Patent Grant
10697921
The invention relates to systems, circuits, and methods for determining aspects of a flame rod. By determining aspects of a flame rod, it is possible to monitor the quality of a flame that may be present in a residential, commercial, or industrial burner. Such burners may be present in residential water heaters and furnaces, for example. Such burners also may be present in industrial boilers and dryers.
Burners ignite a fuel, such as natural gas or heating oil to produce heat. Modern burners typically have one or more sensors capable of monitoring the presence of a smaller ignition flame (e.g., a pilot light) as well as the larger flame that produces the heat. A variety of sensors are known, and they range in functionality (and price) as the use of the burner dictates. For example, high-end flame sensors may analyze the performance of the flame spectroscopically, and alert engineers or service technicians when the burner is not functioning optimally.
Many burners rely on flame rectification to sense the presence of a flame. In flame rectification an AC signal is sent to two electrodes contacted by the flame. Because the current from one half of the AC cycle is preferentially conducted through the flame, the AC signal is rectified to produce a noisy DC voltage. Thus, by observing a heavily-filtered DC voltage, it is possible to determine if the flame is present. If the DC voltage falls below a pre-determined value, the sensor assumes that the flame is out, and a valve shuts off the fuel flow. Flame rectification cannot distinguish between a high-resistance flame and no flame, however, because either condition results in a DC voltage below the acceptable level.
Because of the harsh environment inside the flame, the electrodes for flame rectification must be fabricated from high temperature alloys, such as kanthol, or ceramic material. These electrodes, intended for exposure to flames, are known generally as flame rods. Flame rods are available from a number of manufacturers including, but not limited to, Honeywell Inc. (Golden Valley, Minn.). In many embodiments, the burner or pilot light assembly is the second electrode needed for flame rectification, thus, typically, only one flame rod is necessary to monitor a flame with flame rectification.
Over time, flame rods develop a layer of corrosion, soot, carbonization, contamination, etc. This contamination layer may negatively affect the function of the flame rod by increasing the resistance of the flame rod. As the contamination builds up, the observed DC voltage will decrease to the point that a flame-out (no flame) event is registered. In many cases, the flame-out event will trigger an unnecessary shut-down of the burner. To avoid unnecessary shut downs, flame rods must be serviced regularly to verify that they do not have a contamination layer that will trigger a flame-out event.
Accordingly, there is a need for improved systems, circuits and methods of monitoring an aspect of a flame rod. In particular, it would be advantageous if the systems, circuits and method were capable of monitoring the flame rod for contamination while being able to distinguish a flame rod short from a low-resistivity flame as well as being able to distinguish no flame from a high resistivity flame.
In one embodiment, the invention provides a system for analyzing an aspect of a flame rod. The system comprises energy storage, a pulsed source, a buffer, and a processor. The energy storage is connected to ground and connectable to the flame rod. The pulsed source is connected to the energy storage and provides a voltage pulse or a current pulse. The buffer is connected to the energy storage, and is connectable to the flame rod. The buffer buffers a voltage on the energy storage and the flame rod. The processor is connected to the buffer and the processor determines a first buffered voltage and a second buffered voltage after the pulsed source provides a voltage pulse or a current pulse. The processor additionally produces a first flag based on the first buffered voltage and a second flag based on the second buffered voltage.
In another embodiment, the invention provides a flame rod analysis circuit comprising a capacitor, a transistor switch, and an operational amplifier. The capacitor has a first terminal and a second terminal, wherein the first terminal is connectable to a flame rod and the second terminal connectable to ground. The transistor switch has a source, a drain, and a gate. The source is connected to a positive voltage, the drain is connected to the first terminal, and the gate is connectable to a signal. The operational amplifier has a positive terminal, a negative terminal, and an output. The positive terminal is connected to the first terminal, the negative terminal is connected to the output, and the output is connectable to a processor.
