CN112505124A - Oxygen sensor for improving combustion efficiency and emission standard of gas water heater - Google Patents
Oxygen sensor for improving combustion efficiency and emission standard of gas water heater Download PDFInfo
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- CN112505124A CN112505124A CN202011382080.3A CN202011382080A CN112505124A CN 112505124 A CN112505124 A CN 112505124A CN 202011382080 A CN202011382080 A CN 202011382080A CN 112505124 A CN112505124 A CN 112505124A
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- G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
- G01N27/26—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating electrochemical variables; by using electrolysis or electrophoresis
- G01N27/403—Cells and electrode assemblies
- G01N27/406—Cells and probes with solid electrolytes
- G01N27/407—Cells and probes with solid electrolytes for investigating or analysing gases
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Abstract
The invention relates to the field of sensors, in particular to an oxygen sensor for improving the combustion efficiency and emission standard of a gas water heater. The oxygen sensor changes the structure of the protective cover and the air inlet path of the zirconia ceramic chip, and air enters the probe through the annular space between two layers of the double-layer protective cover by using the double-layer protective cover, thereby achieving the effects of reducing the air flow speed and balancing the temperature difference. The zirconia ceramic wafer in the probe adds an air inlet hole by using a punching process before the test cavity and the diffusion barrier, the air inlet hole can play a role in temporary air storage and air buffering, the problem of signal fluctuation caused by cold and hot airflow impact is reduced, and the diffusion barrier is changed into the zirconia ceramic wafer, so that the diffusion barrier is prevented from being damaged in the production process. In addition, air enters the air inlet hole through the surface protection layer, and gas in the air inlet hole enters the test cavity through the diffusion barrier, so that signal fluctuation is avoided under the buffer action of the air inlet hole, the air inlet process is stable, and signals are stable.
Description
Technical Field
The invention relates to the field of sensors, in particular to an oxygen sensor for improving the combustion efficiency and emission standard of a gas water heater.
Background
The full-premixed combustion of the water heater follows the mixing combustion of gas and oxygen according to a certain theoretical mass proportion, so that the full combustion of fuel can be realized, and the emission of harmful gas is reduced, but the control of the combustion of the traditional gas water heater is realized by controlling the power of a fan through a system, the combustion efficiency of the gas cannot be monitored to achieve the closed-loop control effect, the control precision is low, and the phenomena of insufficient combustion or excessive air can be caused; meanwhile, in the use process of the actual gas water heater, the air pressure and the humidity in different regions are different, the oxygen concentration is different, the oxygen proportion is controlled by the pure control of the power of the fan, the pure control is obviously not ideal enough, the oxygen concentration in tail gas emission can be accurately measured by using the oxygen sensor, the combustion efficiency of gas is monitored in real time, and the control system carries out accurate control on the fan according to the feedback signal of the oxygen sensor, so that the combustion efficiency and the emission standard of the gas water heater are improved.
The limiting current type oxygen sensor has high precision, wide oxygen concentration measuring range and wide application range, and has good prospect especially in the field of household appliances. The limiting current type sensor limits the air inlet speed by controlling the size of an air inlet channel, and further controls the size of limiting current.
However, due to the complex working environment of the sensor, the signal fluctuates due to mechanical oscillation or hot and cold airflow impact, and generally, these influences cannot be avoided. The oxygen sensor can not work normally, and accurate oxygen concentration can not be reflected. In addition, the prior art structure is that air directly enters the test chamber through a diffusion barrier, and an oxygen pumping unit measures an oxygen concentration signal. However, the diffusion barrier is easily polluted because the diffusion barrier is directly contacted with the external environment, and the sensor is easily damaged physically in the assembling process, so that the oxygen signal of the pump suddenly changes to cause the failure of the sensor.
Disclosure of Invention
In order to solve the problems, the invention provides the oxygen sensor for improving the combustion efficiency and the emission standard of the gas water heater, which is not easy to damage and has accurate test.
In order to achieve the purpose, the invention adopts the technical scheme that: the utility model provides an improve gas heater combustion efficiency and emission standard's oxygen sensor, includes the double-deck safety cover, base, sleeve, fine pipe of glass, high temperature line and the connector that connect gradually, be equipped with the zirconia potsherd in the base, the zirconia potsherd from the top down includes outer pump electrode, alumina insulation layer, first zirconia base member, inner pump electrode, second zirconia base member, third zirconia base member, fourth zirconia base member, alumina insulation layer and heater in proper order, be equipped with corresponding electrically conductive aperture between alumina insulation layer and the first zirconia base member, second zirconia base member one end is equipped with the inlet port to the homonymy surface is equipped with the test chamber, be equipped with the diffusion barrier between inlet port and the test chamber, the one end that the second zirconia base member was equipped with the inlet port still is equipped with porous protective layer.
