Combustion System Tube Design for Flame Sensor and Ignitor Access
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Solution Overview
Problem
Existing combustion systems for down-fired water heaters face challenges in serviceability, requiring extensive disassembly and increasing labor costs and time to maintain components like the flame sensor assembly and ignitor assembly, while positioning the burner for optimal combustion can make these components difficult to access.
Innovation Solution
A combustion system design featuring an inner tube with a flange and sensor port within an outer tube, allowing the ignitor and flame sensor assemblies to extend through the port and gap for easy access and removal without disassembling the burner, enhancing serviceability and manufacturability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the burner is positioned lower within the combustion tube to achieve optimal combustion and heat transfer, then combustion efficiency is improved, but the flame sensor assembly and ignitor assembly become difficult to access and remove for maintenance
Solution Approach 1:
The combustion system is divided into separate modular components: the burner assembly can be positioned lower for optimal combustion, while the flame sensor and ignitor assemblies are separated and can be accessed independently through sensor ports in the combustion tube, eliminating the need to disassemble the entire combustion system for maintenance
Solution Approach 2:
The flame sensor assembly and ignitor assembly are extracted from the confined space around the burner and repositioned to extend through sensor ports in the combustion tube, allowing them to be accessed and removed independently without disturbing the burner positioning or other components
2Stability of the object's composition
If the flame sensor assembly and ignitor assembly are fixed together with the burner and blower assembly, then structural stability is improved, but extensive disassembly is required to access and maintain individual components
Solution Approach 1:
The combustion system components are segmented into independently accessible modules: the burner assembly remains fixed for stability, while the flame sensor and ignitor assemblies are separated and accessible through individual sensor ports, allowing maintenance of specific components without disassembling the entire system
Solution Approach 2:
Sensor ports in the combustion tube serve as intermediary access points, allowing the flame sensor and ignitor assemblies to be accessed and removed independently while maintaining the structural integrity and fixed positioning of the burner and blower assemblies
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 design facilitates efficient maintenance and cleaning of the ignitor and flame sensor assemblies without removing other components, reducing labor costs and time while maintaining optimal burner positioning for efficient combustion and heat transfer.
Implementation Method 1
A combustion system design featuring an inner tube with a flange and sensor port within an outer tube, allowing the ignitor and flame sensor assemblies to extend through the port and gap for easy access and removal without disassembling the burner
Implementation Method 2
Hot combustion gases generated during combustion can travel through the combustion tube to the heat exchanger. The heat from the hot combustion gases can be transferred to the water stored in the tank to provide on-demand hot water.
Implementation Method 3
The heat from the hot combustion gases can be transferred to the water stored in the tank to provide on-demand hot water.
Data Source
AI summary
The disclosed technology includes a combustion system providing ease of access to components of the combustion system and optimal placement of a burner such that efficient combustion and heat transfer can occur. The combustion system can include an inner tube having a first end and a second end, the second end having a flange with a sensor port, and an outer tube having a first end and a second end. The inner tube can be disposed within the outer tube. The inner tube can have an outer diameter less than an inner diameter of the outer tube, creating a gap between the outer tube and inner tube. An ignitor assembly and a flame sensor assembly can extend through the sensor port and the gap and be positioned proximate a burner.