Multifunctional combustion controller

Abstract

The utility model relates to a plurality of multifunctional combustion controllers, each multifunctional combustion controller comprises an MCU (Microprogrammed Control Unit), a communication port, a logic port, an input port and an output port, and the communication port, the logic port, the input port and the output port are all connected with the MCU. The input port is used for receiving state information of the UV light flame detector and the ionization flame detector, the output port is used for driving the ignition transformer, the small fire valve, the main fire gas valve, the main fire air valve and the smoke exhaust valve to be opened / closed, and each multifunctional combustion controller is connected with the central control unit. The multifunctional combustion controller has the advantages that the multifunctional combustion controller integrates two paths of independent flame detection modes, has two functions of UV flame detection and ionization type flame detection, is suitable for three working modes of UV flame detection, integrated electrode flame detection and independent electrode flame detection, and can be connected to two flame detection interfaces of an MFCC (Mel Fluid Catalytic Cracking) respectively for burners with two sets of flame detection; and a flame detection signal amplifier does not need to be additionally configured.

Description

Technical Field

[0001] This utility model relates to the field of industrial heat treatment, and in particular to a multifunctional combustion controller. Background Technology

[0002] In industrial production, burners (or nozzles) are widely used; they are devices that organize the mixing and combustion of air and fuel gas in a specific way. With the continuous advancement of combustion technology, the combination of a burner and its auxiliary control valves with a combustion control device to form a combustion unit is becoming increasingly widespread. However, current combustion controllers generally suffer from drawbacks such as limited functionality and few control loops. To achieve various combustion modes for different burners, many additional external auxiliary electrical control devices are needed, resulting in complex, costly, and bulky combined combustion control devices. The main combustion valve requires remote control by a central control unit via long cables. Furthermore, when an industrial furnace is heated by multiple combustion units working together, a complete thermal control system needs to be formed by the combustion control device and the central control unit, establishing a monitoring mechanism for command transmission and status feedback between the central control unit and each combustion unit. Currently, combustion units commonly use multi-core signal cables to connect to the central control unit, with the type of command and status corresponding one-to-one with the number of cores in the cable. If there are many types of commands and statuses, many combustion units, and a long distance between the central control unit and the industrial furnace site, the number of cables increases exponentially, resulting in a large amount of engineering work, maintenance, and is time-consuming and labor-intensive. Summary of the Invention

[0003] The purpose of this invention is to provide a multi-functional combustion controller that has multiple ports and functions, reduces the number of connecting cables between the burner controller and the central control unit, facilitates wiring, and shortens maintenance time.

[0004] To achieve the above objectives, this utility model employs the following technical solution:

[0005] A multi-functional combustion controller is provided, comprising multiple multi-functional combustion controllers. Each multi-functional combustion controller includes an MCU, a communication port, a logic port, an input port, and an output port. The communication port, logic port, input port, and output port are all connected to the MCU. The input port is used to receive status information from UV flame detectors and ionization flame detectors. The output port is used to drive the ignition transformer, pilot flame valve, main flame gas valve, main flame air valve, and exhaust valve to open / close. Each multi-functional combustion controller is connected to a central control unit.

[0006] The input ports include a UV interface and an ionization interface. The UV flame detection is performed by a UV photosensitive tube located at the flame viewing port at the tail end of the burner. The UV photosensitive tube converts the UV light emitted by the flame into a micro-current signal, which is connected to the UV interface. The ionization flame detection is performed by an ionization flame detection electrode located inside the combustion chamber of the burner. The collected ionization micro-current signal is transmitted to the ionization interface from the electrode's transmitting end.

[0007] The ignition electrode and the flame detection electrode are two independent electrodes. The I terminal of the high-voltage side of the ignition transformer is connected to the ignition electrode, and the G terminal of the high-voltage side of the ignition transformer is grounded. Ionization interface one is connected to the flame detection electrode, and the ionization micro-current signal is connected to the signal amplification circuit through a jumper. Ionization interface two is grounded. The ignition electrode and the flame detection electrode are respectively set on both sides of the burner. The output terminal of the signal amplification circuit is connected to the MCU. The signal amplification circuit includes an integrated amplifier chip.