Further, the outer pump electrode and the inner pump electrode are made of platinum materials, and the base is a hexagonal base.
Further, the head of the zirconia ceramic sheet is coated with magnesia-alumina spinel slurry as a protective layer.
Furthermore, the air inlet and the test cavity are filled with carbon films in the preparation process and are removed after sintering.
Also provides a production process of the oxygen sensor, which comprises the following production steps:
s1, the zirconia ceramic plate penetrates into the ceramic and powder ring and then is riveted with the hexagonal base together;
s2, connecting the riveted semi-finished product on an aging test bench, and introducing heating voltage and pump voltage for aging test;
s3, riveting the protective cover after the base is closed, wherein the protective cover is of a double-layer structure;
s4, cutting the lengths of the high-temperature wires and the glass fiber tubes by using a semi-automatic cutting machine, and assembling the high-temperature wires and the glass fiber tubes, the terminals and the connectors into a wire harness assembly;
s5, connecting the wire harness and the hexagonal base together, riveting the sleeve, and then welding the sleeve on the base by using laser welding;
and S6, riveting and closing the position where the tail of the sleeve is connected with the wire harness.
In S2, 5.2V heating voltage and 0.75V pump voltage are introduced for aging test, and the test time is 48 h.
In addition, the preparation process of the zirconia ceramic sheet comprises the following steps:
s1, sintering the signal layer and the heating layer into a whole by adopting a tape casting process and a multilayer laminating co-firing LTCC/HTCC technology;
s2, coating the magnesium aluminate spinel slurry on the head of the zirconia ceramic sheet to be used as a protective layer, and sintering at high temperature to form an irregular micropore structure;
s3, filling the air inlet and the test cavity with carbon films in the preparation process of the zirconia ceramic wafer, and removing the air inlet and the test cavity after sintering;
s4, adopting a micro-structure design for the diffusion barrier, using 15000-mesh carbon powder and zirconia particles as fillers, and leaving cavities through sintering to form micro-small holes as a diffusion-limited structure design;
s5, controlling the size of the diffusion barrier through screen printing, controlling the size of the limiting current within 80-800 uA, and detecting the oxygen concentration range to be 0.1-25%.
The invention has the beneficial effects that: the oxygen sensor changes the structure of the protective cover and the air inlet path of the zirconia ceramic chip, and air enters the probe through the annular space between two layers of the double-layer protective cover by using the double-layer protective cover, thereby achieving the effects of reducing the air flow speed and balancing the temperature difference. The zirconia ceramic wafer in the probe adds an air inlet hole by using a punching process before the test cavity and the diffusion barrier, the air inlet hole can play a role in temporary air storage and air buffering, the problem of signal fluctuation caused by cold and hot airflow impact is reduced, and the diffusion barrier is changed into the zirconia ceramic wafer, so that the diffusion barrier is prevented from being damaged in the production process. In addition, at the outside protective layer of zirconia ceramic wafer coating to the air passes through surface protection layer and gets into the inlet port, and the gas in the inlet port passes through the diffusion barrier and gets into the test chamber, through the cushioning effect of inlet port, has avoided the signal fluctuation, makes the air inlet process stable, and the signal is steady.
Drawings
Fig. 1 is a schematic diagram of the finished structure of the sensor of the present embodiment.
Fig. 2 is a schematic structural diagram of a zirconia ceramic plate of the sensor in the embodiment.
Fig. 3 is a partially enlarged view of the zirconia ceramic sheet of the present embodiment.
The reference numbers illustrate: 1. a protective cover; 2. a base; 3. a sleeve; 4. a glass fiber tube; 5. a high temperature line; 6. a connector; 7. a zirconia ceramic sheet; 71. an outer pump electrode; 72. an alumina insulating layer; 73. a first zirconia matrix; 74. an inner pump electrode; 75. a second zirconia base; 751. an air inlet; 752. a test chamber; 753. a diffusion barrier; 754. a porous protective layer; 76. a third zirconia base; 77. a fourth zirconia matrix; 78. an alumina insulating layer; 79. a heater; 70; conductive apertures.
Detailed Description
The present invention will be described in further detail with reference to the following detailed description and accompanying drawings. The present application may be embodied in many different forms and is not limited to the embodiments described in the present embodiment. The following detailed description is provided to facilitate a more thorough understanding of the present disclosure, and the words used to indicate orientation, top, bottom, left, right, etc. are used solely to describe the illustrated structure in connection with the accompanying figures.
