Wall-hung boiler combustion control method, controller, and wall-hung boiler combustion control assembly

Abstract

The present invention relates to the technical field of wall-hung boiler combustion control. Disclosed are a wall-hung boiler combustion control method, a controller, and a wall-hung boiler combustion control assembly. The wall-hung boiler combustion control method comprises: acquiring in real time a calorific value component of a fuel gas before the fuel gas is mixed with a combustion-supporting gas, or a calorific value component of a mixed gas formed after the fuel gas is mixed with the combustion-supporting gas, so as to obtain a real-time calorific value component; on the basis of the real-time calorific value component, calculating an efficient air-fuel ratio; and on the basis of the efficient air-fuel ratio, adjusting / determining in real time a fuel gas flow / fuel gas volume, and / or a combustion-supporting flow / combustion-supporting gas volume. In this way, high efficient, energy-saving and low-pollution fuel gas combustion is realized, so as to ensure that a wall-hung boiler is in an optimal combustion condition in real time, and is greatly adapted to the effect of the difference in fuel gas composition on the thermal efficiency; and adaptive adjustment of an air-fuel ratio of the wall-hung boiler is realized rapidly and accurately, and the calibration of the air-fuel ratio of combustion performed by professionals is not required during production and mounting.

Description

Wall-hung boiler combustion control methods, controllers, and boiler combustion control components Technical Field

[0001] This invention relates to the field of combustion control technology for wall-hung boilers, specifically to a combustion control method, controller, and combustion control components for a wall-hung boiler. Background Technology

[0002] Previously, the combustion control components of wall-hung boilers on the market were basically developed and tested under standard experimental conditions to determine the gas-air ratio. This air-fuel ratio was a fixed value under different heat loads, achieving efficient combustion. However, due to differences in the production process, installation scenarios, and gas supply lines, the actual air-fuel ratio can vary significantly, deviating from the optimal ratio for combustion. This ultimately affects the boiler's thermal efficiency and emissions performance. Therefore, the gas-air ratio typically needs to be adjusted and corrected again during the integrated testing process on the production line and during user installation. This places high demands on the technical skills of production and installation personnel. Moreover, even after two rounds of air-fuel ratio combustion adjustments, the final result only guarantees the boiler's combustion performance at the time of installation. When external wind and rain, gas pressure, or even gas composition outside the exhaust pipe change, the gas-air ratio will still change, failing to fully achieve the expected energy-saving and emission-reduction effects.

[0003] Currently, with technological advancements, more and more fully premixed wall-hung boilers with adaptive combustion adjustment functions are emerging. For this type of fully premixed wall-hung boiler, most on the market determine and automatically adjust the ratio of gas to air based on the ion current of the combustion flame. Theoretically, there is no need to adjust the air-fuel ratio during production and installation. However, the relationship between ion current and air-fuel ratio is only a trend, a relationship obtained by researchers after fitting a large amount of data. This fitted relationship may deviate slightly from the actual correspondence in use and is not representative.

[0004] In addition, patent CN211261241U uses the detection of ion current as the main criterion for adjusting the fan and gas valve. However, this control algorithm is subject to significant errors in actual use due to factors such as the ion current's variation with combustion conditions, gas source, external humidity, and the accuracy of ion current detection. Furthermore, the time spent using the machine can also cause errors.

[0005] The patent CN112524810B determines the air-fuel ratio by detecting the ion current and further determines the air-fuel ratio by detecting the oxygen content in the emissions. However, this method still suffers from aging of the ion current and damage or inaccurate detection of the oxygen sensor due to excessive water vapor content. Summary of the Invention

[0006] The main objective of this invention is to provide a combustion control method, controller, and combustion control components for a wall-hung boiler, in order to solve the aforementioned problems.

[0007] To achieve the above objectives, this invention proposes a combustion control method for a wall-hung boiler, comprising the following steps:

[0008] The calorific value composition of the gas before mixing with the auxiliary gas is obtained in real time, or the calorific value composition of the mixture formed after mixing with the auxiliary gas is obtained in real time.

[0009] The high-efficiency air-fuel ratio is calculated based on the real-time calorific value composition.

[0010] The gas flow rate / gas volume and / or auxiliary gas flow rate / auxiliary gas volume are adjusted / determined in real time based on the high-efficiency air-fuel ratio.

[0011] The present invention also provides a wall-hung boiler controller, which is used to communicate with external devices, store instructions, and execute the wall-hung boiler combustion control method.

[0012] The present invention also provides a combustion control component for a wall-hung boiler, the combustion control component comprising:

[0013] Combustion chamber;

[0014] A mixer has a first input terminal, a second input terminal, and an output terminal. The first input terminal is connected to a combustion-supporting gas pipeline, the second input terminal is connected to a gas pipeline, and the output terminal is connected to the combustion chamber.

[0015] A gas valve is provided on the gas pipeline; and,

[0016] A gas calorific value meter is connected to the second input terminal of the mixer or to the output terminal of the mixer, and is used to obtain in real time the calorific value composition of the gas before mixing the gas and the auxiliary gas, or the calorific value composition of the mixture formed after mixing the gas and the auxiliary gas.

