Kiln Fuel-Oxidizer Control via Oxygen Sensors
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Solution Overview
Problem
Existing kiln systems for firing ceramic articles require complex manual adjustments to optimize the fuel-to-oxidizer ratio, leading to inefficiencies and increased production scrap due to operator dependency and inability to replicate precise firing conditions.
Innovation Solution
A kiln system with electrically operated adjustment valves and flow rate measuring devices, controlled by a processing unit that adjusts fuel and oxidizer flow rates based on real-time temperature and oxygen concentration measurements to maintain optimal firing conditions, allowing for precise control and automation of the firing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual adjustment of fuel and oxidizer flow rates is used, then flexibility in adjusting weight ratio is achieved, but operation complexity increases and requires expert technicians
Solution Approach 1:
The patent replaces manual mechanical adjustment with an automated control system that uses sensors to detect oxygen concentration and a controller to automatically adjust the weight ratio between fuel and oxidizer, eliminating the need for expert technicians while maintaining adjustment flexibility
Solution Approach 2:
The patent implements a feedback control system where oxygen concentration sensors continuously monitor the firing atmosphere and provide real-time data to the controller, which automatically adjusts the fuel and oxidizer flow rates to maintain optimal weight ratios without manual intervention
2Manufacturing precision
If manual adjustment of weight ratio is performed, then optimization of firing conditions is possible, but production downtime increases due to manual intervention
Solution Approach 1:
The patent enables the kiln system to self-adjust the weight ratio between fuel and oxidizer through automated control based on real-time oxygen concentration measurements, eliminating the need for manual intervention and preventing production downtime while maintaining optimal firing conditions
Solution Approach 2:
The patent ensures continuous optimization of firing conditions through automated real-time adjustment of the weight ratio, allowing the kiln to maintain optimal performance without interruption or downtime associated with manual adjustments
3Measurement precision
If expert technician intervention is required for adjustment, then precise control of weight ratio is achieved, but operator dependency increases and replication becomes difficult
Solution Approach 1:
The patent replaces expert technician judgment and manual adjustment with an automated electronic control system that uses oxygen concentration sensors and programmed algorithms to precisely control the weight ratio, achieving consistent precision without operator dependency
Solution Approach 2:
The patent enables replication of optimal firing conditions by storing and reproducing weight ratio settings through the automated control system, allowing consistent reproduction of ceramic products without relying on individual technician expertise
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
Enables accurate and rapid adjustment of firing conditions, reducing production downtime and scrap, and allowing for consistent reproduction of ceramic products by automating the optimization of fuel-to-oxidizer ratios and temperature control.
Implementation Method 1
a detection device configured to detect the concentration of oxygen inside said firing chamber
Implementation Method 2
a flow rate measuring device configured to measure the flow rate of the fuel or of the oxidiser which is fed to the burner
Implementation Method 3
Each burner comprises a mixing body, in which a predefined quantity (flow rate) of fuel (for example methane gas) and a predefined quantity (flow rate) of oxidiser (typically ambient air having approximately 21% of oxygen) are mixed together to generate a combustion mixture, and a combustion chamber in which said combustion mixture is burnt, thus heating the firing area
Data Source
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AI summary
A method and kiln (1) for the firing of substantially but not necessarily flat base ceramic articles (BC); the kiln (1) comprises: at least one firing chamber (7); at least one burner (4) to burn a combustion mixture to heat the firing chamber (7) so as to fire the base ceramic articles (BC) and obtain ceramic slabs (PC); a detection device (11) to detect a temperature in the firing chamber (7); two flow rate measuring devices (19, 21) to estimate the flow rates of the fuel and the oxidiser fed to the burner (4); and at least one processing unit (20) which is configured to adjust feeding of the fuel and oxidiser depending on the temperature detected by the first detection device (11) and depending on the flow rates of the fuel and the oxidiser estimated by the flow rate measuring devices (19, 21).