Referring to fig. 1-3, the present invention relates to an oxygen sensor for improving combustion efficiency and emission standard of a gas water heater, which includes a double-layer protective cover 1, a base 2, a sleeve 3, a glass fiber tube 4, a high temperature wire 5 and a connector 6, which are connected in sequence, wherein a zirconia ceramic sheet 7 is disposed in the base 2, the zirconia ceramic sheet 7 includes an outer pump electrode 71, an alumina insulating layer 72, a first zirconia base 73, an inner pump electrode 74, a second zirconia base 75, a third zirconia base 76, a fourth zirconia base 77, an alumina insulating layer 78 and a heater 79 in sequence from top to bottom, a corresponding conductive small hole 70 is disposed between the alumina insulating layer 72 and the first zirconia base 73, an air inlet 751 is disposed at one end of the second zirconia base 75, a test cavity 752 is disposed on the same side surface, a diffusion barrier 753 is disposed between the air inlet 751 and the test cavity 752, the end of the second zirconia base 75, at which the gas inlet holes 751 are formed, is further provided with a porous protection layer 754. The outer pump electrode 71 and the inner pump electrode 74 are both made of platinum materials and can catalyze oxygen to be converted into oxygen ions, and the base 2 is a hexagonal base.
The production process of the finished oxygen sensor comprises the following steps:
s1, the zirconia ceramic chip 7 penetrates through the ceramic and powder rings and then is riveted with the hexagonal base 2, the hexagonal base 2 has universal applicability by adopting standard M12X 1.25-6e threads, and the structure is small and exquisite, so that household appliances can be conveniently added and installed;
s2, connecting the riveted semi-finished product on an aging test bench, and introducing 5.2V heating voltage and 0.75V pump voltage for aging test for 48 h;
s3, riveting the protective cover 1 after the base 2 is closed, wherein the protective cover 1 is of a double-layer structure, the double-layer barrier has an air flow buffering effect, and the measured air is controlled to stably contact with an internal signal test electrode, so that signal fluctuation is avoided, the air inlet process is stable, and signals are stable;
s4, cutting the lengths of the high-temperature wire 5 and the glass fiber tube 4 by using a semi-automatic cutting machine, and assembling the high-temperature wire and the glass fiber tube with the terminal and the connector 6 to form a wire harness assembly;
s5, connecting the wire harness and the hexagonal base 2 together, riveting the sleeve 3, and then welding the sleeve 3 on the base 2 by using laser welding, so that the whole structure is firmer;
s6, riveting and closing the position where the tail of the sleeve 3 is connected with the wiring harness, and ensuring that the wiring harness does not fall off.
In this embodiment, the preparation process of the zirconia ceramic sheet includes the following steps:
s1, sintering the signal layer and the heating layer into a whole by adopting a tape casting process and a multilayer laminating co-firing LTCC/HTCC technology, and having low production cost, high production efficiency and good consistency;
s2, coating magnesia alumina spinel slurry on the head of the zirconia ceramic sheet 7 to serve as a protective layer, sintering at high temperature to form an irregular micropore structure, and primarily filtering gas to resist pollutants;
s3, filling the air inlet hole 751 and the test cavity 752 with carbon films in the preparation process of the zirconia ceramic chip 7, and removing the air inlet hole after sintering to ensure the integrity of an air inlet channel;
s4, adopting a micro-structure design for the diffusion barrier 753, using 15000-mesh carbon powder and zirconia particles as fillers, and leaving cavities through sintering to form a micro-pore cavity as a structural design for diffusion limitation, thereby achieving the function of measuring the pump oxygen current;
s5, controlling the size of the diffusion barrier 753 through screen printing, controlling the size of the limiting current within 80uA-800uA, and detecting the oxygen concentration range to be 0.1% -25%.
In the present embodiment, the detailed parameters of the sensor are as follows:
1) sensor type: limiting current type
2) Heating resistance: 1-5 ohm
3) Heater voltage: 3-8V
4) Working power: 2-6W
5) The pump electrode has a pump voltage of 0.6-1.6V
6) The pump current between the pump electrodes is 80-1000 microamperes
7) The hexagonal base 2: screw thread M12 with 1.25-6e, SUS304 material, temperature resistance of 480 deg.C
8) Double-layer protective cover 1: the material SUS310S is resistant to 480 DEG C
9) Wiring harness: polytetrafluoroethylene insulating layer, nickel-plated copper wire, temperature resistance of 250 deg.C
10) The connector 6: the nylon PA66 material can resist the temperature of 140 DEG C
The working principle of the oxygen sensor of the embodiment is as follows: applying a pumping voltage to a zirconia electrolyte pumping oxygen unit, obtaining electrons from oxygen at the cathode side of the pumping unit to generate oxygen ion vacancies in zirconia solid, and enabling oxygen ions to move to the anode under the action of the pumping voltage; the presence of the diffusion barrier 753 limits the ingress of oxygen, limits the rate of pumping oxygen during the increase of the pumping voltage, and as the pumping voltage increases, the pump current gradually saturates and no longer increases, this saturation current being called the limiting current, almost proportional to the ambient oxygen concentration, according to which the oxygen concentration value can be reflected. Through one-time standard gas calibration, the ECU can output an oxygen concentration signal value according to the limit current of the measured gas.
