Patent Grant
10274195
The present disclosure relates generally to systems and methods for admitting air and fuel to a burner of a combustion appliance, and more particularly to a device and method for delivering an accurate air/fuel ratio to a burner of a combustion appliance.
The air/fuel ratio used during the operation of a combustion appliance can affect the efficiency and emissions of the combustion appliance. Example combustion appliances include furnaces, water heaters, boilers, direct/in-direct make-up air heaters, power/jet burners and any other residential, commercial or industrial combustion appliance. In many cases, the flow of gas is adjusted to set the air/fuel ratio. This is often accomplished by modulating a gas valve to control the pressure and thus the flow of gas to the combustion appliance. In some cases, the gas valve is modulated based on signals from one or more pressure or flow sensors placed in the gas and/or air streams. In some cases, turbulent and/or otherwise non-uniform gas and/or air flows can introduce noise into the pressure or flow sensor signals, which can result in a non-uniform or otherwise non-optimal air/fuel ratio. This can reduce the efficiency and/or increase the emissions of the combustion appliance. What would be desirable is an improved air/gas admittance device that provides a more uniform gas and/or air flow to reduce sensor noise and thus improve the efficiency and/or emissions of a combustion appliance.
The present disclosure relates generally to an improved air/gas admittance device that provides a more uniform gas and/or air flow to reduce sensor noise and thus improve the efficiency and/or emissions of a combustion appliance.
In one example, an illustrative air/gas admittance device for use with a combustion unit such as a combustion appliance may include a body having a side wall defining a passageway that extends from an air inlet to an air/gas outlet and a gas pipe having a side wall defining a passageway that extends from a gas inlet to a gas outlet. The side wall of the body may have a gas pipe opening that is in fluid communication with the gas outlet of the gas pipe. An air flow restrictor may be positioned in the body between the gas pipe opening and the air inlet, and a gas flow restrictor may be positioned in the gas pipe downstream of the gas inlet. A first pressure port may be in the side wall of the body, upstream of the gas pipe opening. The first pressure port may be configured to be operatively coupled to a first pressure sensor for measuring a pressure of air within the body. A second pressure port may be in the side wall of the gas pipe. The second pressure port may be configured to be operatively coupled to a second pressure sensor for measuring a pressure of gas within the gas pipe. An air flow smoothing insert may be positioned in the body upstream of the first pressure port.
In another example, an air/gas admittance device for use with a combustion unit may comprise a body having a side wall defining a passageway that extends from an air inlet to an air/gas outlet and a gas pipe having a side wall defining a passageway that extends from a gas inlet to a gas outlet. The side wall of the body may have a gas pipe opening that is in fluid communication with the gas outlet of the gas pipe. An air flow restrictor may be positioned in the body between the gas pipe opening and the air inlet and an air flow smoothing insert may be positioned in the body upstream of the gas pipe opening. The device may further comprise a fan in fluid communication with the air/gas outlet. The fan may be configured to generate an under pressure at the air/gas outlet.
In another example, an air/gas admittance device for use with a combustion unit may comprise a body having a side wall defining a passageway that extends from an air inlet to an air/gas outlet and a gas pipe having a side wall defining a passageway that extends from a gas inlet to a gas outlet. The side wall of the body may have a gas pipe opening that is in fluid communication with the gas outlet of the gas pipe. A first pressure port may be in the side wall of the body, upstream of the gas pipe opening. A first pressure sensor may be operatively coupled to the first pressure port for measuring a pressure of air within the body. A second pressure port may be in the side wall of the gas pipe. A second pressure sensor may be operatively coupled to the second pressure port for measuring a pressure of gas within the gas pipe. An air flow smoothing insert may be positioned in the body upstream of the first pressure port. A gas control valve may be coupled to the gas inlet. A controller may be operatively coupled to the first pressure sensor, the second pressure sensor and the gas control valve. The controller may be configured to use the pressure of air within the body sensed by the first pressure sensor and the pressure of gas within the gas pipe sensed by the second pressure sensor to control the gas valve to produce a desired air/gas mixture at the air/gas outlet.
The preceding summary is provided to facilitate an understanding of some of the innovative features unique to the present disclosure and is not intended to be a full description. A full appreciation of the disclosure can be gained by taking the entire specification, claims, drawings, and abstract as a whole.
The disclosure may be more completely understood in consideration of the following description of various illustrative embodiments in connection with the accompanying drawings, in which:
While the disclosure is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit aspects of the disclosure to the particular illustrative embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure.
The following description should be read with reference to the drawings wherein like reference numerals indicate like elements throughout the several views. The description and drawings show several illustrative embodiments which are meant to be illustrative of the claimed disclosure.
