Torch system with predictive control of automatic fuel replenishment
11957120 ยท 2024-04-16
Inventors
Cpc classification
F23D2900/31012
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V37/0012
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V37/002
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F23D3/28
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F23K5/14
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F23D2202/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
A01M29/12
HUMAN NECESSITIES
A01M1/2066
HUMAN NECESSITIES
F23D2900/31014
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F23K5/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02B20/72
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F23D3/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F23D3/30
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V37/0045
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
A01M29/12
HUMAN NECESSITIES
F23D3/28
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F23D3/30
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F23K5/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
Torches are automatically refilled with a liquid fuel from a central reservoir pumped via a plumbing system, without directly monitoring local torch fuel levels. Instead, each torch includes a passive fuel overfill prevention valve. When refueling, the pump operates until all torches are filled. Refueling can cease after a set time, or when sensors report a backpressure and/or cessation of fuel flow. Pre-calibration establishes torch burning rates and/or maximum refill time. Time between refueling is predicted, based upon total burning time, which can be measured by torch heat sensors or determined according to a usage schedule or direct control of torch ignition and extinguishing by the controller. Reverse pumping can extinguish the torches, and wick ignitors can relight them sequentially. A service provider can monitor fuel consumption, establish a pattern of usage, and supply fuel in time to replenish the central reservoir, and/or other provide maintenance as needed.
Claims
1. An automatically refueled liquid fuel burning torch system comprising: a central fuel reservoir configured to contain a combustible liquid fuel; at least one torch: each of said torches having a substantially enclosed interior and a local fuel reservoir located within said enclosed interior, the local fuel reservoir being configured to contain a local quantity of said fuel; each of said torches further comprising a combustion area exterior to the torch and configured for burning said fuel when drawn by a wick from said local quantity into said combustion area; and each of said torches having a fuel overfill prevention valve (FOP valve) installed therein, said FOP valve being configured to be mechanically controlled by a local fuel level of the local quantity of fuel within the enclosed interior, and to be automatically closed when the local fuel level reaches a determined maximum height within the enclosed interior, thereby preventing further ingress of fuel into the local fuel reservoir; a fuel plumbing system configured to convey said fuel from the central fuel reservoir to the local reservoirs of each of said torches; a refueling system comprising a pump, an electronically actuated shutoff valve, and a controller, the controller being able to actuate the pump and the shutoff valve, the controller being configured to: A) initiate a refueling period by activating said pump and opening said shutoff valve, thereby establishing a fuel pressure within the fuel plumbing system that is above ambient pressure, and thereby causing fuel to flow from the fuel plumbing system into each of said torches until the local fuel level within each of said torches reaches the determined maximum height and the FOP valve within each of the torches is closed; B) terminate the refueling cycle by stopping the pump and closing the shutoff valve, the shutoff valve thereby preventing fuel from flowing out from the fuel plumbing system; C) wait for a pre-calibrated time Tr during which the local fuel levels in the torches are predicted to fall from the determined maximum height to a determined minimum height due to burning of the fuel by the torches; and D) repeat steps A) through C); wherein the torches do not include fuel level sensors or remotely controlled electronic valves; and wherein the torches, while interconnected with each other and with the central reservoir by the fuel plumbing system, are otherwise structurally independent and separate from each other and from the central reservoir.
2. The system of claim 1, wherein the at least one torch comprises a plurality of the torches.
3. The system of claim 1, wherein in step B) the controller is configured to terminate the refueling period at a pre-calibrated time Tf that is required for local fuel levels in all of the torches to rise from the minimum height to the maximum height.
4. The system of claim 1, wherein the system further comprises at least one of: a pressure sensor in communication with the controller and configured to measure a pressure of the fuel within the fuel plumbing system; and a flow rate sensor in communication with the controller and configured to measure a rate of flow of fuel from the central reservoir to the torches; and wherein, in step B), the controller is configured to terminate the refueling period when a pressure increase is detected in the fuel plumbing system indicating a backpressure due to closing of all of the FOP valves, and/or a cessation is detected of the flow of the fuel from the central reservoir to the torches.
5. The system of claim 4, wherein the controller is configured to terminate the refueling period and to suspend any subsequent refueling periods if no backpressure or cessation of the flow of the fuel is detected and the refueling cycle has continued beyond a predicted refueling time Tf by more than a maximum delta time interval.
