Atmospheric Boiler Control via Flame Ionization and Dynamic Air-Gas Ratio
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Solution Overview
Problem
Low-end boilers face challenges in maintaining non-polluting combustion due to variations in gas pressure, gas quality, and obstructions, which can lead to dangerous and inefficient operation, and require costly mechanical components for draft control and water presence verification.
Innovation Solution
A method and device that utilize a programmable control system with a microprocessor to monitor the flame signal and adjust the combustion air and gas ratio dynamically, eliminating the need for mechanical components by shifting the working point on a predefined curve to ensure clean combustion, and incorporating a circulation test to verify water presence without mechanical switches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical components (pressure switches, single contact switches) are used for draft control and water presence verification, then the boiler can detect abnormal conditions, but the device complexity and cost increase significantly
Solution Approach 1:
The patent replaces mechanical pressure switches and single contact water presence switches with an electronic control system that uses a microprocessor to read analog signals from sensors. The microprocessor evaluates combustion quality parameters and water circulation status electronically, eliminating the need for complex mechanical component assemblies while maintaining reliable detection of abnormal conditions.
Solution Approach 2:
The electronic control system serves multiple functions simultaneously: it monitors combustion quality through flame signal analysis, detects water presence and circulation status, evaluates draft conditions, and controls the burner operation. This multi-functional approach consolidates what would traditionally require separate mechanical components for each function into a single integrated electronic system.
2Reliability
If mechanical components are used for draft control, then the boiler can maintain combustion parameters, but the cost increases considerably
Solution Approach 1:
The patent replaces expensive mechanical pressure switches and adjustment mechanisms with a more cost-effective electronic system. The microprocessor-based controller reads signals from simpler sensors and uses software algorithms to evaluate combustion quality and adjust parameters, reducing component costs while maintaining reliable combustion parameter maintenance.
Solution Approach 2:
The system dynamically adjusts combustion parameters by changing the operational state of the burner and fan based on real-time electronic evaluation of flame signals and draft conditions. The microprocessor modifies gas flow and air supply parameters continuously to maintain optimal combustion, replacing the need for expensive mechanical adjustment mechanisms.
3Reliability
If single contact water presence switches are used, then the boiler can be protected from damage, but the reliability of the safety function decreases due to potential malfunction
Solution Approach 1:
The patent replaces mechanical single contact water presence switches with an electronic detection system that uses a microprocessor to evaluate multiple parameters including water circulation status and temperature. This electronic system provides more reliable safety detection by continuously monitoring water presence and circulation patterns, reducing the risk of malfunction while maintaining protective functionality.
Solution Approach 2:
The electronic control system continuously monitors water circulation conditions and provides feedback to the microprocessor, which adjusts burner operation accordingly. This closed-loop feedback mechanism ensures reliable safety protection by continuously verifying water presence and circulation, preventing damage without requiring complex mechanical switch assemblies.
4Adaptability or versatility
If the boiler operates with variations in gas pressure and gas quality, then the boiler can be more adaptable to different conditions, but combustion quality deteriorates and becomes polluting
Solution Approach 1:
The patent implements a feedback control system where the microprocessor continuously monitors flame signal characteristics and draft conditions. Based on this real-time feedback, the system automatically adjusts gas flow and air supply parameters to maintain optimal combustion quality, preventing polluting combustion even when operating under varying gas pressure and gas quality conditions.
Solution Approach 2:
The system dynamically adjusts combustion parameters in real-time based on operating conditions. The microprocessor modifies gas flow rate, air supply, and burner operation continuously to adapt to variations in gas pressure and quality, maintaining clean combustion across different operating scenarios rather than relying on fixed mechanical settings.
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 self-adaptability to abnormal conditions, improves efficiency, and ensures safe operation with clean combustion, reducing costs by eliminating the need for additional sensors and mechanical components, and allowing the boiler to operate effectively even with obstructions.
Implementation Method 1
a sensor placed in the combustion area and generates a measurement signal representative of the combustion
Data Source
Figure 1
Figure 2~4
Figure 3A~3C
AI summary
A control method of a boiler provided with atmospheric burner comprises a valve for controlling the gas sent to a burner (14), means (10) for detecting the flame present in the latter and control means (13) of functional components of the boiler such as the gas valve (15), a fan, provided with its own electric motor, a circulator o pump, a temperature probe, said control means (13) co-operating with a memory (12) wherein a plurality of optimum operating conditions of the boiler is tabulated functions of features related to the flame, to the thermal power and to the value lambda. The working point of the boiler is determined on one of such curves, the ratio between combustion air and gas is modified starting from a current operating value, in order to shift such working point along such curve, it is verified if such variation of the ratio arrives at a predefined value and in that case a previous air-gas ratio of correct operation is reset, in the opposite case the gas flow rate being modified in order to obtain an optimum combustion ratio. Protection is also claimed for a device for accomplishing such method.