Patent Application
20200018481
The present disclosure relates to control of burner operation, and more particularly to detecting characteristics of ionization current resulting from a burner flame.
This section provides background information related to the present disclosure which is not necessarily prior art.
This disclosure relates to gas fired heating appliances use a source of gas and a source of air that are mixed and transmitted to a burner where an igniter initiates combustion. However, the ratio of gas to air in the gas/air mixture is important to maintaining good combustion and keeping efficiency within an acceptable range. While a flame becomes more conductive as the ratio of the air/fuel mixture approaches near-stoichiometric conditions, attempts to use ionic flame monitoring to maintain a peak flame rod current have resulted in incomplete combustion due to shortage of primary air, as disclosed in U.S. Pat. No. 6,356,199 to Niziolek. Moreover, the sensor supplying the ionization signal ages during burner operation as a result of dirt deposited on the sensor and chemical decomposition, which makes the ionization sensor signal no longer reliable since the electrical behavior of the sensor changes, as disclosed in U.S. Pat. No. 6,783,355 to Blaauwwiekel. Thus, ionic flame monitoring equipment is only reliable for indicating a flame presence, and does not provide reliable feedback over time about the quality of the flame.
This section provides a general summary of the disclosure, and is not a comprehensive explanation of the full scope of the disclosure or all of its features.
Various embodiments of a system and apparatus are provided for controlling operation of a gas-fired heating appliance having a burner. In one embodiment, a control apparatus is provided for sensing burner flame instability. The apparatus includes a sensor for sensing a flame and providing an output of a flame current signal, and a controller in communication with the sensor for sensing flame current. The controller is configured to receive the flame current signal and to detect the occurrence of a flame instability condition. The controller detects flame instability from flame current signal data that is measured and Fourier transformed into a frequency spectrum which changes from a stable to instable spectrum when flame instability is caused by an inadequate air-to-fuel ratio. The controller is configured to respond to the flame instability condition by generating an output signal to decrease the flow of fuel to the burner (and thereby increase the air-to-fuel ratio) and/or increase the speed of a combustion air blower that supplies air to the burner (and thereby increase the air-to-fuel ratio) until the controller determines that the flame current signal is indicative of normal combustion. The controller may be configured thereafter to increase the flow of fuel to the burner (and thereby decrease the air-to-fuel ratio) and/or decrease the speed of a combustion air blower that supplies air to the burner (and thereby decrease the air-to-fuel ratio), in a continual search for an optimal air-to-fuel ratio. In contrast the prior art controls, if stable combustion is not reached within a predetermined interval, the burner is shut down, rather than continuing to operate at an inappropriate air-to-fuel ratio. This predetermined interval can be a predetermined time or alternatively a predetermined number of iterations.
According to another aspect of the present disclosure, a method for controlling the operation of a gas-fired heating appliance is provided. The method comprises iteratively sensing a flame and providing an output of a flame current signal. The method further comprises monitoring the flame current signal to detect an occurrence of flame instability by measuring the sensed flame current signal waveform at a given data sampling rate, and transforming the measured data into a spectrum of frequency components of varying amplitude for detecting a change from a generally steady spectrum indicative of flame stability to an instable spectrum indicative of flame instability. The method further includes increasing the speed of the combustion air blower to increase the flow of combustion air to the burner until it is determined that flame is stable. Thereafter the method includes decreasing the speed of the combustion air blower to reduce the flow of combustion air to the burner until it is determined that the flame is stable. In this manner the control “hunts” for the optimum air-to-fuel ratio. However, if the control does not achieve flame stability within a predetermined interval, the burner is shut down, rather than continuing to operate at an inappropriate air-to-fuel ratio. This predetermined interval can be a predetermined time or alternatively a predetermined number of iterations.
Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
Example embodiments will now be described more fully with reference to the accompanying drawings.
In the various embodiments of a control for a heating appliance, a control apparatus is provided for sensing flame instability that may be caused by an inadequate air-to-fuel ratio, for example. The apparatus includes a sensor for sensing a flame and generating a flame current signal, and a controller in communication with the sensor. The controller is configured to receive the flame current signal and to detect the occurrence of a flame instability condition from flame current signal data that is measured and Fourier transformed into a frequency spectrum which changes from a stable to an instable spectrum when flame instability occurs. The controller is configured to respond to the detection of a flame instability condition by adjusting at least one of the fuel flow control to decrease the fuel flow to the burner (thereby increasing the air-to-fuel ratio) and combustion air blower to increase the flow of combustion air to the burner (thereby increasing the air-to-fuel ratio)/The sensor for sensing flame at the burner may be any number of sensor configurations that generate an appropriate flame current signal, as explained below.