6. The system of claim 5, wherein the controller is further configured to issue an alarm indicating that a fuel leakage may have occurred if no backpressure or cessation of the flow of the fuel is detected and the refueling period has continued beyond the predicted refueling cycle time Tf by more than the maximum delta time interval.
7. The system of claim 5, wherein if a backpressure or cessation of the flow of the fuel is detected at a time Tf that is either less than Tf or exceeds Tf by an amount that is less than the maximum delta time interval, the controller is configured to adjust Tf to be equal to Tf.
8. The system of claim 1, wherein the controller is configured to continuously repeat steps A) through C) regardless of whether any of the torches are burning or not.
9. The system of claim 1, wherein the controller is configured to perform steps A) through C) only when the torches are burning.
10. The system of claim 9, wherein a burning schedule is provided to the controller.
11. The system of claim 9, wherein the torches are ignited and extinguished by the controller.
12. The system of claim 11, wherein each of the torches includes an electronic ignitor that can be activated by the controller.
13. The system of claim 12, wherein the at least one torch includes a plurality of torches, and wherein the controller is configured to ignite the torches sequentially, so that an igniting voltage is never applied to two of the torches at the same time.
14. The system of claim 1, wherein the controller is able to extinguish the torches by reversing a direction of flow of the pumping system, thereby draining the fuel out of the local fuel reservoirs of the torches, the torches being thereby extinguished after a time Tw during which residual fuel contained in the wicks of the torches is exhausted.
15. The system of claim 1, further comprising a heat sensor located proximate the wick of a first of the torches and in communication with the controller, said heat sensor being configured to transmit a signal to the controller indicating that one of the torches is burning fuel.
16. The system of claim 15, wherein the at least one torch includes a plurality of the torches having heat sensors located proximate their wicks, and wherein outputs of the torches are combined into a single combined output in communication with the controller, said combined output being configured to toggle between an idle state in which none of the torches is burning and an active state in which at least one of the torches is burning.
17. The system of claim 15, wherein: the controller is able to extinguish the first torch by reversing a direction of flow of the pumping system, thereby draining the fuel out of the local fuel reservoir of the first torch, the first torch being thereby extinguished after a time Tw during which residual fuel contained in the wick of the first torch is exhausted; the controller is able to determine Tw by monitoring the heat sensor; and the controller is subsequently able to extinguish the first torch at a desired time Te by draining the fuel out of the local fuel reservoir of the first torch at a time Te?Tw.
18. A method of maintaining an automatically refueled liquid fuel burning torch system, the method comprising: providing an automatically refueled liquid fuel burning torch system according to claim 1; estimating a total burning time of the torches of the torch system; according to the estimated burning time, predicting a refueling date when the central reservoir of the torch system will require refilling with liquid fuel; and delivering liquid fuel to an operator of the torch system in advance of the refueling date.
19. The method of claim 18, wherein the torch system is a torch system according to claim 15, and wherein estimating a total burning time of the torches comprises determining a burning time of the torches according to the signals transmitted by the heat sensor.
20. The method of claim 19, wherein predicting the refueling date includes determining a usage pattern of the torches according to the signals transmitted by the heat sensor.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
(17) The present invention is a liquid fuel burning torch system that can maintain the burning of a plurality of torches for extended periods of time without user maintenance, without requiring that the torches include fuel level sensors and/or remotely controlled electronic valves, and without requiring that fuel be perpetually maintained at a pressure above ambient within the fuel plumbing system. Embodiments further eliminate any need for the torch operator to track fuel reserves, and to pre-order and provide fuel in advance of periodic refilling of the central reservoir.
