Flexible Flame Detector Carrier Tube for Tilting Burners

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Solution Overview

Problem

Conventional flame detectors face challenges in maintaining accurate flame monitoring due to soot coverage and temperature constraints, requiring precise line-of-sight and being prone to degradation at high temperatures.

Innovation Solution

A flame detector system utilizing a camera and a flexible carrier tube with cooling medium and power supply, mounted near the burner nozzle aperture, allowing for optical access and adjustable tilt to maintain effective flame monitoring, and integrating imaging electronics for reliable operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a camera is mounted at the front end of a rigid carrier tube to monitor the flame, then the optical access is precise, but the device cannot adapt to tilting burner nozzles and line-of-sight requirements are strict

Engineering Contradiction:

Improveadaptability to tilting burner nozzleVSAvoidoptical access precision

Core Design Contradiction:

Adaptability or versatilityVSMeasurement precision

Solution Approach 1:

The carrier tube is made flexible to allow the camera to follow the tilting burner nozzle while maintaining optical access to the flame. The flexibility enables adaptation to different nozzle positions without sacrificing the ability to accurately monitor the flame.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The system transitions from a rigid static structure to a dynamic flexible structure that can adapt its shape and position. The flexible carrier tube allows the camera to dynamically adjust its position according to the burner nozzle tilt angle while maintaining continuous optical access.

Inventive Principle:

Principle #15Dynamics

2Device complexity

If phototubes or photodiodes are used to detect total light intensity, then the device structure is simple, but it requires precise line-of-sight and is sensitive to soot coverage

Engineering Contradiction:

Improvedevice structure complexityVSAvoidflame detection reliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent uses a camera to create an optical copy (image) of the flame rather than directly detecting light intensity with photodetectors. This image copy can be processed to identify flame presence and characteristics, providing more robust detection that is less sensitive to soot coverage and maintains reliability under varying combustion conditions.

Inventive Principle:

Principle #26Copying

3Adaptability or versatility

If the carrier tube is made flexible to accommodate tilting burner nozzle, then adaptability is improved, but the tube may be more susceptible to temperature effects and degradation

Engineering Contradiction:

Improveadaptability to tilting burner nozzleVSAvoidtemperature resistance

Core Design Contradiction:

Adaptability or versatilityVSTemperature

Solution Approach 1:

A flexible conduit is introduced as an intermediary structure that separates the camera (sensitive to temperature) from the high-temperature flame environment. The conduit transmits cooling air and power to the camera while protecting it from direct thermal exposure, enabling the camera to operate reliably in high-temperature conditions.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The flexible carrier tube incorporates a cooling air conduit that delivers cooled air to the camera. This pneumatic cooling system actively manages the temperature at the camera location, allowing the flexible structure to withstand the high-temperature environment while protecting the sensitive electronic components.

Inventive Principle:

Principle #29Pneumatics and hydraulics

4Measurement precision

If a rigid carrier tube is used to maintain precise optical access, then measurement precision is maintained, but the device cannot adapt to changing burner positions or tilts

Engineering Contradiction:

Improveoptical access precisionVSAvoidadaptability to burner position changes

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

Inventive Principle:

Principle #30Flexible shells and thin films

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

Enables improved flame monitoring with a wide field of view, reduced temperature constraints, and cost-efficient data transmission to a burner/boiler management system, while maintaining performance even in high-temperature environments.

Implementation Method 1

the camera is arranged at a front end of the carrier tube such that an optical access of the camera is directed toward the flame

Methodology Applied

Scientific EffectLight detection: Photoelectric Effect

Implementation Method 2

the carrier tube is constructed such that it can carry a cooling medium to the camera

Methodology Applied

Scientific EffectCooling: Cooling

Data Source

PatentUS8274560B2Flame detector for monitoring a flame during a combustion process

Publication Date: 2012.09.25 ABB (SCHWEIZ) AG

AI summary

A flame detector is disclosed for monitoring a flame during a combustion process, comprising a camera and a carrier tube, wherein the camera is arranged at a front end of the carrier tube such that an optical access of the camera is directed toward the flame when the front end of the carrier tube is mounted in the vicinity of a burner nozzle aperture.