In another embodiment, the invention provides a method for analyzing an aspect of a flame rod connected to a pulsed source, energy storage connected to ground, and a buffered processor capable of determining a voltage on the flame rod and the energy storage. The method comprises contacting the flame rod with a flame, providing a voltage pulse or a current pulse to the flame rod and the energy storage, determining a first voltage on the flame rod and the energy storage at a first time, determining a second voltage on the flame rod and the energy storage at a second time, producing a first flag based on the first voltage, and producing a second flag based on the second voltage.
In another embodiment, the invention provides a system for determining the resistance of a flame rod, including a reference resistor, a pulsed voltage source, a buffer, and a processor. The reference resistor has a known resistance and is connectable to the flame rod. The pulsed voltage source is connected to the reference resistor and provides a voltage pulse of a known magnitude. The buffer is connected to the reference resistor and the processor, and is connectable to the flame rod. The buffer buffers a voltage between the reference resistor and the flame rod so that the processor can measure the buffered voltage. The processor determines a peak voltage between the reference resistor and the flame rod when the voltage pulse is provided by the pulsed voltage source. The processor may additionally determine a flame voltage between the reference resistor and the flame rod in the absence of a voltage pulse provided by the pulsed voltage source. The processor may produce a flag when the peak voltage exceeds a threshold voltage. The processor may determine the resistance of the flame rod based upon the resistance of the reference resistor, the magnitude of the voltage pulse, the peak voltage, and the flame voltage.
In another embodiment, the invention provides for a flame rod resistance measuring circuit comprising a reference resistor having a first terminal and a second terminal, the second terminal being connectable to the flame rod, a transistor switch having a source, a drain, and a gate, the source being connected to a positive voltage, the drain being connected to the first terminal, the gate being connectable to a signal, and an operational amplifier having a positive terminal, a negative terminal, and an output, the positive terminal connected to the first terminal, the negative terminal connected to the output, and the output connectable to a processor. The flame rod measuring circuit may additionally comprise a processor and an indicator.
In another embodiment, the invention provides for a method for determining excessive resistance through a flame rod connected to a reference resistor of known resistance, a pulsed voltage source, and a buffered processor capable of determining a voltage between the flame rod and the reference resistor. The method comprises providing a voltage pulse of known magnitude, determining a peak voltage between the reference resistor and the flame rod during the voltage pulse, and comparing the peak voltage to a threshold value. The method my additionally comprise determining a flame voltage between the reference resistor and the flame rod in the absence of the voltage pulse, and determining the resistance of the flame rod based upon the resistance of the reference resistor, the magnitude of the voltage pulse, the peak voltage, and the flame voltage.
Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
A generalized burner unit 100 that may be found in a natural-gas-fueled appliance, for example, is shown in
Burner unit 100 may have one or more flame analysis systems 125 to enable burner unit 100 to monitor the presence of flame 110. In the event that flame 110 is extinguished, flame analysis system 125 will signal shut off valve 120 to close, thus halting the flow of fuel to burner 105. Prior art systems typically use a form of flame rectification (discussed above) that involves positioning flame rod 130 in flame 110 while burner 105 is attached to ground 135. In prior art systems, an AC signal is presented to flame rod 130, and a rectified DC voltage is observed to verify presence of flame 110. When the rectified DC voltage falls below a threshold, it is assumed that flame 110 has been extinguished and shut off valve 120 is closed. Nonetheless, many prior art systems cannot distinguish between a flame 110 having high resistance, flame rod 130 being contaminated, and flame 110 being extinguished.