(18) With reference to
(19) The refueling system further includes a controller 206 that controls the fuel pumping system 214 and other controllable elements of the system. In the illustrated embodiment, the controller 206 receives input from a pressure sensor and/or a flow rate sensor 218 in fluid communication with the fuel plumbing system 204. Note that in
(20) When the torches 200 are in use, as shown in
(21) With reference to
(22) With reference to
(23) In the illustrated embodiment, the float 300 and plug 304 are separate components that are interlinked by a wire or rod 306, so that the plug 302 is caused to rise when the float 300 is lifted up by the liquid fuel 312. The illustrated embodiment further comprises an O-ring 308 located within a tapered internal passage 310 of the seat 302, such that the liquid fuel 312 flows into the fuel reservoir 116, as shown in
(24) As is illustrated in
(25) As is shown in
(26) In addition, as shown in
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(29) If the FOP valve in a torch 200 is closed, as illustrated in
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(31) It is notable that in the embodiment of
(32) According to the present invention, the torches 200 do not include remotely monitored fuel level sensors. Nor does the present invention require that fuel pressure be maintained in the fuel plumbing system 204, 208 at all times. Instead, the controller 206 is configured to implement a predictive method of determining when to activate the pump 210 and thereby refill the torches 200. In embodiments, this predictive method is directed to estimating the amount of burning time Tr that is required to consume a defined percentage of the fuel 312 contained within the local fuel reservoir 116 of a single torch 200. The time Tr is also referred to herein as the refill time for the system, in that it represents the time that will elapse after a refilling of the torches 200 before they will need to be refilled again. If the torches 200 are not all identical to each other in terms of how long they can burn between refills, then Tr can be defined as the minimum amount of burning time that will elapse before at least one of the torches 200 has consumed the defined percentage of its local fuel supply.
(33) Because all of the torches 200 are filled simultaneously and completely when the pump 210 is operated, it is not necessary to separately characterize or monitor each of the torches 200. According to the disclosed method, whenever at least one of the torches 200 needs to be refilled, all of them are refilled. Because the torches operate independently between refills, Tr will be a property of each individual torch, depending on the capacity and shape of the local fuel reservoir and the configuration of the FOP valve 318, and can be determined when the system is first installed.
(34) Once Tr has been determined, the pump 210 can be activated whenever the burning time for the torches 200 reaches Tr. As a simple example, with respect to
(35) As the torches 200 continue to burn fuel, the fuel level 502 in each of the local reservoirs of the torches slowly decreases. However, at a refilling time Tr after the first refueling period 500, a second refueling period 500 is initiated by the controller. The refilling time Tr is chosen according to an initial calibration which indicates that each torch 200 will consume 80% of the fuel within its local reservoir 116 after burning for one hour. At midnight, a reverse-flow pumping cycle 504 is used to drain the remaining fuel out of the torches, thereby causing the torches to be extinguished as soon as the fuel that remains in their wicks 112 is exhausted. In some embodiments, an additional refueling period 500 is initiated after the torches 200 are extinguished, to ensure that the wicks 112 are not damaged by excessive drying, and are ready to be ignited again as needed.
(36) The approach illustrated in
(37) In some embodiments, the upper limits that apply to the time that is required to refill all of the torches is established by pre-calibration during initial installation of the system. With reference to
(38) An additional calibration can be performed and/or repeated at any time by filling 604 the torches 200 and then allowing them to burn without refilling until they are all extinguished due to lack of fuel 606. At this point, the time required to refill all of the torches 200 is measured 610. This measured time, which is referred to herein as Tm 614, established a maximum time required to refill the torches 200 when the plumbing system 204, 208 is already filled with fuel.
(39) Due to the inclusion of the FOP valves 318 in the torches 200, it is not necessary to monitor the levels of fuel in the local reservoirs 116 of the torches 200. It is only necessary to operate the pump 210 for a time Te or Tm to ensure that all of the torches 200 will be filled and all of the FOP valves 318 will be closed. In some of these embodiments, a total refill cycle consists of alternately operating the pump 210 for a time Tm, and then allowing the torches 200 to burn for a time Tr, without any requirement to apply any sensors to the system. Once Te and/or Tm have been determined, in embodiments a refueling period consists merely of operating the pump for the time Te or Tm, depending on whether the plumbing system 204, 208 is full or empty, which will ensure that all of the torches 200 are filled and all of the FOP valves 318 are closed.
(40) In still other embodiments, with reference again to
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(42) In some embodiments, the controller 206 is not necessarily able to determine when the torches 200 are burning and when they are not. In some of these embodiments, the pump 210 is activated by the controller 206 at the end of each time period Tr, regardless of whether the torches 200 are burning. If the torches 200 are not burning, and the internal reservoirs 116 of the torches 200 are already full, then the FOP 318 valves remain closed, and the pumping has no effect, even if it continues during an entire fill time Tf. In other embodiments that monitor the pressure and/or the flow rate of the fuel in the fuel plumbing system 204, 208, when the internal torch reservoirs 116 are already full of fuel 312 the pump 210 is stopped almost immediately after being started. In essence, the pressure and/or flow sensors in these embodiments enable the controller 206 to indirectly determine whether at least one of the torches 200 is burning.
