Flame Indicator Assembly for Enclosed Burner Visual Detection
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Solution Overview
Problem
In fuel-fired heating appliances, particularly those designed to reduce NOx emissions, it is difficult or impossible to visually observe the presence or absence of a burner flame due to enclosed burner assemblies, which complicates ensuring proper operation and compliance with safety regulations.
Innovation Solution
A flame indicator assembly that includes a flame sensor and a visual indicator module, such as light-emitting diodes (LEDs), which are actuated in response to the presence or absence of a flame, providing a visual indication at the burner assembly without the need to observe the flame directly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the burner assembly is enclosed to reduce NOx emissions, then emission control is improved, but visual observation of the flame becomes difficult or impossible
Solution Approach 1:
The patent introduces a flame sensor as an intermediary device that detects the flame's presence and electrical characteristics internally, then transmits this information externally through a visual indicator (such as an LED). This mediator allows flame detection without requiring direct visual observation through the enclosed burner assembly, thus maintaining both emission control and flame monitoring capabilities
Solution Approach 2:
The patent replaces the mechanical/optical system of direct visual observation with an electrical sensing system. The flame sensor uses electrical properties (rectification effect) to detect the flame, and this electrical signal is then converted to a visual indication through an LED, substituting the need for direct optical observation while maintaining the enclosed burner design
2Difficulty of detecting and measuring
If a sight glass is inserted into the burner assembly wall to allow visual inspection, then flame observation is improved, but device complexity and structural integrity are worsened
Solution Approach 1:
The patent extracts the flame detection function from the visual observation requirement. Instead of modifying the burner assembly structure to allow viewing, the flame sensor extracts the flame's electrical characteristics and transmits this information externally, eliminating the need for sight glasses or structural modifications to the burner assembly
Solution Approach 2:
The patent creates a visual copy or representation of the flame status through the LED indicator. Rather than observing the actual flame directly, the system produces a simplified visual signal (light on/off) that copies the essential information about flame presence, eliminating the need for structural modifications to view the real flame
3Measurement precision
If rectification flame sensors are used to detect flame status, then flame detection accuracy is improved, but visual indication capability is lost
Solution Approach 1:
The patent merges two previously separate functions into a single integrated system: the rectification flame sensor for precise electrical detection and the visual indicator (LED) for visual status display. The flame sensor and visual indicator are combined into one assembly where the electrical detection capability and visual indication capability work together, maintaining both measurement precision and visual information display
Solution Approach 2:
The patent implements a feedback loop where the flame sensor continuously monitors the flame's electrical characteristics and this information is immediately reflected in the visual indicator's state. The LED provides real-time visual feedback about the flame status based on the sensor's measurements, ensuring both precise detection and continuous visual information are maintained simultaneously
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
Enables users to visually confirm the status of the flame at the burner assembly, enhancing safety and compliance with regulations by providing a clear indication of flame presence or absence, even in enclosures where direct observation is not possible.
Implementation Method 1
rectification flame sensors rely on the electrical properties of a hydrocarbon flame to detect the status of a flame
Implementation Method 2
The visual indicator module comprises at least one light source. In some embodiments, the at least one light source is a light-emitting diode
Data Source
AI summary
A flame indicator assembly for a fuel-fired heating appliance, the fuel-fired heating appliance including a burner assembly and control electronics. The flame indicator assembly comprises a flame sensor configured to allow the flow of electric current in response to exposure to a flame. The flame sensor is configured for electrical communication with the control electronics of the fuel-fired heating appliance. The flame indicator assembly also comprises a visual indicator module attached to the flame sensor. The visual indicator module comprises at least one light source. The visual indicator module is in operative communication with the flame sensor such that the at least one light source is actuated in response to the flow of electric current. A fuel-fired heating appliance comprising a flame indicator assembly is also disclosed.