Atomization Burner Control for Flexible Fire Rate and Excess Air
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Solution Overview
Problem
Existing fuel burners, such as the AIRTRONIC, lack flexibility in adjusting fuel flow rates, produce excessive heat, are power-hungry, and struggle with controlling temperature and excess air levels, leading to inefficiency and safety issues, particularly when using biodiesel.
Innovation Solution
A burner system with independently controlled DC motors for fuel, atomizing air, and combustion air, equipped with a controller to regulate these flows based on feedback from a gas sensor, allowing for precise adjustment of excess air and heat output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a fixed speed AC motor drives the fuel pump, atomizing air compressor, and combustion air blower, then the burner structure is simple, but the flexibility in adjusting fuel flow rates is limited
Solution Approach 1:
The patent segments the control system by replacing the single fixed-speed AC motor with three independently controlled DC motors, each driving a specific component (fuel pump, atomizing air compressor, combustion air blower). This segmentation enables independent adjustment of each flow rate, resolving the contradiction between structural simplicity and adjustment flexibility.
Solution Approach 2:
The patent transitions from a static fixed-speed motor system to a dynamic system with independently controllable DC motors. Each motor can be adjusted to different speeds based on operational requirements, enabling real-time flexibility in fuel flow rate adjustment while maintaining relatively simple burner structure.
2Power
If the AC motor operates at fixed maximum speed, then the burner produces high heat output, but it consumes excessive power and cannot be adjusted for lower heat requirements
Solution Approach 1:
The patent replaces the fixed-speed AC motor with variable-speed DC motors that can operate at different power levels. This dynamic control allows the burner to produce high heat output when needed while consuming less power during lower heat requirements, resolving the contradiction between power output and energy consumption.
Solution Approach 2:
The patent changes the operational parameters by using DC motors with adjustable speed and voltage control. This enables the burner to vary its heat output and power consumption according to actual needs, rather than operating at fixed maximum levels, thus resolving the contradiction between high heat output and excessive power consumption.
3Device complexity
If the atomizing air flow is not adjustable, then the burner structure is simple, but the combustion efficiency deteriorates when fuel flow rates vary
Solution Approach 1:
The patent segments the air control system by providing independent control of atomizing air flow through a dedicated DC motor-driven compressor. This segmentation allows the atomizing air flow to be adjusted independently based on fuel flow rate requirements, maintaining combustion efficiency without significantly increasing system complexity.
Solution Approach 2:
The patent implements feedback control where the atomizing air flow is adjusted in response to fuel flow rate changes. This feedback mechanism ensures that the atomizing air flow remains optimized for combustion efficiency across varying operating conditions, resolving the contradiction between structural simplicity and combustion reliability.
4Device complexity
If manual adjustment mechanisms are used for fuel flow restriction, then the device complexity is low, but the precision of fuel flow control is insufficient
Solution Approach 1:
The patent replaces manual mechanical adjustment mechanisms with electronically controlled DC motors that drive the fuel pump. This substitution provides precise electronic control of fuel flow rates through variable voltage and pulse width modulation, achieving high measurement precision while keeping the overall device complexity relatively low.
Solution Approach 2:
The patent changes from mechanical adjustment to electrical parameter control. By using DC motors with adjustable voltage and current parameters, the system achieves precise fuel flow control without complex mechanical mechanisms, resolving the contradiction between device complexity and control precision.
5Device complexity
If the burner operates without independent control of combustion air, then the structure is simple, but excess air levels cannot be optimized leading to heat loss
Solution Approach 1:
The patent segments the combustion air control by providing independent DC motor-driven blower control. This segmentation allows precise adjustment of combustion air flow to match fuel flow rates, optimizing excess air levels and minimizing heat loss without significantly increasing system complexity.
Solution Approach 2:
The patent implements electrical parameter control for combustion air flow through variable-speed DC motor control. This enables precise adjustment of air flow parameters to optimize combustion efficiency and minimize excess air-related heat loss, resolving the contradiction between structural simplicity and energy loss reduction.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables flexible heat control, reduces power consumption, minimizes excess air, and enhances safety by maintaining optimal combustion conditions, even in varying fuel types and environments.
Implementation Method 1
Pressurized clean air is forced through the hole, creating a spray so fine that when burned, it creates no smoke, odor or carbon monoxide
Implementation Method 2
Combustion air blower 1108 delivers a flow of air to the flame tube 1116 that combusts with the fuel to provide flame and heat
Implementation Method 3
The burner includes a fuel pump, an atomizing air pump, and a combustion air blower, each with its own independently controlled DC motor
Data Source
AI summary
A burner includes an atomizing chamber, a flame tube in front of the atomizing chamber adapted to direct combusting fuel introduced by the atomizing chamber along an interior of the flame tube, and a controller. The controller is programmed to independently control rate of fuel flow to the atomizing chamber, rate of atomizing air flow to the atomizing chamber, and rate of combustion air to the flame tub. The controller is also programmed to perform operations including regulating, based on output of a gas sensor, at least the rate of combustion air to the flame tube to substantially maintain a first predetermined amount of excess air in the flame tube.