Pilot Flame Device Ionization Sensing for Oxycutting
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Solution Overview
Problem
Existing oxycutting systems with pilot flame devices are unreliable in high-temperature environments, such as continuous casting plants, as the pilot flame can be extinguished by water sprays or air flows, and current sensing technologies cannot accurately detect the presence or absence of the pilot flame, leading to manual re-ignition requirements and potential halting of casting lines.
Innovation Solution
A pilot flame device with a sensing and ignition system using a metal rod and ceramic insulation to generate a stable pilot flame, where the presence of the flame is monitored by ionization current and automatically reignited if absent, ensuring continuous flame presence and reducing manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If infrared sensors are used to detect pilot flame presence, then automatic ignition can be implemented, but the sensor becomes unreliable in high-temperature environments and cannot accurately detect flame presence
Solution Approach 1:
The patent replaces the infrared optical sensing system with an electrical sensing system using a metal rod electrode. Instead of detecting thermal radiation optically, the system uses electrical field interaction with the flame - the flame's ionization creates a conductive path that can be detected electrically between the metal rod and ground, providing reliable detection in high-temperature environments where infrared sensors fail.
2Adaptability or versatility
If pilot flame devices are used in continuous casting plants, then oxycutting can be performed on high-temperature products, but the flame becomes unstable and extinguishes due to water sprays and air flows
Solution Approach 1:
The patent introduces a metal rod electrode as an intermediary element that serves dual purposes: it acts as a sensing element to detect flame presence through electrical field interaction, and simultaneously serves as an ignition electrode to reignite the pilot flame when extinguished. This intermediary enables automatic recovery from extinction events caused by water sprays or air flows in continuous casting environments.
Solution Approach 2:
The system implements feedback control by continuously monitoring the electrical field between the metal rod and ground to detect flame presence. When the flame is detected as extinguished (no conductive path), the system automatically triggers the ignition system to reignite the pilot flame, creating a closed-loop control that maintains flame stability despite external disturbances.
3Ease of operation
If manual re-ignition of the pilot flame is required, then specialized personnel must intervene, but this halts continuous casting operations and reduces productivity
Solution Approach 1:
The patent implements self-service automation where the system automatically detects pilot flame extinction and triggers its own re-ignition without requiring manual intervention. The metal rod electrode continuously monitors flame presence and automatically activates the ignition system when flame loss is detected, enabling the system to service itself and maintain continuous operation of the casting line.
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 system reliably maintains a pilot flame in high-temperature environments, preventing unnecessary halts in continuous casting operations and ensuring consistent ignition of the oxycutting device, while reducing the number of components and system bulk.
Implementation Method 1
the presence of the flame is monitored by ionization current
Implementation Method 2
The hollow tubular element comprises... a ceramic insulation electrically isolating the metal rod from the hollow tubular element
Implementation Method 3
a device arranged to generate a pilot flame for igniting an oxycutting device
Data Source
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AI summary
An oxycutting system comprising an oxycutting device (1) and a device (2) for generating a pilot flame for igniting said oxycutting device, in which said pilot flame device (2) is of the type comprising: at least one element for feeding to a nozzle a combustible mixture for feeding said pilot flame generated at said nozzle, and means for automatically sensing the presence of said pilot flame.