EP3124866A1 - Verfahren und system zur überwachung und regelung der verbrennung in gasbrennern - Google Patents

Verfahren und system zur überwachung und regelung der verbrennung in gasbrennern Download PDF

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Publication number
EP3124866A1
EP3124866A1 EP16181377.9A EP16181377A EP3124866A1 EP 3124866 A1 EP3124866 A1 EP 3124866A1 EP 16181377 A EP16181377 A EP 16181377A EP 3124866 A1 EP3124866 A1 EP 3124866A1
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EP
European Patent Office
Prior art keywords
electrode
burner
combustion
signal
air
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP16181377.9A
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English (en)
French (fr)
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EP3124866B1 (de
Inventor
Giancarlo PIROVANO
Loris BERTOLI
Manuela LIPPI
Giovanni COSI
Maurizio Achille Abate
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Sit SpA
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Sit SpA
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N1/00—Regulating fuel supply
    • F23N1/002—Regulating fuel supply using electronic means
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23D—BURNERS
    • F23D14/00—Burners for combustion of a gas, e.g. of a gas stored under pressure as a liquid
    • F23D14/02—Premix gas burners, i.e. in which gaseous fuel is mixed with combustion air upstream of the combustion zone
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N1/00—Regulating fuel supply
    • F23N1/02—Regulating fuel supply conjointly with air supply
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N1/00—Regulating fuel supply
    • F23N1/02—Regulating fuel supply conjointly with air supply
    • F23N1/022—Regulating fuel supply conjointly with air supply using electronic means
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N1/00—Regulating fuel supply
    • F23N1/04—Regulating fuel supply conjointly with air supply and with draught
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N1/00—Regulating fuel supply
    • F23N1/04—Regulating fuel supply conjointly with air supply and with draught
    • F23N1/042—Regulating fuel supply conjointly with air supply and with draught using electronic means
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N3/00—Regulating air supply or draught
    • F23N3/002—Regulating air supply or draught using electronic means
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N5/00—Systems for controlling combustion
    • F23N5/02—Systems for controlling combustion using devices responsive to thermal changes or to thermal expansion of a medium
    • F23N5/12—Systems for controlling combustion using devices responsive to thermal changes or to thermal expansion of a medium using ionisation-sensitive elements, i.e. flame rods
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N2229/00—Flame sensors
    • F23N2229/12—Flame sensors with flame rectification current detecting means

Definitions

  • the present invention relates to a method for monitoring and controlling combustion in combustible gas burners for appliances such as boilers, water heaters, fireplaces and the like, equipped with modulating fans for the combustion air. It also relates to a combustion control system operating in accordance with said method.
  • the recognisable limits of the known methods are mainly linked to the reliability of the results of the frequency spectrum analyses and their correlation with the combustion process, as well as to the complexity of the calculation and analysis algorithms used.
  • the problem addressed by the present invention is that of providing a method for monitoring and controlling combustion in a burner of a combustible gas appliance, as well as a combustion control system operating in accordance with said method, that are structurally and functionally designed to overcome the limitations described above with reference to the cited prior art.
  • Another aim of the invention is to provide a method and a control system that are simple to manage and characterise both during installation and during use of the burner of the appliance.
  • 1 indicates overall a burner, represented only schematically, equipped with a combustion control system, produced to operate in accordance with the combustion monitoring and control system of the present invention.
  • the burner 1 is housed in an appliance, not represented, intended for the production of domestic hot water and/or slaved to a room heating circuit, in a manner that is known per se and not illustrated in the figures.
  • the burner 1 comprises a combustion chamber 2, which is fed by a first pipe 3 and a second pipe 4, suitable for introducing into said combustion chamber 2 a flow of air and, respectively, a flow of combustible gas.
  • the second pipe 4 enters the first pipe 3 upstream of the combustion chamber 2 (premix burner).
  • a fan 5 with variable rotation speed.
  • the fan is located downstream of the mixing zone, but may also alternatively be located upstream of said air/gas mixing zone.
  • 6 indicates a modulating valve located on the gas pipe 4 for regulating the flow of gas injected into the burner.
  • the combustion chamber 2 is connected downstream to a flue 7, through which the combustion exhaust gases are evacuated.
  • control device 9 indicates a combustion monitoring sensor, described in greater detail below, which is connected to a control device 9 provided with an electronic circuit unit suitable for controlling the burner according to the method of the present invention, as illustrated below.
  • the control device is also operatively connected both to the fan 5 and to the modulating valve 6 for regulating said units.