[0008] The ignition electrode and the flame detection electrode are the same electrode. The I terminal of the high-voltage side of the ignition transformer is connected to the electrode. The G terminal of the high-voltage side of the ignition transformer is connected to the moving contact 1 of the relay through ionization interface 1. The normally open stationary contact 1 of the relay is grounded through ionization interface 2. The L terminal of the low-voltage side of the ignition transformer is connected to ignition interface 1. Ignition interface 1 is connected to AC power L through the moving contact 2 of the relay. The N terminal of the low-voltage side of the ignition transformer is connected to ignition interface 2. Ignition interface 2 is connected to AC power N through the normally open stationary contact 2 of the relay. The coil of the relay is connected to the digital output terminal of the MCU. The electrode is installed on the burner side.

[0009] The output ports include valve output ports, which are connected to the large air valve, large gas valve, smoke exhaust valve, and small gas valve respectively.

[0010] The communication port is an RS485 communication port, used to connect to the communication module of the PLC in the central control unit.

[0011] The logic ports are input / output ports. The input / output ports are connected to the digital output ports and digital input ports of the PLC in the central control unit, respectively, or the input / output ports are connected to the digital input / output modules of the touch screen.

[0012] Compared with the prior art, the beneficial effects of this utility model are:

[0013] 1. For medium and large industrial furnaces, there are many burners. The communication module of the central control unit is connected to the master-slave communication cable between the communication port and the multi-functional combustion controller (MFCC). There is no need to add an additional digital input / output module to the central control unit to connect to each burner one by one. This saves the number of connecting cables, makes wiring convenient, reduces construction work and saves operation and maintenance costs.

[0014] 2. For industrial furnaces with fewer burners, a multi-functional combustion controller (MFCC) can be connected to the digital input / output modules of the central control unit (PLC) via logic ports (i.e., the input / output ports of the MFCC are connected one-to-one with the digital input / output modules of the central control unit (PLC)), or connected to a touch screen with digital ports (i.e., the input / output ports of the MFCC are connected one-to-one with the digital input / output modules of the touch screen). This saves on the number of connecting cables, makes wiring convenient, reduces construction work, and saves on operation and maintenance costs.

[0015] 3. Each multi-functional combustion controller is connected to the central control unit via a logic port or a communication port. Either the logic port or the communication port can be selected, which is suitable for industrial furnace control systems of different sizes.

[0016] 4. The multi-functional combustion controller (MFCC) has independent and integrated flame detection, and has both UV flame detection and ionization flame detection functions. It is applicable to three working modes: UV flame detection, integrated electrode flame detection, and independent electrode flame detection. Moreover, for burners with two sets of flame detection, they can be connected to the two flame detection interfaces of the MFCC respectively without the need for additional flame detection signal amplifier. It is fully functional and easy to implement.

[0017] 5. The Multifunctional Combustion Controller (MFCC) integrates up to four independent valve output ports, which can be flexibly adapted to combustion units with various valve configurations. Compared with the traditional long-distance connection between the main fire valve, exhaust valve and central control unit, the MFCC is connected to the nearest small fire valve, main gas valve, main air valve and exhaust valve, shortening the cable distance, saving cables and reducing the amount of construction work.

[0018] 6. The indicator lights on the combustion controller panel can display various working statuses. The switches and buttons can realize the single start and stop operation of the valve, making it convenient for operators to check the operating status of the equipment, simplifying maintenance and improving work efficiency. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the principle of a multi-functional combustion controller.

[0020] Figure 2 This is a schematic diagram showing the connection between the multi-functional combustion controller and the central control unit using logic coding.

[0021] Figure 3 This is a schematic diagram of the network topology for communication connection between the multi-functional combustion controller and the central control unit.

[0022] Figure 4 This is a schematic diagram of a two-state burner with integrated electrodes and its matching valves.

[0023] Figure 5 This is a schematic diagram of a 3-state burner structure with separate electrodes and its matching valves.

