Flame Sensor Moisture Purge Before Ignition in Heating Appliances
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Solution Overview
Problem
Conventional flame sensing systems in heating appliances are prone to producing false positive outputs due to moisture accumulation in the combustion cabinet, leading to inaccurate detection of flame presence and potential safety hazards.
Innovation Solution
A method to verify the accuracy of flame sensing system outputs by checking the status of the gas valve and using additional sensors, followed by moisture expulsion from the combustion cabinet using an inducer motor or blower system to ensure accurate flame detection before ignition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional flame sensing systems are used without moisture removal, then the system structure remains simple, but false positive outputs occur due to moisture accumulation in the combustion cabinet
Solution Approach 1:
The system performs preliminary moisture detection and expulsion actions before flame ignition. The controller activates the inducer motor or blower system to remove moisture from the combustion cabinet prior to ignition, preventing false positive readings from the flame sense probe while maintaining overall system simplicity
Solution Approach 2:
The patent introduces an intermediary moisture detection mechanism that mediates between the flame sensing system and moisture in the combustion cabinet. By detecting moisture presence separately and triggering expulsion actions, the system achieves reliable flame detection without requiring complete system redesign
2Measurement precision
If moisture is not expelled from the combustion cabinet, then energy consumption remains low, but the flame sensing system produces inaccurate outputs
Solution Approach 1:
The system implements periodic moisture detection and expulsion cycles rather than continuous operation. The controller periodically checks for moisture conditions and activates the inducer motor or blower only when moisture is detected, achieving accurate flame sensing while minimizing energy consumption through on-demand moisture removal
Solution Approach 2:
The system changes operational parameters dynamically - switching between normal operation and moisture expulsion modes based on detected conditions. By adjusting the operational state of the inducer motor or blower system based on moisture levels, the patent achieves precise flame measurement without excessive energy consumption
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
Prevents false positive outputs by ensuring the flame sensing system provides reliable data, thereby maintaining the functionality and safety of the heating appliance by expelling moisture and ensuring proper combustion initiation.
Implementation Method 1
The transformer can provide a high voltage to the flame detection circuit and a flame current for a conductivity provided by the flame. In operation, when the flame is lit, the flame sensing system detects a current (e.g., alternating current (AC)) conducted from the flame sense probe, through the flame, and back to ground.
Implementation Method 2
A method to verify the accuracy of flame sensing system outputs by checking the status of the gas valve and using additional sensors, followed by moisture expulsion from the combustion cabinet using an inducer motor or blower system to ensure accurate flame detection before ignition.
Data Source
AI summary
Systems and methods for pre-ignition moisture removal in heating appliances are provided. The heating appliance may be configured, prior to initiating a combustion process using a combustion system of the heating appliance, to determine whether a flame sensing unit is producing false positive outputs. In some instances, such false positive outputs may be caused by moisture within the combustion cabinet of the heating appliance. To attempt to eliminate any false positive outputs, the heating appliance may perform ana action to expel the moisture from the combustion cabinet. For example, an inducer may be activated to expel the moisture using airflow. This ensures that the flame sensing unit is producing accurate data before the combustion process is initiated.