Gas Boiler Pressure Sensor Self-Diagnosis During Pre-Purge
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing gas boilers lack the ability to monitor and control additional parameters beyond pressure difference, leading to complex and expensive fault detection systems.
Innovation Solution
A method utilizing a differential pressure sensor to measure the pressure difference between a measuring point upstream of the main flow restrictor and a reference point, combined with an evaluation unit to detect faults during a pre-purge phase and subsequent operating phases, allowing for cost-effective error detection and calibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional sensors and evaluation devices are added to monitor more parameters in gas boilers, then fault detection capability is improved, but device complexity and cost increase
Solution Approach 1:
The existing differential pressure sensor is made multi-functional by utilizing it for both its original pressure difference measurement function and a new fault detection function. The evaluation unit processes the pressure difference signal to detect sensor failures, disconnections, and calibration issues, allowing one sensor to serve multiple purposes without adding additional sensors.
Solution Approach 2:
The system performs self-diagnosis using its own existing sensor and evaluation unit. The evaluation unit continuously monitors the pressure difference signal and automatically detects faults such as sensor failures, disconnections, or calibration drifts, enabling the system to monitor itself without external diagnostic equipment.
2Reliability
If additional sensors and evaluation devices are added to monitor more parameters in gas boilers, then fault detection capability is improved, but cost increases
Solution Approach 1:
The existing differential pressure sensor is made multi-functional by utilizing it for both its original pressure difference measurement function and a new fault detection function. The evaluation unit processes the pressure difference signal to detect sensor failures, disconnections, and calibration issues, allowing one sensor to serve multiple purposes without adding additional sensors.
Solution Approach 2:
The system performs self-diagnosis using its own existing sensor and evaluation unit. The evaluation unit continuously monitors the pressure difference signal and automatically detects faults such as sensor failures, disconnections, or calibration drifts, enabling the system to monitor itself without external diagnostic equipment.
3Device complexity
If only pressure difference control is implemented in gas boilers, then device simplicity is maintained, but additional parameters cannot be monitored or controlled
Solution Approach 1:
The existing differential pressure sensor is made multi-functional by utilizing it for both its original pressure difference measurement function and a new fault detection function. The evaluation unit processes the pressure difference signal to detect sensor failures, disconnections, and calibration issues, allowing one sensor to serve multiple purposes without adding additional sensors.
Solution Approach 2:
The system performs self-diagnosis using its own existing sensor and evaluation unit. The evaluation unit continuously monitors the pressure difference signal and automatically detects faults such as sensor failures, disconnections, or calibration drifts, enabling the system to monitor itself without external diagnostic equipment.
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 simple and cost-effective fault detection and calibration of gas boilers by identifying issues such as missing sensors or poor connections, extending the service life and improving operational reliability.
Implementation Method 1
a differential pressure sensor to measure the pressure difference between a measuring point upstream of the main flow restrictor and a reference point
Data Source
Figure 1
AI summary
The invention relates to a method for evaluating a quasi-stationary pressure difference detectable by a sensor at a gas boiler, wherein the sensor is a differential pressure sensor or a mass flow sensor, wherein the gas boiler has a mixing device (4) for mixing fuel flowing from a fuel inlet (G) and air flowing from an air inlet (L) to form a fuel-air mixture, a blower (5) for drawing the fuel and air through the mixing device (4), a main flow restrictor (3) for limiting a mass flow of fuel into the mixing device (4), a control valve (2) arranged upstream of the main flow restrictor (3) for controlling a mass flow of fuel into the mixing device (4), and a safety valve (1) arranged upstream of the control valve (2) for interrupting the mass flow of fuel.wherein the sensor detects a differential pressure between a pressure (p2) at a measuring point upstream of the main flow throttle (3) and downstream of the control valve (2) and a reference pressure (p0, p1) at a reference measuring point and transmits it to an evaluation electronics unit, wherein the evaluation electronics unit compares the differential pressure during a pre-rinse phase in which the safety valve (1) is closed with the differential pressure after the pre-rinse phase and detects a fault by the comparison.