filtration pretreatment unit, based on the raw gas pressure data output by the pipeline pressure real-time acquisition unit and the temperature and pressure linkage measured data output by the cavity temperature synchronous detection unit, combined with the preset pipeline health assessment model, comprehensively judges the impurity blockage risk level, and matches and activates the corresponding filtration and purification strategy according to the impurity blockage risk level, outputting clean intake air condition parameters.

3. The backfire prevention gas burner system according to claim 1, characterized in that, The pre-processing module for operating conditions includes: The safety ratio threshold precision calibration unit, based on the clean intake air condition parameters output by the pre-operating condition detection and pre-treatment module, combined with the inherent properties of the burner, calibrates the theoretical safety ratio threshold range under different operating load segments and outputs it. The dynamic deviation correction unit for operating conditions, based on the theoretical safe ratio threshold range output by the precise calibration unit for safe ratio thresholds, introduces measured data of temperature and pressure linkage operating conditions and clean air intake operating parameters to quantitatively correct the deviation between theoretical and actual operating conditions and output adaptive precise ratio control commands. The gas intake flow adaptive control unit executes the adaptive precise proportioning control command output by the working condition dynamic deviation correction unit, adaptively adjusts the opening of the gas intake proportional valve, and outputs a stable gas supply flow value. The combustion air distribution adaptation and adjustment unit uses the stable gas supply flow value output by the gas intake flow adaptive control unit as a benchmark, and synchronously matches and adjusts the combustion fan speed and damper opening degree according to the dynamic safety ratio value in the adaptive precise ratio control command, so as to output compliant mixed gas parameters.

4. The backfire prevention gas burner system according to claim 1, characterized in that, The tempering anomaly closed-loop reset module includes: The real-time backfire anomaly detection unit compares the real-time flame position monitoring feedback data output by the combustion mixture flow limiting and speed control module with the preset safe combustion reference position. When the flame front is detected to deviate in the opposite direction and cross the warning boundary, it is determined to be a backfire anomaly and outputs a backfire detection result signal. After receiving the backfire judgment result signal output by the backfire anomaly real-time judgment unit, the emergency gas cut-off valve of the main gas line is closed and the backflow prevention barrier is activated, and the emergency gas cut-off barrier completion signal is output. The forced air cooling extinguishing and cooling unit, based on the emergency gas cut-off and backflow isolation completion signal output by the emergency gas cut-off and backflow isolation unit, starts the forced air cooling purging program, extinguishes the residual flame in the cavity and forcibly reduces the cavity temperature to a safe range, and outputs a safe no-residual-flame working condition signal. The fault parameter tracing and calibration unit, based on the safe and flameless operating condition signal output by the forced air cooling extinguishing and cooling unit, reads historical operating data to trace the cause of backfire, performs targeted calibration of control parameters, and outputs a fault calibration completion signal. The system full self-test and compliance reset unit initiates a full system safety and compliance self-test based on the fault calibration completion signal output by the fault parameter tracing calibration unit. After the self-test is passed, a compliance reset operation is performed to restore the burner to normal operation.

5. A method of using a backfire-preventing gas burner system, characterized in that, Includes the following steps: S1, Pre-operating condition detection and pre-processing: Perform pre-operating condition detection and pre-processing on the burner to obtain clean intake air operating condition parameters and output them; S2, Dynamic modulation of gas and air ratio: Based on the clean air intake condition parameters output by S1, the gas and air ratio is dynamically modulated to output compliant mixed gas parameters; S3, combustion mixture flow rate control: S31, Real-time Calculation of Mixed Gas Flow Rate: Based on the compliant mixed gas parameters output by S2, combined with the flow cross-sectional area of ​​the premixed cavity, the initial flow rate of the mixed gas before entering the combustion zone is calculated in real time, and the measured data of the mixed gas flow rate is output. S32, Multi-level flow restriction gradient control: The measured mixed airflow velocity data output by S31 is compared with the preset multi-level backfire prevention safety flow velocity standard. Based on the flow velocity deviation, the corresponding multi-level flow restriction gradient control strategy is matched and executed, and the mixed airflow after one flow restriction regulation is output. S33, Flow velocity steady-state verification and feedback: After the mixed airflow is output by S32 once for flow restriction and control, its flow velocity is continuously monitored, and closed-loop verification is performed to check whether it has stably converged to the backfire prevention safety range, and output steady-state qualified airflow condition data. S34, Online monitoring of flame front position: Based on the steady-state compliant airflow condition data output by S33, the flame sensor is used for real-time monitoring and outputs real-time flame position monitoring feedback data; S4, Backfire Anomaly Closed-Loop Reset: Based on the real-time flame position monitoring feedback data output by S3, a backfire anomaly closed-loop reset is performed to complete safety blocking, hazard elimination, and automatic restart when backfire occurs.

