Flame detection system and method, and boiler

Abstract

A flame detection system according to the present invention comprises: a current-to-voltage conversion unit for converting a flame current value into a voltage value; an actual voltage data unit for securing actual voltage data during combustion; a reference voltage data unit for securing reference voltage data in a state in which no film is formed on a flame detection rod; and a voltage data comparison unit for comparing the reference voltage data with the actual voltage data to determine a film formation level of the flame detection rod.

Description

Flame detection system and detection method, and boiler

[0001] The present invention relates to a flame detection system and a flame detection method, and to a boiler. More specifically, it relates to a flame detection system and a detection method that determines the level of film formation on a flame detection rod and indicates whether the flame detection rod has been cleaned, and to a boiler.

[0002] Generally, a boiler is configured such that a main heat exchanger is installed inside the casing, a burner is installed above the main heat exchanger, and a blower is installed above the burner. The combustion gases generated during combustion can be configured to move downward inside the main heat exchanger and then move upward, exchanging heat with water as they do so, and then being discharged to the outside of the boiler casing.

[0003] A burner that generates combustion gas is equipped with a burner body having a plurality of flame holes, and on one side of the burner body, an ignition rod for igniting the mixed gas ejected through the flame holes and a flame detection rod for determining whether the gas is ignited are respectively installed.

[0004] The flame detection rod forms a closed circuit with the flame (spark) generated through the flame hole of the burner body, and can determine whether the gas is ignited based on whether there is a flow of flame current through the closed circuit.

[0005] Generally, the flame detection rod of a burner is installed adjacent to the burner body to detect the flame generated from the burner's flame port, and for this purpose, its end may be positioned at an angle toward the burner body.

[0006] As the burner is used frequently, a film, such as soot, that obstructs the flow of current may form on the surface of the flame detection rod. Since this film obstructs the flow of flame current, the flame detection rod may fail to detect whether the gas has ignited.

[0007] Generally, since flame detection via a flame detection rod is performed only through an ON / OFF method via a photocoupler as shown in Fig. 6, it can be determined that there is no problem until the device turns off, even if a film is formed on the surface and sensitivity decreases. In other words, it is difficult to determine whether there is a problem with the flame detection rod until a failure occurs in which the flame is not detected. Furthermore, in order to identify the cause of the failure to detect the flame, repetitive service activities such as inspecting various components including the ignition transformer, gas control valve, ignition rod, flame detection rod, and PCB may occur, leading to increased service costs.

[0008] The present invention was devised to solve the problems of the prior art as described above, and aims to provide a flame detection system, a detection method, and a boiler that can easily provide information on the necessity of cleaning the flame detection rod by quantitatively determining the level of film formation on the surface of the flame detection rod.

[0009] A flame detection system according to a preferred embodiment of the present invention for achieving the above-mentioned purpose comprises a current-voltage conversion unit that converts a flame current value into a voltage value, an actual voltage data unit that secures actual voltage data during combustion, a reference voltage data unit that secures reference voltage data in a state where no film is formed on the flame detection rod, and a voltage data comparison unit that determines the level of film formation on the flame detection rod by comparing the reference voltage data and the actual voltage data.

[0010] The voltage data comparison unit determines whether cleaning of the flame detection rod is necessary based on the level of film formation determined by the judgment.

[0011] The flame detection system according to the present invention further includes a notification unit that emits a cleaning notification signal when the voltage data comparison unit determines that cleaning of the flame detection rod is required.

[0012] The notification signal in the notification section is a visual or auditory signal, or a combined form of visual and auditory signals.

[0013] The actual voltage data includes the current voltage value obtained by converting the flame current value into a voltage value in real time, and the time taken to reach the current voltage after the start of combustion.

[0014] The reference voltage data includes a reference voltage, which is the voltage at the point where a flame is normally detected after the start of combustion when no film is formed on the surface of the flame detection rod, and a reference time, which is the time required to reach the reference voltage from the start of combustion.

[0015] A flame detection method according to a preferred embodiment of the present invention for achieving the above-mentioned purpose comprises the steps of converting a flame current value into a voltage value and obtaining actual voltage data during combustion, and determining the level of film formation on the flame detection rod by comparing the actual voltage data with reference voltage data in a state where no film is formed on the surface of the flame detection rod.

