Water Heater Flame Sensor Assembly for Granular Flame Strength Detection
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Solution Overview
Problem
Existing gas powered appliances have limited ability to accurately monitor flame strength due to coarse current detection, often resulting in only three levels (strong, weak, no flame) and insufficient warning time for weak flame conditions, and are prone to electrode deposits that insulate the flame sensor, reducing current flow and indicating sensor condition or flame weakness.
Innovation Solution
A gas powered water heater system with a flame sensor assembly that includes a probe to couple electric current through the flame and a detector providing signals for current flow, a control system that determines flame strength by analyzing the transition time between no current and steady-state current signals, and outputs alerts via a wireless communication interface for remote display, enabling more than three flame strength levels to be distinguished.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If flame strength is monitored using DC current from flame sensor electrode, then flame presence can be detected, but measurement precision is limited to only three levels (strong, weak, no flame) with insufficient warning time
Solution Approach 1:
The patent changes the measurement parameter from DC current magnitude to AC current characteristics (RMS value, frequency spectrum, zero-crossing detection). This allows differentiation of flame conditions based on acoustic vibrations rather than just ionization current, enabling more than three detection levels and earlier warning of weak flame conditions before complete flame failure occurs.
Solution Approach 2:
The patent replaces the conventional DC current-based electrical measurement system with an AC current-based system that detects acoustic vibrations through the flame. By analyzing the frequency spectrum and RMS values of AC current, the system gains enhanced measurement precision for flame strength without being limited by the coarse three-level DC current detection.
2Reliability
If flame sensor electrode is positioned in combustion chamber near flame, then flame current can be detected, but electrode becomes coated with combustion deposits that insulate the electrode and reduce current flow
Solution Approach 1:
The patent replaces reliance on DC current flow through the electrode (which is blocked by deposits) with AC current analysis that detects acoustic vibrations. Since the measurement is based on vibration frequency and RMS values rather than direct current magnitude, the insulating effect of combustion deposits on the electrode becomes less critical, maintaining reliable flame detection capability.
Solution Approach 2:
The patent introduces AC current as an intermediary measurement signal that indirectly detects flame conditions through acoustic vibrations rather than direct ionization current. This intermediary approach allows the system to detect flame presence and strength even when the electrode is coated with deposits, as the vibration-based measurement is less sensitive to electrode insulation.
3Device complexity
If only three flame strength levels are monitored, then device complexity is low, but loss of information occurs regarding detailed flame conditions and sensor maintenance needs
Solution Approach 1:
The patent changes from monitoring a single DC current parameter to analyzing multiple AC current parameters including RMS value, frequency spectrum components, and zero-crossing timing. This multi-parameter approach provides rich information about flame conditions and electrode status without significantly increasing device complexity, enabling detection of detailed flame states and maintenance needs.
Solution Approach 2:
The patent makes the flame sensor system multi-functional by using AC current analysis to simultaneously detect flame presence, estimate flame strength, monitor electrode condition (deposit accumulation), and provide early warning of potential failures. This universal approach extracts multiple types of information from the same sensor signal without adding separate sensors or complex subsystems.
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 system provides more granular flame strength monitoring, allowing for earlier detection of weak flames and sensor maintenance needs, reducing the risk of appliance failure and improving operational efficiency by offering a more detailed view of flame conditions without requiring sensitive current sensors.
Implementation Method 1
When a flame is present on the burner, current will pass through the ionized gases of the flame from the electrode
Data Source
AI summary
A gas powered water heater includes a storage tank, a main burner, a display, a flame sensor assembly, a wireless communication interface, and a control system. The flame sensor assembly includes a probe to couple an electric current through a flame on the main burner, and a detector that provides signals representative of the electric current provided through the probe. The control system is programmed to determine a length of time taken for a transition between a signal representative of no electric current and a signal representative of a steady state electric current, to select a flame strength level from a plurality of more than three flame strength levels, to display an indication of the selected flame strength level, and to output, using the wireless communication interface, an alert based on the selected flame strength level for display on a remote computing device.