Atomization Burner Flow Control for Flexible Fire Rate
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Solution Overview
Problem
Existing atomization burners, such as the AIRTRONIC, face challenges with inflexible fuel flow rates, excessive heat output, inefficient power consumption, and difficulties in controlling temperature and excess air levels, particularly when using diesel or biodiesel fuels, which can lead to inefficient operation and safety issues.
Innovation Solution
A burner system with a controller that independently adjusts the rates of fuel flow, atomizing air flow, and combustion air flow, using DC motors and a gas sensor to maintain optimal excess air levels and adjust heat output, incorporating features like adjustable speed motors and an air gap to prevent oxidized hydrocarbon accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed speed AC motor is used to drive the fuel pump, atomizing air compressor, and combustion air blower, then the burner structure is simple, but the fuel flow rate is inflexible and heat output cannot be adjusted
Solution Approach 1:
The patent replaces fixed speed AC motors with variable speed DC motors that can be dynamically controlled through pulse width modulation (PWM). This allows the fuel pump, atomizing air compressor, and combustion air blower to operate at different speeds, enabling flexible adjustment of fuel flow rate and heat output while maintaining a relatively simple control structure through microcontroller-based PWM signaling.
2Adaptability or versatility
If the atomizing air flow is not adjustable, then the device structure is simple, but the fuel flow rate range is limited and combustion efficiency decreases
Solution Approach 1:
The patent makes the atomizing air compressor variable speed through DC motor control with PWM adjustment. This dynamic control allows the atomizing air flow rate to be adjusted independently to match different fuel flow rates, expanding the operational range and maintaining combustion efficiency across varying load conditions without adding complex mechanical flow control mechanisms.
3Measurement precision
If manual adjustment of combustion air flow is used, then the control mechanism is simple, but temperature control precision and excess air level optimization are difficult
Solution Approach 1:
The patent incorporates an oxygen sensor that measures the excess air level in the combustion process and feeds this information back to the microcontroller. The microcontroller then automatically adjusts the combustion air blower speed via PWM control to maintain optimal excess air levels, replacing manual adjustment with automated feedback control for precise temperature and combustion optimization.
4Use of energy by moving object
If a single AC motor drives all components at fixed maximum speed, then the power system is simple, but power consumption is excessive and operational flexibility is lost
Solution Approach 1:
The patent replaces the single fixed speed AC motor system with variable speed DC motors controlled through PWM technology. This allows each motor (fuel pump, atomizing air compressor, combustion air blower) to operate at the minimum necessary speed for the current load, significantly reducing power consumption while maintaining operational flexibility. The microcontroller coordinates all three motors to work efficiently together at varying speeds.
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 achieves more efficient and flexible heat output, reduced power consumption, improved temperature control, and safer operation by maintaining optimal excess air levels, enhancing the burner's performance with diesel and biodiesel fuels.
Implementation Method 1
Pressurized clean air is forced through the hole, creating a spray so fine that when burned, it creates no smoke, odor or carbon monoxide
Implementation Method 2
Combustion air blower 1108 delivers a flow of air to the flame tube 1116 that combusts with the fuel to provide flame and heat
Data Source
AI summary
A burner includes an atomizing chamber, a flame tube in front of the atomizing chamber adapted to direct combusting fuel introduced by the atomizing chamber along an interior of the flame tube, and a controller. The controller is programmed to independently control rate of fuel flow to the atomizing chamber, rate of atomizing air flow to the atomizing chamber, and rate of combustion air to the flame tub. The controller is also programmed to perform operations including regulating, based on output of a gas sensor, at least the rate of combustion air to the flame tube to substantially maintain a first predetermined amount of excess air in the flame tube.