Combustion Control via Optical Sensing and Segmented Loops
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Solution Overview
Problem
Existing combustible gas burner systems face limitations in maintaining an optimal air/gas ratio due to electrode wear, reliance on single closed control loops, and challenges in detecting air passage alterations and air density changes, leading to inefficient combustion and potential safety issues.
Innovation Solution
An apparatus and method for monitoring and controlling combustion in combustible gas burners by adjusting the gas mixture through a combination of a fan with variable speed and an adjustable valve, managed by a controller processing data from multiple sensors, allowing for precise adjustment of air and gas flow to maintain optimal combustion conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single closed control loop is used for combustion control, then the system is simple to implement, but the adjustment quality is poor for high modulation ratios and the response is slow
Solution Approach 1:
The single closed control loop is segmented into multiple independent control loops: a first control loop for adjusting gas flow rate and a second control loop for adjusting air flow rate. Each loop operates independently with its own sensor feedback, enabling parallel processing of control actions. This segmentation allows the system to achieve high modulation ratios with improved adjustment quality while maintaining simple implementation, as each loop can be tuned independently for optimal performance.
2Device complexity
If electrode wear is not addressed, then the system structure remains simple, but the precision and reliability of combustion monitoring deteriorate
Solution Approach 1:
The worn electrode sensor is extracted and replaced with an optical sensor system consisting of a light source and a photodetector. The optical sensor measures combustion parameters by detecting light properties (intensity, color temperature) rather than relying on electrical conductivity, thereby eliminating the wear issue while maintaining measurement precision. This extraction replaces the problematic electrode with a non-contact measurement system that does not suffer from material degradation.
Solution Approach 2:
The electrical measurement system (electrode-based) is replaced with an optical measurement system (light source and photodetector). This substitution transitions from a mechanical/electrical interaction with the flame to an optical interaction, eliminating wear problems inherent in electrode materials while maintaining the ability to monitor combustion parameters such as temperature and composition with high precision.
3Device complexity
If air passage alterations and air density changes are not detected, then the system remains simple, but the estimation of actual burner power becomes imprecise
Solution Approach 1:
The optical sensor system serves multiple functions simultaneously: it measures combustion temperature, detects air passage alterations, and compensates for air density changes. By using a single multi-functional optical measurement system rather than separate sensors for each parameter, the invention achieves precise burner power estimation while keeping the system structure relatively simple. The optical measurements provide comprehensive data that can be processed to determine all relevant combustion parameters.
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 solution enables precise adjustment of air and gas flow, overcoming limitations of existing systems by ensuring efficient, stable, and safe combustion across varying conditions, with the ability to self-learn and adapt to changing operating conditions.
Implementation Method 1
an optical sensor, positioned in a zone close to the flame of the burner and adapted to measure one or more combustion parameters, in particular a temperature of the flame and/or a composition of the flame
Implementation Method 2
a combustible gas burner, adapted to burn a mixture of gas formed by a first gas and a second combustible gas
Data Source
AI summary
The apparatus and method according to the present invention are adapted to adjust, in a combustible gas burner, a mixture of gas formed by a first gas and a second combustible gas, wherein the gas mixture is provided through the appropriate mixing of an amount of said first gas by means of a first adjustment element and an amount of said combustible gas by means of a second adjustment element. Said first or second adjustment elements are managed, during operation, by a controller, which processes the data coming from at least two sensors.