  • the sensor 8 is arranged in the proximity of the burner flame, and is suitable for being powered by a voltage generator, as well as being connected to an electronic circuit suitable for measuring the resulting potential at the sensor.
  • the senor 8 comprises an electrode, indicated by E, which is placed in the flame or in the proximity thereof.
  • the electrode E designed as a mono-electrode structure, can conveniently serve both as a flame ignition element and as an element suitable for measuring the potential generated in response to the application of a voltage signal to the electrode, during the combustion process, in accordance with the method of the present invention.
  • a suitable switching unit is provided for electrically connecting the electrode E with the respective control circuits of the above-mentioned functions.
  • the electrode E when it measures the response signal, is disconnected from the voltage generator (and connected to the measuring device).
  • the macroscopic effect generated by the introduced external load, due to the movement of the load particles, is an alteration of the electrical field of the plasma.
  • This electrical field is propagated around the particle over a distance in the order of the 'Debye length'. This distance, as mentioned above, is greater for electrons, i.e. in cases where the introduced load is positive. On the other hand, it is smaller in the case of positive ions, i.e. when the introduced load is negative.
  • an electrical voltage signal with a determined wave form over time is applied to the electrode E; this potential is equivalent to the interference load mentioned in the preceding description.
  • the electrode assumes a potential value determined by the motion of the plasma loads caused by the voltage signal applied to the electrode and responding to the dynamics described above. The changes in this potential are then measured by the electronic circuit and processed in the manner that will be described below.
  • the underlying concept of the method of the invention is therefore the fact that the trend of the resulting response signal at the electrode E is unequivocally determined by the composition of the fuel/air mixture prior to combustion.
  • Knowledge of this composition is essential in order to be able to predict certain key effects of the combustion process, such as the quantities of CO 2 and CO produced and the thermal power produced.
  • an impulsed periodic electrical voltage signal is applied to the electrode E, and said signal has an interference effect on the motion of the loads present in the plasma, such that said electrode, once the applied impulse has ceased, assumes a potential value determined by the motion of said loads, which is measured by the electronic circuit and processed in the manner that will be described below.
  • the method of the invention essentially comprises two macro operating phases: a first phase, indicated by A, of acquisition and processing of data relating to operating conditions applied to the burner, and a second phase, indicated by B, of calculating the air number ⁇ or the generated thermal power P, in a real operating condition of the burner.
  • Both of these phases comprise, in turn, a sequence of operating steps that will be described in detail below.
  • a first operating step of phase A involves identifying and reproducing in the burner a plurality (1, 2, ..., n) of combustion conditions, in each of which a respective power P (P1, P2, ..., Pn) is applied and for each power (i.e. deriving from the combustion of a corresponding flow of combustible mixture) an air number ( ⁇ 1, ⁇ 2, ..., ⁇ m) is applied, said air number ⁇ expressing the ratio between the quantity of air in the combustion process and the quantity of air for stoichiometric combustion.
  • Each condition can also be repeated a preset number of times, in order to verify that the measurements made are not influenced by conditions of anomalous operation of the burner or by drift or by variability of the flame.
  • an electrical voltage signal is applied in each of said (n * m) operating conditions (Pi, ⁇ j) to the electrode E.
  • a measurement is made, for example by means of a sampling, of the resulting voltage signal at the electrode E, calculating the respective parameters of the wave form of the response signal for each of said operating conditions applied to the burner.
  • an interpolation function or correlation table is calculated, indicated by F, based on the previously acquired data, suitable to allow the unequivocal interpolation or correlation of the power P, the air number ⁇ and the characteristic parameters of the wave form of the response signal at the electrode E in the combustion process of the burner.
  • an impulsed periodic voltage signal S is applied to the electrode E and the trend over time of the resulting electrical voltage signal S' at the electrode is measured (measuring the dimensions of the characteristic values of the signal), once the application of the impulsed signal S has ceased.
  • the signal S comprises, over the signal period T, a first positive impulse N1 of preset amplitude, followed by a second negative impulse N2 of preset amplitude.
  • the times of application of the impulses are preferably the same, for example in the order of approximately 10 milliseconds, the duration of the time interval between the first and second impulses being less than the duration of the time interval between the second impulse and a subsequent first impulse, the period of the signal S being selected appropriately, for example preferably in the order of 50 milliseconds to 1 second, and more preferably in the order of approximately 100 milliseconds.
  • the amplitude of the impulse of the signal S is selected according to convenience and is preferably the same in terms of absolute value for both the impulses N1 and N2.
  • the impulsed signal S is not periodic.