[0017] In the technical solution of this invention, the real-time calorific value composition directly affects the amount of gas flow / volume participating in complete combustion. By acquiring the real-time calorific value composition and calculating the efficient air-fuel ratio (i.e., the air-fuel ratio when the gas can burn completely), the gas flow / volume and / or auxiliary gas flow / volume are adjusted / determined in real time. This achieves efficient, energy-saving, and low-pollution gas combustion, ensuring the wall-hung boiler is in optimal combustion condition in real time, effectively adapting to the impact of gas composition differences on thermal efficiency, and adapting to the future trend of hydrogen blending in natural gas. Compared to the conventional method of judging and adjusting the air-fuel ratio based on the ion current of the combustion flame, the obtained data is more accurate and better guarantees the accuracy of data after long-term operation. Simultaneously, it enables rapid and accurate adaptive adjustment of the air-fuel ratio of the wall-hung boiler, eliminating the need for professional personnel to perform combustion air-fuel ratio adjustments during production and installation. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0019] Figure 1 is a flowchart of an embodiment of the combustion control method for wall-hung boilers provided by the present invention;

[0020] Figure 2 is a flowchart of another embodiment of the combustion control method for wall-hung boilers provided by the present invention;

[0021] Figure 3 is a flowchart of step S1 in Figure 2;

[0022] Figure 4 is a structural schematic diagram of the combustion control component of the wall-hung boiler provided by the present invention;

[0023] Figure 5 is a partial structural schematic diagram of the combustion control component of the wall-hung boiler in Figure 4;

[0024] Figure 6 is an exploded view of Figure 5;

[0025] Figure 7 is a cross-sectional view of Figure 5;

[0026] Figure 8 is a cross-sectional view of a portion of the combustion control component of the wall-hung boiler in Figure 4;

[0027] Figure 9 is an exploded view of a portion of the combustion control component of the wall-hung boiler in Figure 4;

[0028] Figure 10 is a cross-sectional view of a portion of the combustion control component of the wall-hung boiler shown in Figure 4.

[0029] Explanation of icon numbers:

[0030] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0031] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0032] It should be noted that if the embodiments of the present invention involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicators will also change accordingly.

[0033] Furthermore, if the embodiments of this invention involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the meaning of "and / or" throughout the text includes three parallel solutions; for example, "A and / or B" includes solution A, solution B, or a solution where both A and B are satisfied simultaneously. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0034] Previously, the combustion control components of wall-hung boilers on the market were basically developed and tested under standard experimental conditions to determine the gas-air ratio. This air-fuel ratio was a fixed value under different heat loads, achieving efficient combustion. However, due to differences in the production process, installation scenarios, and gas supply lines, the actual air-fuel ratio can vary significantly, deviating from the optimal ratio for combustion. This ultimately affects the boiler's thermal efficiency and emissions performance. Therefore, the gas-air ratio typically needs to be adjusted and corrected again during the integrated testing process on the production line and during user installation. This places high demands on the technical skills of production and installation personnel. Moreover, even after two rounds of air-fuel ratio combustion adjustments, the final result only guarantees the boiler's combustion performance at the time of installation. When external wind and rain, gas pressure, or even gas composition outside the exhaust pipe change, the gas-air ratio will still change, failing to fully achieve the expected energy-saving and emission-reduction effects.

[0035] Currently, with technological advancements, more and more fully premixed wall-hung boilers with adaptive combustion adjustment functions are emerging. For this type of fully premixed wall-hung boiler, most on the market determine and automatically adjust the ratio of gas to air based on the ion current of the combustion flame. Theoretically, there is no need to adjust the air-fuel ratio during production and installation. However, the relationship between ion current and air-fuel ratio is only a trend, a relationship obtained by researchers after fitting a large amount of data. This fitted relationship may deviate slightly from the actual correspondence in use and is not representative.

[0036] In view of this, the present invention provides a combustion control method for a wall-hung boiler, and Figures 1 to 3 are flowcharts of the combustion control method for a wall-hung boiler provided by the present invention.

[0037] Please refer to Figures 1 and 5. The combustion control method for the wall-hung boiler includes the following steps:

[0038] Step S3: Obtain the calorific value composition of the gas before mixing the gas and the auxiliary gas, or the calorific value composition of the mixture formed after mixing the gas and the auxiliary gas, to obtain the real-time calorific value composition.

[0039] Specifically, in one embodiment of the present invention, the real-time calorific value composition is obtained by measuring a gas calorific value meter. More specifically, the combustion control component of the wall-hung boiler includes a combustion chamber, a mixer, a gas valve, and a gas calorific value meter. The first input end of the mixer is connected to a gas-supporting pipeline, the second input end of the mixer is connected to a gas pipeline, and the first output end and the second input end are respectively connected to the combustion chamber. The gas calorific value meter is connected to the second input end or to the output end of the mixer. Thus, when the gas calorific value meter is connected to the second input end, it can be used to obtain the calorific value composition of the gas before the gas and the supporting gas are mixed in real time. When the gas calorific value meter is connected to the output end of the mixer, it can be used to obtain the calorific value composition of the mixture formed after the gas and the supporting gas are mixed in real time.

[0040] Step S6: Calculate the high-efficiency air-fuel ratio based on the real-time calorific value composition.

[0041] Step S7: Adjust / determine the gas flow rate / gas volume and / or auxiliary gas flow rate / auxiliary gas volume in real time according to the high-efficiency air-fuel ratio.

[0042] In this invention, the real-time calorific value directly affects the amount of gas flow / volume involved in complete combustion. By acquiring the real-time calorific value and calculating the efficient air-fuel ratio (i.e., the air-fuel ratio at which the gas can burn completely), the gas flow / volume and / or auxiliary gas flow / volume are adjusted / determined in real time. This achieves efficient, energy-saving, and low-pollution gas combustion, ensuring the boiler is in optimal combustion conditions in real time. It effectively adapts to the impact of gas composition differences on thermal efficiency and can also adapt to the gas composition impact brought about by the future trend of hydrogen blending into natural gas. Compared to the conventional method of judging and adjusting the air-fuel ratio based on the ion current of the combustion flame, the obtained data is more accurate and better guarantees the accuracy of data after long-term operation. Simultaneously, it enables rapid and accurate adaptive adjustment of the boiler's air-fuel ratio, eliminating the need for professional personnel to perform combustion air-fuel ratio adjustments during production and installation.

[0043] It should be noted that the calorific value components refer to the concentrations of various combustible components in the gas, and the calorific value can be calculated based on the concentrations of each component.

