Gas Burner Control Calibration via Stoichiometric Reference
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Solution Overview
Problem
Existing gas burner control calibration methods depend on burner load, requiring separate calibrations for each load setting, which is inefficient.
Innovation Solution
A method that enriches and then leans the gas/combustion air mixture based on a sensor's measurement signal, starting from a stoichiometric combustion air ratio, allowing for independent calibration regardless of burner load, using a carbon monoxide sensor to adjust the gas flow and maintain a desired combustion air ratio.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If calibration is performed for each burner load setting, then combustion quality is optimized for each load, but calibration time and operational complexity increase significantly
Solution Approach 1:
The patent changes the calibration approach from load-specific to load-independent by using a standardized enrichment procedure that identifies the stoichiometric air ratio (λ=1) as a reference point. This reference point remains valid across all burner loads, eliminating the need for separate calibrations at each load setting while maintaining combustion quality.
Solution Approach 2:
The calibration method becomes universal and applicable to all burner load settings through the use of a single stoichiometric reference point (λ=1). The procedure enriches the gas/air mixture from a lean state until the sensor signal reaches its maximum, identifying λ=1 regardless of the burner load, which then serves as the basis for all subsequent load operations.
2Reliability
If multiple calibrations are performed for different burner loads, then combustion performance is optimized across all loads, but device complexity and calibration procedure complexity increase
Solution Approach 1:
The patent simplifies the calibration procedure by changing from multiple load-specific calibrations to a single load-independent calibration. The key parameter change is using the maximum sensor signal point (stoichiometric λ=1) as a universal reference that works for all burner loads, reducing procedural complexity while maintaining performance.
3Measurement precision
If the gas/combustion air mixture is enriched until carbon monoxide concentration reaches a limit value, then calibration is achieved, but combustion air ratio accuracy is limited and additional leaning is required
Solution Approach 1:
The patent converts the harmful effect of carbon monoxide formation (which occurs during enrichment) into a beneficial calibration signal. The maximum carbon monoxide concentration point directly indicates the stoichiometric air ratio (λ=1), providing a precise reference point for calibration without requiring additional leaning steps.
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 consistent combustion quality across varying gas qualities and burner loads by automatically calibrating the gas burner control, ensuring a stable gas/air mixture composition without the need for multiple calibrations.
Implementation Method 1
a carbon monoxide sensor which is assigned to an exhaust gas flow discharged from the gas burner and which detects a carbon monoxide concentration in the exhaust gas when oxygen is present in the exhaust gas
Implementation Method 2
a gas burner (10) supplied with a gas/combustion air mixture (12) for combustion
Data Source
Figure 1
Figure 2
AI summary
The method involves measuring the concentration of a combustible or oxidizing component in the exhaust gas by using a sensor. The gas-combustion air-mixture is enriched for calibration based on a relative poor gas-combustion air-mixture, which is led to the gas burner for combustion. The gas-combustion air-mixture is enriched until measuring signal by the sensor rises and falls to approximately zero.