Flame Measuring System Using Non-Contact Pyrometry
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Solution Overview
Problem
Current technologies are inadequate for effectively measuring the appearance geometry and temperature characteristics of industrial burner flames, especially in industrial furnaces, due to limitations in direct measurement methods and the inability to simulate furnace conditions accurately.
Innovation Solution
A flame measuring system for industrial burners is developed, which includes a test chamber simulating an industrial furnace environment, a flame detection rod with a heated area, thermal radiation sensors, and a control module to adjust fuel and air flow, allowing for simultaneous operation and flame measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a thermocouple is used for direct flame temperature measurement, then measurement precision is improved, but measurement time increases significantly due to single-point measurement requirements
Solution Approach 1:
The patent replaces the mechanical contact-based thermocouple measurement system with a non-contact optical measurement system using a pyrometer. The pyrometer measures flame temperature by detecting thermal radiation in the infrared spectrum, eliminating the need for physical insertion into the flame. This substitution maintains measurement precision while dramatically reducing measurement time since multiple points can be measured simultaneously without sequential probing.
Solution Approach 2:
The patent transitions from one-dimensional single-point measurement (thermocouple inserted at one location) to two-dimensional or three-dimensional spatial measurement using a pyrometer that can scan across the flame front. By moving the measurement approach from a single spatial point to multiple spatial points simultaneously or sequentially through scanning, the system achieves complete flame temperature mapping much faster than sequential thermocouple measurements.
2Ease of operation
If the industrial burner is arranged in open space for measurement, then measurement accessibility is improved, but flame characteristics differ from actual industrial furnace conditions
Solution Approach 1:
The patent segments the measurement system into two independent parts: the industrial burner remains in its actual industrial furnace environment (ensuring reliable flame characteristics), while the pyrometer measurement system operates externally through the furnace wall or opening (ensuring measurement accessibility). This segmentation allows the burner to function in its intended environment while enabling non-contact temperature measurement without disrupting the flame conditions.
Solution Approach 2:
The patent introduces an intermediary measurement approach where the pyrometer measures flame temperature through the furnace wall or opening rather than requiring direct access to the flame. This intermediary method allows measurements to be taken from outside the furnace environment, maintaining both the actual industrial furnace conditions for reliable flame characteristics and accessibility for measurement operations.
3Loss of information
If multiple thermocouples are used to measure complete flame temperature characteristics, then measurement completeness is improved, but device complexity and measurement time increase
Solution Approach 1:
The patent replaces multiple mechanical thermocouples with a single pyrometer system that can measure temperature at multiple spatial locations. The pyrometer uses optical detection to measure thermal radiation from different flame zones, achieving complete temperature characteristic mapping without the complexity of installing, calibrating, and managing multiple thermocouple sensors throughout the flame.
Solution Approach 2:
The patent makes the pyrometer a universal measurement tool that can measure temperature at multiple flame locations by adjusting its aiming position or using scanning capabilities. A single pyrometer device performs the function that would otherwise require multiple thermocouples, reducing device complexity while maintaining measurement completeness for flame temperature characteristics.
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 system enables accurate measurement of flame temperature distribution with minimal interference to the flame flow field, significantly reducing measurement time and providing results closer to actual industrial furnace conditions.
Implementation Method 1
a thermal radiation sensor disposed outside the test chamber for receiving a thermal radiation of each heated position of the heated area on the flame detection rod
Implementation Method 2
a flame detection rod having an end inserted in the test chamber and having a heated area corresponding to the industrial burner
Data Source
AI summary
A flame measuring system of an industrial burner and a method thereof are provided. The flame measuring system of the industrial burner includes: a test chamber; an industrial burner installed on the test chamber; a flame detection rod inserted in the test chamber; a thermal radiation sensor disposed outside the test chamber to receive a thermal radiation on the flame detection rod; a pressure gage inserted in the test chamber; a control module electrically connected to a regulating valve of the industrial burner; a signal module electrically connected to the pressure gage and the thermal radiation sensor; and a host electrically connected to the control module and the signal module. The signal module receives analog signal data of the pressure gage and the thermal radiation sensor, converts the analog signal data into digital signal data, and transmits the digital signal data to the host for processing, calculation, and analysis.