[0044] It should also be noted that, in this invention, the phrase "real-time adjustment / determination of gas flow rate / gas volume and / or auxiliary gas flow rate / auxiliary gas volume" can be understood as follows: It can mean that the auxiliary gas flow rate / auxiliary gas volume remains constant, while the ratio of gas and auxiliary gas in the mixture is adjusted solely by real-time adjustment / determination of the gas flow rate / gas volume; it can also mean that the gas flow rate / gas volume remains constant, while the ratio of gas and auxiliary gas in the mixture is adjusted solely by real-time adjustment / determination of the auxiliary gas flow rate / auxiliary gas volume; or it can mean that the gas flow rate / gas volume and the auxiliary gas flow rate / auxiliary gas volume are simultaneously adjusted / determined in real-time to achieve the adjustment of the ratio of gas and auxiliary gas in the mixture.

[0045] In addition, in the above adjustment / determination, "adjustment" can be understood as making corrections based on the original flow / volume, while "determination" can be understood as directly obtaining the flow / volume data output.

[0046] Furthermore, the flow rate is the volume of gas / fuel flowing in per unit time, and the volume is the size of the space within the pipeline for gas / fuel.

[0047] Furthermore, referring to Figure 2, the procedure prior to step S6 also includes:

[0048] Step S4: Obtain the real-time gas flow rate / gas volume to get the real-time gas flow rate / real-time gas volume.

[0049] In this step, the gas flow rate / gas volume can be obtained directly in real time using a gas flow meter installed in the gas pipeline; alternatively, the gas flow rate / gas volume can be obtained in real time using an auxiliary gas flow meter and a mixing gas flow meter. The difference between the data measured by the mixer flow meter and the data measured by the auxiliary gas flow meter is the gas flow rate / gas volume. The auxiliary gas flow meter is installed in the auxiliary gas pipeline, and the mixer flow meter is installed at the output end of the mixer. Furthermore, because the flow meters operate in a suitable environment and are technologically mature, the accuracy of the data after long-term operation can be guaranteed.

[0050] Step S6 specifically includes:

[0051] The high-efficiency air-fuel ratio is calculated based on the real-time gas flow rate / real-time gas volume and the real-time calorific value composition.

[0052] In this step, the gas flow rate / volume is closely and directly related to the efficient air-fuel ratio. Therefore, by first calculating an air-fuel ratio based on the real-time gas flow rate / volume, and then correcting the air-fuel ratio based on the real-time calorific value composition, a more accurate air-fuel ratio can be obtained, namely the efficient air-fuel ratio. This improves the accuracy of data calculation and facilitates the subsequent adjustment / determination of gas flow rate / volume and / or auxiliary gas flow rate / volume, thereby improving the combustion efficiency of the gas.

[0053] Furthermore, referring to Figure 2, the procedure prior to step S6 also includes:

[0054] Step S5: Obtain the real-time combustion gas flow rate / combustion gas volume to obtain the real-time combustion gas flow rate / combustion gas volume.

[0055] In this step, the combustion gas flow rate / volume can be directly measured using a combustion gas flow meter installed in the combustion gas pipeline; alternatively, the combustion gas flow rate / volume can be obtained in real time using a gas flow meter and a mixing gas flow meter. The difference between the data measured by the mixer flow meter and the data measured by the gas flow meter is the combustion gas flow rate / volume. The gas flow meter is installed in the gas pipeline, and the mixer flow meter is installed at the output end of the mixer. Furthermore, due to the suitable operating environment and mature technology of the flow meters, the accuracy of the data after long-term operation can be guaranteed.

[0056] Step S7 specifically includes:

[0057] Step S71: Calculate the real-time air-fuel ratio based on the real-time gas flow rate / real-time gas volume and the real-time auxiliary gas flow rate / real-time auxiliary gas volume.

[0058] In this step, the flow rate / volume of the combustion-supporting gas is also closely and directly related to the real-time air-fuel ratio. Therefore, by combining the real-time flow rate / volume of the combustion-supporting gas with the real-time flow rate / volume of the combustion-supporting gas, more accurate and reliable real-time air-fuel ratio data can be obtained, resulting in higher accuracy of subsequent adjustments.

[0059] Step S72: Compare the real-time air-fuel ratio and the high-efficiency air-fuel ratio. If the real-time air-fuel ratio is greater than the high-efficiency air-fuel ratio, increase the opening of the gas valve and / or decrease the output power of the fully premixed fan to increase the gas flow rate / gas volume and / or decrease the auxiliary gas flow rate / auxiliary gas volume. If the real-time air-fuel ratio is less than the high-efficiency air-fuel ratio, decrease the opening of the gas valve and / or increase the output power of the fully premixed fan to decrease the gas flow rate / gas volume and / or increase the auxiliary gas flow rate / auxiliary gas volume.

[0060] Specifically, the gas flow rate / gas volume is adjusted by the gas valve. That is, increasing the opening of the gas valve increases the gas flow rate / gas volume, and decreasing the opening of the gas valve decreases the gas flow rate / gas volume.

[0061] Specifically, by adjusting the flow rate / volume of the combustion-supporting gas using a fully premixed fan, increasing the output power of the fully premixed fan increases the flow rate / volume of the combustion-supporting gas, while decreasing the output power of the fully premixed fan decreases the flow rate / volume of the combustion-supporting gas.

[0062] It should be noted that in this invention, the two technical features mentioned above can be set simultaneously or one of them can be set selectively. Specifically, in one embodiment of this invention, the two technical features mentioned above are set simultaneously, that is, the gas flow rate / gas volume is adjusted by the gas valve and the auxiliary gas flow rate / auxiliary gas volume is adjusted by the fully premixed fan. In this way, the real-time air-fuel ratio gradually becomes consistent with the high efficiency air-fuel ratio, thereby ensuring efficient combustion of gas.

[0063] More specifically, the gas valve is located in the gas pipeline, and the fully premixed fan is located in the mixer.

[0064] It should be noted that by combining the calorific value composition of the gas with the gas flow / volume data, the real-time heat load of the wall-hung boiler can be calculated quickly and accurately, achieving rapid temperature control.

[0065] It should be noted that in this invention, the order of steps S3, S4 and S5 described above is not limited. Steps S3, S4 and S5 can be performed in any order, or steps S4, S3 and S5 can be performed simultaneously.

