Optical Burner Flame Detection for Safe Hydrogen Ignition
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Solution Overview
Problem
Existing burner control systems are inadequate for hydrogen gas due to unreliable flame supervision and unsafe combustion initiation, leading to potential explosions and loud ignition bangs, which are unfamiliar to consumers accustomed to natural gas systems.
Innovation Solution
A burner control system with a controller, optical sensor, and controllable valve that monitors hydrogen flames using UV light levels to ensure safe operation, including pre-ignition spark detection and safety procedures to prevent gas accumulation and explosions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional control methods with fixed switching points are used, then the control logic is simple, but the efficiency is poor and emissions are high when ambient temperature or water temperature curves deviate from expected values
Solution Approach 1:
The patent applies dynamics by making the switching points adaptive rather than fixed. The control system dynamically adjusts the switching points based on actual ambient temperature and water temperature measurements, allowing the control logic to adapt to varying environmental conditions and optimize heating efficiency in real-time.
Solution Approach 2:
The patent implements feedback by continuously monitoring ambient temperature and water temperature and using this information to adjust the switching points. The control system receives feedback from temperature sensors and modifies its operation accordingly, creating a closed-loop control system that optimizes efficiency based on actual conditions.
2Loss of energy
If the burner is switched off early based on fixed temperature differences, then energy consumption is reduced, but the heating circuit temperature may be insufficient leading to inadequate room temperature
Solution Approach 1:
The patent applies preliminary action by calculating and storing multiple switching points in advance based on different ambient temperatures and temperature differences. When operation begins, the system selects the appropriate pre-calculated switching point based on current conditions, enabling energy-efficient early shutdown while ensuring the heating circuit reaches sufficient temperature.
Solution Approach 2:
The patent implements parameter changes by adjusting the switching temperature differences based on ambient temperature conditions. The system modifies operational parameters (switching points) according to environmental conditions, allowing energy savings in mild conditions while maintaining heating adequacy in colder conditions.
3Loss of energy
If high switching temperature differences are used, then energy consumption is reduced, but the risk of overheating increases when ambient temperature is higher than expected
Solution Approach 1:
The patent applies dynamics by making the switching points adaptive rather than fixed. The control system dynamically adjusts the switching points based on actual ambient temperature and water temperature measurements, allowing the control logic to adapt to varying environmental conditions and optimize heating efficiency in real-time.
Solution Approach 2:
The patent implements preliminary anti-action by pre-calculating multiple switching points for different ambient temperature conditions and selecting the appropriate one before operation begins. This prevents overheating by ensuring the switching point is already set to an appropriate temperature difference based on expected ambient conditions, countering potential overheating risks before they occur.
4Productivity
If multiple switching points are calculated and stored for different ambient temperatures, then efficiency is optimized across varying conditions, but the control system complexity and memory requirements increase
Solution Approach 1:
The patent applies preliminary action by calculating and storing multiple switching points in advance based on different ambient temperatures and temperature differences. When operation begins, the system selects the appropriate pre-calculated switching point based on current conditions, enabling energy-efficient early shutdown while ensuring the heating circuit reaches sufficient temperature.
Data Source
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AI summary
The present disclosure relates to a burner control system, comprising a controller, a burner connectable to a combustible gas supply and comprising a controllable valve coupled to the controller, an optical sensor arranged at the burner and coupled to the controller, wherein the controller is configured to determine a use state of the burner, from a group of use states comprising at least an ignition state, based on a measurement signal of the optical sensor that is indicative for a light level corresponding to said use state, and to selectively control the controllable valve in dependency of said use state of the burner.