6. The method of using a backfire prevention gas burner system according to claim 5, characterized in that, The specific steps of S1 are as follows: S11, Real-time pipeline pressure acquisition: Real-time acquisition of gas pressure values ​​inside gas transmission and distribution pipelines, outputting raw gas pressure data; S12, Synchronous detection of cavity temperature: Based on the raw gas pressure data collected by S11, determine the corresponding safe operating temperature threshold range, synchronously and in real time detect the working temperature in the burner premixing cavity, and output the actual measured data of temperature and pressure linkage. S13, Intake air impurity filtration pretreatment: Based on the raw gas pressure data collected by S11 and the measured temperature and pressure linkage operating conditions data output by S12, combined with the preset pipeline health assessment model, the impurity blockage risk level is comprehensively judged, and the corresponding filtration and purification strategy is activated according to the impurity blockage risk level, and clean intake air operating condition parameters are output.

7. The method of using a backfire prevention gas burner system according to claim 5, characterized in that, The specific steps of S2 are as follows: S21, Precise Calibration of Safety Ratio Threshold: Based on the clean air intake condition parameters output by S1, combined with the inherent properties of the burner, the theoretical safety ratio threshold range under different operating load segments is calibrated and output; S22, Dynamic Deviation Correction of Operating Conditions: Based on the theoretical safe ratio threshold range output by S21, the measured data of temperature and pressure linkage operating conditions and clean air intake operating parameters are introduced to quantitatively correct the deviation between theoretical and actual operating conditions and output adaptive precise ratio control commands. S23, Adaptive control of gas intake flow: Executes the adaptive precise proportioning control command output by S22, adaptively adjusts the opening of the gas intake proportional valve, and outputs a stable gas supply flow value. S24, Combustion-Assisted Air Distribution Adaptation and Adjustment: Based on the stable gas supply flow value output by S23, and according to the dynamic safety ratio value in the adaptive precise ratio control command, the combustion-assisted fan speed and damper opening degree are synchronously matched and adjusted to output compliant mixed gas parameters.

8. The method of using a backfire prevention gas burner system according to claim 5, characterized in that, The specific steps of S4 are as follows: S41, Real-time backfire anomaly detection: The real-time flame position monitoring feedback data output by S3 is compared with the preset safe combustion reference position. When the flame front is detected to deviate in the opposite direction and cross the warning boundary, it is determined to be a backfire anomaly, and the backfire detection result signal is output. S42, Emergency Gas Cut-off and Backflow Isolation: After receiving the backfire judgment result signal output by S41, execute the operation of closing the emergency shut-off valve of the main gas line and starting the backflow isolation, and output the emergency gas cut-off isolation completion signal. S43, Forced air cooling extinguishes residual flame and reduces temperature: Based on the emergency gas cut-off isolation completion signal output by S42, the forced air cooling purging procedure is started to extinguish the residual flame in the cavity and force the cavity temperature to be reduced to a safe range, and outputs a safe no-residual-flame condition signal. S44, Fault Parameter Tracing and Calibration: Based on the safe backfire-free operating condition signal output by S43, historical operating data is read to trace the cause of backfire, and the control parameters are calibrated accordingly, and a fault calibration completion signal is output. S45, System Full Self-Check and Compliance Reset: Based on the fault calibration completion signal output by S44, a full system safety and compliance self-check is initiated. After the self-check is passed, a compliance reset operation is performed to restore the burner to normal operation.

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