[0066] Specifically, in this invention, the combustion-supporting gas can be pure oxygen or air mixed with oxygen, etc.

[0067] Furthermore, referring to Figure 2, the procedure prior to step S6 also includes:

[0068] Step S1: Confirm the actual oxygen content in the air.

[0069] In this step, the oxygen content in the air of different regions is determined, and the air-fuel ratio is adjusted accordingly to reduce the impact of regional factors on combustion efficiency, thereby ensuring that the fuel gas can be fully burned.

[0070] It should be noted that, in this invention, the method for confirming the actual oxygen content in the air is not limited, and can be confirmed by oxygen flow meters, pressure gauges (the measured pressure data is combined with the regional altitude to calculate the oxygen content), etc.

[0071] Specifically, in one embodiment of the present invention, please refer to Figure 3, step S1 specifically includes:

[0072] Step S11: Keep the gas flow rate / gas volume constant, adjust the air flow rate / air volume, and calculate the heat output power of the wall-hung boiler corresponding to each air flow rate / air volume data to obtain the maximum heat output power.

[0073] More specifically, in one embodiment of the present invention, step S11 specifically includes:

[0074] Step S111: Based on the preset oxygen content, real-time airflow / real-time air volume Q air Real-time gas flow rate / Real-time gas volume Q gas Water flow rate Q W The first thermal output power P is calculated based on the outlet water temperature T2 and the return water temperature T1. 输出 ;

[0075] Step S112: Maintain gas flow rate / gas volume Q gas Keeping the airflow / air volume Q constant, gradually increase it. air And the second thermal output power P' was calculated. 输出 When the second thermal output power P' 输出 Less than or equal to the first thermal output power P 输出 Or the second thermal output power P' 输出Stop increasing airflow / air volume when it no longer increases with increasing airflow / air volume;

[0076] Step S113: Maintain gas flow rate / gas volume Q gas Keep the airflow / air volume Q constant, and gradually decrease it. air And the third thermal output power P″ was calculated. 输出 When the third thermal output power P″ 输出 Less than or equal to the first thermal output power P 输出 When the airflow / air volume Q is stopped, the reduction is stopped. air ;

[0077] Step S114: Compare the second thermal output power P' 输出 and the third thermal output power P″ 输出 The maximum thermal output power P is obtained. 输出max .

[0078] Step S12: Obtain the actual oxygen content data in the air based on the air flow / air volume data, gas flow / gas volume data, and gas calorific value composition data at the maximum heat output power.

[0079] It should be noted that, in one embodiment of the present invention, the preset oxygen content is 20.9%.

[0080] Step S6 specifically includes:

[0081] The high-efficiency air-fuel ratio is calculated based on the real-time gas flow rate / real-time gas volume, the real-time calorific value composition, and the actual oxygen content data.

[0082] In this step, the efficient air-fuel ratio data calculated by combining the oxygen content data in the air is more accurate and effective.

[0083] Specifically, please refer to Figure 2. In another embodiment of the present invention, the method further includes the following step before step S3:

[0084] Step S2: Set the initial air-fuel ratio.

[0085] Step S7 specifically includes:

[0086] Step S71': Correct the initial air-fuel ratio in real time according to the high-efficiency air-fuel ratio to obtain the real-time air-fuel ratio.

[0087] Step S72': Adjust the gas flow rate / gas volume and / or auxiliary gas flow rate / auxiliary gas volume in real time according to the real-time air-fuel ratio.

[0088] In this way, when a delay occurs in the calculation due to factors such as hardware components, the data can still be used based on the initial air-fuel ratio before correction.

[0089] It should be noted that step S72' may specifically include:

[0090] judge Whether it is greater than a first preset value, where α is the real-time air-fuel ratio and α0 is the high-efficiency air-fuel ratio;

[0091] If yes, adjust the gas flow / gas volume by adjusting the opening of the gas valve, or adjust the output power of the premixed fan to adjust the auxiliary gas flow / auxiliary gas volume. If no, repeat the previous step.

[0092] This avoids frequent adjustments to the gas flow / volume and the auxiliary gas flow / volume, thus preventing frequent adjustments to the gas valve and the fully premixed fan, which would affect their service life.

[0093] Further, step S2 specifically includes:

[0094] Step S21: Obtain the unit calorific value composition based on the gas flow rate per unit time and the gas calorific value composition / mixture calorific value composition, or obtain the unit calorific value composition based on the gas unit volume and the gas calorific value composition / mixture calorific value composition.

[0095] Step S22: Adjust the ratio of the combustion gas flow rate / combustion gas volume per unit time to the unit calorific value component, and monitor the output power of the wall-hung boiler corresponding to each ratio in real time to obtain the optimal output power of the wall-hung boiler.

[0096] Step S23: Based on the required combustion gas flow rate / combustion gas volume per unit time corresponding to the optimal output power, directly set the initial air-fuel ratio, or replace the original initial air-fuel ratio to obtain a new initial air-fuel ratio.

[0097] In this way, the accurate actual oxygen content and initial air-fuel ratio are obtained, ensuring that the accuracy of the wall-hung boiler's adaptive adjustment is not affected by the oxygen content of the geographical environment.

[0098] Furthermore, for ease of understanding of the present invention, in one case, step S22 specifically includes:

[0099] Step S221: Monitor the output power of the wall-hung boiler corresponding to the unit calorific value component in step S11 to obtain the first output power P1;

[0100] Step S222: Keep the gas flow rate / gas volume per unit time constant, gradually increase the auxiliary gas flow rate / auxiliary gas volume per unit time, and monitor the output power of the wall-hung boiler in real time to obtain the second output power. When the second output power P2 is less than or equal to the first output power P1, stop increasing the auxiliary gas flow rate / auxiliary gas volume per unit time (the specific adjustment process is shown in Table 1 below).

[0101] Step S223: Keep the gas flow rate / gas volume per unit time constant, gradually reduce the auxiliary gas flow rate / auxiliary gas volume per unit time, and monitor the output power of the wall-hung boiler in real time to obtain the third output power P3. When the third output power P3 is less than or equal to the first output power P1, stop reducing the auxiliary gas flow rate / auxiliary gas volume per unit time (the specific adjustment process is shown in Table 1 below).

