ATOMIZATION BURNER WITH FLEXIBLE FIRE RATE

Abstract

An atomizing burner and corresponding method for turning an atomizing burner from an ON state to an OFF state. The burner has independently controllable flows of atomizing air, combustion air, and fuel flow, the burner in the ON state having flow values of burner parameters including flow of atomizing air, flow of combustion air, and fuel flow. The method includes: changing, in response to an OFF instruction, flow of at least one of the flow of atomizing air, combustion air and/or fuel to a lower non-zero value; first discontinuing, after a first period of time since the changing, flow of fuel and flow of atomizing air; maintaining, for a second period of time since the first period of time, flow of combustion air; second discontinuing, after the maintaining, flow of combustion air; wherein the maintaining prevents buildup of excess heat inside the burner during the transition to the OFF state.

Claims

1-12. (canceled)

13. A method for turning a burner from an OFF state to an ON state, the burner having independently controllable flows of atomizing air, combustion air, and fuel, the burner in the ON state having flow values of burner parameters including flow of atomizing air, flow of combustion air, and flow of fuel, the method comprising: first setting the flow of combustion air to purge excess heat from the burner; second setting, after the first setting, the flow of fuel to prime the burner; first changing, after the second setting, the flow of combustion air and the flow of fuel to values that support inducing ignition; igniting, after the first changing, the flow of fuel; detecting, after the igniting, flame in a flame tube of the burner; and second changing, in response to the detecting, the flow of atomizing air, the flow of combustion air, and/or the flow of fuel to support a target heat output of the burner.

14. The method of claim 13, wherein the first setting sets the flow of combustion air to a maximum output of the burner for a period of time.

15. The method of claim 14, wherein the second setting occurs after the period of time of the first setting.

16. The method of claim 13, wherein the second setting occurs after a predetermined period of time from commencement of the first setting.

17. The method of claim 13, wherein the igniting comprises: third setting the flow of atomizing air to a value that supports inducing ignition; and turning on an ignitor.

18. The method of claim 13, wherein the second changing comprises changing, in response to the detecting, the flow of atomizing air, the flow of combustion air, and the flow of fuel to values that support a target heat output of the burner.

19. An burner having an atomizing head and a flame tube, comprising: a DC fuel motor adapted to deliver a flow of fuel to the atomizing head; a DC atomizing air motor adapted to provide a flow of atomizing air to an opening in the atomizing head where atomizing air will atomize the flow of fuel; a DC combustion air motor adapted to deliver a flow of combustion air to the flame tube to aid in combustion of atomized fuel; a controller comprising a combination of hardware and software programmed to turn the burner ON and OFF, wherein to turn a burner ON from OFF the controller will cause the burner to perform operations comprising: first setting the flow of combustion air to purge excess heat from the burner; second setting, after the first setting, the flow of fuel to prime the burner; first changing, after the first setting, the flow of combustion air and the flow of fuel to values that support inducing ignition; igniting, after the first changing, the flow of fuel; detecting, after the igniting, flame in a flame tube of the burner; and second changing, in response to the detecting, the flow of atomizing air, the flow of combustion air, and/or the flow of fuel to support a target heat output of the burner.

20. The burner of claim 19, wherein the first setting sets the flow of combustion air to a maximum output of the DC combustion air motor for a period of time.

21. The burner of claim 20, wherein the second setting occurs after the period of time of the first setting.

22. The burner of claim 19, wherein the second setting occurs after a predetermined period of time from commencement of the first setting.

23. The burner of claim 19, wherein the igniting comprises: third setting the flow of atomizing air to a value that supports inducing ignition; and turning on an ignitor.

24. The burner of claim 19, wherein the changing comprises changing, in response to the detecting, the flow of atomizing air, the flow of combustion air, and the flow of fuel to values that support a target heat output of the burner.

Description

DRAWINGS

[0014] Various embodiments in accordance with the present disclosure will be described with reference to the drawings, in which:

[0015] FIG. 1 shows an embodiment of the invention.

[0016] FIG. 2 shows an embodiment of the invention inside of a burner.

[0017] FIG. 3 is an exploded view of the embodiment of FIG. 2.

[0018] FIG. 4 shows the atomizing chamber and flame tube of FIG. 2.

[0019] FIG. 5 shows the support and photodiode of FIG. 2.

[0020] FIG. 6 shows the microcomputer of FIG. 2.

[0021] FIG. 7 shows the ignitor transformer of FIG. 2.

[0022] FIG. 8 shows the compressor of FIG. 2.

[0023] FIG. 9 shows the fuel metered pump of FIG. 2.