[0016] The flame detection method according to the present invention further includes the step of determining whether cleaning of the flame detection rod is required based on the level of film formation on the flame detection rod, and the step of emitting a notification signal through a notification unit when it is determined that cleaning is required.

[0017] The comparison between the reference voltage data and the actual voltage data compares whether the actual voltage reached the reference voltage after the start of combustion, and if the actual voltage reached the reference voltage, the time taken to reach the reference voltage.

[0018] The flame detection method according to the present invention further includes the step of cleaning the flame detection rod by removing the coating of the flame detection rod after the generation of a notification signal.

[0019] The flame detection method according to the present invention further includes the step of resetting the notification unit after cleaning the flame detection rod.

[0020] The flame detection method according to the present invention further includes the step of displaying the next scheduled cleaning time of the flame detection rod through the notification unit or another display unit after resetting the notification unit.

[0021] If, after combustion begins, the actual voltage reaches the reference voltage and the time required to reach the reference voltage is within the reference time, it is determined that cleaning the flame detection rod is unnecessary; however, if the actual voltage does not reach the reference voltage, or if the time required to reach the reference voltage exceeds the reference time, it is determined that cleaning the flame detection rod is required.

[0022] If it is determined that cleaning of the flame detection rod is required, the degree of necessity for cleaning is classified into multiple levels based on whether the actual voltage has reached the reference voltage and the time required to reach the reference voltage.

[0023] According to the flame detection system and detection method and boiler of the present invention, the level of formation of a film formed on the surface of a flame detection rod can be quantitatively determined using a flame detection voltage to provide a cleaning notification and information regarding the next cleaning cycle.

[0024] In addition, by providing information when a problem occurs due to film formation on the flame detection rod, it is possible to clean only the flame detection rod, thereby eliminating the need to inspect or replace other parts, which shortens service time and reduces service costs.

[0025] In addition, consumers can easily check whether the flame detector needs cleaning and can also clean the flame detector themselves by referring to the manual.

[0026] FIG. 1 is a configuration diagram of a flame detection system according to one embodiment of the present invention.

[0027] FIG. 2 is a process diagram showing the process of operation carried out by a flame detection method according to one embodiment of the present invention.

[0028] Figure 3 shows graphs comparing the change in voltage data over time during the normal detection of the flame and the process of film progression.

[0029] Figure 4 is a flowchart showing an example of a process that indicates, step by step, whether cleaning is necessary when a flame is detected normally and during the process of forming a film.

[0030] Figure 5 is a comparison table showing an example of the relationship between voltage, resistance, and time when a flame is normally detected and when a film is formed.

[0031] Figure 6 is a process diagram showing the process of operation carried out by a method for cleaning a flame detection rod of a boiler according to the prior art.

[0032] Hereinafter, a flame detection system, a detection method, and a boiler according to a preferred embodiment of the present invention will be described in detail with reference to the attached drawings.

[0033]

[0034] FIG. 1 is a configuration diagram of a flame detection system according to one embodiment of the present invention. FIG. 1 is a configuration diagram showing the flame detection system applied to a boiler (1).

[0035] A flame detection system according to one embodiment of the present invention may be provided in various combustion devices including a boiler (1) that generates a flame by burning fuel, and may include a flame detection rod (10), a control unit (20), and a notification unit (30).

[0036] A flame detection rod (10) is installed adjacent to the burner body with its end inclined toward the burner body to detect a flame generated from the flame hole of the burner. As the burner is used frequently, a surface film, such as soot, that obstructs the flow of current may form on the surface of the flame detection rod (10). The film formed on the surface of the flame detection rod (10) obstructs the flow of flame current, which may prevent the flame detection rod (10) from detecting whether the gas is ignited.

[0037] The control unit (20) converts the flame current value flowing through the flame detection rod (10) and the surface of the burner into a voltage value, obtains actual voltage data during combustion, and compares it with reference voltage data. Through the comparison result, it determines the level of film formation on the flame detection rod (10) and whether cleaning is necessary, and if it determines that cleaning of the flame detection rod (10) is necessary, it can control the operation of the notification unit (30).

[0038] The actual voltage data may include the current voltage value obtained by converting the flame current value into a voltage value, and the time required to reach the current voltage after the start of combustion. Since the actual voltage data includes voltage values ​​measured in real time, it can be quantitatively obtained while combustion continues.