[0102] Step S224: Compare the second output power P2 and the third output power P3 to obtain the optimal output power.

[0103] In this way, the most efficient combustion heat exchange condition can be determined under the gas flow rate / gas volume per unit time, and the corresponding parameters under this condition can be used to calculate the actual oxygen content and the initial air-fuel ratio.

[0104] Table 1

[0105] In another embodiment of the present invention, step S22 specifically includes:

[0106] Step S221': Monitor the output power of the wall-hung boiler corresponding to the unit calorific value component in step S11 to obtain the first output power;

[0107] Step S222': Keep the gas flow rate / gas volume per unit time constant, gradually increase the auxiliary gas flow rate / auxiliary gas volume per unit time, and monitor the output power of the wall-hung boiler in real time to obtain the second output power. When the second output power no longer increases with the increase of the auxiliary gas flow rate / auxiliary gas volume per unit time, stop increasing the auxiliary gas flow rate / auxiliary gas volume per unit time.

[0108] Step S223': Keep the gas flow rate / gas unit volume constant within a unit time, gradually reduce the auxiliary gas flow rate / auxiliary gas unit volume within a unit time, and monitor the output power of the wall-hung boiler in real time to obtain the third output power. When the third output power no longer increases with the decrease of the auxiliary gas flow rate / auxiliary gas unit volume within a unit time, stop reducing the auxiliary gas flow rate / auxiliary gas unit volume within a unit time.

[0109] Step S224: Compare the second output power and the third output power to obtain the optimal output power.

[0110] Furthermore, the formula for calculating the output power of the wall-hung boiler is: P 输出 =C×ρ×Q W ×(T2-T1);

[0111] In the formula, P 输出 This refers to the output power of the wall-hung boiler.

[0112] C is the specific heat capacity of water;

[0113] ρ is the density of water;

[0114] Q W Water flow rate / water volume;

[0115] T2 is the outlet water temperature;

[0116] T1 is the return water temperature.

[0117] More specifically, in one embodiment of the present invention, the water flow rate / water volume is obtained by a water flow meter, the outlet water temperature is obtained by an outlet water temperature sensor, and the return water temperature is obtained by a return water temperature sensor.

[0118] Specifically, based on the above-described embodiment where "the combustion-supporting gas is air" and "step S3 is preceded by step S2, setting the initial air-fuel ratio," step S2 specifically includes:

[0119] Set the initial air-fuel ratio based on the actual oxygen content in the air.

[0120] Therefore, if the local ambient oxygen content is known, the initial air-fuel ratio can be set by manually inputting the oxygen content parameter, thereby eliminating the adjustment process of the initial air-fuel ratio matching procedure and reducing energy consumption.

[0121] The present invention also provides a wall-hung boiler controller, which is used to communicate with external devices, store instructions, and execute the wall-hung boiler combustion control method described above.

[0122] The present invention also provides a combustion control component 100 for a wall-hung boiler. Please refer to Figures 4 to 10. The combustion control component 100 includes a combustion chamber, a mixer 1, a gas valve 2, and a gas calorific value meter 3. The mixer 1 has a first input terminal 11, a second input terminal 12, and an output terminal. The first input terminal 11 is connected to a gas-supporting pipeline, the second input terminal 12 is connected to a gas pipeline, and the output terminal is connected to the combustion chamber. The gas valve 2 is located on the gas pipeline. The gas calorific value meter 3 is connected to the second input terminal 12 of the mixer 1 or to the output terminal of the mixer 1, and is used to obtain in real time the calorific value composition of the gas before mixing the gas and the gas-supporting pipeline, or the calorific value composition of the mixture formed after mixing the gas and the gas-supporting pipeline.

[0123] Thus, by setting the gas calorific value meter 3 to measure the calorific value composition of the gas before mixing with the auxiliary gas, or the calorific value composition of the mixture formed after mixing with the auxiliary gas, the air-fuel ratio can be quickly and accurately adaptively adjusted. The gas flow rate / gas volume and / or auxiliary gas flow rate / auxiliary gas volume can be adjusted / determined in real time. This can well adapt to the impact of gas composition differences on thermal efficiency, and can also adapt to the impact of gas composition brought about by the future trend of natural gas hydrogen blending. This achieves high-efficiency, energy-saving, and low-pollution gas combustion, ensuring that the wall-hung boiler is in the best combustion condition in real time. Moreover, compared with the existing wall-hung boilers that use ion current data measured by ion current sensors to determine and adjust the air-fuel ratio, the wall-hung boiler combustion control component 100 provided by this invention has higher accuracy in measuring and calculating the data, and can better guarantee the accuracy of the data after long-term operation.

[0124] It should be noted that when the gas calorific value meter 3 is connected to the second input terminal 12, it can be used to obtain the calorific value composition of the gas before the gas and auxiliary gas are mixed in real time. When the gas calorific value meter 3 is connected to the output terminal of the mixer 1, it can be used to obtain the calorific value composition of the mixed gas formed after the gas and auxiliary gas are mixed in real time.

[0125] Furthermore, the wall-hung boiler combustion control component 100 also includes a combustion-supporting gas flow meter 54, which is located in the combustion-supporting gas pipeline and is used to measure the combustion-supporting gas flow rate / volume.

[0126] Specifically, the wall-hung boiler combustion control component 100 also includes a gas flow meter 5, which is installed in the gas pipeline and is used to measure the gas flow rate / gas volume.

[0127] It should be noted that in this invention, the above two technical features can be set simultaneously or one of them can be set selectively. Specifically, please refer to Figure 4. In one embodiment of this invention, the above two technical features are set simultaneously, that is, the wall-hung boiler combustion control component 100 also includes a gas-supporting flow meter 54 and a gas flow meter 5. The gas-supporting flow meter 54 is located in the gas-supporting pipeline, and the gas flow meter 5 is located in the gas pipeline.