[0024] FIG. 10 shows the blower of FIG. 2.

[0025] FIG. 11 shows a prior art blower.

[0026] FIG. 12 is a flowchart of an embodiment of an OFF protocol.

[0027] FIG. 13 is a flowchart for an embodiment of an ON protocol.

DETAILED DESCRIPTION

[0028] In the following description, various embodiments will be illustrated by way of example and not by way of limitation in the figures of the accompanying drawings. References to various embodiments in this disclosure are not necessarily to the same embodiment, and such references mean at least one. While specific implementations and other details are discussed, it is to be understood that this is done for illustrative purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without departing from the scope and spirit of the claimed subject matter.

[0029] Several definitions that apply throughout this disclosure will now be presented. The term “substantially” is defined to be essentially conforming to the particular dimension, shape, or other feature that the term modifies, such that the component need not be exact. For example, “substantially cylindrical” means that the object resembles a cylinder, but can have one or more deviations from a true cylinder. The term “comprising” when utilized means “including, but not necessarily limited to”; it specifically indicates open-ended inclusion or membership in the so-described combination, group, series and the like. The term “a” means “one or more” unless the context clearly indicates a single element. The term “about” when used in connection with a numerical value means a variation consistent with the range of error in equipment used to measure the values, for which ±5% may be expected. “First,” “second,” etc., are labels to distinguish components or steps of otherwise similar names, but does not imply any sequence or numerical limitation.

[0030] As used herein, the term “front”, “rear”, “left,” “right,” “top” and “bottom” or other terms of direction, orientation, and/or relative position are used for explanation and convenience to refer to certain features of this disclosure. However, these terms are not absolute, and should not be construed as limiting this disclosure.

[0031] Shapes as described herein are not considered absolute. As is known in the burner art, surfaces often have waves, protrusions, holes, recess, etc. to provide rigidity, strength and functionality. All recitations of shape (e.g., cylindrical) herein are to be considered modified by “substantially” regardless of whether expressly stated in the disclosure or claims, and specifically accounts for variations in the art as noted above.

[0032] Referring now to FIG. 1, a conceptual drawing of a burner 100 according to an embodiment of the invention is shown. Various components are connected by various pathways which can communicate air and/or liquid, such that all pathways are to be considered fluid pathways. It is to be understood for purposes of the conceptual nature of FIG. 1 that each “pathway” refers generically to a path by which a fluid moves from one point to of burner 100 to another, and does not imply any structure or location of the pathway; pathway may not even be a structure at all, as it may simply refer to the path travelled by fluid under gravity.

[0033] An atomizing air pump 102, such as an air compressor, is provided to deliver clean air along a pathway 104 to an atomizing chamber supporting at least one atomizing head 106. Atomizing head 106 has a convex surface with an orifice for spray dispensing fuel consistent with the Babington atomization principle. When fuel is poured over atomizing head 106 (as described below) and ignited, the combusting fuel will generate a flame plume 108 laterally in a flame tube (not shown in FIG. 1). Atomizing air pump 102 includes a first adjustable speed DC motor 110, which is controlled by a microcomputer 112. Microcomputer 112 thus controls the flow speed of atomizing air provided by atomizing air pump 102.

[0034] A fuel tank 114 is provided with fuel 116 for burner 100, and is preferably located such that the top surface of fuel 116 is below atomizing head 106. An inlet pathway 118 extends from fuel tank 114 to fuel pump 120, and an outlet pathway 122 extends from fuel pump 120 to a point above atomizing head 106. Fuel pump 120 includes a second speed adjustable DC motor 124, which is controlled by microcomputer 112. Microcomputer 112 thus controls the rate of fuel flow 126 delivered from fuel tank 114 to atomizing head 106.

[0035] As is known in the art, the amount of fuel 126 delivered to atomizing head 106 may exceed the amount that is actually ignited by burner 100. Excess fuel 128 falls by gravity along a return pathway 130 which directs the excess fuel 128 back into fuel tank 114.

[0036] A blower 132 is provided to deliver clean air for combustion along a pathway 134 to the area in front of and around atomizing head 106, preferably through the interior of the flame tube (not shown). Blower 132 includes a third speed adjustable DC motor 136, which is controlled by microcomputer 112. Microcomputer 112 thus controls the rate of combustion air to feed flame plume 108.

[0037] The conceptual design of FIG. 1 may be implemented using various known structures for the components. The various fluid pathways may be constructed from hoses, pipes, or segments thereof connected together in a known manner. In the alternative, the various pathways could be drilled through solid material, such as a steel block. In yet another alternative, the various pathways could be partially defined in opposing blocks that form the pathways when the blocks are connected together. Combinations of the above, as well as other connection forming techniques may be used.

