Gas Mixture Regulator for Boiler Power Modulation
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Solution Overview
Problem
Current domestic boilers with total air-gas pre-mixing systems face limitations in power modulation, particularly at low power levels, leading to inefficient operation, increased pollution, and breakdowns due to sequential ignition and extinction of the burner, which affects combustion hygiene and overall efficiency.
Innovation Solution
A device for regulating a gas mixture that modulates the flow rates of first and second gases through joint regulation of their flow rates and valve positions, using a mechanical configuration with a stepper motor for precise control, allowing for stable gas and air mixture regulation over a wide power range, including low power settings, and avoiding sequential operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a conventional air-gas mixer with proportional pressure regulation is used, then the gas pressure is regulated proportionally to air pressure, but the power modulation range is limited (ratio does not exceed 10) and low power modulation below 2 kW is not satisfactory
Solution Approach 1:
The invention divides the gas flow regulation into two independent pathways: a main gas inlet (21) with a first valve (31) for primary gas supply, and a secondary gas inlet (21') with a second valve (32) for additional gas supply. This segmentation allows independent control of gas flow at different power levels, enabling continuous modulation from 0.5 kW to 30 kW without the limitations of conventional single-pathway proportional regulation systems.
2Power
If sequential operation is adopted when setpoint is below minimum allowed power, then the average value matches the setpoint, but the number of burner ignitions and shutdowns increases leading to pollution and breakdowns
Solution Approach 1:
The invention enables continuous operation of the burner across the entire power range from 0.5 kW to 30 kW by providing two gas inlet pathways that can be independently regulated. This eliminates the need for sequential on/off operation, maintaining continuous combustion and avoiding the pollution and efficiency losses associated with repeated ignitions and shutdowns while still achieving the desired average power output.
3Manufacturing precision
If the second inlet has a diameter 2-10 times the first inlet and conical valves are used, then fine adjustment of gas mixture proportions is achieved without high-precision machining
Solution Approach 1:
The invention changes the geometric parameters of the valve components: the second valve (32) has a diameter 2-10 times larger than the first valve (31), and both valves have conical shapes. This parameter change allows coarse proportion control through simple geometric relationships rather than requiring high-precision machining, making the device easier to manufacture while maintaining fine adjustment capability through the valve positioning mechanisms.
Data Source
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AI summary
The invention relates to a device (1) for regulating a gas mixture comprising: -a mixing housing (10) comprising a mixing chamber (11) which opens into a first inlet (21) for a first gas, a second inlet (22) for a second gas and a discharge (20) for the gas mixture; -a first valve (31) arranged to regulate the flow rate of the first gas through the first inlet, and -a second valve (32) arranged to regulate the flow rate of the second gas through the second inlet, the first and second valves being integrally connected together by a connecting member (40), to jointly regulate the flow rates of the first and second gases, and the first and second valves and the first and second inlets being shaped and dimensioned such that the joint regulation of the flow rates of the first and second gases automatically regulates the gas mixture to the desired proportions.