Modular Gas-Air Mixer With Interchangeable Inserts
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Solution Overview
Problem
Current gas-air mixers for boilers require separate configurations for different energy levels and gas families, leading to increased production complexity, costs, and the need for multiple molds, as they cannot efficiently modulate fan speeds or handle varying gas qualities without separate mixers.
Innovation Solution
A modular gas-air mixer design featuring a turbulator and valve system that adjusts air turbulence and flow without changing the inner or outer body, allowing a single mixer to serve multiple energy levels and gas families by modifying the turbulator and valve system, thereby reducing production and inventory costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate gas-air mixer configurations are used for different energy levels, then the mixing performance for each specific energy level is optimized, but the production complexity and costs increase due to the need for multiple molds and continuous mold changes
Solution Approach 1:
The gas-air mixer is divided into modular components: a common body structure and interchangeable inserts (gas valve assemblies). Each insert is designed for specific energy levels, allowing rapid replacement during production without changing the entire mixer or molds, thus maintaining mixing performance while reducing production complexity
Solution Approach 2:
A single mixer body design serves multiple energy levels (24 kW, 45 kW, etc.) by accepting different insert configurations. The universal body structure with standardized mounting interfaces allows the same mold to produce mixers for various boiler capacities, eliminating the need for multiple specialized molds
2Manufacturing precision
If separate gas-air mixer configurations are used for different energy levels, then the mixing performance for each specific energy level is optimized, but the production costs increase due to the need for multiple molds and continuous mold changes
Solution Approach 1:
By segmenting the mixer into a permanent body and replaceable inserts, the production process uses one mold for the body and simpler secondary processes for inserts. This eliminates costly continuous mold changes and reduces overall production costs while maintaining optimized mixing performance through insert-specific designs
Solution Approach 2:
The insert components can be discarded after wear or damage and replaced with new inserts rather than replacing the entire expensive mixer body. This recovery approach reduces long-term production and maintenance costs while preserving the investment in the precision-machined body
3Ease of manufacture
If the gas-air mixer uses a fixed configuration, then the production process is simplified, but the ability to adapt to different gas families and energy levels is reduced
Solution Approach 1:
The mixer transitions from a fixed configuration to a dynamic, reconfigurable system where inserts can be changed based on gas family requirements and energy levels. The standardized interface allows rapid reconfiguration without complex adjustments, maintaining production simplicity while enhancing adaptability
Solution Approach 2:
Different inserts provide varying parameters (hole patterns, sizes, arrangements) to accommodate different gas families and energy levels within the same body. This parameter variability is achieved through modular insert design rather than changing the entire mixer configuration
4Productivity
If higher fan speeds are used to increase modulation rate, then the gas-air mixture amount increases, but the noise level and pressure loss increase
Solution Approach 1:
The insert design optimizes local flow characteristics at the gas injection points with specifically configured holes and passages. This local optimization ensures efficient mixing at lower fan speeds, achieving high modulation rates without the need for high-speed operation that would generate excessive noise
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 efficient modulation of gas-air mixtures across different energy levels and gas families with reduced pressure loss and noise, maintaining safe fan speeds, and minimizing production costs by using a single modular design for various boiler capacities.
Implementation Method 1
the negative pressure (the vacuum effect) is obtained by means of a venturi arranged on the suction side of the fan, wherein a locally higher flow velocity and negative pressure are obtained by locally reducing the flow cross-section (Bernoulli-equation)
Implementation Method 2
an air inlet channel body (31) including a narrowing section (312)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates to a gas-air mixer (venturi) (1) which is used to transfer gas and air into the combustion chamber in gas burning devices such as boilers upon mixing thereof, comprising at least one outer body (2) which has at least one gas inlet (21) for gas transfer to its inner part and has a volume inside, at least one inner body (3) which is placed inside the outer body (2), comprises an inlet for air passage and an outlet for air-gas mixture, and at least one opening (33) for gas passage therein from the outer body (2), at least one turbulator (4) and/or valve system (5) which is positioned on the air inlet of the inner body (3) and used for making the air turbulent and/or adjusting the air passage amount.