METHOD AND APPARATUS FOR MONITORING AND CONTROLLING COMBUSTION IN COMBUSTIBLE GAS BURNER APPARATUS
20250052423 ยท 2025-02-13
Inventors
- Filiberto Rimondo (Padova, IT)
- Roberto Mottola (Padova, IT)
- Loris Barduca (Padova, IT)
- Loris Bertoli (Padova, IT)
- Fernando Carpignani Panebianco (Padova, IT)
Cpc classification
F23N1/022
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F23N2229/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F23N2225/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F23N5/123
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F23N2241/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F23N2235/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F23N2233/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F23L5/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F23K2900/05002
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F23N2225/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F23N5/242
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
Abstract
The apparatus and method according to the present invention are adapted to adjust, in a combustible gas burner, a mixture of gas formed by a first gas and a second combustible gas, wherein the gas mixture is provided through the appropriate mixing of an amount of said first gas by means of a first adjustment element and an amount of said combustible gas by means of a second adjustment element. Said first or second adjustment elements are managed, during operation, by a controller, which processes the data coming from at least two sensors.
Claims
1. A method for controlling the composition of a gas mixture for a burner, said mixture comprising a first gas, regulated by a fan of which the number of revs per minute, n, is controlled and a second combustible gas, regulated by a valve of which the degree of opening, s, is controlled; wherein a first sensor is adapted to provide a signal proportionate to the number of revs per minute of the fan and a second flame sensor is adapted to provide a signal proportionate to an electrical feature of the flame of the burner, and wherein said method comprises three control loops for adjusting the thermal power, W, supplied by the burner: a first quick adjustment control loop adapted to set the number of revs n of said fan and the position, s, of the actuator of said valve based on values of reference contained in a table, T1, T2, and associated with the thermal power value, W, required for the burner, a second slow adjustment control loop adapted to monitor the combustion through the detections of said first flame sensor and a third slow adjustment control loop adapted to monitor the combustion through the calculation of the ratio between the variation of the detection of said first flame sensor and the variation of the position, s, of the actuator of said valve, which caused it.
2. The method according to claim 1 wherein the values of reference contained in said table T, are selected so as to set a combustion having a preset air number, .
3. The A method according to claim 1 comprising an initial calibration procedure, wherein the following steps are performed: setting a number of revs per minute, n, of the fan and a position, s, of the actuator of the valve and starting the burner, said number of revs per minute, n, and said position s being contained in a table, T1, of values of reference measured in the laboratory; starting the burner; modifying the composition of said gas mixture, acting on the position s of the actuator of the valve, and the corresponding reading of said at least one electrical parameter of the flame of the burner, R, until a value s1 is identified, which corresponds to a minimum of said electrical parameter of the flame of the burner, Rmin, corresponding, in turn, to an excess air value, , equal to 1; further modifying the composition of said gas mixture, acting on the position s of the actuator of the valve, until a value s* is reached, which corresponds to the desired excess air, *; detecting the value of said electrical parameter of the flame of the burner, R*, corresponding to the required excess air value, *; updating said table, T1, with the s* value; repeating the previous steps for different values of number of revs per minute, n, and position s of the actuator of the valve.
4. The A method according to claim 3 comprising the following steps: measuring, by means of a third pressure sensor associated with said fan, the atmospheric pressure, P0, with the fan at a standstill; starting the fan at a number of revs per minute n1; measuring, by means of said third pressure sensor, the pressure of said first gas, Pn1; calculating the pressure variation P=P.sub.n1P.sub.0; updating said table T1, with the value Pn1 and P=P.sub.n1P.sub.0.
5. The A method according to claim 1 comprising an adjustment step, wherein the following steps are performed: reading the thermal power value, W1, required for the burner; reading the value of the number of revs, n, of the fan; reading, from a table, T1, T2, of a number of revs, n1, of the fan and a degree of opening, s1, of the adjustment valve corresponding to the thermal power value, W1, required for the burner; if n is different from n1, setting the fan motor at a number of revs equal to n1; setting the actuator of the adjustment valve to obtain a degree of opening, s1.
6. The A method according to claim 1 comprising an adjustment step, wherein the following steps are performed: reading the detection of the flame sensor, R; comparison between R and the value, R1, present in the table, T1, T2 corresponding to W1, n1 and s1; if |RR1| is less than a certain predetermined tolerance n1 and s1 are maintained; otherwise, the actuator of the adjustment valve is acted upon until a value s1.sub.n is reached, whereby there is correspondence between the measured R and the R1 value provided for the power W1; the actuator of the adjustment valve is set so as to obtain a degree of opening, s1.sub.n.