[0024] Figure 6 This is a schematic diagram of the structure of a 3-state burner equipped with UV flame detection and its matching valves.

[0025] Figure 7 This is a schematic diagram of the regenerative burner structure and its associated valves.

[0026] Figure 8 This is a schematic diagram of the structure of a self-preheating burner and its associated valves.

[0027] Figure 9 This is a schematic diagram of the connection of a split electrode.

[0028] Figure 10 This is a schematic diagram of ignition and flame detection using an integrated electrode.

[0029] Figure 11 This is the main process of the multi-functional combustion controller.

[0030] Figure 12 This is a schematic diagram of the ignition process.

[0031] Figure 13 This is a schematic diagram of the fire's progress.

[0032] Figure 14 This is a schematic diagram of the air-cooling process.

[0033] Figure 15 This is a schematic diagram of the smoke extraction process.

[0034] In the diagram: 101-Direct flame burner; 102-Regenerative burner; 103-Self-preheating burner; 2-Ignition burner; 301-Integrated electrode; 302-Ignition electrode; 303-Flame detection electrode; 4-UV probe; 501-Gas valve; 502-Small gas valve; 503-Main gas valve

[0035] 601-Air valve 602-Main air valve 7-Smoke exhaust valve 8-Smoke exhaust port 9-Preheater 10-Ignition transformer 11-Relay 12-Jump wire 13-Heat storage body. Detailed Implementation

[0036] The present invention will now be described in detail with reference to the accompanying drawings. However, it should be noted that the implementation of the present invention is not limited to the following embodiments.

[0037] The following embodiments are implemented based on the technical solution of this utility model, providing detailed implementation methods and specific operation processes. However, the protection scope of this utility model is not limited to the following embodiments. Unless otherwise specified, the methods used in the following embodiments are conventional methods.

[0038]

Example 1

[0039] A multi-functional combustion controller integrates multiple functions of combustion unit, including ignition, flame detection, and valve control, into a single controller. In addition to basic ignition, it features two flame detection channels and four valve operation channels, enabling localized operation of various combustion modes for different types of burners without the need for additional auxiliary electrical equipment. The controller panel indicator lights display various operating states, and switches and buttons allow for local operation. When the remote function is selected, communication with the central control unit can be established in two ways: the first method uses logic ports and 8421 encoding to separately encode commands and statuses, saving cable cores and materials; the second method uses bus communication, connecting multiple combustion controllers to the central control unit via communication cables to form a communication network, maximizing savings in cable quantity and engineering work, reducing maintenance costs, and saving time and effort, offering excellent economic efficiency and cost-effectiveness.

[0040] The Multifunctional Combustion Controller (MFCC) works in conjunction with the central control unit to achieve combustion operation of the integrated electrode burner. (See...) Figure 4 .

[0041] Due to structural size limitations, low-power burners can only install one electrode, employing an integrated electrode for ignition and flame detection. Because of the low power, the energy provided by the spark generated by the electrode is sufficient to ignite the air-fuel mixture, resulting in successful ignition. A two-state pulse combustion system is used, meaning the burner stops when the flame is extinguished and then burns at full power for heating. The heat output is regulated by periodically controlling the combustion time duty cycle.

[0042] The combustion unit includes a burner 101, an integrated electrode 301, a gas valve 501, an air valve 601, an ignition transformer 10, and an MFCC. Ignition and flame detection are as follows: Figure 10 As shown.

[0043] The integrated electrode is connected to the I terminal of the high-voltage side of the ignition transformer 10; the G terminal of the high-voltage side of the ignition transformer is connected to the ionization interface 1 of the multi-functional combustion controller, and then connected to the moving contact a3 of the relay 11 through the jumper 12; the normally closed stationary contact a1 of the relay is connected to the input terminal of the amplifier circuit, and the normally open stationary contact a2 is grounded through the ionization interface 2; the moving contact b3 of the relay is connected to the L terminal of the low-voltage side of the ignition transformer through the ignition interface 1; the normally open stationary contact b2 of the relay is connected to the AC power live wire L; the AC power neutral wire N is connected to the N terminal of the low-voltage side of the ignition transformer through the ignition interface 2.

