Flow-Activated Pilot Flame Shut-Off for Gas Water Heater Fuel Economy
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Solution Overview
Problem
Existing flow heaters with gas burners for heating water lack efficient control over gas supply, leading to unnecessary fuel consumption and potential gas leaks, as the pilot flame burns continuously regardless of water flow requirements.
Innovation Solution
Incorporating a shut-off unit with a mechanical or proportional valve to interrupt the gas supply to the ignition flame feed line based on water flow parameters, ensuring gas is only supplied when water is flowing, thereby reducing fuel consumption and preventing unintentional gas escape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pilot flame burns continuously to ensure ignition capability, then the ignition reliability is improved, but the fuel consumption increases and gas safety deteriorates
Solution Approach 1:
The patent implements periodic action by switching the pilot flame operation from continuous burning to on-demand burning. The electronic control unit activates the pilot flame only when water flow is detected through the flow sensor, and deactivates it when no water flow is present. This periodic operation pattern maintains ignition reliability when needed while eliminating continuous fuel consumption, directly resolving the contradiction between ignition reliability and fuel consumption.
2Reliability
If the pilot flame burns continuously to ensure ignition capability, then the ignition reliability is improved, but the gas safety deteriorates due to potential gas leaks
Solution Approach 1:
The patent applies periodic action by controlling the gas supply to the pilot flame to occur only during periods when water flow is detected. The electronic control unit receives signals from the flow sensor and accordingly activates or deactivates the gas supply valve and ignition. This ensures that gas is present in the system only when needed for actual heating operation, eliminating the continuous gas supply that creates leak risks, thus resolving the contradiction between ignition reliability and gas safety.
Solution Approach 2:
The patent replaces the traditional mechanical continuous gas supply system with an electronically controlled gas supply system. The electronic control unit, flow sensor, and solenoid valve work together to provide precise control over gas flow based on actual heating demand. This substitution allows for intelligent control strategies that improve both ignition reliability and gas safety by ensuring gas is supplied only when water flow is detected, eliminating the inherent safety risks of continuous mechanical gas supply.
3Loss of energy
If the gas supply is interrupted to the ignition flame feed line to reduce fuel consumption, then the fuel economy is improved, but the ignition capability deteriorates
Solution Approach 1:
The patent implements feedback control through the flow sensor and electronic control unit. The flow sensor continuously monitors water flow conditions and provides feedback signals to the electronic control unit. Based on this feedback, the control unit automatically adjusts the gas supply to the pilot flame - activating it when water flow is detected and deactivating it when no flow is present. This feedback mechanism ensures that ignition capability is maintained precisely when needed (during water flow) while eliminating fuel waste during non-operational periods, resolving the contradiction between fuel economy and ignition capability.
Solution Approach 2:
The system performs self-service by automatically detecting water flow conditions and controlling its own gas supply and ignition operations without external intervention. The flow sensor detects water flow and the electronic control unit autonomously activates or deactivates the pilot flame and main burner based on this detection. This self-service capability ensures that ignition capability is automatically maintained when water flow occurs while conserving fuel during non-operational periods, resolving the contradiction between fuel economy and ignition capability.
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 enhances operational reliability and economy by ensuring gas is used only when needed, reducing fuel consumption and preventing gas leaks, while maintaining a high level of safety and adaptability.
Implementation Method 1
at least one gas burner for heating running water as required
Implementation Method 2
a thermal connection to the heat exchanger for heating the water
Implementation Method 3
heat exchanger for heating the water
Data Source
Figure 1
AI summary
The invention is based on a heater device (10), in particular a continuous-flow heater device, with at least one gas burner (12) for heating running water as required and with at least one pilot flame supply line (14) for supplying gas to a pilot flame (16) of the gas burner (12) Es it is proposed that the heater device has a shut-off unit (18) which has at least one shut-off valve (20) and which is intended to interrupt a gas supply to the ignition flame feed line (14) depending on at least one flow parameter of the water.