7. The A method according to claim 1 comprising an adjustment step, wherein the following steps are performed: varying the position, s, of the actuator of said valve by an amount s; reading the detection of the flame sensor, R2; calculating R=R2R and R/s; calculating the difference between the measured R/s and the value present in the table T; if the difference is less than a certain predetermined tolerance and the sign is the same, n1 and s1 are maintained; otherwise an alarm signal is produced or a new calibration procedure is made.
8. An apparatus for monitoring and controlling the composition of a gas mixture comprising a first gas and a second combustible gas, said apparatus comprising: a fan for adjusting the flow of a first gas, a valve adapted to adjust the composition of said gas mixture, a burner adapted to burn said gas mixture, a first sensor adapted to measure the number of revs of the fan, at least one second sensor arranged close to the flame of the burner and adapted to measure at least one electrical parameter of the flame of the burner, a controller adapted to pilot said fan and said valve based on the processing of the signals coming from said first sensor and from said at least one second sensor.
9. The apparatus according to the preceding claim 1, wherein said controller comprises at least one memory unit configured to store tables, T1, T2, comprising values of number of revs per minute, n, of the fan and values of opening, s, the adjustment valve (6), corresponding to thermal power values, W, of the burner and adapted to allow the combustion to proceed with a desired air number value .
10. The An apparatus according to the preceding claim 1, wherein said tables, T1, T2, comprise values of at least one electrical parameter of the flame of the burner corresponding to said values of number of revs per minute, n, of the fan and to said values of opening, s, of the adjustment valve.
11. The An apparatus according to claim 8 wherein said controller is adapted to update the contents of said tables, T1, T2.
12. The An apparatus according to claim 8 comprising a further absolute pressure sensor associated with said fan and adapted to measure the pressure of said gas mixture.
13. The An apparatus according to claim 8 to comprising a further temperature and absolute pressure sensor associated with said fan and adapted to measure the temperature and pressure of said gas mixture.
Description
BRIEF DESCRIPTION OF THE FIGURES
[0038] Further features and advantages of the invention will become apparent from the reading of the following detailed description, given by way of non-limiting example, with the aid of the figures shown in the accompanying tables, in which:
[0039]
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[0052] The following description of exemplary embodiments relates to the accompanying drawings. The same reference numbers in the various drawings identify the same elements or similar elements. The following detailed description does not limit the invention. The scope of the invention is defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
[Adjustment of the Combustion with at Least Two Sensors]
[0053] With reference to the attached
[0054] Said adjustment element 5 can be placed upstream or downstream indifferently of the mixing point 11 between said first 3 and said second combustible gas 4.
[0055] Said first adjustment element 5 comprises a fan with a varying number of revs, which can be set by means of a first drive command and said second adjustment element 6 comprises a valve, which can be adjusted by means of a second drive command.
[0056] In a preferred embodiment of the invention, said at least two sensors comprise a first sensor 12 adapted to measure the number of revs of the fan 5 and a second flame sensor 8 associated with the flame of the burner 2, as shown in
[0057] In further detail, said second flame sensor 8 is preferably arranged close to the flame of the burner and is adapted to measure the resistance R.sub.el, or the electrical conductivity, G.sub.el, or other electrical parameters of the flame of the burner 2; said first sensor 12 is preferably placed inside the fan 5 and is adapted to measure the rotation speed of the electric motor of said fan 5, for example, expressed in number of revs per minute.
[0058] In another preferred embodiment of the invention, said adjustment element 5 is associated with a third absolute pressure sensor, or absolute pressure and temperature sensor 7. Said sensor 7 is preferably placed at the entrance or exit of the fan 5, which, in turn, may be placed both upstream and downstream of the mixing point 11.
[0059] Said controller 9 preferably comprises a microprocessor, or an equivalent electronic processing element, and at least one associated memory unit 13. Said controller 9 is adapted to carry out readings and cyclically process the signals coming from the aforesaid sensors 7, 8, 12 and produce, based on said processing and a comparison thereof with values of reference stored in tables allocated in the memory unit 13, appropriate drive signals for said fan 5 and said adjustable valve 6.
[0060] The drive signals and/or the measurements of the sensors, which determined them, and/or the various operating parameters, which are calculated to estimate the optimum operating point, may also be stored in the memory unit 13 associated with the microprocessor of the controller 9, so as to update and cyclically complete said tables containing the optimum settings of the fan 5 and of the valve 6 of the apparatus, as well as create and store new tables, as a function of the changed operating boundary conditions. Thereby, the present invention allows obtaining a method for monitoring and controlling the combustion of a burner, which is capable of self-learning and self-adjustment for achieving the optimum working conditions of the burner in terms of efficiency, stability and user safety.