[0039] The reference voltage data may include a reference voltage, which is the voltage at which a flame is normally detected after combustion starts when no film is formed on the surface of the flame detection rod (10), and the time required to reach the reference voltage after combustion starts.

[0040] Reference voltage data can be obtained experimentally, or through data obtained when the boiler is installed and the first combustion begins, or through data obtained immediately after cleaning the flame detection rod (10). When reference voltage data is obtained experimentally or through actual combustion, data related to the reference voltage can be automatically stored in the control unit (20) or input and stored in the control unit (20) by an operator.

[0041] Judgment factors for determining the film formation level and cleaning status by comparing actual voltage data and reference voltage data may include whether the actual voltage has reached the reference voltage, and if the actual voltage has reached the reference voltage, the time taken to reach the reference voltage after the start of combustion.

[0042] The control unit (20) may include a current detection unit (21), a current voltage conversion unit (22), an actual voltage data unit (23), a reference voltage data unit (24), and a voltage data comparison unit (25).

[0043] The current detection unit (21) detects the electric flow, i.e., the current, generated by the flame detection rod (10) and the flame on the burner surface in real time, and may include a current sensor. Data detected by the current detection unit (21) can be transmitted in real time to the current voltage conversion unit (22).

[0044] The current voltage conversion unit (22) can convert the flame current value obtained in real time into a voltage value in real time.

[0045] The actual voltage data section (23) may include the actual voltage obtained by converting the value of the flame current flowing through the flame detection rod (10) and the burner surface into a voltage value in real time after combustion starts, and the actual time taken to reach the actual voltage, i.e., the current voltage, after combustion starts.

[0046] The reference voltage data section (24) may include a reference voltage, which is the voltage at which a flame is normally detected after combustion starts when no film is formed on the surface of the flame detection rod (10), and the time required to reach the reference voltage after combustion starts.

[0047] The voltage data comparison unit (25) compares reference voltage data with actual voltage data to determine the level of film formation and the need for cleaning of the flame detection rod (10), and controls the operation of the notification unit (30) when it is determined that cleaning is necessary. The voltage data comparison unit (25) can determine the need for cleaning of the flame detection rod (10) in stages. For example, the cleaning necessity determination stage can be classified into a normal state where no film is formed, normal flame detection is performed, and cleaning is not required; a preliminary emergency state where the flame is detected normally but film formation is in progress, requiring caution; and an emergency state where cleaning is required immediately because the film is formed to the extent that normal flame detection is difficult.

[0048] In the notification unit (30), if it is determined by the control of the voltage data comparison unit (25) that cleaning of the flame detection rod (10) is necessary, a cleaning notification signal for cleaning the flame detection rod may be emitted to the user. The cleaning notification signal may consist only of a visual signal or an auditory signal, or it may be a combination of a visual signal and an auditory signal. For example, the notification unit (30) may be a display unit that emits a visual signal or a speaker that emits an auditory signal. Additionally, the notification unit (30) may include both a display unit and a speaker. Furthermore, the notification unit (30) may be composed of various known notification means.

[0049] Additionally, the next cleaning cycle of the flame detection rod (10) may be displayed through the notification unit (30). That is, the next cleaning cycle may be displayed differently depending on the level of film formation on the surface of the flame detection rod (10) currently. For example, if the cleaning necessity judgment step in the voltage data comparison unit (25) is determined to be in a preliminary emergency state, the notification unit (30) may display the scheduled cleaning time according to the level of film formation.

[0050]

[0051] FIG. 2 is a process diagram showing the process of operation carried out by a flame detection method according to an embodiment of the present invention, and FIG. 3 are graphs comparing the change in voltage data over time in the case where the flame is normally detected and in the process of the film being applied.

[0052] When the boiler starts operating, voltage is generated in the flame detection circuit and a flame is generated in the burner. When a flame is generated, an electric current flows through the flame on the flame detection rod (10) and the surface of the burner.

[0053] The current flowing through the flame detection rod (10) and the burner surface is detected in real time by a current sensor constituting the current detection unit (21), and the current value detected by the current detection unit (21) can be converted into a voltage value in real time after being transmitted to the current voltage conversion unit (22).

[0054] In the actual voltage data section (23), the voltage value can be quantitatively obtained including the time taken from the start of combustion to the current current measurement point. That is, the voltage value according to the time taken can be quantitatively obtained as shown in the graph of FIG. 3.

