Thermostatic Stove Control Using Flame Sensor Override
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Solution Overview
Problem
Existing thermostatic control devices for portable liquid fuel stoves are labor-intensive and inconvenient to operate, requiring manual adjustment of the burner unit to maintain desired temperatures, especially in demanding conditions like military field operations.
Innovation Solution
A thermostatic control device that includes a temperature sensor, controller, and flame sensor to automatically regulate the stove's temperature by simulating the presence or absence of a flame, using a compressor and fuel delivery system, allowing for precise temperature control without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual adjustment of the burner unit is used to maintain desired temperature, then the appliance can be operated without additional control systems, but the operation becomes labor-intensive and inconvenient
Solution Approach 1:
The system performs self-service temperature control by automatically monitoring temperature via the temperature sensor and adjusting the burner output through the controller without requiring manual intervention. The flame sensor continuously monitors combustion status and the system self-regulates fuel flow and air mixture to maintain desired temperature, eliminating the need for manual adjustment while keeping the control architecture relatively simple.
Solution Approach 2:
The system implements feedback control by continuously monitoring the actual temperature with a temperature sensor and comparing it to the desired setpoint. The controller automatically adjusts the burner output based on this feedback, creating a closed-loop control system that maintains precise temperature control without manual intervention. The flame sensor provides additional feedback on combustion status to ensure safe and efficient operation.
2Productivity
If automated temperature control is implemented, then manual labor is reduced, but the device complexity increases due to additional sensors and control mechanisms
Solution Approach 1:
The controller serves multiple functions: it regulates burner output based on temperature feedback, monitors flame presence through the flame sensor, and coordinates the operation of both the temperature sensor and flame sensor data. This multi-functionality consolidates control logic into a single device, improving productivity while limiting the increase in overall system complexity.
Solution Approach 2:
The system replaces manual mechanical adjustment of the burner with an automated electronic control system. The controller electronically regulates fuel flow and air mixture based on sensor inputs, substituting mechanical manual operation with automated electronic control. This increases temperature regulation efficiency while the electronic nature of the system keeps the added complexity manageable.
3Reliability
If the control device is integrated into the appliance, then the system operates as a unified unit, but retrofitting to existing appliances becomes difficult
Solution Approach 1:
The control system is segmented into separate functional modules: a temperature sensor that can be positioned near the appliance, a flame sensor, and a controller that can be mounted remotely. This segmentation allows the components to be installed on existing appliances without requiring complete integration into the original appliance structure, maintaining reliability while enabling retrofitting capability.
Solution Approach 2:
The controller acts as an intermediary device that interfaces with the existing appliance components. Rather than requiring deep integration into the appliance's internal structure, the controller receives data from external sensors and controls the burner through standard interfaces, serving as a mediator between the new control system and the existing appliance architecture. This enables reliable operation while maintaining adaptability for retrofitting.
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 reliable and efficient temperature control of food preparation or sanitation appliances, reducing manual labor and ensuring consistent performance across varying conditions, while being retrofittable to existing appliances.
Implementation Method 1
a temperature sensor... When the temperature sensor senses that the actual temperature of the appliance
Implementation Method 2
a flame sensor which senses the presence or absence of a flame in the burner
Implementation Method 3
The appliance comprises a compressor which supplies pressurized air to the burner
Data Source
AI summary
A thermostatic control device for controlling the temperature of a food preparation or sanitation appliance comprises a temperature sensor, a controller in communication with the temperature sensor, and means for operatively connecting the controller to the appliance. When the temperature sensor senses that the actual temperature of the appliance is equal to or greater than a maximum threshold temperature, the controller shuts-off the compressor and overrides the flame sensor such that the appliance acts as if a flame is present. When the temperature sensor senses that the actual temperature of the appliance is equal to or less than a minimum threshold temperature, the controller starts-up the compressor and overrides the flame sensor such that the appliance acts as if a flame is absent.