Gas valves are often driven by electronic control systems which evaluate feedback signals from pressure and/or flow sensors. When pressure sensors are used, the pressure sensors may relay pressure readings to a controller which controls a position of the gas valve. The position of the gas valve may be adjusted to optimize the air to fuel (A/F) ratio in order to achieve low emissions of CO, NOx and/or to increase efficiency (e.g. save fuel). The pressure sensors may be placed to sense pressures before and/or after air and gas restrictors in an air/gas admittance device. Ideally, signals from the pressure signals are stable and largely free of oscillations and/or other noise caused by air or gas flow disturbances in the admittance device. Unstable pressure sensor signals can result in a non-uniform or otherwise non-optimal air/fuel ratio, which can reduce the efficiency and/or increase the emissions of the combustion unit. The air/gas admittance device described herein provides a more uniform gas and/or air flow, which reduces sensor noise and can improve the efficiency and/or emissions of a downstream combustion unit.
The gas valve assembly 12 may include one or more actuators to modulate the flow of gas that is provided to the air/gas admittance device 14. The valve controller 18 may control the gas valve assembly 12 based on signals from one or more pressure or flow sensors 22a-22c in order to provide a desired air/fuel ratio to the downstream fan or blower 16. In the example shown, the downstream fan or blower 16 mixes the air and gas streams and provides the mixed air/gas stream to a combustion chamber of the downstream combustion unit 17.
In the example shown, the gas valve assembly 12 is shown coupled to the air/gas admittance device 14. The air/gas admittance device 14 may be configured to provide air and gas (e.g. fuel) at a desired ratio to a downstream combustion unit 17. The illustrative air/gas admittance device 14 includes a body 26 having a side wall 78 defining a passageway 64 extending from an air inlet 50 to an air/gas outlet 62 (see, for example,
In some cases, the valve or damper 72 is not provided.
The body 26 of the air/gas admittance device 14 may also include an air/gas outlet flange 36 mounted adjacent to an air/gas outlet, or second, end 32 thereof. The air/gas outlet flange 36 may include one or more apertures 58 for receiving a fastening mechanism, including but not limited to a bolt, screw, etc. The air/gas outlet flange 36 may be configured to be connected (e.g. via apertures 58 and a fastening mechanism) to the fan or blower 16. In some cases, the air/gas outlet flange 36 may be directly coupled to a housing of the fan or blower 16. As the fan and/or blower 16 turns, the fan or blower 16 may generate an under pressure at the air/gas outlet 62 and/or in the passageway 64 of the air/gas admittance device 14, drawing air in through the air inlet 50 and gas inlet 68 and to the air/gas outlet 62, as will be described in more detail herein.
The air/gas admittance device 14 may include a gas pipe 28 extending generally orthogonal to the body 26. The gas pipe 28 may have a side wall 82 defining a passageway 66 extending from a gas inlet 68 to a gas pipe outlet 70 (see, for example,
The air/gas admittance device 14 may include a plurality of pressure ports formed in the side wall 78 of the body 26 and/or the side wall 82 of the gas pipe 28. In the example shown, the pressure ports may include a first pressure port 20a, a second pressure port 20b, and a third pressure port 20c (collectively, 20) extending through the side walls 78, 82 and into the passageways 64, 66. The pressure ports 20 may each be configured to receive or be operatively coupled with a pressure (or other) sensor 22a, 22b, 22c (collectively, 22). The pressure sensors 22 may be in operative communication with a fluid (e.g. air, gas, and/or an air/gas mixture) within the passageways 64, 66 to allow for pressure readings of the air, gas, and/or air/gas mixture to be obtained. The pressure sensors 22 may be in operative communication (e.g., through a wired 24a, 24b, 24c or wireless connection) to the valve controller 18. The pressure sensors 22 may provide pressure readings to the valve controller 18, which in turn may adjust a flow of gas from the gas valve assembly 12 to achieve a desired air/fuel ratio. More specifically, in order to achieve low emissions of CO, NOx and/or to increase efficiency (e.g. save fuel), the gas valve assembly 12 may be operated to control the air/fuel ratio (e.g. Lamba) of the mixed air stream provided to the combustion unit 17. In some applications, Lambda may be a function of the pressure amplification ratio. The pressure readings may be used to determine a pressure amplification ratio defined by the following equation:
where Pgas is a pressure of the gas (e.g. obtained at pressure sensor 22b), Pair is a pressure of the air (e.g. obtained at pressure sensor 22a), and PRef is a reference pressure of an air/gas mixture (e.g. obtained at pressure sensor 22c). In order to maintain lambda (e.g. air/fuel ratio) at a desired (e.g. relatively constant) value, it is desirable to maintain the pressure amplification ratio (Pamp) at a constant value. In the example shown, the valve controller 18 may obtain pressure readings from the three pressure sensors (e.g. 22a, 22b, 22c) and determine a Pamp value. The valve controller 18 may then adjust a position of the gas valve assembly 12 (and hence adjust a flow of gas to the gas inlet 68 of the air/gas admittance device 14) to maintain the Pamp value essentially constant. For best performance and control, it is desirable for the pressure readings to be stable and free from oscillations and/or other noise caused by turbulent and/or non-uniform air and/or gas flows.
