Flame Sensor Inspection for Stable Combustion State Detection

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Solution Overview

Problem

Existing combustion apparatus monitoring systems struggle to accurately determine the state of the apparatus based on the flame state of the burner, particularly due to fluctuations in power supply voltage affecting discharge current and discharge probability.

Innovation Solution

An inspection device that includes a flame sensor, application voltage generation unit, discharge number measurement unit, light emission information generation unit, and determination unit, which generates light emission information through a linear function of discharge counts over time and compares this information with reference data to determine the state of the combustion apparatus.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If discharge current from flame sensor is used directly for determining combustion state, then the system is simple to operate, but measurement precision deteriorates due to power supply voltage fluctuations

Engineering Contradiction:
Improveease of operationVSAvoidmeasurement precision
Core Design Contradiction:
Ease of operationVSMeasurement precision

Solution Approach 1:

The patent transforms the discharge current parameter into a discharge probability parameter by counting discharge occurrences over multiple measurement cycles. This parameter transformation eliminates the influence of power supply voltage fluctuations while maintaining operational simplicity. The discharge probability is calculated as the ratio of discharge occurrence times to total measurement cycles, providing a stable metric for combustion state determination.

Inventive Principle:
Principle #35Parameter changes

2Measurement precision

If discharge probability based on multiple measurement cycles is used, then measurement precision improves, but loss of time increases due to repeated measurements

Engineering Contradiction:
Improvemeasurement precisionVSAvoidloss of time
Core Design Contradiction:
Measurement precisionVSLoss of time

Solution Approach 1:

The patent performs a fixed number of measurement cycles (excessive action) to ensure statistical reliability of discharge probability, then stops measurements once the predetermined number is reached regardless of whether convergence is achieved. This approach prevents excessive time consumption while maintaining measurement precision through sufficient sampling.

Inventive Principle:
Principle #16Partial or excessive action

3Device complexity

If only overall discharge probability is measured, then device complexity remains low, but measurement precision deteriorates because local flame state variations cannot be detected

Engineering Contradiction:
Improvedevice complexityVSAvoidmeasurement precision
Core Design Contradiction:
Device complexityVSMeasurement precision

Solution Approach 1:

The patent segments the flame measurement into multiple spatial regions by positioning multiple flame sensors at different locations within the combustion chamber. Each sensor measures discharge probability in its specific region, enabling detection of local flame state variations. The segmentation approach maintains low device complexity by using simple ultraviolet detection tubes positioned at strategic locations.

Inventive Principle:
Principle #1Segmentation

Data Source

PatentUS12624835B2Inspection device
Publication Date: 2026.05.12 AZBIL CORP
  • US12624835B2 patent drawing
  • US12624835B2 patent drawing
  • US12624835B2 patent drawing

AI summary

To grasp a state of a combustion apparatus based on a flame state of a burner, a discharge number measurement unit measures the number of discharges of a flame sensor per unit time. A light emission information generation unit generates, as light emission information, information obtained based on a value obtained by dividing a total (accumulation) of the number of discharges per unit time measured by the discharge number measurement unit by a total measurement time. A determination unit determines the state of the combustion apparatus to be inspected based on the light emission information generated by the light emission information generation unit as described above.