Burner Flame Sensor Interface Circuit Adaptation

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Solution Overview

Problem

Existing burner control systems preconfigured for photoresistors are not compatible with other types of flame sensors, leading to inefficiencies and waste due to the large volume, difficulty in production, and specific calibration requirements of photoresistors, which are being phased out.

Innovation Solution

A burner system equipped with a phototransistor or photodiode sensor and an interface electric circuit that converts the sensor's signals into voltage and current levels compatible with control systems originally designed for photoresistors, allowing for seamless adaptation without modifying the entire control system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If photoresistor sensors are used in burner control systems, then flame detection function is maintained, but device volume increases and manufacturing complexity worsens

Engineering Contradiction:

Improveflame detection functionVSAvoidsensor volume

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent changes the electrical parameters of the sensor output by using a phototransistor or photodiode with specific electrical characteristics that produce voltage and current levels matching the original photoresistor specifications. This allows direct replacement without modifying the control system's expected input parameters.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates an electrical signal copy of what the original photoresistor would produce, using the phototransistor/photodiode interface circuit to replicate the voltage and current characteristics. This enables the new sensor to function as a direct substitute in existing systems.

Inventive Principle:

Principle #26Copying

2Reliability

If photoresistor sensors are used in burner control systems, then flame detection function is maintained, but manufacturing precision requirements increase

Engineering Contradiction:

Improveflame detection functionVSAvoidsensor calibration precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent selects phototransistors or photodiodes with inherent electrical parameters that naturally match the photoresistor output range, reducing the need for post-manufacturing calibration and precision adjustments.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If photoresistor sensors are used in burner control systems, then flame detection function is maintained, but adaptability to other sensor types decreases

Engineering Contradiction:

Improveflame detection functionVSAvoidsensor type compatibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent makes the burner control system adaptable to multiple sensor types by using an interface circuit that can accommodate different photodetector technologies (phototransistors, photodiodes) while maintaining compatibility with the original photoresistor-based system architecture.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Reliability

If photoresistor sensors are used in burner control systems, then flame detection function is maintained, but device complexity increases

Engineering Contradiction:

Improveflame detection functionVSAvoidcontrol system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts the complexity from the sensor replacement process by using an interface circuit that handles all adaptation requirements, allowing the main control system to remain unchanged and simple.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces an interface electric circuit as an intermediary between the new photodetector sensor and the existing control system. This mediator handles signal conditioning and parameter matching, isolating the complexity from the main control system.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 the use of phototransistor or photodiode sensors in existing burner control systems, improving compatibility and reducing production complexities while maintaining effective flame detection and combustion control.

Implementation Method 1

a sensitive element of a flame comprising a phototransistor or photodiode in use facing the flame in order to receive an electromagnetic wave emitted by the flame and to generate a detecting signal having a voltage and/or a current that is variable as a function of the electromagnetic wave emitted by the flame

Methodology Applied

Scientific EffectPhotoelectric Effect: Photoelectric Effect

Data Source

PatentEP3612768B1Burner comprising a detecting sensor for a flame and method of modification of a burner

Publication Date: 2021.03.10 GIORDANO CONTROLS SPA

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Figure 4~5

AI summary

A burner (100) comprising a sensor (1) for detecting a flame (2) comprising a sensitive element (3) of the flame (2) comprising a phototransistor or photodiode in use facing the flame (2) to receive an electromagnetic wave emitted by the flame (2) and an interface electric circuit (6) connected between the sensitive element (3) and an output (5) of the circuit configured for converting the detecting signal (4) generated by the sensitive element (3) into a flame signal (2) suitable for being received by a control system (103) of the burner (100).