In some cases, an air flow smoothing insert 42 may be positioned within the passageway 64 of the body 26. Alternatively, or additionally, a gas flow smoothing insert (not shown), similar in form and function to the air flow smoothing insert 42 may be positioned within the passage way 82 of the gas pipe 28. The air flow smoothing insert 42 may be configured to filter and reduce or eliminate flow disturbances from the air entering the air/gas admittance device 14. This may result in a more stable flow uniformly spread over the whole air passageways 64. As a result, the pressure readings obtained at the pressure sensors 22 may be more stable and largely free from oscillations and/or other noise in a compact simple assembly.
The air flow smoothing insert 42 may include a plurality of openings 44 separated by a plurality of walls 45. In some cases, a portion of the openings 44 may have a generally hexagonal cross-sectional shape. In other words, the air flow smoothing insert 42 may have a generally honeycomb type configuration. However, it is contemplated that the openings 44 may have any cross-sectional shape desired, including, but not limited to, circular, oblong, square, rectangular, polygonal, etc.
The body 26 of the air/gas admittance device 14 may include two (or more) additional pressure ports 20d, 20f formed in the side wall 78 of the body 26. The pressure ports 20d, 20f may be positioned generally opposite from or 180° from (e.g. opposing) the pressure ports 20a, 20c described above with respect to
In the example show, a gas flow restrictor 46 may be positioned within the passageway 66 of the gas pipe 28. The gas flow restrictor 46 may have a reduce diameter DG relative to the passageway 66. The diameter DG of the gas flow restrictor 46 may be precisely controlled to provide a predictable and consistent flow of gas into the body 26 of the air/gas admittance device 14 to aid in providing a constant and/or precise air/fuel ratio to the combustion unit. In some cases, the gas flow restrictor 46 may be removably positioned within the passageway 66. This may allow the gas flow restrictor 46 to be changed to accommodate different burner loads and/or different air/gas ratios. That is, different diameter DG gas flow restrictors 46 may be used in differing applications or configurations to provide a desired flow of gas to achieve a desired air/fuel ratio for a given combustion unit 17.
The gas pipe 28 of the air/gas admittance device 14 may include an additional pressure ports 20e formed in the side wall 82 of the gas pipe 28. The pressure port 20e may be positioned generally opposite from or 180° from (e.g. opposing) the pressure port 20b shown in
The body 26 of the air/gas admittance device 14 may include an opening 80 extending through the side wall 78 thereof. The opening 80 may be downstream of the air flow restrictor 60 and upstream of the reference pressure port 20c, 20f A second end 76 of the gas pipe 28 may be secured to the side wall 78 of the body 26 such that the gas pipe outlet 70 (and passageway 66) is in fluid communication with the opening 80 and the passageway 64 of the body 26.
The gas flow restrictor 46 may be positioned with the gas pipe 28 (e.g. within the passageway 66) downstream of the gas inlet 68 and upstream the gas pipe outlet 70. In the example shown, the gas flow restrictor 46 may also be positioned downstream of the gas pressure port 20b, 20e. This may allow a gas pressure reading to be obtained upstream of the gas flow restrictor 46 and prior to the gas mixing with air.
The air flow restrictor 60 may be positioned downstream of the air inlet 50 and upstream of the opening 80 (and/or gas pipe outlet 70) in the side wall 78. In the example shown, the air pressure port 20a, 20d may be positioned between the air flow smoothing insert 42 and the air flow restrictor 60 to obtain an air pressure reading upstream of the air flow restrictor 60 and prior to mixing with gas. As such, the air pressure port 20a, 20d may be positioned upstream of the air flow restrictor 60 and upstream of the opening 80 (and/or gas pipe outlet 70) in the side wall 78.