In contrast to the prior art, the invention described herein allows burner unit 100 to successfully halt the flow of fuel to burner 105 in the event that flame 110 is extinguished, but without the need to rely on flame rectification. Rather flame analysis systems 125 of the invention rely on modeling flame 110 as a negative current source. Flame analysis systems 125 of the invention can still monitor flame rod 130 to determine the condition of flame 110, however, flame analysis system 125 of the invention can distinguish between flame 110 having high resistance, flame rod 130 being contaminated, and flame 110 being extinguished. Because flame analysis systems 125 of the invention allow for the determination of various states of flame 110 and flame rod 130, it is advantageous to additionally incorporate alert 140 in some embodiments utilizing flame analysis systems of the invention. Alert 140 may comprise a series of light emitting diodes, for example, that can signal to a consumer or service technician the state of burner unit 100.
An embodiment of a flame analysis system 200 of the invention is shown in
As understood by one skilled in the art, when referencing a parameter, such as voltage, resistance, current, etc., it is not necessary to determine an actual value for voltage, resistance, current, etc. to determine the condition of the flame rod or the flame. For example, it is possible to compare a signal value representative of a voltage, resistance, current, etc. to a comparison value, or another signal value corresponding to another voltage, resistance, current, etc. of interest to determine a condition of the flame rod or the flame. Where it is stated that processor 240 determines voltage, resistance, current, etc., the statement is intended to include embodiments in which processor 240 determines actual values of voltage, resistance, current, etc., and embodiments in which processor 240 determines signal values representative of voltage, resistance, current, etc.
Pulsed source 220 typically provides a voltage pulse 225 at regular intervals to energy storage 210. (In some embodiments pulsed source 220 provides a current pulse to energy storage 210.) Assuming flame rod 130 has not been grounded, voltage pulse 225 will result in energy storage 210 becoming charged. Over some period of time, the energy stored in energy storage 210 will drain through flame 110 to ground 135. However, because flame 110 is effectively a negative current source, flame 110 will ultimately pull energy storage 210 down, typically below ground 135. This behavior is illustrated by decay waveform 235 present between buffer 230 and processor 240. That is, when flame 110 and flame rod 130 are working properly, each voltage pulse 225 results in the voltage on energy storage 210 rising to nearly the peak of voltage pulse 225, then decaying away, and then being pulled negative.
Voltage pulse 225 and decay waveform 235 are better illustrated in
In the event that flame 110 has gone out, the voltage on energy storage 210 will decay slightly after voltage pulse 225 because of the natural decay through energy storage 210. However, in the event of a flame out, energy storage 210 will typically stay charged until the next voltage pulse 225. The resulting waveform, depicted as flame out waveform 320 in
In the event that flame rod 130 has become contaminated or corroded, the resistance (RF) of flame rod 130 to the negative current produced by flame 110 increases. Because of this increased resistance, the voltage on energy storage 210 takes longer to decay to a negative value, thus producing service flame rod waveform 330. Of course, as flame rod 130 becomes more contaminated or corroded, the rate of decay of service flame rod waveform 330 will decrease.
In some embodiments, it may be beneficial to collect all of waveform 235 resulting from the decay of voltage on energy storage 210 through flame rod 130. Techniques such as logarithmic approximation or polynomial fitting may be used to uniquely determine the shape of waveform 235 with suitable processors.