[0044] Work process:

[0045] During ignition, the coil of the relay inside the MFCC is energized (the relay coil is connected to the digital output terminal of the MCU chip), the moving contact a3 of the relay contacts the normally open stationary contact a2 of the relay, the G terminal of the high-voltage side of the ignition transformer 10 is grounded, the moving contact b3 of the relay contacts the normally open stationary contact b2 of the relay, energizing the low-voltage side of the ignition transformer, and the I terminal of the high-voltage side of the ignition transformer discharges through electrode 301 to ignite the burner. After ignition is completed, the relay coil is de-energized and reset, the moving contact b3 of the relay separates from the normally open stationary contact b2 of the relay, the low-voltage side of the ignition transformer is de-energized, and the high-voltage side of the ignition transformer stops discharging. The moving contact a3 of the relay disengages from the normally closed stationary contact a2 and returns to contact with the normally closed stationary contact a1. Electrode 301 captures the ionization micro-current signal generated by the flame, which sequentially passes through the I terminal, high-voltage coil, G terminal of the high-voltage side of the ignition transformer, ionization interface 1 of the MFCC, the line, the moving contact a3 of the relay, and the normally closed stationary contact a1 of the relay, before being transmitted to the amplification circuit and finally sent to the MCU for flame monitoring. During ignition, the MFCC controls the gas valve 501 and air valve 601 to open, introducing gas and combustion air into the burner for mixing, which is then ignited by the electrode spark. Once ignition is complete and the MFCC detects a flame signal, it keeps the gas valve and air valve open, allowing the burner to continuously burn and provide heat. Each multi-functional combustion controller transmits burner command / status feedback information to the central control unit via 8421 encoding in a logical coding manner, as follows:

[0046] 1) The central control unit transmits burner command information to the multi-functional combustion controller, which then executes the corresponding actions. The 8421 coded command information is as follows:

[0047] The numerical code 0010 indicates air cooling;

[0048] The numerical code 0011 indicates a large fire;

[0049] The digital code 0100 indicates a reset;

[0050] The numerical code 1001 indicates forced ignition;

[0051] The numerical code 1010 indicates forced smoke extraction;

[0052] The numerical code 1011 indicates a forced fire;

[0053] 2) The multi-functional combustion controller transmits the burner status feedback information to the central control unit. The 8421 coded status feedback information is as follows:

[0054] The numerical code x000 indicates that the device has stopped working;

[0055] The numerical code x001 indicates that there is fire;

[0056] The numerical code x010 indicates air cooling / smoke exhaust;

[0057] The numerical code x011 indicates a large fire;

[0058] The numerical code x1xx indicates an alarm;

[0059] The numerical code 1a01 indicates forced low fire, where 'a' represents a periodic transition between 0 and 1;

[0060] The numerical code 1a11 indicates a forced fire;

[0061] The numerical code 10a0 indicates smoke extraction;

[0062] The numerical code 1xxx indicates remote operation;

[0063] The numeric code 0xxx indicates local operation.

[0064]

Example 2

[0065] A multi-functional combustion controller (MFCC) is proposed based on Embodiment 1, which adds the ability to cooperate with a central control unit to realize the combustion operation of a high-power burner. (See...) Figure 5 , Figure 6 .

[0066] High-power burners, due to their large size, have ample space to install two electrodes or one electrode plus one UV probe. Because the main flame has a large volume of air and fuel gas, the energy of the electrode spark is insufficient for reliable ignition. Furthermore, the power variation of the two-state flame is large, failing to meet the requirements for precise heat supply adjustment. Based on these two factors, a three-state pulse combustion mode is adopted: stop, small flame pulse, and main flame pulse.

[0067] The combustion unit includes a burner 101, an ignition electrode 302, a flame detection electrode 303 (or a UV probe 4), a small gas valve 502, a main gas valve 503, a main air valve 602, an ignition transformer 10, and an MFCC. The electrode connections are as follows: Figure 9 As shown.