(43) In other embodiments, the controller 206 is able to directly determine when the torches 200 are burning and when they are not. In some of these embodiments, a schedule of operation is provided to the controller. In other embodiments, the torches 200 are ignited and extinguished by the controller 206, for example by activating wick ignitors 320 to initiate burning and by reversing the pumping direction 216 to extinguish the torches 200, such that the controller 206 is necessarily aware of when the torches 200 are burning and when they are not. In still other embodiments, a heat sensor 322 in communication with the controller 206 is provided proximate the wick 112 of at least one of the torches 200, thereby enabling the controller 206 to detect whether and when the torch 200 is burning. In some of these embodiments where heat sensors 322 are provided with a plurality of the torches 200, the outputs of the heat sensors 322 are combined, so that only a single interconnection with the controller 206 is required. For example, the outputs of the heat sensors 322 can be combined into a logical OR output, such that the combined output toggles between an idle state in which none of the torches 200 is burning and no refilling is required, and an active state in which at least one of the torches 200 is burning and requires periodic refilling.
(44) The provision of heat sensors 322 in embodiments can also improve the safety of the system, in that, if a leak in the plumbing system 204, 208 allows the fuel to drain out of the local torch reservoirs 116, thereby unexpectedly extinguishing the torches 200, the controller 206 will cease to initiate any additional refueling cycles 500 and, in embodiments, will issue an alarm to a user indicating that a failure and potential fuel leak has occurred.
(45) Providing at least one heat sensor 322 proximate the wick 112 of a torch 200 also enables the controller 206, in embodiments, to determine the wick burning time, Tw, during which the torches 200 will continue burn after their local reservoirs 116 are emptied by reverse flow, so that the torches can be extinguished at a desired time Te by emptying their local fuel reservoirs 116 at a time Te?Tw.
(46) With reference to
(47) In embodiments that include a reservoir level sensor 220, as shown in
(48) With continued reference to
(49) In various embodiments, the disclosed method includes establishing a usage pattern applicable to the torches 200, for example determining an average amount of fuel that is consumed per week or per month, and then ordering and delivering replacement fuel and/or scheduling maintenance according to the usage pattern. In some of these embodiments, the usage pattern is established according to time periods during the year. For example, typical daily or weekly fuel consumptions can be separately established for the Summer, Fall, Winter, and Spring, or for any other period or cycle.
(50) In various embodiments where the torches 200 include remotely actuated wick ignitors 320, the wick ignitors 320 are individually operable by the controller 206, so that the controller 206 is able to stagger the ignition of the torches 200. For example, in some embodiments, if the controller 206 is commanded to ignite all of the torches 200, it applies an ignition voltage to the wick ignitors 320 sequentially rather than simultaneously. This approach of staggering the wick ignitions 320 ensures that the power applied by the controller 206 to the wick ignitors 320 never exceeds the power required to ignite a single torch 200, thereby greatly reducing the power and current capacity that is required by the torch ignition system.
(51) It should be note that, according to the present invention, while the torches 200 are interconnected with each other and with the central reservoir 202 by the fuel plumbing system 204, 208, the torches 200 in the disclosed system are otherwise structurally independent and separate from each other and from the central reservoir 202, although embodiments further include wires that convey signals and/or electrical power between devices, such as heat sensors 322 and/or wick ignitors 320, that are deployed with the torches 200, and the central controller 206.
(52) The foregoing description of the embodiments of the invention has been presented for the purposes of illustration and description. Each and every page of this submission, and all contents thereon, however characterized, identified, or numbered, is considered a substantive part of this application for all purposes, irrespective of form or placement within the application. This specification is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of this disclosure.
(53) Although the present application is shown in a limited number of forms, the scope of the invention is not limited to just these forms, but is amenable to various changes and modifications without departing from the spirit thereof. The disclosure presented herein does not explicitly disclose all possible combinations of features that fall within the scope of the invention. The features disclosed herein for the various embodiments can generally be interchanged and combined into any combinations that are not self-contradictory without departing from the scope of the invention. In particular, the limitations presented in dependent claims below can be combined with their corresponding independent claims in any number and in any order without departing from the scope of this disclosure, unless the dependent claims are logically incompatible with each other.