Integrated Controller for Pressurized IR Burner Systems
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing controllers for infrared (IR) burner systems are costly, making small IR systems unattractive due to high compliance costs with codes, and noisy combustion air blowers prevent their use in retail or restaurant settings, leading customers to opt for more expensive operating electric or convection heat sources.
Innovation Solution
A compact modular controller for IR burner arrays that integrates a gas control device and premix blower, reducing auxiliary equipment costs and noise, while maintaining compliance with codes, by providing a pre-mixed air/gas combustible mixture and including safety and monitoring features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional auxiliary equipment is used for IR burner systems, then code compliance is achieved, but system cost increases significantly
Solution Approach 1:
The patent combines the gas control valve and premix blower into a single integrated controller unit. This merging of previously separate auxiliary equipment components reduces the overall system complexity and cost while maintaining all necessary code-compliance functions for small IR burner systems.
2Use of energy by moving object
If traditional combustion air blowers are used, then adequate air supply is provided, but noise level increases
Solution Approach 1:
The patent extracts the blower from its traditional separate location and integrates it within the controller housing. This repositioning and integration of the combustion air blower reduces noise propagation while maintaining adequate air supply to the burner system.
3Device complexity
If integrated controller is used, then auxiliary equipment cost decreases, but device integration complexity increases
Solution Approach 1:
The patent merges the gas control valve and premix blower into a single integrated controller unit, reducing auxiliary equipment costs. The design accepts increased manufacturing integration complexity as a trade-off to achieve significant cost reductions in the overall system.
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 solution significantly reduces the total system cost by lowering auxiliary equipment costs to 20% while maintaining IR burner costs at 80%, making small IR systems economically viable and reducing noise, allowing their use in previously inaccessible settings.
Implementation Method 1
The gas control device mixes the air and gas to form a pressurized combustible mixture
Implementation Method 2
a pressurized combustible mixture which is fed into the burner
Data Source
AI summary
An operating and control package for at least one pressurized burner. The operating and control package comprises a controller and a gas control device. The controller is an integrated packaged unit for supplying and controlling a pre-mixed air/gas pressurized burner. A housing is provided for containing the controller. The housing is preferably located at the end of the burner manifold. The gas control device comprises a gas control valve for receiving gas entering the control package and a premix blower located within the housing for receiving gas from the gas control valve and air entering the control package. The gas control device mixes the air and gas to form a pressurized combustible mixture which is fed into the burner.