Burner Temperature Control Using Compressor and Flame Sensor Override

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Solution Overview

Problem

Existing methods for controlling the temperature of appliances heated by burners require manual adjustment and are inefficient, as they often necessitate a constant fuel flow, leading to waste and high costs, and may shut down when the temperature is between threshold settings.

Innovation Solution

A method that senses the appliance's temperature and uses a compressor to control air supply to the burner, overriding the flame sensor to maintain a stable temperature by simulating the presence or absence of a flame, thereby adjusting fuel flow accordingly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If a flame sensor is used to control the burner operation, then fuel consumption is reduced, but the appliance may shut down when the temperature is between threshold settings

Engineering Contradiction:

Improvefuel consumptionVSAvoidcontinuous operation

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

A compressor is introduced as an intermediary device between the temperature sensor and the burner control system. The compressor delivers pressurized air to the burner, enabling temperature control through air supply modulation rather than direct fuel control, thus preventing false flame-out shutdowns while maintaining energy efficiency

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the traditional mechanical flame sensor control system with a compressed air delivery system. Instead of relying on flame presence to control fuel flow, the system uses a compressor-driven air delivery mechanism that responds to temperature sensor signals, eliminating the shutdown problem while maintaining fuel conservation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If manual adjustment of the burner output is required, then temperature control precision is improved, but labor intensity increases

Engineering Contradiction:

Improvetemperature control precisionVSAvoidlabor intensity

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The system performs self-service temperature control by automatically monitoring temperature via a sensor and adjusting the compressor operation accordingly. The appliance regulates its own temperature without requiring manual intervention, eliminating labor intensity while maintaining precise temperature control through the compressed air delivery mechanism

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

A temperature sensor provides continuous feedback to the control system, which automatically adjusts the compressor operation to maintain the desired temperature. This closed-loop feedback system eliminates the need for manual adjustment while preserving temperature control precision

Inventive Principle:

Principle #23Feedback

3Reliability

If a constant flow of fuel is supplied to maintain a flame, then the flame remains stable, but fuel waste and costs increase

Engineering Contradiction:

Improveflame stabilityVSAvoidfuel waste

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

Instead of continuous fuel flow, the system uses periodic compressor operation to deliver pressurized air to the burner only when needed for temperature maintenance. This periodic action replaces constant fuel consumption with on-demand air supply, reducing fuel waste while maintaining operational stability

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The system changes the control parameter from direct fuel flow control to compressed air delivery control. By modulating the compressor operation and air pressure rather than maintaining constant fuel flow, the system achieves stable burner operation with significantly reduced fuel consumption

Inventive Principle:

Principle #35Parameter changes

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

This approach allows for automatic temperature control without manual intervention, reducing fuel waste and costs, while maintaining the appliance at a set temperature by efficiently managing the burner's operation between threshold temperatures.

Implementation Method 1

sensing the actual temperature of the appliance

Methodology Applied

Scientific EffectTemperature sensing:

Implementation Method 2

a compressor which delivers pressurized air to the burner

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 3

a flame sensor, which senses the presence or absence of a flame

Methodology Applied

Scientific EffectFlame sensing:

Data Source

PatentUS8141789B2Method for controlling the temperature of an appliance

Publication Date: 2012.03.27 MARINE CANADA ACQUISTION INC

AI summary

A method of controlling the temperature of a food preparation or sanitation appliance includes sensing the actual temperature of the appliance. When the temperature of the appliance is greater than a maximum threshold temperature, a compressor which supplies pressurized air to a burner is shut-off and a flame sensor, which senses the presence or absence of a flame, is overridden so the appliance acts as if a flame is present. When the actual temperature is less than a minimum threshold temperature, the compressor is started.