In other embodiments, waveforms 235 may be adequately characterized by making voltage measurements at predetermined intervals after voltage pulse 225 is sent to energy storage 210, and comparing the voltage measurements to kxVi wherein kx=−1 to 1, and Vi is the magnitude of the voltage pulse. The sequence of measurements, as identified with subscripts, is meant to aid one of skill in the art in interpreting the waveforms presented in
In one embodiment, flame analysis system 200 will record two buffered voltage measurements, V1 and V3 at times t1 and t3, respectively, allowing processor 240 to produce a first flag indicative of a flame rod short by comparing V1 to k1Vi and a second flag indicative of no flame by comparing V3 to k3Vi. In another embodiment, waveform 235 may be better characterized by making three buffered voltage measurements V1, V2, and V3 at times t1, t2, and t3, respectively, allowing processor 240 to produce a first flag indicative of a flame rod short by comparing V1 to k1Vi, a second flag indicative of no flame by comparing V3 to k3Vi, and a third flag indicative of a contaminated flame rod by comparing by comparing V2 to k2Vi. The approximate locations of times t1, t2, and t3 are shown in
Typically, first buffered voltage measurement, V1, at time t1 indicates the presence of a short between flame rod 130 and ground 135. That is, if flame rod 130 has shorted to ground, V1 will be smaller than a first multiplier, k1, of voltage pulse 225, e.g., V1<k1Vi. If V1<k1Vi, processor 240 produces a first flag indicating a flame rod 130 short. However if V1>k1Vi, the normal operable state, processor 240 does not produce a first flag. Processor 240 will typically be programmed to measure V1 a short period after voltage pulse 225 is completed. In some embodiments, processor 240 may be triggered by a separate signal (not shown) that also triggers pulsed source 220 so that V1 is measured at an appropriate time. Processor 240 may additionally comprise memory to allow processor 240 to store values of V1 for later data collection and analysis. First multiplier, k1, is less than 0.99, typically less than 0.9, more typically less than 0.8.
Typically, second buffered voltage measurement V3 at time t3 indicates the presence of flame 110 on flame sensor 130. That is, if flame 110 has gone out, the voltage at energy storage 210 will not be pulled down sufficiently to pass through threshold k3Vi. Multiplier k3 is typically small, and may be positive or negative. In some embodiments, k3=0. If V3>k3Vi, processor 240 produces a second flag indicative of no flame. The second flag, indicative of no flame, typically initiates a sequence by which the fuel feeding burner 105 is interrupted with shut off valve 120. However if V3<k3Vi, the normal operable state, processor 240 does not produce a second flag.
Typically, third buffered voltage measurement V2 at time t2 indicates the condition of flame rod 130. That is, if flame rod 130 has become contaminated or corroded, V2 will be greater than a second multiplier, k2, of voltage pulse 225, e.g., V2>k2Vi. If V2>k2Vi, processor 240 produces a third flag indicating that flame rod 130 is contaminated. However, if V2<k2Vi, the normal operable state, processor 240 does not produce a third flag. Second multiplier, k2, is greater than 0.01, typically greater than 0.1, more typically greater than 0.2.
In other embodiments, processor 240 has memory to store the values of V3. Processor 240 may be additionally configured to average the values of V3 to produce an average second buffered voltage, and processor 240 may compare V3 to the average second buffered voltage. Processor 240 may be programmed to produce a fourth flag, indicative of low flame, in the event that V3 is greater than the average second buffered voltage. The stored values of V3 may be additionally accessed for data collection and analysis.
The sequence of measurements taken by flame analysis system 200 capable of producing first, second, and third flags, is depicted by flow chart 400 shown in
Assuming that V1 is greater than k1Vi, processor 240 determines V2 at t2 in step 440. After determining the value of V2, processor 240 compares the value of V2 to k2Vi in step 450. If V2 is greater than k2Vi, processor 240 produces FLAME ROD CONTAMINATED flag 455. FLAME ROD CONTAMINATED flag 455 may trigger a series of events not shown, such as causing an LED to illuminate or producing an audible alarm.
Regardless of whether V2 is greater than k2Vi, processor 240 next determines V3 at t3 in step 470. After determining the value of V3, processor 240 compares the value of V3 to k3Vi in step 480. If V3 is greater than k3Vi, processor 240 produces FLAME OUT flag 485. FLAME OUT flag 485 may trigger a series of events not shown, such as terminating the flow of fuel to burner 105.
In the event that V3 is less than k3Vi, flame analysis system 200 determines that flame rod 130 and flame 110 are functioning properly, and flow chart 400 terminates with finish step 498. Processor 240 typically returns to start 402 with the introduction of a subsequent voltage pulse 225 from pulsed source 220. The time between subsequent voltage pulses 225 is greater than hundredths of a second, typically greater than tenths of a second, more typically greater than seconds.