It is further understood that the terms "connected," "secured," "disposed," and the like are used broadly and their meanings in the present application will be understood by those skilled in the art based on the specific situation, unless otherwise explicitly specified or limited.
The above embodiments are merely illustrative of the preferred embodiments of the present invention, and not restrictive, and various changes and modifications to the technical solutions of the present invention may be made by those skilled in the art without departing from the spirit of the present invention, and the technical solutions of the present invention are intended to fall within the scope of the present invention defined by the appended claims.
Claims (8)
1. The utility model provides an improve gas heater combustion efficiency and emission standard's oxygen sensor which characterized in that: including the double-deck safety cover, base, sleeve, fine pipe of glass, high temperature line and the connector that connect gradually, be equipped with the zirconia potsherd in the base, the zirconia potsherd from the top down includes outer pump electrode, alumina insulation layer, first zirconia base member, inner pump electrode, second zirconia base member, third zirconia base member, fourth zirconia base member, alumina insulation layer and heater in proper order, be equipped with corresponding electrically conductive aperture between alumina insulation layer and the first zirconia base member, second zirconia base member one end is equipped with the inlet port to the homonymy surface is equipped with the test chamber, be equipped with the diffusion barrier between inlet port and the test chamber, the one end that the second zirconia base member was equipped with the inlet port still is equipped with porous protective layer.
2. The oxygen sensor for improving combustion efficiency and emission standard of a gas water heater according to claim 1, wherein: the outer pump electrode and the inner pump electrode are made of platinum materials, and the base is a hexagonal base.
3. The oxygen sensor for improving combustion efficiency and emission standard of a gas water heater according to claim 1, wherein: the head of the zirconia ceramic sheet is coated with magnesia-alumina spinel slurry as a protective layer.
4. The oxygen sensor for improving combustion efficiency and emission standard of a gas water heater according to claim 1, wherein: the air inlet and the test cavity are filled with carbon films in the preparation process, and are removed after sintering to form a cavity.
5. A process for producing an oxygen sensor according to claim 1, wherein: the production steps are as follows:
s1, the zirconia ceramic plate penetrates into the ceramic and powder ring and then is riveted with the hexagonal base together;
s2, connecting the riveted semi-finished product on an aging test bench, and introducing heating voltage and pump voltage for aging test;
s3, riveting the protective cover after the base is closed, wherein the protective cover is of a double-layer structure;
s4, cutting the lengths of the high-temperature wires and the glass fiber tubes by using a semi-automatic cutting machine, and assembling the high-temperature wires and the glass fiber tubes, the terminals and the connectors into a wire harness assembly;
s5, connecting the wire harness and the hexagonal base together, riveting the sleeve, and then welding the sleeve on the base by using laser welding;
and S6, riveting and closing the position where the tail of the sleeve is connected with the wire harness.
6. The production process of an oxygen sensor according to claim 5, characterized in that: in S2, a 5.2V heating voltage and a 0.75V pump voltage are applied for aging test, and the test time is 48 h.
7. The production process of an oxygen sensor according to claim 5, characterized in that: the preparation process of the zirconia ceramic sheet comprises the following steps:
s1, sintering the signal layer and the heating layer into a whole by adopting a tape casting process and a multilayer laminating co-firing LTCC/HTCC technology;
s2, coating the magnesium aluminate spinel slurry on the head of the zirconia ceramic sheet to be used as a protective layer, and sintering at high temperature to form an irregular micropore structure;
s3, filling the air inlet and the test cavity with carbon films in the preparation process of the zirconia ceramic wafer, and removing the air inlet and the test cavity after sintering to form a cavity;
s4, adopting a micro-structure design for the diffusion barrier, using 15000-mesh carbon powder and zirconia particles as fillers, and leaving cavities through sintering to form micro-small holes as a diffusion-limited structure design;
and S5, controlling the size of the diffusion barrier by screen printing.
8. The production process of an oxygen sensor according to claim 7, characterized in that: in S5, the size of the diffusion barrier is controlled by screen printing, the size of the limiting current is controlled within 80uA-800uA, and the detected oxygen concentration ranges from 0.1% to 25%.
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| CN202011382080.3A CN112505124A (en) | 2020-11-30 | 2020-11-30 | Oxygen sensor for improving combustion efficiency and emission standard of gas water heater |
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| CN202011382080.3A CN112505124A (en) | 2020-11-30 | 2020-11-30 | Oxygen sensor for improving combustion efficiency and emission standard of gas water heater |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN117233233A (en) * | 2023-11-14 | 2023-12-15 | 苏州工业园区福特斯汽车电子有限公司 | Intelligent wide-area five-wire oxygen sensor chip and manufacturing method thereof |
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Application publication date: 20210316 |