[0038] Referring now to FIGS. 2 and 3, and non-limiting example of an embodiment of a burner 200 consistent with the concept of FIG. 1 is shown. Burner 200 includes a tube assembly 202, a blower 204, a microcomputer 206, a fuel reservoir 208, an ignition transformer 210, an atomizing air compressor 212, and a fuel metered pump 214. The various components are supported by a housing 216. Components are connected and mounted in manners known in the burner art and not further discussed herein.

[0039] Referring now to FIGS. 3 and 4, the combustion chamber 408 components of burner 200 are described in more detail. A tube assembly 202 includes an outer air tube 402, an inner flame tube 404, and an end cap 405. Blower 204 blows combustion air into the gap between inner flame tube 404 and outer air tube 402. Various air louvers 407 are provided in inner flame tube 404 to inject air in order to create a swirling combustion process inside inner flame tube 404. Perforated air pathways (not shown) may be provided on the end cap 405 to permit passage of combustion air to cool flame tube assembly 202 and/or to shape combusting fuel as it emerges from the air tube flame tube assembly. The mechanics of the role of the combustion air and non-limiting examples of hole/louver placement are found in U.S. Pat. No. 8,622,737 entitled PERFORATED FLAME TUBE FOR A LIQUID FUEL BURNER, the contents of which is incorporated by reference in its entirety. However, the invention is not so limited, and any number or displacement of holes could be used to introduce air in the inner flame tube 404.

[0040] An atomizing chamber 408 is rearward of the flame tube 404, and receives fuel from fuel reservoir 208 (pathway not shown). A mounting ring 412 is mounted on the rear of atomizing chamber 408. A support 410 is mounted in rearward of ring 412, and supports a photodiode 504 (FIG. 5). Atomizing chamber 408 includes an aperture 414 substantially at the center thereof, through which light from within the inner flame tube 404 can reach photodiode 504. Atomizing heads as known in the art (e.g., head 106 in FIG. 1) are rearward of lateral holes 418. A front casing 406 (which is part of the blower 204) has a flange that engages with the rear of outer air tube 402. However, the invention is not so limited, and other forms of atomizing chambers may be used.

[0041] Referring now to FIG. 5, the support 410 is shown in more detail. Support 410 supports a circuit board 502, which in turn supports photodiode 504. Photodiode 504 is part of a flame detection device described in more detail in U.S. Provisional Patent Application 62/274,879 discussed above. However, the invention is not so limited, and other forms and/or locations of flame detection could be used.

[0042] Referring now to FIG. 6, microcomputer 206 is shown in more detail. From hardware perspective, microcomputer 206 includes housing components 602, circuit board components 604, and display 606. The circuit board components includes standard computer components such as at least one interface, display, processor, memory, wireless modem, jack for wired modem, etc. as is well known in the art and not discussed further herein. Microcomputer 206 also includes software and/or stored data to control the operation of burner 200 as discussed further herein. Software may be periodically updated to allow for new control protocols. The invention is not limited to the particulars of the implementation of microcomputer 206, and the functionality therein may be in one unit as shown, multiple units, and/or work in cooperation with an external computer.

[0043] Referring now to FIG. 7, ignition transformer 210 is shown in more detail. Ignition transformer 210 includes housing components 702 and a printed circuit board 704. As is known in the burner art, ignition transformer 210 converts available external power (AC or DC, not shown) into the power to generate a spark that it provides to electrodes (not shown) in atomizing chamber 408. However, the invention is not so limited, and other forms of ignitors may be used.

[0044] Referring now to FIG. 8, atomizing air pump 212 is shown in more detail. Atomizing air pump 212 includes a DC motor 802 below a frame 804, a bearing 806, a piston 808, a piston bushing 810, a counterweight 812, an O-ring 814, a piston ring 816, and a compressor cylinder head 818. However, the invention is not so limited, and other forms of atomizing air pumps may be used. DC motor 802 drives piston 808 to provide clean air to the holes in atomizing heads 418 to spray fuel.

[0045] Referring now to FIG. 9, fuel pump 214 is shown in more detail. A bottom base plate 902, a support plate 904 and a top plate 906 define an inner chamber 908 with fluid inlet and outlet pathways 910 and 912. A DC motor 914 drives gears 916 within inner chamber 908 to draw fluid from fuel reservoir 208 to atomizing chamber 408. However, the invention is not so limited, and other forms of fuel pumps may be used.