[0128] Further, please refer to Figures 4 to 10. The mixer 1 is a Venturi mixer 1, and the first input terminal 11 is connected to the gas flow meter 54, and the second input terminal 12 is connected to the gas flow meter 5.

[0129] Specifically, please refer to Figures 5 to 7. In one embodiment of the present invention, the inner peripheral wall of the second input end 12 of the mixer 1 is recessed to form a first slot 121, and the peripheral sidewall of the second input end 12 has a second slot 122 extending through it in the inward and outward directions. The second slot 122 is disposed away from the mixing chamber of the mixer 1 relative to the first slot 121. A boss 51 is provided on the outer periphery of one end of the gas flow meter 5, and the boss 51 is adapted to be locked in the first slot 121. A U-shaped pin 6 is provided on the outer periphery of the mixer 1, and the U-shaped pin 6 is locked in the second slot 122, pressing the boss 51 into the first slot 121.

[0130] It should be noted that when assembling the mixer 1 and the gas flow meter 5, one end of the gas flow meter 5 is first inserted into the first slot 121, and then the U-shaped pin 6 is engaged in the second slot 122, so that the gas flow meter 5 is pressed tightly by the U-shaped pin 6 and the side wall of the first slot 121, thereby achieving reliable fixing of the gas flow meter 5, ensuring tightness, preventing gas leakage, and making the operation simple and convenient.

[0131] Further, please refer to Figure 7, a sealing ring 8 is provided between one end of the gas flow meter 5 inserted into the second input terminal 12 and the bottom wall of the first slot 121.

[0132] Specifically, please refer to Figures 9 and 10. In one embodiment of the present invention, the first input end 11 of the mixer 1 is provided with at least one first inner sidewall 111 and at least one first outer sidewall 112. The first outer sidewall 112 is spaced apart on the outer periphery of the first inner sidewall 111 to form a third slot with the first inner sidewall 111. One end of the gas flow meter 54 is provided with at least one second inner sidewall 41 and at least one second outer sidewall 42. The second outer sidewall 42 is spaced apart on the outer periphery of the second inner sidewall 41 to form a fourth slot with the second inner sidewall 41. The second inner sidewall 41 is engaged in the third slot with an interference fit, and the first outer sidewall 112 is engaged in the fourth slot with an interference fit, or the second outer sidewall 42 is engaged in the third slot with an interference fit, and the first inner sidewall 111 is engaged in the fourth slot with an interference fit. Thus, the gas flow meter 54 is installed tightly, and because the gas flow meter 54 is lightweight, its installation is more stable and reliable.

[0133] Specifically, please refer to Figure 8. In one embodiment of the present invention, the gas calorific value meter 3 is inserted into the mixer 1 from the side wall of the second input end 12 via a Pitot tube 31, thereby connecting to the second input end 12 of the mixer 1 for real-time acquisition of the calorific value composition of the gas and the auxiliary gas before mixing.

[0134] Specifically, in another embodiment of the present invention, the gas calorific value meter 3 is inserted into the mixer 1 from the side wall of the output end via a Pitot tube 31, thereby connecting to the output end of the mixer 1 for real-time acquisition of the calorific value composition of the mixture formed after the gas and auxiliary gas are mixed.

[0135] Meanwhile, the gas calorific value meter 3 adopts the principle of Pitot tube 31, with total pressure at the gas inlet and static pressure at the gas outlet. The gas enters the gas chamber of the gas calorific value meter 3 through the pressure difference, thereby avoiding direct connection with the gas pipeline and greatly reducing space restrictions. This allows the gas calorific value meter 3 to be installed on a conventional fully premixed wall-mounted boiler without changing its external dimensions and core component installation, facilitating the iterative application of new technologies and structures.

[0136] Specifically, please refer to Figure 4. The wall-hung boiler combustion control assembly 100 also includes a fully premixed fan 7, which is located in the mixer 1 and is used to charge the mixer 1 with combustion-supporting gas and to adjust the air-fuel ratio.

[0137] Specifically, the wall-hung boiler combustion control assembly 100 also includes a wall-hung boiler controller, which is signal-connected to the gas valve 2 and the gas calorific value meter 3. More specifically, the wall-hung boiler controller can be wired or wirelessly connected to the gas valve 2 and the gas calorific value meter 3. Further, the wall-hung boiler controller is signal-connected to the auxiliary gas flow meter 54, the gas flow meter 5, and the fully premixed fan 7.

[0138] Furthermore, the gas pipeline includes a first section of pipeline connected to the upstream end of the gas valve 2 and a second section of pipeline connected to the downstream end of the gas valve 2. The gas calorific value meter 3 is located in the second section of pipeline or the mixing pipeline so that when the gas valve is in the closed state, the auxiliary gas can be used to replace the gas in the gas calorific value meter.

[0139] Thus, by closing the gas valve 2 and replacing the gas in the gas calorimeter 3 with auxiliary gas, the gas calorimeter 3 is calibrated to zero. This allows for the calibration of the gas calorimeter 3 under standard and abnormal operating conditions, determining the data of the gas calorimeter 3 under normal and abnormal conditions. This facilitates adaptive adjustments when the gas calorimeter 3 is in an abnormal operating condition, ensuring the measurement accuracy of the gas calorimeter 3, and consequently ensuring the accuracy of the air-fuel ratio judgment and adjustment of the wall-hung boiler.

[0140] Furthermore, in one embodiment of the present invention, the combustion control component 100 of the wall-hung boiler also includes a manual switch, which is connected to the gas valve 2 to control the working state of the gas valve 2 and to replace the gas in the gas calorimeter 3 with auxiliary gas / air; thus, the user can manually zero the gas calorimeter 3 according to actual usage needs, improving practicality and user experience.

[0141] In addition, based on one embodiment described above, "the wall-hung boiler combustion control component 100 also includes a wall-hung boiler controller, which is signal-connected to the gas valve 2 and the gas calorimeter 3," the wall-hung boiler combustion control component 100 further includes a control switch. The control switch is signal-connected to the wall-hung boiler controller and is used to send a control signal to the wall-hung boiler controller, so that the wall-hung boiler controller receives the control signal to control the working state of the gas valve 2 and to control the replacement of the gas in the gas calorimeter 3 with auxiliary gas / air. In this way, the wall-hung boiler controller can periodically zero the gas calorimeter 3 according to actual usage.