Flame rod analysis circuit 500, which is an embodiment of flame analysis system 200, is shown in
As prompted by signal 540, transistor switch 520 will allow an amount of current to pass through transistor switch 520 to energize capacitor 510. Assuming flame rod 130 is in flame 110 and not grounded, the voltage on capacitor 510 will decay with time through flame rod 130 to produce a voltage waveform as described above. By measuring a buffered voltage at output 537, it is possible for processor 240 to determine voltages at various time points after voltage pulse 225 is transmitted through transistor switch 520. Because operational amplifier 530 buffers the voltage on capacitor 510, processor 240 is protected from current spikes that might damage processor 240.
Electrical components suitable for the construction of flame rod analysis circuit 500 according to invention are available from a number of suppliers, including Digi-Key electronics (Thief River Falls, Minn.). P-channel MOSFETs produced by Zetex, such as ZXMP6A13FCT-ND, are suitable for use as transistor switch 520. Operational amplifiers produced by Texas Instruments, such as TL062ID are suitable for use as operational amplifier 530. Integrated circuits produced by Freescale Semiconductor, such as MC9S08AW60CFGE, are suitable for use as processor 240. One of skill in the art may substitute other components for these components to produce different flame rod analysis circuits that are equally capable of performing the measurements described herein.
The invention additionally provides a flame rod resistance analyzer 600 for determining the resistance of a flame rod, as is shown in
Assuming the circuitry is properly isolated, and buffer 230 is not drawing any current, the current, I, passing through reference resistor Rr returns to ground via flame rod 130. Accordingly, Vp=VF+RFI. Thus, the resistance of flame rod 130, RF, is equal to
Therefore by knowing Rr and Vi, and measuring Vp during voltage pulses, and VF between voltage pulses, it is possible to directly measure the resistance of the flame rod. Using this method, the processor can calculate the resistance of the flame rod, RF, and compare it to a threshold resistance. Should the resistance of the flame rod, RF, exceed the threshold, the processor may produce a flag.
In some embodiments of flame rod resistance analyzer 600, it is not necessary to actually calculate RF because the relationship between Vp and VF is sufficient to determine excessive resistance through flame rod 130 by measuring only Vp. For example, as the resistance of flame rod 130, RF, increases, Vp will approach Vi, assuming VF is small in magnitude. By measuring Vp during the voltage pulse, and comparing Vp to Vi, processor 240 can determine excessive resistance through flame rod 130, and produce a flag indicating excessive resistance through flame rod 130.
In some embodiments of flame rod analysis system 200 employing voltage pulses and having reference resistor Rr, excessive resistance through flame rod 130 can be determined by comparing Vp to Vi, as described above. In other embodiments of flame rod analysis system 200 employing voltage pulses and having reference resistor Rr, the length of time between voltage pulses is sufficient that all energy stored in energy storage 210 dissipates through flame rod 130, allowing a measurement of VF. See, for example, good flame waveform 310 in
An exemplary embodiment of flame rod analysis circuit 500 is shown in
An alternative embodiment of the flame rod analysis circuit 500 is shown in
Like
Thus, the invention provides, among other things, systems, circuits, and methods for determining aspects of a flame rod. Various features and advantages of the invention are set forth in the following claims.
The present application is a continuation of U.S. patent application Ser. No. 12/467,091, filed May 15, 2009, the entire contents of which are hereby incorporated.
