Burner Air-Fuel Ratio Modulation via Common Drive
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Solution Overview
Problem
Conventional blown air burners powered by liquid fuel face challenges in maintaining a stable air/fuel ratio due to variations in turbine speed, pressure drops, and changing conditions, leading to combustion instability, noise, inefficiency, and fouling, as existing solutions are either bulky, expensive, or limit independent modulation of air and fuel.
Innovation Solution
A burner design where the fuel oil supply pump and turbine share a common drive mechanism, allowing independent modulation of fuel oil pressure and air flow through a variable-speed motor and pressure sensors, ensuring a constant air/fuel ratio and optimizing combustion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a common drive mechanism is used for the pump and turbine, then the device complexity is reduced and electrical consumption is lowered, but the ability to independently modulate air and fuel supply is limited
Solution Approach 1:
The common drive mechanism is segmented into two independent control paths: one for the pump (fuel supply) and one for the turbine (air supply). Each component can be modulated independently through separate control valves and sensors, allowing independent adjustment of fuel and air flow rates while sharing the same motor drive.
Solution Approach 2:
The system implements dynamic modulation capabilities where the pump and turbine can adjust their operating parameters in real-time based on feedback from pressure sensors and flow measurements. This allows the burner to adapt to varying combustion requirements while maintaining the energy efficiency of a common drive.
2Manufacturing precision
If mechanical regulation means such as valves and pressure regulators are used, then the air/fuel ratio can be adjusted, but the device complexity increases and the response time is delayed
Solution Approach 1:
Pressure sensors are installed in the fuel supply line and air supply circuit to provide real-time feedback on the actual pressure and flow conditions. This feedback is used by the control system to automatically adjust the pump and turbine operation, maintaining the optimal air/fuel ratio without requiring complex mechanical regulation means.
Solution Approach 2:
The patent replaces traditional mechanical regulation means (valves, pressure regulators) with an electronic control system that uses sensors and a control unit to modulate the pump and turbine. This substitution reduces mechanical complexity while improving response time and precision of air/fuel ratio control.
3Productivity
If the turbine speed is varied to adjust air flow, then the combustion can be optimized, but the fuel pressure from the pump varies causing combustion instability
Solution Approach 1:
Pressure sensors monitor the fuel pressure in real-time, and when turbine speed varies causing fuel pressure fluctuations, the control system automatically adjusts the pump operation to compensate. This feedback loop maintains stable fuel pressure even when air flow is modulated, ensuring combustion stability.
Solution Approach 2:
The control system anticipates fuel pressure variations that will result from turbine speed changes and pre-adjusts the pump operation accordingly. This preliminary action prevents combustion instability before it occurs by maintaining proper fuel pressure in advance of the turbine speed variation.
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
This solution stabilizes combustion, improves efficiency and hygiene, reduces noise and electrical consumption, extends operating cycles, and reduces mechanical wear, while allowing for flexible installation on existing boilers.
Implementation Method 1
a pump (5) which ensures the pressurized fuel supply
Implementation Method 2
a turbine (7) which ensures the pressurized air supply by drawing in outside or combustion air to inject it into a circuit
Implementation Method 3
These two components are driven by a variable speed motor (6)
Implementation Method 4
at least one pressure sensor (9) placed at the outlet of the pump (5)
Implementation Method 5
The fuel oil supply is controlled by one or more solenoid valves
Data Source
Figure 1
Figure 2
AI summary
The burner has a burner plate (1) connected to a fuel oil supply circuit by a conduit (2) having an electromagnetic valve (4) connected to a pump (5) that supplies pressurized fuel oil, by a speed control motor (6) and a turbine (7). The turbine and the pump define a common drive, and the pump and the motor are associated with modulation units having a measurement device and an electronic unit. The modulation units adjust pressure of the fuel oil independent of the rotational speed of the motor to maintain speed of the pump from a predefined threshold value of the speed of the motor.