Flame Rod Combustion Control for Exhaust Blockage Detection
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Solution Overview
Problem
Conventional combustion apparatuses face challenges in accurately monitoring and responding to sudden changes in air-fuel ratios, experiencing delays in thermocouple reactions, and require complex structures with multiple components for CO and pressure sensing, leading to inefficiencies and safety concerns, especially in detecting abnormal conditions like exhaust blockages.
Innovation Solution
A combustion apparatus with flame current detecting means that determines the distribution of flame current values and adjusts air and fuel supply based on these readings, incorporating flame detecting means to identify normal or abnormal conditions, and environment information to optimize air supply ratios, thereby enhancing response speed and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thermocouple is used to monitor combustion conditions, then combustion monitoring is achieved, but the response speed is delayed due to thermal time constant
Solution Approach 1:
The patent combines multiple sensing functions (flame detection, ion current measurement, temperature monitoring) into a single integrated flame rod assembly. This unified sensor structure enables simultaneous measurement of combustion parameters without the delays inherent in separate thermocouple-based systems, achieving both reliable monitoring and rapid response.
Solution Approach 2:
The patent replaces the thermal-based thermocouple measurement system with an electrical/ion-based detection system using flame rods. By substituting thermal conduction principles with electrical conductivity and ion current measurement, the system eliminates thermal time constant delays and achieves instantaneous response to combustion condition changes.
2Reliability
If CO sensors and pressure sensors are used individually for monitoring, then comprehensive combustion monitoring is achieved, but device complexity and component quantity increase
Solution Approach 1:
The flame rod serves multiple functions simultaneously: detecting flame presence, measuring ion current for air-fuel ratio monitoring, sensing temperature effects, and detecting combustion abnormalities. This multi-functional sensor eliminates the need for separate CO sensors, pressure sensors, and thermocouples, reducing component quantity while maintaining comprehensive monitoring capability.
Solution Approach 2:
The patent integrates flame detection, ion current measurement, and temperature sensing into a single flame rod assembly. By merging these sensing functions into one unified component, the system achieves comprehensive combustion monitoring without increasing device complexity or the number of separate parts.
3Ease of operation
If monitoring means are disposed in each burner for multi-burner systems, then individual burner control is improved, but device complexity and control process complexity increase
Solution Approach 1:
The patent implements separate flame rod monitoring for each burner, allowing independent detection and control of each burner's combustion conditions. This segmentation enables individual burner optimization while the standardized flame rod design keeps the overall system manageable and reduces control complexity through modular architecture.
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 solution enables rapid detection and control of combustion changes, improving safety by preventing sudden deteriorations due to exhaust blockages and optimizing combustion performance based on environmental conditions, resulting in enhanced monitoring accuracy and convenience.
Implementation Method 1
flame current detecting means set at a certain detection position and detects a flame current value included in the flame which is generated by the combustion means
Data Source
AI summary
A combustion apparatus. Combustion means (burner) generates flame by combustion. Air supply means (intake fan) supplies air to the combustion means. Flame current detecting means (FRB) is set at a certain detection position and detects a flame current value included in the flame which is generated by the combustion means. Determination means (control device) determines a distribution where the flame current value that is detected is included for the flame current detecting means. Control means (control device), when the flame current value is not included in a distribution, which is set as normal values, outputs a control command of increasing or decreasing at least one of the supply of the air by the air supply means and the supply of fuel based on a determination result by the determination means.