To generate a flame current signal, an alternating current line voltage source may be applied across a flame zone that lies between a flame probe electrode and an electrical contact at the burner that is spaced from the probe electrode. Since a flame is characterized by a stream of ions that induce flame ionization, the flame imparts a direct current voltage to the alternating current that is applied across the flame probe electrode and the electrical contact (e.g., electrical ground). This phenomenon is referred to as flame rectification. The resulting flame current waveform generally varies depending on flame consistency. Thus, in the presence of a flame, a time varying flame current signal is generated that is characterized by various frequency components, such as that of the 60 Hertz frequency of the line voltage applied across the flame. However, when a flame current signal in normal combustion is viewed on an oscilloscope (as shown in
In the apparatus of the first embodiment, the flame current input signal is measured, or digitized, at a high sampling rate and then transformed by a Fast Fourier Transform algorithm. The flame current signal is first passed through an analog filter to attenuate all frequency components above the frequency range in which the signal is to be analyzed. Nyquist's theorem indicates that a sampling rate should be at least twice the maximum frequency component of the filtered signal for the sampled data to accurately represent the input signal, where the frequency resolution is Δv−1/T (the inverse of the time T over which the waveform is measured and Fourier transformed). In the present application, the primary frequency range of interest is from near DC (direct current) to at least 1 kilohertz. The sampled flame current signal establishes a time record of data for a given time portion of the flame current signal. Using a Fast Fourier Transform algorithm, the signal's time record is then transformed into a frequency spectrum that shows the frequency components of the input signal. This Fast Fourier Transform technique provides an advantage of speed in measuring the entire spectrum of frequency in a short time, as explained below.
If 1024 sampled data values are measured at 256 kilohertz, for example, it would take only 4 milliseconds to capture a spectrum from the highest to lowest frequency, where the highest frequency is determined by the period of two consecutive samples (128 kHz), and the lowest frequency is determined by the period of all samplings (¼ milliseconds=250 Hz). The output spectrum would represent frequencies from 250 Hertz to 128 kilohertz with frequency resolution points at every 250 Hertz. The magnitude of the spectrum and its frequencies is proportional to the square root of the Fast Fourier Transform.
The Fast Fourier Transform also enables the flame current signal data to be analyzed to identify variations in the flame that have hitherto been observed only by complex acoustic or optic techniques, which are generally referred to as thermo-acoustic spectrum. The controllers of the various embodiments are configured to analyze the flame current signal to identify variations within the flame current signal data that are comparable to thermo-acoustic spectra for identifying flame variations, as explained below.
In normal combustion conditions where air flow to the burner is in excess of that required for stoichiometry, the flame exhibits a generally flat thermo-acoustic spectrum. Similarly, during normal combustion conditions, the sampled flame current signal data that is measured and Fourier transformed provides a generally steady frequency spectrum. When combustion approaches a lean condition, it creates instabilities in the frequency spectrum, which may be visibly observed via a display output of a spectrum analyzer, for example. A spectrum analyzer is capable of displaying a spectrum over a given frequency range, where the spectrum displayed changes as properties of the signal change. One example of a spectrum analyzer is an SR760 Fast Fourier Transform spectrum analyzer. In a Fast Fourier Transform spectrum analyzer, the flame current input signal may be digitized at a high sampling rate for an interval in which the waveform is measured and Fourier transformed. The magnitude of the spectrum represents the total signal amplitude at each discrete frequency value/component, and allows for determining the amplitude of various frequency components within the frequency span of the spectrum.
