Heating furnace using gas pulse modulation temperature control mode
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Solution Overview
Problem
Existing heating systems face challenges in providing precise control over discharge air temperature, leading to issues like stratification and inefficient energy use, as they are typically sized for peak periods and lack the ability to adjust heat output effectively.
Innovation Solution
A heating control system with a constant burner and a pulsed burner, utilizing a temperature map and microprocessor to adjust the operation of the pulsed burner based on temperature set points, allowing for variable speed air circulation and multiple heat output levels, enabling fine temperature adjustments and energy-saving modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If existing heating systems are sized for peak periods and operate at 100% or 75% heat output, then maximum heat requirement is met, but discharge air temperature becomes too high causing stratification and poor temperature control
Solution Approach 1:
The heating system divides the burner into multiple independent zones (first burner zone, second burner zone, third burner zone) that can be controlled separately. This segmentation allows the system to operate at different heat output levels (100%, 75%, 50%, 25%) by selectively activating specific zones, thereby achieving precise discharge air temperature control and preventing stratification while maintaining the ability to meet peak heating demands.
2Reliability
If heating systems operate at fixed high heat output levels, then peak heating demand is satisfied, but energy consumption increases during moderate temperature conditions
Solution Approach 1:
The heating system dynamically adjusts its heat output by selectively activating different burner zones based on the heating demand. The control system can operate at multiple heat output levels (100%, 75%, 50%, 25%) rather than running at fixed high output, allowing the system to consume less energy during moderate temperature conditions while still reliably meeting peak heating demands when required.
3Adaptability or versatility
If heating systems use two fixed heating stages (100% and 75% output), then peak periods are covered, but fine temperature adjustments and wider operating range are limited
Solution Approach 1:
The burner is segmented into multiple independently controllable zones that can be combined in different configurations. This allows the system to provide four distinct heat output levels (100%, 75%, 50%, 25%) rather than just two fixed stages, enabling both fine temperature adjustments and a wider operating range to adapt to various heating conditions.
Solution Approach 2:
Instead of using only full or partial burner activation, the system employs selective zone activation where only the necessary portions of the burner are activated based on demand. This partial action approach enables precise temperature control by activating only the required heat output level, avoiding excessive heating and allowing fine adjustments across a wider operating range.
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 improved discharge air temperature control, reduces stratification, and operates efficiently by adjusting heat output based on demand, achieving a wider range of temperature and heat output levels while minimizing energy consumption.
Implementation Method 1
a gas furnace, such as a residential gas furnace, is used in a heating system to heat the air
Implementation Method 2
a circulating fan is used to pull air from the enclosure into the HVAC system through ducts and to push the air back into the enclosure through additional ducts after conditioning the air
Data Source
AI summary
A heating control system that includes a heating unit with a constant burner and a pulsed burner. The constant burner is configured to remain active during operation. The pulsed burner is configured to toggle between an active mode and an inactive mode. The heating control system further includes a memory operable to store a temperature map that maps temperatures to percentages of a period that the pulsed burner is active and a microprocessor operably coupled to the heating unit and the memory. The microprocessor is configured to transmit a first electrical signal to activate the constant burner, obtain a temperature set point, determine the percentage of the period that the pulsed burner is active using the temperature set point and the temperature map, and transmit a second electrical signal to toggle the pulsed burner based on the determination of the percentage of the period that the pulsed burner is active.