[0061] The appended
[Starting Calibration on Initial Start-Up]
[0062] With reference to the attached
[Initial Calibration and Construction of Table T2]
[0063] With reference to the attached
[0064] By using the first flame sensor 8 arranged close to the flame of the burner 2 and a second sensor 12 of the number of revs n of the fan 5, it is possible to update the values of the column R and s, as described below: after fixing the value of the number of revs of the fan 5, n, corresponding to a certain thermal power W, the R value is traced, so that the desired excess air value, * is obtained, based on the following calibration sequence: [0065] a number of revs per minute, n, is set for the fan 5, and kept constant; [0066] the value of the gas flow rate is increased (or decreased) 40, by acting on the position s of the actuator of the adjustable valve 6, until a value s1 is identified, corresponding to the minimum of the value of the electrical flame resistance R (or another measured electrical flame parameter), corresponding, in turn, to an excess air value, , equal to 1, according to the trend of the curve shown in
[0071] After constructing and updating table T2, as described in the calibration stage, this will be stored in the memory unit 13 and will be constantly updated during the operation of the burner, as described below.
[Combustion Control SequencesUpdating Table T2]
[0072] The control sequence provides a first quick adjustment control loop and at least a second slow adjustment control loop.
[Quick Control Loop]
[0073] With reference to the attached
[0074] Therefore, the fan 5 is driven 50 at a number of revs n1 corresponding to the amount of air needed for the required power W1 and, similarly, the actuator of the valve 6 will be brought 50 to the opening position s1. In table T2, in use, corresponding n and s values correspond to each thermal power value required of the burner in order to obtain, in the combustion , the desired, *.
[Slow Control Loop_1Correct Combustion Verification and Dynamic Adjustment of Valve Opening Ending]
[0075] With reference to the attached
[0076] According to this second adjustment control loop, a first monitoring of the combustion is carried out cyclically, exploiting the detections of said first flame sensor 8, verifying that the current R value does not deviate from the R1 value, provided in table T2 for W1 and corresponding to n1 and s1 and to the desired excess air value *.
[0077] If the measured R is equal, or sufficiently close to R1 in the table in use, for example, if the distance between the measured R and R1 is less than 10% of the original value of R1, further actions are not carried out; whereas, if the measured R is not sufficiently close to R1, for example, if the distance between the measured R and R1 is 10% greater than the original value of R1, then, while the n value is kept constant, the actuator of the valve 6 is moved into different positions until it reaches an s1.sub.n value whereby there is correspondence between the measured R and the R1 value provided for said power. Therefore, the s1.sub.n, value replaces the previous s1 value in the table.
[Slow Control Loop_2Correct Combustion Further Verification]
[0078] With reference to the attached
[0079] With reference to the attached
[0085] In further detail, the corresponding change R in the electrical flame resistance is detected and compared with the corresponding values listed in table T2, checking that the R/s ratio corresponds to the value and the sign listed in table T2 for the current value of the number of revs n. In fact, if the value of the ratio R/s detected were of a different sign to that shown in table T2 then the excess air would be <1 and the boiler might have to work in a potentially dangerous situation producing excess CO.
[0086] The procedure described above can also be useful for verifying any blockages, also partial, of the chimney and consequently producing adequate alarm signals for the user. This can happen simply by controlling the congruity of the value of the number of revs per minute of the fan 5: if the current number of revs is greater than the number required, the cause might be a reduced draught in the chimney. With reference to the attached
[0087] Should a recalibration be necessary: [0088] update table T2, in use, contained in said memory unit 13, associated with said controller 9. [0089] send appropriate drive signals to the valve 6, which are adapted to produce the previously calculated degree of opening of the valve 6, s.
[0090] Instead of the electrical flame resistance, R, other electrical parameters detected by said first sensor can be used, such as, the flame conductivity G or the flame capacity C, for example.
[0091] The method for monitoring and controlling the combustion of a burner for combustible gas apparatuses according to the invention allows continuously establishing the optimum working conditions of the burner, ensuring the thermal power required in a very wide range, from 100% of the nominal power value of the burner to about 5% of said nominal value. Furthermore, through the method according to the invention, it is possible to cause the burner to work with a desired excess air, , which can be set from a minimum value equal to 1 to a maximum value, also greater than 2 and, in particular, it can be set at an optimum value of just over 1, e.g., equal to 1.25.
