Oil Burner Ignitor Control for Electrode Life Extension
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Solution Overview
Problem
Oil-fired burner ignitors in intermittent mode operate for extended periods, leading to reduced operational life and inefficient energy use due to constant high-temperature operation.
Innovation Solution
Implement a control method that initially operates the burner in interrupted ignition mode during heat calls and switches to intermittent ignition mode if flame quality is insufficient, reverting back to interrupted mode after a predetermined number of cycles or upon specific conditions like power loss or lost flame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the ignitor operates in intermittent mode (on when fan motor is on), then the burner can maintain continuous ignition capability, but the ignitor operates for extended periods at maximum temperature which shortens its operational life
Solution Approach 1:
The patent applies dynamics by making the ignition mode adjustable and adaptable rather than fixed. The control system dynamically switches between interrupted and intermittent ignition modes based on real-time flame quality monitoring and operational conditions, optimizing the balance between ignition reliability and ignitor lifespan
Solution Approach 2:
The patent changes the operational parameters of the ignitor by introducing multiple ignition modes (interrupted vs. intermittent) with different duty cycles and timing characteristics. The system can modify the ignitor's on-time, off-time, and activation frequency based on flame quality assessments and operational history
2Reliability
If the ignitor operates in intermittent mode for extended periods, then continuous ignition is maintained, but energy consumption increases due to unnecessary high-temperature operation
Solution Approach 1:
The patent implements feedback control by continuously monitoring flame quality parameters (flame presence, stability, and characteristics) and using this information to adjust ignition mode and duration. The system only maintains intermittent ignition when flame quality is insufficient, and switches to interrupted mode when flame quality is adequate, thereby reducing unnecessary energy consumption
Solution Approach 2:
The patent uses periodic action by implementing interrupted ignition mode where the ignitor operates in periodic pulses rather than continuously. The ignition spark is delivered at regular intervals during the fan motor operation, providing sufficient ignition capability while allowing the ignitor to cool down and conserve energy between pulses
3Stability of the object's composition
If the system switches to intermittent ignition mode to address insufficient flame quality, then flame stability improves, but the ignitor experiences increased thermal stress and reduced lifespan
Solution Approach 1:
The patent applies dynamics by implementing adaptive ignition mode selection that responds to real-time flame quality conditions. The system dynamically transitions between interrupted and intermittent modes based on whether flame quality thresholds are met, ensuring intermittent mode is only used when necessary for flame stabilization
Solution Approach 2:
The patent uses feedback control where flame quality parameters (detected during flame proven state) are continuously monitored and fed back to the control system. This feedback determines whether to maintain intermittent mode for flame stabilization or switch to interrupted mode to protect the ignitor, creating a self-regulating system that balances flame stability with ignitor protection
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
Extends the operational life of ignitor electrodes and promotes energy efficiency by optimizing ignition mode based on flame quality assessments, reducing unnecessary high-temperature operation.
Implementation Method 1
High pressure oil burners depend on a high voltage electric spark to supply the heat required to start the combustion process. As the air-oil mixture leaves the burner, the spark vaporizes and ignites a very small portion of the mixture.
Implementation Method 2
The DC voltage then turns power transistors on and off very quickly, sending current through the primary coil of a small internal transformer at a frequency of 15,000 to 30,000 Hz. A secondary coil of the special high frequency transformer produces the high voltage ignitor output that also has a frequency in the range of 15,000 to 30,000 Hz.
Implementation Method 3
The high frequency allows the voltage to peak at the output voltage of 14,000 volts. This high voltage current supplies an intense, active spark at the electrode tips.
Implementation Method 4
This initial flame is hot enough to ignite the rest of the mixture.
Data Source
AI summary
A controller for an oil fired burner for operating the ignitor initially in an interrupted mode, and instructing the burner to switch to intermittent ignition for a plurality of call-for-heat (“CFH”) cycles if it is determined that the flame quality is insufficient during the flame-proved period. On the last predetermined iteration cycle, a reset condition occurs; setting a counter back to zero, and a retry ignition is performed to operate once again in interrupted ignition mode. When the apparatus is in interrupted ignition mode, if the current CFH cycle ends normally by satisfying the call, the ignition will remain in the interrupted ignition mode.