Flame Signal Ratio Control for Combustion Calibration
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Solution Overview
Problem
Existing methods for regulating combustible mixtures in burners are imprecise, inefficient, and environmentally harmful due to assumptions of constant relationships between flame signals and combustion conditions, leading to incomplete calibration, high CO emissions, and limitations in operating ranges and power levels.
Innovation Solution
A method that dynamically adjusts the combustion conditions by measuring the ratio of initial to final flame signals during a rapid fan velocity reduction, independent of mixture temperature and preheat, to calculate a new set point for precise combustion control, reducing CO emissions and allowing frequent operation across various power levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If periodic self-test or automatic calibration is performed to correct set point, then measurement precision is improved, but loss of time increases and productivity decreases
Solution Approach 1:
The patent applies preliminary action by pre-calculating and storing correction values in a lookup table during manufacturing or initial setup. These correction values are prepared in advance based on expected operating conditions, allowing the system to quickly retrieve and apply corrections without performing time-consuming real-time calibration procedures during operation.
Solution Approach 2:
The patent implements dynamics by making the set point correction a continuous, adaptive process rather than a periodic static one. The correction value is dynamically selected from the lookup table based on current operating parameters such as power level and flame characteristics, allowing the system to adapt to changing conditions without stopping operation for recalibration.
2Measurement precision
If calibration is performed frequently to maintain accuracy, then measurement precision is improved, but productivity decreases due to temperature control deactivation
Solution Approach 1:
The correction values are pre-calculated and stored in advance, eliminating the need for frequent real-time calibration operations. This allows the system to maintain high measurement precision by applying pre-prepared corrections without interrupting the burner operation or deactivating temperature control.
Solution Approach 2:
The patent ensures continuous operation by applying corrections from the lookup table without stopping the burner or deactivating temperature control. The useful action of maintaining precise combustion control continues uninterrupted, as the correction values are retrieved and applied in real-time based on current operating conditions.
3Adaptability or versatility
If the system operates outside predefined power range, then adaptability is improved, but measurement precision deteriorates due to invalid calibration assumptions
Solution Approach 1:
The patent achieves universality by creating a lookup table that covers multiple power levels and operating conditions. This single data structure serves multiple functions by providing appropriate correction values for different power ranges, allowing the system to maintain measurement precision across a wide operating range without requiring separate calibration procedures for each condition.
Solution Approach 2:
The system dynamically selects the appropriate correction value from the lookup table based on the current power level and operating conditions. This dynamic adaptation allows the system to maintain measurement precision whether operating within or outside the originally predefined power range, as the correction is always matched to the actual operating state.
4Device complexity
If single-point calibration is performed to simplify the process, then device complexity is reduced, but measurement precision deteriorates due to relationship variability
Solution Approach 1:
The patent applies preliminary action by pre-calculating and storing multiple correction values for different operating conditions during manufacturing. This approach maintains device complexity at a low level (simple lookup table) while achieving high measurement precision by having pre-prepared corrections ready for various power levels and flame conditions.
Solution Approach 2:
The patent uses parameter changes by storing correction values that account for variations in operating parameters such as power level, gas flow rate, and flame characteristics. The lookup table contains pre-calculated corrections for different parameter combinations, allowing the system to maintain measurement precision across varying conditions without complex real-time calculation.
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 method provides precise and reliable combustion regulation, reducing CO emissions by up to 1/10, enabling frequent operation without temperature fluctuations, and maintaining combustion stability within safety limits across a wide power range.
Implementation Method 1
This signal can be either a current signal (I) or an impedance (R) the values of which are inversely related
Data Source
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AI summary
A method for regulating the combustible mixture such as air/gas, air/methane gas or the like fed to a burner, said method consisting of measuring a flame signal correlated with the composition of said mixture fed by feed members controlled by combustion control means arranged to regulate the combustion on the basis of the flame signal. During burner operation the mixture feed conditions are modified within a narrow time interval such as to obtain a flame signal variation; a ratio between values of this latter at the end and at the beginning of said interval is compared with a predetermined reference value; and, on the basis of the deviation of this ratio from said reference value, the flame set point is regulated, as consequently is the air or gas of the mixture if this is rendered necessary.