Surface Burner Manufacturing via Perforated Cover Alignment
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Solution Overview
Problem
The existing methods for manufacturing surface burners with burner plates and covers are prone to errors due to the precision required in attaching knitted fiber fabrics, leading to potential gaps and channels that can result in suboptimal or dangerous operation and damage to the burner.
Innovation Solution
A method involving perforating the burner cover along the first edge, aligning it on the burner plate, securing the main portion to the plate by welding, and then separating the relief area, ensuring proper attachment and minimizing the risk of misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the woven fiber fabric is attached to the burner plate in the area of the recess with high precision, then the distance between the fabric and burner plate remains constant, but the attachment process becomes demanding and prone to errors
Solution Approach 1:
The recess is created in the burner plate before the woven fiber fabric is attached. This preliminary action allows the fabric to be positioned and secured more easily, as the recess provides a predefined location that guides proper placement and reduces alignment complexity during the attachment process
Solution Approach 2:
The recess acts as an intermediary structure between the burner plate and the woven fiber fabric. It provides a mechanical interface that facilitates attachment while maintaining a constant distance, thereby reducing the precision demands on the attachment process itself
2Reliability
If the recess is misaligned during attachment, then gaps and channels form that can carry flames, but correcting this requires rework and increases error risk
Solution Approach 1:
The recess is pre-formed in the burner plate before attachment, establishing the correct position and geometry in advance. This preliminary preparation ensures that when the woven fiber fabric is attached, it naturally aligns with the recess, preventing misalignment errors and eliminating the need for complex correction procedures
Solution Approach 2:
The recess structure provides a built-in alignment guide and positioning feature that cushions against misalignment errors. By designing the attachment interface with this preliminary geometric constraint, the system tolerates minor positioning variations and prevents the formation of dangerous gaps and channels
3Ease of manufacture
If the burner cover is attached before perforation, then alignment is easier, but the perforation process becomes more complex and time-consuming
Solution Approach 1:
The burner cover is perforated before being attached to the burner plate. This preliminary perforation allows the cover to be prepared in advance, and the perforation process can be optimized independently. The alignment features are then used to quickly position the pre-perforated cover during attachment, maintaining efficiency while ensuring proper alignment
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
This method allows for the production of surface burners with reliable and precise operation, enabling effective monitoring and control of combustion quality while minimizing wear and tear and ensuring safe operation.
Implementation Method 1
The burner plate is a perforated plate, usually made of metal. The burner plate serves to distribute the fuel-air mixture evenly within the flame zone.
Implementation Method 2
The burner cover is permeable to the fuel-air mixture. Its purpose is to favorably influence the combustion of this mixture. For example, the burner cover can cool the flames and/or influence flame formation, particularly with regard to flame geometry.
Implementation Method 3
securing the main area to the burner plate along the first edge, for example by welding
Data Source
Figure 1
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AI summary
The invention relates to a method (76) for manufacturing a surface burner (28) with a burner plate (54) and a burner cover (62), comprising a main area (72), a recess area (80) having a recess (66), and a first edge (70) separating the main area (72) and the recess area (80), comprising the following steps: • Perforating (78) the burner cover (62) along the first edge (70); • Aligning (90) the burner cover (62) on the burner plate (54) so that the recess area (80) largely rests on a monitoring area (68) of the burner plate (54); • Attaching (98) the main area (72) to the burner plate (54) along the first edge (70), for example by welding; • Separating and removing (100) the recess area (80).The invention also relates to a surface burner (28) with a burner plate (54) and a burner cover (62), manufactured in a method (76) according to the present invention.