[0142] The above description is merely a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural transformations made using the contents of the present invention's specification and drawings under the inventive concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A combustion control method for a wall-hung boiler, characterized in that, The combustion control method for the wall-hung boiler includes the following steps: The calorific value composition of the gas before mixing with the auxiliary gas is obtained in real time, or the calorific value composition of the mixture formed after mixing with the auxiliary gas is obtained in real time. The high-efficiency air-fuel ratio is calculated based on the real-time calorific value composition. The gas flow rate / gas volume and / or auxiliary gas flow rate / auxiliary gas volume are adjusted / determined in real time based on the high-efficiency air-fuel ratio.

2. The combustion control method for a wall-hung boiler as described in claim 1, characterized in that, Before the step of calculating the high-efficiency air-fuel ratio based on the real-time calorific value composition, the following is also included: Real-time gas flow rate / gas volume is obtained to get real-time gas flow rate / real-time gas volume; The step of calculating the high-efficiency air-fuel ratio based on the real-time calorific value composition specifically includes: The high-efficiency air-fuel ratio is calculated based on the real-time gas flow rate / real-time gas volume and the real-time calorific value composition.

3. The combustion control method for a wall-hung boiler as described in claim 2, characterized in that, Before the step of calculating the high-efficiency air-fuel ratio based on the real-time calorific value composition, the following steps are also included: Real-time acquisition of combustion-supporting gas flow rate / volume yields real-time combustion-supporting gas flow rate / volume. The steps of adjusting / determining the gas flow rate / gas volume and / or the auxiliary gas flow rate / auxiliary gas volume in real time according to the high-efficiency air-fuel ratio specifically include: The real-time air-fuel ratio is calculated based on the real-time gas flow rate / real-time gas volume and the real-time auxiliary gas flow rate / real-time auxiliary gas volume. By comparing the real-time air-fuel ratio and the high-efficiency air-fuel ratio, if the real-time air-fuel ratio is greater than the high-efficiency air-fuel ratio, the opening of the gas valve is increased and / or the output power of the fully premixed fan is decreased to increase the gas flow rate / gas volume and / or decrease the auxiliary gas flow rate / auxiliary gas volume. If the real-time air-fuel ratio is less than the high-efficiency air-fuel ratio, the opening of the gas valve is decreased and / or the output power of the fully premixed fan is increased to decrease the gas flow rate / gas volume and / or increase the auxiliary gas flow rate / auxiliary gas volume.

4. The combustion control method for a wall-hung boiler as described in claim 3, characterized in that, Real-time gas flow rate / volume is obtained through a gas flow meter, and real-time auxiliary gas flow rate / volume is obtained through an auxiliary gas flow meter; or, The gas flow rate / gas volume and the auxiliary gas flow rate / auxiliary gas volume are obtained in real time using one of the gas flow meters and the auxiliary gas flow meters, as well as the mixed gas flow meter.

5. The combustion control method for a wall-hung boiler as described in any one of claims 1-4, characterized in that, Adjust the gas flow / gas volume by means of the gas valve; and / or Adjust the flow rate / volume of the combustion-supporting gas by using a fully premixed fan.

6. The combustion control method for a wall-hung boiler as described in claim 2 or 3, characterized in that, The combustion-supporting gas is air; Before the step of calculating the high-efficiency air-fuel ratio based on the real-time calorific value composition, the following steps are also included: Confirm the actual oxygen content in the air; The step of calculating the high-efficiency air-fuel ratio based on the real-time calorific value composition specifically includes: The high-efficiency air-fuel ratio is calculated based on the real-time gas flow rate / real-time gas volume, the real-time calorific value composition, and the actual oxygen content data.

7. The combustion control method for a wall-hung boiler as described in any one of claims 1-3, characterized in that, Before the step of obtaining the real-time calorific value composition of the gas before mixing the gas and the auxiliary gas, or the calorific value composition of the mixture formed after mixing the gas and the auxiliary gas, the method further includes: Set the initial air-fuel ratio; The steps of adjusting / determining the gas flow rate / gas volume and / or the auxiliary gas flow rate / auxiliary gas volume in real time according to the high-efficiency air-fuel ratio specifically include: The initial air-fuel ratio is corrected in real time based on the efficient air-fuel ratio to obtain the real-time air-fuel ratio. The gas flow rate / gas volume and / or auxiliary gas flow rate / auxiliary gas volume are adjusted in real time according to the real-time air-fuel ratio.