[0046] Referring now to FIG. 10, blower 204 is shown in more detail. The outer shell is defined by front casing 406, and intermediate support 1002, and rear casing 1004. A DC motor 1006 drives a blower wheel 1008 to draw air through an opening in rear casing 1004 and blows it out front casing 406 into the space between inner and outer tubes 402 and 404 as discussed above. Intermediate support provides a mounting point for both motor 1006 and blower wheel 1008.

[0047] The above embodiment combusts fuel in a manner consistent with the Babington atomization principle. Fuel pump 214 delivers fuel over the atomizing heads 416. Atomizing air pump 212 pumps air through holes in the atomizing heads, spraying the delivered fuel into the inner flame tube 404. Blower 204 delivers combustion air into the inner flame tube 404 to facilitate combustion of the fuel. Ignition transformer 210 ignites the fuel spray to induce combustion.

[0048] Microcomputer 206 is connected to the three DC flow motors 802, 914, and 1006. As DC motors, their speed is adjustable to adjust the flow rates of fuel, atomizing air and combustion air. Microcomputer 206 can thus control the speeds of the three flow parameters that define how much heat burner 200 produces, such as by controlling the amount of voltage applied or rate of pulsing of the motors. The invention is not limited to the manner in which the microcomputer 206 controls the speed of the DC motors.

[0049] As noted above, in an atomization burner the flow of compressed air, combustion air and fuel must maintain a certain relationship in order to properly combust the fuel. Microcomputer 112 is accordingly programmed with protocols to set those three flow parameters to meet the desired goal of the system, which may be a target operating temperature of an appliance (e.g., 350 degrees) or certain heat output (e.g., low, medium, high and gradations there between). Preferably this is done algorithmically and/or through a database of parameters to meet the specific needs of the environment, such as the type of appliance, type of fuel, external temperature, presence of rain, etc. For example, the amount of heat needed to heat a stockpot cooker is different than to heat an oven, the latter being larger and traditionally operating at higher temperatures. Microcomputer could thus maintain one set of operating protocols for an oven, another for a stockpot cooker, etc.

[0050] The protocols could be specific, e.g., to reach a desired heat output set all three flow parameters to a certain value. The protocols may be adaptive, in that they are based on the current state of the burner relative to the target state; for example the flow parameters to heat an oven to 400 degrees from a starting state of room temperature may be different than if the starting state (or current state) of the oven is already at 300 degrees. The protocols may work on the “bang-bang” methodology, or may adjust the flow rates in response to current or predicted conditions to “soft land” at the target output to minimize overshoot. The protocols may call for certain flow parameters to use higher heat output under cold or rainy conditions or decrease heat output under hotter conditions. Other protocols may also be used. Protocols based on combinations of factors may also be used. The embodiments are not limited to the nature of the protocols used.

[0051] Microcomputer 206 can be programmed to implement specific turn ON and turn OFF protocols for the burner 200.

[0052] With respect to the ON protocol, the parameters for flow of atomizing air, combustion air and fuel may be different for ignition of the fuel as compared to running the blower. An ON protocol implemented by microcomputer 112 could thus be to set the flow parameters to a combination particular to ignition, detect the presence of flame via the flame detector, and then set the flow parameters to a combination particular to running the burner 200. Some or all of the parameters may be the same or different for ignition relative to running.

[0053] A non-limiting example of an ON protocol with respect to burner 100 of FIG. 1 is shown in FIG. 12, as implemented by microcomputer 112 to adjust the speed of motors 110, 124 and 136. Beginning with an OFF state in which all motors are inactive, an ON command is received at step 1202. At step 1204 the blower purges any residual heat from burner 100, preferably by setting the motor 136 to its maximum speed (e.g., 6500 rpm) for a period of time (e.g., 30 seconds or until the ambient burner temperature drops below a certain value). After completion of step 1204 the fuel pump 120 primes the fuel to the atomizing head 106, preferably by starting with a low speed of motor 124 (e.g., 600 rpm) increasing gradually to a fuel priming speed (e.g., 1200 rpm) and maintain the fuel priming speed for a period of time (e.g., 15 seconds); the objective is to drive all of the air out of the fuel lines and to adequately wet the atomizing head 106. At step 1208, the blower and fuel pump outputs are reduced to a speed to induce ignition (e.g., motor 124 to 400 rpm and motor 136 to 3500 rpm). After the burner reaches the new speeds, at step 1210 the fuel is ignited by turning on the ignitor and setting motor 112 of atomizing air compressor 102 to an ignition speed (e.g., 2200 rpm). At step 1212 the presence of flame is detected in the flame tube (e.g., through the methodology of U.S. patent application Ser. No. 15/153,98975, incorporated herein by reference in its entirety, although the invention is not so limited). In response to confirmation of flame the ignitor is shut off at step 1214, and at step 1216 the various flow parameters of burner 100 are changed to output the desired amount of heat.

