Burner Combustion Control via Microprocessor Sensor Monitoring
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Solution Overview
Problem
Conventional methods for controlling combustion quality in atmospheric boilers with closed chambers, such as C-type boilers, face issues with condensate formation in Venturi apparatus, generation of false signals due to air pressure switches independent of gas flow rates, and insufficient responsiveness to system changes, leading to inefficient control of combustive air flow.
Innovation Solution
A control device with a microprocessor-based system that monitors ionization current, supply voltage, and current absorbed by the fan, using sensors and comparators to adjust the electric valve and fan speed, ensuring reliable combustion control independent of gas flow rates and boiler conditions, and eliminating the need for air pressure switches and mechanical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an air pressure switch is used to control combustive air flow rate, then the control function is achieved, but false signals are generated that are independent of gas flow rate
Solution Approach 1:
The patent replaces the mechanical air pressure switch system with an electronic control system that uses a microprocessor to read sensors and generate control signals. This substitution eliminates the false signals problem because the new system directly measures relevant parameters (ionization current, fan current, voltage) and processes them logically to determine actual combustion conditions, rather than relying on indirect pressure measurements that can be misleading.
Solution Approach 2:
The patent implements multiple feedback loops where sensors continuously monitor combustion parameters (ionization current, fan current, supply voltage) and feed this information back to the microprocessor. The microprocessor adjusts the control signals to the electric valve and fan based on this feedback, ensuring the control system responds to actual combustion conditions rather than generating false signals independent of real gas flow rates.
2Speed
If conventional combustion control systems are used, then basic control function is provided, but responsiveness to system changes is insufficient
Solution Approach 1:
The patent implements continuous monitoring of multiple parameters (ionization current, fan current, supply voltage) with feedback to the microprocessor that can immediately detect and respond to system changes. This rapid feedback mechanism enables the system to respond quickly to combustion conditions while maintaining reliability through comprehensive parameter monitoring and logical processing of all inputs before generating control signals.
Solution Approach 2:
The replacement of mechanical pressure switches with an electronic microprocessor-based system enables much faster response times. The electronic system can read sensor inputs and update control signals within milliseconds, compared to the slower mechanical response of conventional pressure switches, thereby improving both responsiveness and reliability simultaneously.
3Ease of manufacture
If air pressure switches and mechanical components are used, then combustion control is achieved, but device complexity and maintenance requirements increase
Solution Approach 1:
The patent systematically replaces mechanical components (air pressure switches, Venturi tubes, mechanical linkages) with electronic sensors and a microprocessor-based control system. This substitution reduces the number of mechanical parts that require assembly and maintenance, simplifying the overall system while achieving the same combustion control function through electronic means.
Solution Approach 2:
The microprocessor-based control system serves multiple functions: it reads multiple sensor inputs (ionization current, fan current, voltage), processes this information logically, and generates control signals for both the electric valve and fan. This multi-functional electronic controller replaces what would otherwise require multiple separate mechanical components, reducing device complexity and easing manufacture.
4Reliability
If Venturi apparatus is used for fan connection, then pneumatic control is achieved, but condensate formation compromises functioning
Solution Approach 1:
The patent replaces the pneumatic Venturi apparatus with an electronic control system that uses electrical sensors and a microprocessor. This substitution eliminates the condensate formation problem entirely because the new system uses electrical signals rather than pneumatic pathways where moisture can accumulate and compromise function.
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 solution provides reliable and responsive combustion control, reducing false signals and condensate-related issues, ensuring efficient air flow management and compliance with combustion quality standards, while simplifying maintenance and calibration based on real-time operating conditions.
Implementation Method 1
a sensor means, preferably a flame ionization sensor (12), suitably arranged in the combustion chamber (CC) of the burner (BR) so as to be immersed in the flame (Fl) after the lighting of the burner (BR) itself; it is thus able to detect the actual value of the ionization current of the flame (Fl) in the combustion chamber (CC)
Data Source
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AI summary
The present invention relates to a method of controlling a burner provided with combustion chamber, combustive air supply means driven by a motor, at least one combustible fluid supply duct interceptable by a respective electric valve means, and at least one exhaust duct for the combustion gases, characterized in that it comprises the following steps: - predetermining a minimum value and a maximum value for the current absorbed by the motor of said supply means; - establishing, for a plurality of flow rate values of combustible fluid supplied to the burner, the minimum supply voltage of the motor of the supply means for ensuring a combustive air flow rate suitable for ensuring correct combustion; - supplying combustible fluid to said burner at a predetermined flow rate; - detecting the supply voltage of said supply means and the current absorbed by the motor of said supply means; - checking that, for the supplied combustible fluid flow rate, the supply voltage is greater than a predetermined threshold value and that the value of the current absorbed does not diverge from a predetermined threshold value, and - generating an output control signal when at least one of the values of voltage and current does not comply with the respective thresholds.