As shown in
The reference pressure port 20c and opposing reference pressure port 20f, it is contemplated that these pressure ports may be positioned between the opening 80 (and/or gas pipe outlet 70) and the air/gas or mixed outlet 62 of the body 26 to obtain a pressure reading of the mixed gas and air. In other words, the reference pressure ports 20c, 20f may be positioned downstream of the gas pipe outlet 70. While the air and gas are referred to as mixed within the downstream portion of the air/gas admittance device 14, it should be noted that the gas and air may not be completely mixed. Further mixing of the air and gas may occur in downstream components, such as, but not limited to the fan or blower 16.
In many cases, the valve controller 18 may include an input/output block (I/O block) 104 having a number of wire terminals for receiving one or more wires from the gas valve assembly 12, the pressure sensors 22a-22c of the air/gas admittance device 14, and/or the combustion unit 17. While the term I/O may imply both input and output, it is intended to include input only, output only, as well as both input and output. The I/O block 104 may be used to communicate one or more signals to and/or from the gas valve assembly 12, air/gas admittance device 14, and/or combustion unit. The valve controller 18 may have any number of wire terminals for accepting connections from the gas valve assembly 12, air/gas admittance device 14, and/or combustion unit 17. How many and which of the wire terminals are actually used at a particular installation may depend on the particular configuration of the gas valve assembly 12, air/gas admittance device 14 and/or combustion unit 17.
In some cases, as illustrated, the valve controller 18 may include a communications or data port 106. The communication ports 106 may be configured to communicate with the processor 100 and may, if desired, be used to either upload information to the processor 100, download information from the processor 100, provide commands to the processor 100, send commands from the processor 100, and/or perform any other suitable task. The communication port 106 may be a wireless port such as a Bluetooth™ port or any other wireless protocol. In some cases, communication port 106 may be a wired port such as a serial port, a parallel port, a CAT5 port, a USB (universal serial bus) port, or the like. In some instances, the communication port 106 may be a USB port and may be used to download and/or upload information from a USB flash drive. Other storage devices may also be employed, as desired. In some cases, a separate device may be in communication with the processor 100 of the valve controller 18.
As noted above, the valve controller 18 may be in wired or wireless communication with an external device. The external device may be a computing device separate from the gas valve assembly 12. For example, the external device may be a personal computer, tablet computer, smart phone, laptop computer, a server, or other computer as desired. In some cases, the external device may not be a part of the gas valve assembly 12 or combustion unit 17. For example, the external device may be a portable device which travels with an installer.
In a first example, an illustrative air/gas admittance device for use with a combustion unit may comprise a body having a side wall defining a passageway that extends from an air inlet to an air/gas outlet and a gas pipe having a side wall defining a passageway that extends from a gas inlet to a gas outlet. The side wall of the body may have a gas pipe opening that is in fluid communication with the gas outlet of the gas pipe. An air flow restrictor may be positioned in the body between the gas pipe opening and the air inlet and a gas flow restrictor may be positioned in the gas pipe downstream of the gas inlet. A first pressure port may be in the side wall of the body, upstream of the gas pipe opening. The first pressure port may be configured to be operatively coupled to a first pressure sensor for measuring a pressure of air within the body. A second pressure port may be in the side wall of the gas pipe. The second pressure port may be configured to be operatively coupled to a second pressure sensor for measuring a pressure of gas within the gas pipe. An air flow smoothing insert may be positioned in the body upstream of the first pressure port.
Alternatively or additionally to any of the examples above, in another example, the air/gas admittance device may further comprise a third pressure port in the side wall of the body downstream of the gas pipe opening. The third pressure port may be configured to be operatively coupled to a third pressure sensor for measuring a pressure adjacent the air/gas outlet.
Alternatively or additionally to any of the examples above, in another example, the first pressure port may be positioned upstream of the air flow restrictor, and the second pressure port may be positioned upstream of the gas flow restrictor.
Alternatively or additionally to any of the examples above, in another example, the air/gas admittance device may further comprise an outlet flange mounted to the body adjacent to the air/gas outlet.
Alternatively or additionally to any of the examples above, in another example, the air/gas admittance device may further comprise a fan mounted to the outlet flange for creating an under pressure at the air/gas outlet of the body.
Alternatively or additionally to any of the examples above, in another example, the air/gas admittance device may further comprise a fourth pressure port in the side wall of the body, upstream of the gas pipe opening and opposing the first pressure port and a fifth pressure port in the side wall of the gas pipe and opposing the second pressure port.
Alternatively or additionally to any of the examples above, in another example, the air/gas admittance device may further comprise a sixth pressure port in the side wall of the body, downstream of the gas pipe opening and opposing the third pressure port.
