Ignition Spark Detection Using EMI Sensing in Fuel-Fired Burners
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Solution Overview
Problem
Fuel-fired appliances often experience delays in diagnosis and repair due to the inability to effectively detect the presence or absence of sparking during ignition trials, leading to unnecessary downtime and service technician intervention.
Innovation Solution
A system comprising a controller, antenna, and optical detector is used to monitor electromagnetic interference (EMI) and electrical characteristics near the igniter, determining operational status by detecting changes in EMI or electrical noise levels during ignition trials, thereby accurately assessing spark presence or absence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If traditional flame detection methods are used without spark detection, then the system structure remains simple, but the diagnosis time increases significantly and service technician intervention is required
Solution Approach 1:
The system performs preliminary spark detection during the ignition trial phase by monitoring EMI signals. The controller actively detects the presence or absence of sparks before attempting to ignite fuel, allowing early identification of igniter failures and preventing unnecessary lockouts. This preliminary action eliminates the need for service technician intervention in cases of igniter failure.
2Measurement precision
If spark detection using EMI monitoring is implemented, then the accuracy of spark presence detection is improved, but the device complexity increases due to additional sensors and control logic
Solution Approach 1:
The system uses the existing control system's antenna and signal processing capabilities to detect EMI from sparks. The controller leverages its existing electromagnetic sensing infrastructure, originally designed for other purposes, to also detect spark presence. This multi-functional use of existing components achieves accurate spark detection without requiring entirely new specialized sensors.
Solution Approach 2:
The system uses electromagnetic interference (EMI) signals as an intermediary to indirectly detect spark presence. Rather than directly observing the spark, the controller monitors the EMI signals generated by the spark in the fuel/air mixture. This intermediary approach enables accurate remote detection of spark events without requiring direct contact sensors near the igniter.
3Reliability
If the system enters lockout state upon ignition failure, then safety is improved by preventing uncontrolled fuel accumulation, but productivity decreases due to extended downtime requiring service technician visit
Solution Approach 1:
The controller performs preliminary detection of spark presence during the ignition trial phase, before fuel is fully introduced. By detecting whether the igniter is producing sparks during the ignition trial, the system can identify igniter failures early and prevent unnecessary lockout states, thereby maintaining appliance availability while still ensuring safety through controlled fuel introduction.
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 enables timely and accurate detection of igniter operation, reducing downtime by allowing for immediate identification of spark issues and preventing unnecessary lockouts, thus improving the efficiency and reliability of fuel-fired appliances.
Implementation Method 1
The antenna may be configured to detect operation of the ignition assembly. The control module may be connected to the antenna to receive the detected signal. In some cases, the control module may monitor the signal from the antenna, and determine a relative amount of electromagnetic interference (EMI) or electrical noise adjacent the igniter.
Implementation Method 2
A system comprising a controller, antenna, and optical detector is used to monitor electromagnetic interference (EMI) and electrical characteristics near the igniter
Implementation Method 3
the igniter is configured to produce a spark that ignites fuel during an ignition trial when the fuel fired appliance is operating properly
Data Source
AI summary
A control system for a fuel-fired appliance and methods of operating are disclosed. In an illustrative embodiment, when an electrical characteristic of an optical detector, such as a resistance, does not change by at least a predetermined amount during an ignition trial, and/or when a level of EMI or electrical noise detected by an antenna in a burner assembly of the fuel-fired appliance does not increase during the ignition trial, the control system may determine that the ignition assembly is not sparking properly. In some instances, the control system may also be programmed to activate an indicator that would indicate to a user or technician a potential problem with the ignition assembly (e.g. not sparking properly to ignite fuel).