Single Electrode Combustion Control via Plasma Signal Correlation
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Solution Overview
Problem
Existing combustion control methods for fuel gas burners face limitations in maintaining optimal air/fuel ratios across varying power levels and gas types, leading to unreliable results and electrode wear issues, especially in modulating burners.
Innovation Solution
A method using a single electrode to apply and measure electrical signals in the combustion plasma, correlating power and air ratios through discrete Fourier transform and regression analysis to ensure accurate and repeatable combustion control across different conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple flame sensors and frequency spectrum analysis are used to monitor combustion, then combustion control capability is improved, but device complexity and reliability deteriorate due to electrode wear and ageing
Solution Approach 1:
The patent extracts the essential combustion monitoring function from complex multi-sensor systems and frequency spectrum analysis, retaining only the core capability of measuring combustion parameters through a single electrode. This simplification eliminates the reliability issues associated with multiple sensors and complex processing while maintaining effective combustion control.
Solution Approach 2:
The patent employs a single electrode that can be easily replaced rather than investing in multiple durable sensors. This approach accepts the limited lifespan of a single electrode but eliminates the complexity and reliability problems of maintaining multiple sensors, effectively treating the electrode as a consumable component.
2Difficulty of detecting and measuring
If frequency spectrum analysis is applied to combustion signals, then combustion parameter measurement is improved, but measurement precision deteriorates due to unreliable frequency spectrum results
Solution Approach 1:
The patent replaces complex frequency spectrum analysis with a simpler direct measurement approach using a single electrode to detect combustion parameters. This substitution eliminates the inaccuracies inherent in frequency spectrum methods while maintaining the ability to detect and measure combustion characteristics effectively.
3Adaptability or versatility
If modulating burners operate across wide power ranges, then adaptability is improved, but combustion control reliability deteriorates due to varying optimal air/gas ratios
Solution Approach 1:
The patent implements a dynamic combustion control system that automatically adjusts air/gas ratios in real-time according to the actual operating conditions and power level. This dynamic adaptation allows the modulating burner to maintain reliable combustion control across the entire power range without requiring manual intervention or complex pre-programmed control curves.
4Manufacturing precision
If multiple experimental conditions are tested to establish control curves, then manufacturing precision is improved, but loss of time increases due to extensive testing requirements
Solution Approach 1:
The patent enables the combustion control system to self-adjust and self-calibrate during operation rather than requiring extensive pre-establishment of control curves through multiple experimental conditions. The system automatically learns optimal air/gas ratios during normal operation, eliminating the need for time-consuming installation testing while maintaining high precision control.
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 provides reliable and efficient combustion control by accurately determining air/fuel ratios and thermal power, reducing electrode wear and simplifying installation and operation, while maintaining optimal combustion conditions across the burner's power range.
Implementation Method 1
A voltage signal is applied to an electrode in the combustion plasma of a burner and, following disconnection of the signal, a series of samplings of the resultant signal at the electrode is carried out
Data Source
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AI summary
A method is described for monitoring and controlling combustion in a burner (1) of a fuel gas apparatus, of the type comprising a sensor (8) with an electrode (El) located in or close to the flame and capable of being supplied by a voltage generator and also connected to an electronic circuit suitable for measuring the resultant potential at the electrode. The method comprises a first phase of acquiring and processing data from experimental conditions and a second phase of evaluating the desired combustion characteristic, under an actual operating condition of the burner. In the first phase a plurality of experimental combustion conditions for the burner (1) are preselected, applying to the burner in each of said conditions a power (PI, P2, Pn) and a further significant parameter of the combustion characteristics (Kl, K2, Km), under each of the experimental conditions applying an electrical voltage signal to said electrode (El) and carrying out a sampling of the response signal, calculating, on the basis of the sequence of sampled values, the characteristic parameters of the waveform of the signal for each of the experimental conditions, for the purposes of calculating a correlation function, on the basis of the acquired experimental data, capable of unambiguously correlating the power and the further significant parameter of the combustion characteristics with the characteristic parameters of the waveform of the signal at the electrode. The second phase comprises the steps of applying a voltage signal to the electrode (El) and carrying out sampling of the resultant response signal, calculating, on the basis of the sequence of sampled values, the characteristic parameters of the waveform of the response signal at the electrode, and calculating the estimated value of the desired combustion characteristic by using the correlation function.