Alternatively or additionally to any of the examples above, in another example, the air/gas admittance device may further comprise an air inlet flange coupled to the body adjacent to the air inlet.
Alternatively or additionally to any of the examples above, in another example, the air/gas admittance device may further comprise an air damper coupled to the air inlet flange.
Alternatively or additionally to any of the examples above, in another example, the air/gas admittance device may further comprise a gas inlet flange coupled to the gas pipe adjacent to the gas inlet.
Alternatively or additionally to any of the examples above, in another example, the air/gas admittance device may further comprise a gas valve coupled to the gas inlet flange.
Alternatively or additionally to any of the examples above, in another example, the air flow smoothing insert may be positioned upstream of the air flow restrictor.
Alternatively or additionally to any of the examples above, in another example, the air/gas admittance device may further comprise a gas flow smoothing insert positioned upstream of the second pressure port.
In another example, an air/gas admittance device for use with a combustion unit may comprise a body having a side wall defining a passageway that extends from an air inlet to an air/gas outlet and a gas pipe having a side wall defining a passageway that extends from a gas inlet to a gas outlet. The side wall of the body may have a gas pipe opening that is in fluid communication with the gas outlet of the gas pipe. An air flow restrictor may be positioned in the body between the gas pipe opening and the air inlet and an air flow smoothing insert may be positioned in the body upstream of the gas pipe opening. The device may further comprise a fan in fluid communication with the air/gas outlet. The fan may be configured to generate an under pressure at the air/gas outlet.
Alternatively or additionally to any of the examples above, in another example, the air/gas admittance device may further comprise a first pressure port in the side wall of the body, upstream of the gas pipe opening. The first pressure port may be configured to be operatively coupled to a first pressure sensor for measuring a pressure of air within the body. The air/gas admittance device may further comprise a second pressure port in the side wall of the gas pipe. The second pressure port may be configured to be operatively coupled to a second pressure sensor for measuring a pressure of gas within the gas pipe.
Alternatively or additionally to any of the examples above, in another example, the air/gas admittance device may further comprise a third pressure port in the side wall of the body downstream of the gas pipe opening. The third pressure port may be configured to be operatively coupled to a third pressure sensor for measuring a pressure adjacent the air/gas outlet.
Alternatively or additionally to any of the examples above, in another example, the air/gas admittance device may further comprise an outlet flange mounted to the body adjacent to the air/gas outlet, and wherein the fan is mounted directly to the outlet flange.
Alternatively or additionally to any of the examples above, in another example, the air/gas admittance device may further comprise a gas inlet flange coupled to the gas pipe adjacent to the gas inlet and a gas valve mounted directly to the gas inlet flange.
In another example, an air/gas admittance device for use with a combustion unit may comprise a body having a side wall defining a passageway that extends from an air inlet to an air/gas outlet and a gas pipe having a side wall defining a passageway that extends from a gas inlet to a gas outlet. The side wall of the body may have a gas pipe opening that is in fluid communication with the gas outlet of the gas pipe. A first pressure port may be in the side wall of the body, upstream of the gas pipe opening. A first pressure sensor may be operatively coupled to the first pressure port for measuring a pressure of air within the body. A second pressure port may be in the side wall of the gas pipe. A second pressure sensor may be operatively coupled to the second pressure port for measuring a pressure of gas within the gas pipe. An air flow smoothing insert may be positioned in the body upstream of the first pressure port. A gas control valve may be coupled to the gas inlet. A controller may be operatively coupled to the first pressure sensor, the second pressure sensor and the gas control valve. The controller may be configured to use the pressure of air within the body sensed by the first pressure sensor and the pressure of gas within the gas pipe sensed by the second pressure sensor to control the gas valve to produce a desired air/gas mixture at the air/gas outlet.
Alternatively or additionally to any of the examples above, in another example, the air/gas admittance device may further comprising a third pressure port in the side wall of the body downstream of the gas pipe opening and a third pressure sensor operatively coupled to the third pressure port for measuring a pressure adjacent the air/gas outlet. The controller may be configured to use the pressure of air within the body sensed by the first pressure sensor, the pressure of gas within the gas pipe sensed by the second pressure sensor, and the pressure adjacent the air/gas outlet sensed by the third pressure sensor to control the gas valve to produce a desired air/gas mixture at the air/gas outlet.
It should be understood that this disclosure is, in many respects, only illustrative. The various individual elements discussed above may be arranged or configured in any combination thereof without exceeding the scope of the disclosure. Changes may be made in details, particularly in matters of shape, size, and arrangement of steps without exceeding the scope of the disclosure. The disclosure's scope is, of course, defined in the language in which the appended claims are expressed.
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