[0092] Furthermore, the method and apparatus for monitoring and controlling the combustion of a combustible gas burner according to the invention allows verifying the safety of the apparatus and, in particular, of the , in particular, always ensuring that the is greater than 1 over the whole spectrum of operation, through a direct measurement and not through an estimate or a plausibility test.
[Realization with Third SensorCalibration Value n]
[0093] In the case of a preferred embodiment of the invention using a first sensor 12 adapted to measure the number of revs per minute of the fan 5, a second flame sensor 8 arranged close to the flame of the burner 2 and a third absolute pressure sensor 7 associated with the gas mixture, the calibration can also provide updating the value of the parameter n in table T2.
[0094] With reference to the attached
[0095] The correlation between thermal power W and number of revs n of the fan 5 must be precise otherwise there is the risk of having less air than necessary and therefore excess gas and combustion characterized by a sub-optimal air number A. Therefore, the product between the density p and the volumetric flow rate of the air Q must be kept constant so that if the density of the air decreases, the volume of air must be increased to ensure that the mass of air introduced into the burner 2 is always correct.
[0096] Again, with reference to the appended
[0097] In table T2, in order to control and update the value of the parameter n, it is possible, for example, to carry out a first reading of the pressure sensor 7 to measure the atmospheric pressure P0 and the ambient temperature TO with the fan at a standstill, and a second reading of the pressure sensor 7 to measure the pressure Pn1, after switching on the fan 5, at a constant speed n1 and thus, evaluate the change in pressure P=P.sub.n1P.sub.0 representative of the initial boiler installation conditions. Thereby, the ratio between P and n, is stably fixed, starting from the assumption that an amount of air Qa1 (independently of the gas) will always correspond to a certain power W1, substantially tracing the correct load curve with boiler installed and thus the corresponding value n1.
[0098] If this procedure is repeated periodically, it may also be useful for verifying possible blockages, also partial, of the chimney and consequently producing adequate alarm signals for the user.
[0099] In summary, if the system possesses said pressure sensor 7, the air temperature and density are checked with every start-up, as well as any blockage of the chimney, updating, if necessary, in table T2 in use, the figure relative to the number of revs of the fan 5, n, thus also updating the trend of the curve binding the thermal power of the burner to the number of revs of the fan 5, W=f (Qa)=f (n).
[0100] If the system is provided with a flame sensor 8 and with a rotation speed sensor 12 of the fan 5, then, with every start-up and with every new request for thermal power W1, a number of revs of the fan 5, n1 is determined by means of a quick control loop referring to the current table T2 and a degree of opening of the valve 6, s1, to which both the requested thermal power should correspond and an electrical flame resistance value R1 corresponding to an optimum excess air value.
[0101] If a first slow control loop based on the measurement of the electrical flame resistance R=f(n) detects that, at the opening of the valve 6, s1, in table T2 an R1 value is present, different to the one expected, then the degree of opening s of the valve 6 is modified until a value s1, which allows reaching the desired value R1 and table T2 is updated, replacing the s1 value with the previous one s1. If the difference between s1 and s1 is greater than a certain threshold, a new calibration of the system can be provided, given that the operating conditions have probably changed, or the burner can be stopped, given that the current combustion conditions are deemed to be dangerous.
[0102] Furthermore, a second slow control loop, at predetermined intervals of time, further verifies that the combustion is proceeding optimally by controlling the ratio R/s through the following sequence: [0103] slightly decrease (or increase) the amount of gas by setting a variation in the degree of opening of the valve 6, s; [0104] detect the corresponding variation R of the electrical flame resistance and compare with the corresponding values listed in T2, verifying that the ratio R/s corresponds to the value and to the sign listed in T2 for the current value of the number of revs n. If the value of the ratio R/s detected was also only of a sign different to that shown in table T2 then the excess air would be <1 and the boiler might have to work in a potentially dangerous state, producing excess CO. The determining advantage of the second control loop is that it operates reliably, also with minimum powers, where the first control loop is imprecise, or the correct detection of the electrical flame parameters is practically impossible.
[0105] The method according to the present invention, in each of the embodiments thereof, can be used, with some possible variations, in each step of burner operation: in the initial calibration stage, in the first start-up stage after implementation, as well as during the normal operation stage.
[0106] The method according to the present invention in each of the embodiments thereof, is further adapted to be used for monitoring the current operating conditions and updating the tables containing the optimum settings of the fan 5 and the valve 6 of the apparatus as a function of the changed operating boundary conditions, so as to ensure the optimized working of the burner in an increasing number of situations, succeeding in preventing malfunctioning, which is potentially harmful both for the burner and the users.