Boiler Oxygen Sensor Feedback Control for Lower-Cost Combustion Tuning
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Solution Overview
Problem
Existing water heating systems are inefficient and unable to effectively and cost-efficiently monitor the amount of oxygen in products of combustion, relying on expensive NDIR sensors.
Innovation Solution
A water heating system with a combustion chamber, burner, oxygen sensor, and control unit that detects oxygen levels in combustion products and adjusts combustion parameters to optimize oxygen levels, using a more affordable oxygen sensor and feedback control system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If NDIR sensors are used to monitor oxygen levels in combustion products, then measurement precision is improved, but device cost increases significantly
Solution Approach 1:
The patent replaces expensive NDIR sensors with a more affordable oxygen sensor that may have shorter lifespan or lower precision but achieves sufficient performance for the application. This substitution directly addresses the cost issue while maintaining adequate oxygen monitoring capability for combustion optimization.
Solution Approach 2:
The invention changes the measurement parameter or sensor type from NDIR (infrared-based) to an alternative oxygen sensing mechanism. This parameter change allows the system to achieve acceptable oxygen level monitoring at a lower cost, resolving the contradiction between measurement precision and device cost.
2Use of energy by moving object
If oxygen levels in combustion products are monitored and controlled, then energy efficiency is improved, but device complexity increases
Solution Approach 1:
The patent implements a feedback control system where oxygen sensor readings are continuously monitored and used to adjust combustion parameters. This feedback mechanism optimizes energy efficiency by ensuring complete combustion while preventing excessive oxygen consumption, and the control logic is designed to manage system complexity through automated adjustments.
Solution Approach 2:
The system uses the oxygen sensor data to automatically self-adjust combustion parameters without requiring external intervention. The control unit processes sensor information and modifies burner operation autonomously, improving energy efficiency while keeping the control architecture relatively simple through self-regulating mechanisms.
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
The system efficiently monitors and controls oxygen levels in combustion products, optimizing water heating performance while reducing costs compared to traditional systems.
Implementation Method 1
An oxygen sensor is coupled to the combustion chamber and positioned within the combustion chamber to detect an amount of oxygen remaining in the products of combustion
Implementation Method 2
A heat exchanger system is coupled to the combustion chamber to heat water in the heat exchanger with the products of combustion
Implementation Method 3
The burner causes combustion of gas to create products of combustion
Data Source
AI summary
Water heating system and method including a boiler, a combustion chamber, and a burner housed inside the chamber. A conduit fluidly coupled to the combustion chamber to channel gas into the chamber wherein the burner causes combustion of gas. An oxygen sensor is coupled to the chamber and positioned within the chamber to detect an amount of oxygen in the products of combustion. The oxygen sensor outputs data representative of the amount to a control unit. The control unit controls the feedback control of the water heating system and wherein the combustion of the gas in the chamber is controllable by the control unit at least based on the data. A heat exchanger system is coupled to the chamber to heat water in the heat exchanger with the products. At least one flue coupled to the heat exchanger system to channel products out of the heat exchanger system.