8. The combustion control method for a wall-hung boiler as described in claim 7, characterized in that, The step of setting the initial air-fuel ratio specifically includes: The unit calorific value composition can be obtained based on the gas flow rate per unit time and the calorific value composition of the gas / mixture, or based on the gas volume per unit time and the calorific value composition of the gas / mixture. Adjust the ratio of the combustion gas flow rate / unit volume of combustion gas per unit time to the unit calorific value component, and monitor the output power of the wall-hung boiler corresponding to each ratio in real time to obtain the optimal output power of the wall-hung boiler. The initial air-fuel ratio can be directly set based on the required combustion gas flow rate / unit volume of combustion gas per unit time corresponding to the ratio of the optimal output power, or the original initial air-fuel ratio can be replaced to obtain a new initial air-fuel ratio; The steps of adjusting the ratio of the combustion gas flow rate / unit volume of combustion gas per unit time to the unit calorific value component, and monitoring the output power of the wall-hung boiler corresponding to each ratio in real time to obtain the optimal output power of the wall-hung boiler specifically include: The first output power is obtained by monitoring the output power of the wall-hung boiler corresponding to the unit calorific value component in the step of obtaining the unit calorific value component based on the gas flow rate per unit time and the gas calorific value component / mixed gas calorific value component, or based on the gas unit volume and the gas calorific value component / mixed gas calorific value component. Keep the gas flow rate / gas volume per unit time constant, gradually increase the auxiliary gas flow rate / auxiliary gas volume per unit time, and monitor the output power of the wall-hung boiler in real time to obtain the second output power. When the second output power is less than or equal to the first output power, stop increasing the auxiliary gas flow rate / auxiliary gas volume per unit time. Keep the gas flow rate / gas volume per unit time constant, gradually reduce the auxiliary gas flow rate / auxiliary gas volume per unit time, and monitor the output power of the wall-hung boiler in real time to obtain the third output power. When the third output power is less than or equal to the first output power, stop reducing the auxiliary gas flow rate / auxiliary gas volume per unit time. By comparing the second output power and the third output power, the optimal output power is obtained; The steps of adjusting the ratio of the combustion gas flow rate / unit volume of combustion gas per unit time to the unit calorific value component, and monitoring the output power of the wall-hung boiler corresponding to each ratio in real time to obtain the optimal output power of the wall-hung boiler specifically include: The first output power is obtained by monitoring the output power of the wall-hung boiler corresponding to the unit calorific value component in the step of obtaining the unit calorific value component based on the gas flow rate per unit time and the gas calorific value component / mixed gas calorific value component, or based on the gas unit volume and the gas calorific value component / mixed gas calorific value component. Keep the gas flow rate / gas volume per unit time constant, gradually increase the auxiliary gas flow rate / auxiliary gas volume per unit time, and monitor the output power of the wall-hung boiler in real time to obtain the second output power. When the second output power no longer increases with the increase of the auxiliary gas flow rate / auxiliary gas volume per unit time, stop increasing the auxiliary gas flow rate / auxiliary gas volume per unit time. Keep the gas flow rate / gas volume per unit time constant, gradually reduce the auxiliary gas flow rate / auxiliary gas volume per unit time, and monitor the output power of the wall-hung boiler in real time to obtain the third output power. When the third output power no longer increases with the decrease of the auxiliary gas flow rate / auxiliary gas volume per unit time, stop reducing the auxiliary gas flow rate / auxiliary gas volume per unit time. The optimal output power is obtained by comparing the second output power and the third output power.

9. The combustion control method for a wall-hung boiler as described in claim 7, characterized in that, The combustion-supporting gas is air; The step of setting the initial air-fuel ratio specifically includes: Set the initial air-fuel ratio based on the actual oxygen content in the air.

10. A wall-hung boiler controller, characterized in that, The wall-hung boiler controller is used to communicate with external devices, store instructions, and execute the wall-hung boiler combustion control method as described in any one of claims 1-9.

11. A combustion control component for a wall-hung boiler, characterized in that, The combustion control components of the wall-hung boiler include: Combustion chamber; A mixer has a first input terminal, a second input terminal, and an output terminal. The first input terminal is connected to a combustion-supporting gas pipeline, the second input terminal is connected to a gas pipeline, and the output terminal is connected to the combustion chamber. A gas valve is provided on the gas pipeline; and, A gas calorific value meter is connected to the second input terminal of the mixer or to the output terminal of the mixer, and is used to obtain in real time the calorific value composition of the gas before mixing the gas and the auxiliary gas, or the calorific value composition of the mixture formed after mixing the gas and the auxiliary gas.

12. The combustion control assembly for a wall-hung boiler as described in claim 11, characterized in that, The wall-hung boiler combustion control assembly further includes a gas flow meter, which is installed in the gas pipeline; and / or, the wall-hung boiler combustion control assembly further includes a gas flow meter, which is installed in the gas pipeline; The combustion control assembly of the wall-hung boiler also includes a combustion-supporting gas flow meter and a gas flow meter, wherein the combustion-supporting gas flow meter is installed in the combustion-supporting gas pipeline and the gas flow meter is installed in the gas pipeline; The mixer is a Venturi mixer, and the first input terminal is connected to the gas flow meter, and the second input terminal is connected to the gas flow meter.

13. The combustion control assembly for a wall-hung boiler as described in claim 11 or 12, characterized in that, The combustion control assembly of the wall-hung boiler also includes a gas flow meter; The inner peripheral wall of the second input end of the mixer is recessed to form a first slot, and the peripheral sidewall of the second input end is penetrated by a second slot in the inward and outward direction. The second slot is disposed away from the mixing chamber of the mixer relative to the first slot. The outer periphery of one end of the gas flow meter is provided with a boss, which is adapted to be snapped into the first slot. The mixer is provided with a U-shaped pin on its outer periphery. The U-shaped pin is engaged in the second slot and presses the boss into the first slot. The combustion control assembly of the wall-hung boiler also includes a gas flow meter; The first input end of the mixer is provided with at least one first inner sidewall and at least one first outer sidewall. The first outer sidewall is provided at intervals on the outer periphery of the first inner sidewall to form a third slot with the first inner sidewall. One end of the gas flow meter is provided with at least one second inner sidewall and at least one second outer sidewall. The second outer sidewall is provided at intervals on the outer periphery of the second inner sidewall to form a fourth slot with the second inner sidewall. The second inner sidewall is fitted into the third slot with an interference fit, and the first outer sidewall is fitted into the fourth slot with an interference fit; or, the second outer sidewall is fitted into the third slot with an interference fit, and the first inner sidewall is fitted into the fourth slot with an interference fit. The gas calorific value meter is inserted into the mixer from the side wall of the second input end via a pitot tube, or the gas calorific value meter is inserted into the mixer from the side wall of the output end via a pitot tube; The wall-hung boiler combustion control assembly also includes a fully premixed fan, which is located in the mixer; The wall-hung boiler combustion control assembly further includes the wall-hung boiler controller as described in claim 10, wherein the wall-hung boiler controller is signal-connected to the gas valve and the gas calorific value meter; The gas pipeline includes a first section of pipeline connected to the upstream end of the gas valve and a second section of pipeline connected to the downstream end of the gas valve. The gas calorific value meter is located in the second section of pipeline or the mixing pipeline.

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