[0055] FIG. 3(a) shows the time required to detect a flame normally after combustion starts and the appropriate voltage value when no film is formed on the surface of the flame detection rod (10). The time required to detect a flame normally after combustion starts is t1, and the maximum voltage value when the flame is detected normally is v1. When the flame is detected normally, the voltage value remains at v1. As shown in FIG. 3(a), the fluctuations in voltage values ​​and the time required when no film is formed on the surface of the flame detection rod (10) can be classified as reference voltage data and stored in the reference voltage data section (24).

[0056] If there is a difference between the real-time data obtained from the actual voltage data section (23) and the reference data stored in the reference voltage data section (24), it can be determined that a film has been formed on the surface of the flame detection rod (10).

[0057] If, as shown in Fig. 3(b), the voltage value measured after combustion reaches a reference voltage value that normally detects the flame and remains constant, but the time (t2) taken to reach the reference voltage value is longer than the reference time (t1), it can be determined that a film is being formed on the surface of the flame detection rod (10) (film progression state). If normal detection of the flame is possible but it is determined that a film is being formed, the level of film formation can be determined based on the time taken to reach the reference voltage. The longer the time taken to reach the reference voltage, the more the film formation is determined to have progressed. The film progression state can be subdivided into multiple stages depending on the level of film formation.

[0058] As shown in (c) of Fig. 3, if the voltage value measured after combustion does not reach the reference voltage value for normally detecting the flame, or if it takes a long time to reach it, it can be determined that the flame detection rod (10) is in a dangerous state where it cannot normally detect the flame (dangerous state). In this case, it can be determined that cleaning of the flame detection rod (10) is required immediately.

[0059] If the current flame detection status is determined to be a film progression state or a film danger state, the notification unit (30) can provide notification information to the consumer in the form of a visual or auditory notification method, or a combination of visual and auditory notification methods.

[0060] In the film progression state, the consumer may be informed of the scheduled cleaning cycle of the flame detection rod (10). The scheduled cleaning cycle may vary depending on the level of film formation on the surface of the flame detection rod (10). In the film danger state, the consumer may be provided with information that the flame detection rod (10) must be cleaned immediately.

[0061] Consumers who receive notification information through the notification unit (30) can clean the flame detection rod (10) through the service center or clean the flame detection rod (10) directly according to the manual.

[0062] After the film formed on the surface of the flame detection rod (10) is completely removed through cleaning the flame detection rod (10), the notification unit (30) is reset. When the notification unit (30) is reset, the next scheduled cleaning time of the flame detection rod (10) may be displayed on the notification unit (30) or a separate display unit. The next scheduled cleaning time of the flame detection rod (10) can be determined through previously acquired data, that is, time data up to the point in time when cleaning was performed with the film completely removed.

[0063]

[0064] Figure 4 is a flowchart showing an example of a process indicating whether cleaning is necessary in stages when a flame is normally detected and during the process of forming a film, and Figure 5 is a comparison table showing an example of comparing the relationship between voltage, resistance, and time when a flame is normally detected and during the process of forming a film.

[0065] As shown in Fig. 5, in the absence of an oxide film, the insulation resistance remains constant, and the time required to reach the maximum voltage, i.e., the reference voltage, can be within 1 second. At this time, flame detection is performed normally.

[0066] If an oxide film is present, the insulation structure of the flame detection rod (10) is altered due to the film. That is, the insulation resistance to reach the maximum voltage, i.e., the reference voltage, increases, and the time required to reach the reference voltage also increases. If the time to reach the reference voltage is within 7 seconds, flame detection can be performed normally. If the time to reach the reference voltage is approximately 15 seconds, flame detection cannot be performed normally. For example, flame detection may occur only once out of 10 attempts.

[0067] In this way, the time required to reach the reference voltage may vary depending on the level of film formation on the surface of the flame detection rod (10). Accordingly, the reference voltage data stored in the reference voltage data section (24) and the actual voltage data can be compared to the notification signal through the notification section (30) as shown in FIG. 4.

[0068] For example, if the time taken for the flame voltage to reach the reference voltage after combustion is within 5 seconds, it is determined to be a normal state where normal flame detection is performed; if the time is between 5 and 15 seconds, it is determined to be a state requiring cleaning; and if the time exceeds 15 seconds, it is determined to be a dangerous state where the boiler operation must be stopped immediately and the flame detection rod (10) must be cleaned, and a warning can be issued. That is, if the time taken for the flame voltage to reach the reference voltage after combustion starts exceeds 5 seconds, an initial cleaning notification is generated, and the time at this time can be recorded.