[0068] Ignition electrode 302 is connected to terminal I on the high-voltage side of the ignition transformer, and terminal G on the high-voltage side of the ignition transformer is directly grounded. Flame detection electrode 303 is connected directly to the signal amplification circuit via ionization interface 1 and line 12. If UV flame detection is used, the signal amplification circuit is directly connected via the UV interface. An ultraviolet photosensitive tube is installed inside the UV probe, which can receive the ultraviolet light from the flame and convert it into a micro-current signal. Terminals L and N on the low-voltage side of the ignition transformer are connected to ignition interfaces 1 and 2, respectively, as in Example 1.

[0069] Work process:

[0070] During ignition, the low-voltage side of the ignition transformer 10 is energized, and the high-voltage side of the ignition transformer discharges and ignites through the ignition electrode 302. Simultaneously, the pilot flame gas valve 502 opens. In engineering practice, the pilot flame combustion air duct does not have a control valve and directly introduces a small volume of air. The air and gas mix in the burner and are ignited by a spark. The flame detection electrode or UV probe simultaneously monitors the flame. When the MFCC detects a flame signal, it keeps the pilot flame gas valve 502 open, allowing the pilot flame to continue burning. The pilot flame can provide sufficient energy to ignite the main flame. When the main flame needs to burn, the MFCC opens the main gas valve 503 and the main air valve 602 through the main gas valve interface and the main air valve interface, allowing a larger amount of gas and combustion air to enter the burner for full-power combustion and heating.

[0071]

Example 3

[0072] A multi-functional combustion controller (MFCC) is added to the embodiments 1-2 to enable combustion operation of regenerative burners in conjunction with a central control unit, see [link to embodiment 1]. Figure 7 .

[0073] Regenerative burners periodically switch between combustion and regenerative flue gas extraction modes to achieve energy-saving combustion. An ignition burner is configured to ignite the main flame of the regenerative burner during the combustion cycle. The ignition burner is small in power and size, making it suitable for ignition and flame monitoring using integrated electrodes, while the main burner is best monitored using a UV probe.

[0074] The regenerative combustion unit includes a regenerative burner 102, an ignition burner 2, an integrated electrode 301, a UV probe 4, an ignition transformer 10, a small gas valve 502, a main gas valve 503, a main air valve 602, a smoke exhaust valve 7, and an MFCC.

[0075] The connection of ignition burner 2 is the same as in Example 1. First, MFCC ignites ignition burner 2. After successful ignition, the small gas generator 502 is continuously turned on to keep ignition burner 2 in a constant-burning state. MFCC monitors the flame status of ignition burner 2 in real time. Once it goes out, it will alarm, cut off the main flame gas and re-ignite. After three consecutive failed ignition attempts, a fault will be reported.

[0076] Work process:

[0077] During the combustion cycle, the MFCC closes the exhaust valve 7, opens the main gas valve 503 to connect the main combustion gas, and opens the main air valve 602. The combustion airflow of the main combustion gas passes through the heat storage body 13 and absorbs heat before entering the burner, mixing with the gas, and is ignited by the constant-burning flame of the ignition burner 2 to begin combustion and heating. The MFCC monitors the main combustion status through the UV probe 4; if no flame is detected, an alarm is triggered. It also monitors the valve position of the exhaust valve 7; if the valve is not detected to be closed, an alarm is triggered and the main combustion is cut off. During the exhaust cycle, the MFCC closes the main gas valve 503 and the main air valve 602, and opens the exhaust valve 7. The high-temperature flue gas in the furnace flows through the heat storage body 13, where heat is stored. Then, the low-temperature flue gas is discharged through the exhaust valve 7. The MFCC monitors the valve position of the main air valve 602; if the valve is not detected to be closed, an alarm is triggered and the exhaust valve 7 is closed.

[0078]

Example 4

[0079] A multi-functional combustion controller (MFCC) is added to the embodiments 1-3 to enable combustion operation of a self-preheating burner in conjunction with a central control unit, such as... Figure 8 .

[0080] The self-preheating burner has a built-in preheater, which transfers the waste heat of the flue gas to the combustion air during combustion to achieve energy-saving combustion.