| Number | Name | Date | Kind |
|---|---|---|---|
| 2116943 | Hamilton | May 1938 | A |
| 2260977 | Jones | Oct 1941 | A |
| 2360532 | Yates | Oct 1944 | A |
| 2626657 | Wilson | Jan 1953 | A |
| 3266026 | Plambeck | Aug 1966 | A |
| 3574495 | Landis | Apr 1971 | A |
| 3632285 | Foster | Jan 1972 | A |
| 4034235 | Wade | Jul 1977 | A |
| 4088984 | Muramoto | May 1978 | A |
| 4113419 | Cade | Sep 1978 | A |
| 4461615 | Inoue | Jul 1984 | A |
| 4494924 | Tanaka | Jan 1985 | A |
| 4527125 | Miyanaka | Jul 1985 | A |
| 4537068 | Wrobel | Aug 1985 | A |
| 4672324 | van Kampen | Jun 1987 | A |
| 4710125 | Nakamura | Dec 1987 | A |
| 4965048 | Ogasawara | Oct 1990 | A |
| 4972324 | Tanaka | Nov 1990 | A |
| 4984981 | Pottebaum | Jan 1991 | A |
| 5051936 | Gleason, III et al. | Sep 1991 | A |
| 5073104 | Kemlo | Dec 1991 | A |
| 5194728 | Peterson | Mar 1993 | A |
| 5256057 | Grow | Oct 1993 | A |
| 5300836 | Cha | Apr 1994 | A |
| 5347982 | Binzer | Sep 1994 | A |
| 5439374 | Jamieson | Aug 1995 | A |
| 5472336 | Adams | Dec 1995 | A |
| 5538416 | Peterson | Jul 1996 | A |
| 5722822 | Wilson et al. | Mar 1998 | A |
| 6059195 | Adams | May 2000 | A |
| 6084518 | Jamieson | Jul 2000 | A |
| 6354830 | de Nanclares | Mar 2002 | B1 |
| 6356199 | Niziolek | Mar 2002 | B1 |
| 6794771 | Orloff | Sep 2004 | B2 |
| 6985080 | Kociecki | Jan 2006 | B2 |
| 7088253 | Grow | Aug 2006 | B2 |
| 7329389 | Horovitz | Feb 2008 | B2 |
| 7353140 | Daw | Apr 2008 | B2 |
| 20060257801 | Chian | Nov 2006 | A1 |
| 20060257802 | Chian | Nov 2006 | A1 |
| 20060257804 | Chian | Nov 2006 | A1 |
| 20060257805 | Nordberg | Nov 2006 | A1 |
| 20100291494 | Branecky | Nov 2010 | A1 |
| Entry |
|---|
| Gayesco, LLC, “Flame Rods,” Retrieved from the Internet [Online] Available May 9, 2008 at: URL < http://waybackmachine.org/web/20080509075438/http://www.gayesco.com/flame_rods.htm> printed on Apr. 21, 2010 ( 2 pages). |
| jimtrade.com, “Gas Burners Flame Rod Detectors,” [Retrieved from the Internet] [Online] Available May 1, 2006, at: URL < http://web.archive.org/web/20060501201220/http://articles.jimtrade.com/1/20.htm> printed Apr. 21, 2010 (3 pages). |
| Vandermeer, “Flame Safeguard Controls in Multi-Burner Environments,” Apr. 1998 (34 pages). |
| Office Action from the Mexican Patent Office for Application No. MX/A/2010/005347 dated Dec. 2, 2013 (2 pages). |
| Office Action from the Mexican Patent Office for Application No. MX/A/2014/010779 dated Mar. 11, 2016 (5 pages). |
| United States Patent Office Notice of Allowance for U.S. Appl. No. 12/467,091 dated Sep. 25, 2018 (8 pages). |
| Office Action from the Canadian Intellectual Property Office for Application No. 2703681 dated Mar. 30, 2017 (3 pages). |
| Office Action from the Canadian Intellectual Property Office for Application No. 2703681 dated May 20, 2016 (4 pages). |
| Notice of Allowance from the Mexican Intellectual Property Office for Application No. MX/A/2014/010779 dated Aug. 16, 2016 (2 pages). |
| Number | Date | Country | |
|---|---|---|---|
| 20160274049 A1 | Sep 2016 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 12467091 | May 2009 | US |
| Child | 15165819 | US |