[0054] With respect to a non-limiting example of an OFF protocol, flow parameters would continue (i.e., not be set to zero) but at least one of the flow parameters would be changed to preferably reduce the heat output, produce minimal pollution during the shutdown protocol, and impose minimal stress on the system. The change may increase or decrease the different flow parameters as needed to transition a shutdown transition state. After the transition state is reached the parameters are maintained for a first period of time to at least allow the transition state to stabilize. At the end of the first period of time the atomizing air and fuel flow would be stopped (e.g., by electric braking of the motors, and either simultaneously or in succession) while the flow of combustion air continues, possibly at different levels; the flow of combustion air is no longer for combustion purposes, but instead is preventing heat from building up in burner 200. After a second period of time, the combustion air flow is stopped (e.g., by electric breaking of the motor). The first and second times may be predetermined, or based on reaching detected target conditions. In addition and/or the alternative, the protocol may include reversing the flow of fuel (e.g., via reverse operation of motor 914) to clear the fuel lines.

[0055] A non-limiting example of an OFF protocol with respect to burner 100 of FIG. 1 is shown in FIG. 13, as implemented by microcomputer 112 to adjust the speed of motors 110, 124 and 136. Beginning with an ON state in which all motors are active, an OFF command is received at step 1302. At step 1304 the speed of motors 110, 124 and 136 changes to predefined non-zero transition levels (e.g., 1200 rpm for the atomizing air pump 102, 300 rpm for the fuel pump 120, and 3000 rpm for the blower 132) and maintained for a period of time (e.g., 1-3 seconds) to allow burner 100 to stabilize. At step 1306, atomizing air pump 102 and fuel pump 120 reduce speed (e.g., discontinue of power flow or electric braking, such reduction preferably being to zero rpm to discontinue flow entirely); preferably the reduction is simultaneous, but it may be sequential. At step 1308, blower continues to operate to remove excess heat, preferably by increasing motor 136 to maximum (e.g., 6500 rpm) and maintaining air flow for a period of time (e.g., 2 minutes) or until the burner or appliance heated by the burner drops to a desired temperature 150 F. When the target time/temperature is reached, at step 1310 blower 132 shuts down; air pump 102 and fuel pump 120 would also shut down at this point if they have not previously done so.

[0056] The above embodiments overcome various drawbacks over the prior art AIRTRONIC burner, particularly in connection with portable cooking appliances.

[0057] For example, the minimum fuel flow rate for burner 200 is about 0.155 GPH, which is on the order of 40% of the heat output and fuel consumed compared to the AIRTRONIC. The embodiments herein can thus generate less heat, and consume less fuel, than the AIRTRONIC. The embodiments also consume less power because unlike the AIRTRONIC the motors 802/914/1006 need not operate at maximum output. The current variable firing rate range of 0.155 GPH to 1.0 GPH far exceeds the operating ranges of the prior art AIRTRONIC burner.

[0058] Since the embodiments herein can generate less heat than the AIRTRONIC, it can be used with lighter/smaller cooking appliances, and/or enables off-grid self-powered capabilities. By way of non-limiting example, as discussed above an oven for use with the AIRTRONIC would be overbuilt to withstand the heat output and weighs on the order of 800 lbs., with a corresponding high specific heat that makes the oven slow to heat or cool. Embodiments herein can be used with an oven on the order of 200-250 lbs., which is cheaper to build, consumes less fuel to transport, easier to relocate on site, and can heat or cool much faster than its larger counterpart.

[0059] The embodiments herein can also operate without reliance on the “bang-bang” methodology, instead reducing the fuel flow rate as the target temperature is approached. This reduces the likelihood of overshooting the target temperature. Embodiments may precision load match the heat output of the burner with the load requirement of the appliance.

[0060] The embodiments herein also eliminate any need for a second blower in the appliance to prevent heat buildup. As noted above, when the AIRTRONIC is turned OFF, heat must be prevented from building up inside the flame tube; since the main blower is not active, a secondary blower is often present to provide venting air for 90-120 seconds. In the embodiments herein, blower 132 can continue to run during that period to provide the venting air. The embodiments herein thus remove any need for the secondary blower (although such a secondary blower may nonetheless still be present).

[0061] The embodiments herein are directed to use of burner with cooking appliances. However, the invention is not so limited, and other environments could be used.

[0062] The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. It will, however, be evident that various modifications and changes may be made thereunto without departing from the broader spirit and scope of the invention as set forth in the claims.