Gas Appliance Ignition Control System with Thermopile Power
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Solution Overview
Problem
Existing gas burning appliance ignition systems are inefficient and costly due to the need for constant pilot flame operation, manual lighting, and reliance on DC-to-DC converters, which can malfunction and reduce battery life.
Innovation Solution
A system that includes a central control unit, spark generator, pilot and main valve control devices, flame sensor, and thermopile, which automatically ignites the pilot flame and routes power between a battery source and thermopile to optimize energy use and extend battery life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a thermopile receives thermal energy from a pilot burner to power the fuel valve and burner control, then the system can operate with converted thermal energy, but the pilot must remain lit at all times which increases fuel consumption
Solution Approach 1:
The system uses periodic action by only operating the pilot burner when heating is required (on-demand operation). The control system activates the pilot only during heating cycles rather than keeping it continuously lit, thereby reducing fuel consumption while still providing sufficient thermal energy to the thermopile for power generation when needed.
2Use of energy by moving object
If a DC-to-DC converter is used to convert current from the pilot flame to power a microprocessor and stepper motor, then the system can operate with converted electrical energy, but the converter may malfunction and increase cost
Solution Approach 1:
The invention extracts and eliminates the DC-to-DC converter from the system. Instead of using a complex converter circuit, the system directly uses the thermopile-generated voltage to power the control system, thereby removing the malfunction-prone component and reducing overall system cost while maintaining operational reliability.
3Use of energy by moving object
If an unpowered rechargeable energy source is used to provide power to the combustion control system, then the system can operate with stored energy, but the battery experiences constant drain requiring frequent replacement
Solution Approach 1:
The system implements self-service by using the thermopile to generate electrical power from the pilot burner's thermal energy. This self-generated power supplies the control system directly, eliminating the need for an external battery and its associated constant drain, replacement, and monitoring requirements.
4Extent of automation
If a spark generator is used to automatically ignite the pilot flame, then the ignition process is automated, but additional electrical current is required from the power source
Solution Approach 1:
The system applies preliminary action by using the battery-powered spark generator to ignite the pilot flame at the start of each heating cycle. This brief automated ignition consumes minimal electrical energy from the battery, after which the pilot burner sustains itself and generates continuous thermal power for the control system, making the initial electrical investment worthwhile.
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
The system provides efficient and cost-effective ignition and control of gas burning appliances by automating the ignition process and reducing battery drain, eliminating the need for constant pilot flame operation and DC-to-DC converters.
Implementation Method 1
A thermopile is an electronic device that converts thermal energy into electrical energy. Thermopiles have been used within modules for gas burning fireplaces.
Implementation Method 2
The spark generator is adapted for sparking, wherein the spark generated is proximate to the pilot burner. The spark is adapted for igniting fuel received by the pilot thereby generating a pilot flame.
Implementation Method 3
reading flame sensor data from a flame sensor adapted for monitoring a presence of a pilot flame
Data Source
AI summary
A system for controlling a gas burning appliance is disclosed. The system includes a central control unit. A pilot valve and main valve controls the flow of fuel from a fuel source to the pilot and main valve, respectively, and are configured for accepting an electrical current from a thermopile and from a power source. A spark generator generates for igniting fuel received by the pilot thereby generating a pilot flame. A flame sensor is adapted for monitoring the presence of a pilot flame. A thermopile proximate to the pilot burner is configured for generating an output electrical current for powering the pilot and main valve control devices. A relay routes electrical current between the power source and thermopile to the pilot and main valve control devices. A flame height regulating device conductively coupled with the power source is configured for adjusting a height of a main flame.