[0081] The self-preheating combustion unit includes a main burner 103, an electrode 302, a UV probe 4, an ignition transformer 10, a small gas valve 502, a main gas valve 503, a main air valve 602, a smoke exhaust valve 7, a smoke exhaust port 8, a preheater 9, and an MFCC.

[0082] The main burner section of a self-preheating burner is similar to that of a conventional burner, and it can use any one of three ignition and flame detection methods: integrated electrode, separate electrode, or electrode + UV.

[0083] Work process:

[0084] Unlike regenerative burners, the exhaust valve of a self-preheating burner is synchronized with combustion. That is, when the main flame is burning, the MFCC simultaneously opens the main gas valve 503, the main air valve 602, and the exhaust valve 7. Hot flue gas flows through the outer cavity of the preheater 9, and combustion air flows through the inner cavity of the preheater 9. The two exchange heat through heat conduction through the cavity wall. The combustion air carries back some of the heat from the hot flue gas to achieve energy-saving combustion.

Claims

1. A multifunctional combustion controller, characterized in that, There are multiple multi-functional combustion controllers. Each multi-functional combustion controller includes an MCU, a communication port, a logic port, an input port, and an output port. The communication port, logic port, input port, and output port are all connected to the MCU. The input port is used to receive status information from the UV flame detector and the ionization flame detector. The output port is used to drive the ignition transformer, the pilot flame valve, the main flame gas valve, the main flame air valve, and the exhaust valve to open / close. Each multi-functional combustion controller is connected to the central control unit.

2. The multifunctional combustion controller according to claim 1, characterized in that, The input ports include a UV interface and an ionization interface. The UV flame detection is performed by a UV photosensitive tube located at the flame viewing port at the tail end of the burner. The UV photosensitive tube converts the UV light emitted by the flame into a micro-current signal, which is connected to the UV interface. The ionization flame detection is performed by an ionization flame detection electrode located inside the combustion chamber of the burner. The collected ionization micro-current signal is transmitted to the ionization interface from the electrode's transmitting end.

3. A multifunctional combustion controller according to claim 2, characterized in that, The ignition electrode and the flame detection electrode are two independent electrodes. The I terminal of the high-voltage side of the ignition transformer is connected to the ignition electrode, and the G terminal of the high-voltage side of the ignition transformer is grounded. Ionization interface one is connected to the flame detection electrode, and the ionization micro-current signal is connected to the signal amplification circuit through a jumper. Ionization interface two is grounded. The ignition electrode and the flame detection electrode are respectively set on both sides of the burner. The output terminal of the signal amplification circuit is connected to the MCU. The signal amplification circuit includes an integrated amplifier chip.

4. A multifunctional combustion controller according to claim 2, characterized in that, The ignition electrode and the flame detection electrode are the same electrode. The I terminal of the high-voltage side of the ignition transformer is connected to the electrode. The G terminal of the high-voltage side of the ignition transformer is connected to the moving contact 1 of the relay through ionization interface 1. The normally open stationary contact 1 of the relay is grounded through ionization interface 2. The L terminal of the low-voltage side of the ignition transformer is connected to ignition interface 1. Ignition interface 1 is connected to AC power L through the moving contact 2 of the relay. The N terminal of the low-voltage side of the ignition transformer is connected to ignition interface 2. Ignition interface 2 is connected to AC power N through the normally open stationary contact 2 of the relay. The coil of the relay is connected to the digital output terminal of the MCU. The electrode is installed on the burner side.

5. A multifunctional combustion controller according to claim 1, characterized in that, The output ports include valve output ports, which are respectively connected to the large air valve, the large gas valve, the smoke exhaust valve, and the small gas valve.

6. A multifunctional combustion controller according to claim 1, characterized in that, The communication port is an RS485 communication port, used to connect to the communication module of the PLC in the central control unit.

7. A multifunctional combustion controller according to claim 1, characterized in that, The logic ports are input / output ports, which are connected to the digital output ports and digital input ports of the PLC in the central control unit, respectively, or to the digital input / output modules of the touch screen.

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