Premix Gas Burner Plate Structure Deep Drawing
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Solution Overview
Problem
Existing premix gas burners face challenges in maintaining controlled dimensional tolerances and preventing flashback due to uncontrolled slit sizes in the end caps, which can lead to inconsistent functional operation and potential flame instability.
Innovation Solution
A premix gas burner design featuring a metal mounting plate, a mixing chamber, and a plate structure with a convex shape and elongated section, where the plate structure is created by cutting and folding a metal plate and deep drawing to control the groove and slit sizes, ensuring precise assembly and reducing the risk of flashback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the plate structure is formed by simple cutting and folding without deep drawing, then the manufacturing process is simpler, but the dimensional tolerances of slits and grooves are uncontrolled leading to functional inconsistency
Solution Approach 1:
The manufacturing process is segmented into distinct operations: cutting, folding, and deep drawing. This allows each operation to be optimized independently, with deep drawing specifically applied to create precisely controlled grooves and slits in the end caps, thereby achieving controlled dimensional tolerances without overwhelming complexity
Solution Approach 2:
The plate structure is preliminarily formed by cutting and folding into the convex shape with elongated section and end caps before the final deep drawing operation. This preliminary formation establishes the basic geometry and positions where precise slits are needed, allowing the deep drawing to focus specifically on creating controlled dimensional features where required
2Ease of operation
If the slits in the end caps are larger, then the assembly is easier, but flashback risk increases and flame stability is compromised
Solution Approach 1:
The slit dimensions are precisely controlled through the deep drawing process, which allows for exact parameter specification. The slits are made sufficiently small to prevent flashback while maintaining assembly feasibility through controlled tolerances, resolving the contradiction between assembly ease and flashback prevention
3Productivity
If the burner components are assembled without accounting for thermal expansion, then the assembly process is faster, but the burner lifetime is reduced due to thermal stress
Solution Approach 1:
The plate structure is designed with intentional clearance from the porous burner deck, explicitly accounting for thermal expansion of the burner deck during operation. This clearance prevents thermal stress and deformation that would otherwise reduce burner lifetime, while the assembly process remains efficient through simple positioning without complex fastening mechanisms
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 controlled dimensional tolerances and precise slit sizes enhance the burner's operational consistency and reduce the risk of flashback, leading to improved manufacturing precision and longer burner lifetime, while allowing for thermal expansion without compromising performance.
Implementation Method 1
combustion is stabilized on the porous burner deck after premix gas has flown from the mixing chamber through the porous burner deck
Implementation Method 2
The plate structure is provided in the mixing chamber for flow of premix gas through the perforations of the plate structure before the premix gas flows through the porous burner deck
Data Source
Figure 1~2
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Figure 5~6
AI summary
The premix gas burner comprises a metal mounting plate (102), a mixing chamber (108) and a porous burner deck (110). The porous burner deck encloses the mixing chamber. Combustion is stabilized on the porous burner deck after premix gas has flown from the mixing chamber through the porous burner deck. The burner also comprises a plate structure (106) comprising a plurality of perforations (112). The plate structure is provided in the mixing chamber for flow of premix gas through the perforations of the plate structure before the premix gas flows through the porous burner deck. The circumference of the porous burner deck has the shape of a rectangle of which the two short sides have been rounded. The plate structure has along its length an elongated section (131) and two end caps (133). Each of the end caps is provided at an end of the elongated section. The plate structure is provided via cutting and folding of a metal plate into the convex shape of the plate structure. The elongated section of the plate structure comprises at least one groove (135) created by deep drawing. The at least one groove is provided on the crest line of the plate structure. The at least one groove is convex in the same direction as the plate structure. In each of the two end caps two edges (137) of the metal plate join parallel to the length direction of the elongated section in order to form the end caps.