[0069] After the notification for cleaning the flame detection rod, cleaning of the flame detection rod (10) is performed, and when cleaning is completed, the notification of the notification unit (30) is reset. The notification reset of the notification unit (30) may be manually set by the worker performing the cleaning, or it may be automatically reset when the flame voltage reaches the reference voltage within a reference time when the boiler is restarted after cleaning is completed.

[0070]

[0071] As described above, a flame detection system, a detection method, and a boiler according to a preferred embodiment of the present invention have been described in detail with reference to the attached drawings; however, the present invention is not limited to the above-described embodiment and can be implemented with various modifications within the scope of the claims.

[0072] [Explanation of the symbol]

[0073] 10 : Flame detection rod 20 : Control unit

[0074] 21: Current sensing unit 22: Current-voltage converter

[0075] 23: Actual voltage data section 24: Reference voltage data section

[0076] 25: Voltage data comparison unit 30: Notification unit

Claims

1. A current-voltage converter that converts a flame current value into a voltage value; Actual voltage data section for securing actual voltage data during combustion; A reference voltage data unit for securing reference voltage data in a state where no film is formed on the flame detection rod; and A flame detection system comprising: a voltage data comparison unit that determines the level of film formation of a flame detection rod by comparing reference voltage data and actual voltage data.

2. In Paragraph 1, A flame detection system in which the voltage data comparison unit determines whether cleaning of the flame detection rod is necessary based on the level of film formation determined above.

3. In Paragraph 2, A flame detection system further comprising a notification unit that emits a cleaning notification signal when the voltage data comparison unit determines that cleaning of the flame detection rod is required.

4. In Paragraph 3, A flame detection system in which the notification signal in the above notification unit is a visual or auditory signal, or a combined form of a visual signal and an auditory signal.

5. In Paragraph 1, The above actual voltage data includes a current voltage value obtained by converting a flame current value into a voltage value in real time, and a flame detection system including the time taken to reach the current voltage after the start of combustion.

6. In Paragraph 5, A flame detection system comprising reference voltage data, a reference voltage which is the voltage at the point in time when a flame is normally detected after the start of combustion in a state where no film is formed on the surface of the flame detection rod, and a reference time which is the time required to reach the reference voltage from the start of combustion.

7. A step of converting flame current values ​​into voltage values ​​and obtaining actual voltage data during combustion; and A flame detection method comprising the step of determining the level of film formation on a flame detection rod by comparing reference voltage data and actual voltage data when no film is formed on the surface of the flame detection rod.

8. In Paragraph 7, A step of determining whether cleaning of the flame detection rod is necessary based on the level of film formation on the flame detection rod; and A flame detection method further comprising the step of emitting a notification signal through a notification unit when it is determined that cleaning is required.

9. In Paragraph 7, A flame detection method that compares reference voltage data and actual voltage data, determines whether the actual voltage has reached the reference voltage after the start of combustion, and if the actual voltage has reached the reference voltage, compares the time taken to reach the reference voltage.

10. In Paragraph 8, A flame detection method comprising an additional step of cleaning a flame detection rod by removing the coating of the flame detection rod after a notification signal is generated.

11. In Paragraph 10, A flame detection method comprising the additional step of resetting the notification unit after cleaning the flame detection rod.

12. In Paragraph 11, A flame detection method further comprising the step of displaying the next scheduled cleaning time of the flame detection rod through the notification unit or another display unit after resetting the notification unit.

13. In Paragraph 8, A flame detection method that determines that cleaning of the flame detection rod is unnecessary if, after combustion begins, the actual voltage reaches a reference voltage and the time required to reach the reference voltage is within a reference time, and determines that cleaning of the flame detection rod is necessary if the actual voltage does not reach the reference voltage or if, even if it reaches the reference voltage, the time required exceeds the reference time.

14. In Paragraph 13, A flame detection method that classifies the degree of necessity for cleaning a flame detection rod into multiple stages based on whether the actual voltage has reached a reference voltage and the time required to reach the reference voltage, when it is determined that cleaning of the flame detection rod is necessary.

15. A boiler comprising a flame detection system according to any one of claims 1 to 6.

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