From the Fast Fourier Transform of flame current data, the controllers of the various embodiments can determine whether the amplitude of frequencies across the entire spectrum represents a generally flat ‘thermo-acoustic’ spectrum indicative of normal or stable combustion, as in the example shown in
According to one aspect of the present disclosure, a system is provided for controlling a fuel-fired heating appliance. Referring to
The apparatus provides for detecting flame instability that may be caused by an inadequate air-to-fuel ratio, in controlling operation of a burner 102. The apparatus includes a probe sensor 104 that senses a flame at the burner 102 and provides an output of a flame current signal. The apparatus further includes a controller 110 in communication with the sensor 104. The controller 110 is preferably programmable, and encoded with an instruction operable to output a signal to operate the fuel flow control 140 to increase or decrease the flow rate of fuel provided to the burner, and/or to increase or decrease the speed of the combustion air blower 130 to increase or decrease the flow rate of combustion air to the burner 102. The controller 110 is further configured to monitor the flame current signal to detect flame instability by measuring the sensed flame current signal waveform at a given data sampling rate and transforming the measured data into a spectrum of frequency components to identify a change from a generally steady spectrum indicative of flame stability to an instable spectrum indicative of flame instability. Such flame instability may be caused by an inadequate air flow relative to fuel flow to the burner 102, for example. In response to detecting a change of the measured spectrum to an instable spectrum indicative of flame instability, the controller 110 adjusts one of the speed of the combustion air blower 130 or the fuel flow control 140 to increase the air flow relative to the fuel flow until the controller 110 detects that the sensed flame current signal is indicative of flame stability associated with normal combustion. Once stable combustion is achieved, the controller 110 may attempt to fine tune the combustion by increasing the fuel flow and/or decreasing to air flow rate. The adjustment increments during this fine tuning are preferably smaller than the adjustment increments during flame stability correction, and preferably range from 0.1, 0.2, 0.25 and 0.5 of the increments used during flame stability correction. In accordance with the principles of this invention, if the controller is unable to achieve flame stability within a predetermined interval, then the controller shuts down the burner. This predetermined interval can be a predetermined passage of time (e.g., from the detection of flame instability), or a predetermined number of attempts to correct flame instability, or a predetermined change in either the fuel flow rate or combustion air flow rate.
At a point prior to shut down (e.g., at a point less than the predetermined interval), or upon shutdown (e.g., either or concurrent or subsequent to shutdown), the system can generate an alert to occupants in the space. This allows the occupants in the space to take preemptive or corrective action before the temperature in the space becomes uncomfortable. The alert can be in the form of a visual signal on the control (e.g., a blinking light, or a message on the display), or an audible signal generated by the control (e.g., a beep, a buzz, or a chirp), or both. The alert may alternatively, or in addition, be provided by email, text message, autocall, or notification in an application running on a cell phone, tablet, or other device. The alert can be provided to the users of the space, to the managers of the space, and/or to third party servicers.
After the burner is shut down, the controller may attempt to restart the burner after a predetermined refractory period. Alternatively, if the controller is operating with a multi-stage appliance, the controller may simply shut down operation in the stage in which flame instability cannot be resolved, and operate only in the stage or stages in which the flame is stable.
In
As shown in
Also shown in
Accordingly,
Referring to
If at 570 the controller determines that the flame is stable, then at 605 the controller resets the interval counter. Then at 610 the controller 110 reduces the air flow and or increases the fuel flow to reduce the air-to fuel ratio to fine tune the combustion. The reduction in air flow and/or the increase in fuel flow at 610 is preferably in smaller amounts than the increase in air flow and/or the decrease in fuel flow at 590. For example the increments/decrements at 610 may be 0.1, or 0.2 or 0.25 or even 0.5 of the increments/decrements at 590. In this manner the controller is constantly hunting for the optimum air-to-fuel ratio, which can change over time as the appliance operates. At 600 the controller operates the burner with the new air-to-fuel ration, and the cycle continues.
In contrast to prior art systems, the flame correction is supervised, and if the flame cannot be corrected in a predetermined interval, the burner is shut off. This interval can be the passage of a predetermined time, but it could also be a particular number of correction attempts, or a particular amount of corrective adjustments to the fuel flow and/or to the air flow. The interval counter is set after the first determination of flame instability, and the interval counter is reset after the first determination of flame stability. The interval can be predetermined, or it can be dynamically determined, for example, based upon the determined stability of the flame, and/or the frequency, duration, and extend of deviation from stable combustion.
If the controller 110 turns of the burner, the controller can optionally be programmed to restart the burner after a predetermined refractory period. Further, if the controller is part of a multi-stage appliance, the controller could turn off the burner for operation in the stage where instability occurs, and continue to operate the burner at other stages where the flame can be or is stabilized.
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