  • Figure 5 shows the trend of the voltage signal S' measured at the electrode E following the application of the first and second impulses. It has been observed that both the wave forms of the signal S' associated respectively with the first and the second impulse have a decreasing exponential trend in terms of absolute value relative to the ground potential, with different time constants for each of them.
  • the exponential trends of both the first and second sections of the curve of the signal S' are characterised by respective time constants ⁇ 1 and ⁇ 2 (or equivalently by respective gradients a 1 , a 2 of the tangents at the origin of the respective exponential curves).
  • Figure 2 shows schematically the trend of the correlation function F relating to the plotting of the data acquired in phase A.
  • the graph illustrates, along the three Cartesian axes, the power (P), the time (t) and the signal S' obtained in the data acquisition phases.
  • the curves of each signal S' are reported (characterised by a pair of values for the time constants ⁇ 1 , ⁇ 2 ), measured in the corresponding condition of the air number applied (Pi, ⁇ j).
  • the values assumed by the function F can be represented in the form of a correlation table, in which the values for the power P, air number ⁇ and time constants ⁇ 1 and ⁇ 2 are correlated for each operating condition applied to the burner.
  • the correlation function or table F obtained in phase A, therefore serves to correlate, in an unequivocal manner, the significant parameters of the combustion characteristics (power and air number) with the respective time constants of the characteristic exponential functions of the trend of the response signal S' measured at the electrode E in the combustion process of the burner.
  • This correlation function or table F is used, in the manner described below, to evaluate the combustion process in a real operating condition of the burner, in other words to derive the values of the significant parameters of the combustion process (for example, power and air number) by calculating the values of the time constants ⁇ 1 and ⁇ 2 that characterise the response signal S' to the signal S in that operating condition.
  • the second phase B provides for the following operating steps, for example designed to calculate the air number in a real operating condition of the burner.
  • phase A may be applied to a sample appliance or boiler in order to identify, by means of the correlation function or table, the relationship between the combustion parameters, while phase B is applied to the same or other appliances for verifying and if necessary correcting the combustion parameters in a real operating condition of the respective burner.
  • a first operating step provides for the application of the voltage signal S to the electrode E and for the acquisition, in a second operating step B2, of the electrical signal S' measured on the electrode after the application of the signal S, in a manner entirely similar to that described for phase A.
  • a third subsequent step B3 provides for the calculation of the time constants ⁇ 1 and ⁇ 2 (or equivalently the gradients a 1 , a 2 ) that characterise the respective sections of the curve relating to the response signal S' to the impulsed signal S applied to the electrode E in the real operating condition.
  • Figure 3 shows the bundle of parameterised curves with the air number ( ⁇ 1, ⁇ 2, ⁇ 3,..., ⁇ n) that represent the trend of the constant ⁇ 2 according to changes in the power at the burner.
  • the graph of Figure 3 is therefore a different way of visualising the data present in the table or function F of Figure 2 .
  • the power P is relatively insensitive to changes in the air number ⁇ , and it is therefore possible to estimate, with a good approximation, the power value Px (or a limited range of power values) to which the value assumed by the constant ⁇ 2 corresponds. It may be provided that, for a certain value of the constant ⁇ 2 , the average value of the power values visible in the graph at ⁇ 2 is calculated.
  • the value of the air number ⁇ is read by means of the function or table F.
  • Figure 4 shows the bundle of parameterised curves with the power value (P1, P2, ..., Pn) that represent the trend of the air number ⁇ according to changes in the constant ⁇ 1 .
  • the graph of Figure 4 therefore represents a different way of visualising the data present in the correlation table or function F of Figure 2 .
  • phase B it is possible to refer in phase B to a correlation table, deriving therefrom the values for power (P stim ) and air number ( ⁇ stim ) correlated with the values of the tabulated time constants ⁇ 1 and ⁇ 2 , which are therefore suitable for characterising the combustion process of the analysed real operating condition.
  • ⁇ stim the air number correlated with the combustion process of the operating condition of the burner.
  • the method of the invention may provide for a calibration or recentring cycle, which may be based on observation of the ionisation current and/or on the values of the characteristic time constants ⁇ 1 and ⁇ 2 (or equivalently on the values of the respective gradients a 1 , a 2 ).
  • the calibration cycle may, for example, provide for the burner to be made to operate with increasingly rich air/fuel mixtures, increasing the percentage of the gas flow delivered to the burner.
  • the curves of the correlation function or table F can then be recentred and calibrated, recovering any previously accumulated deviations or drifts.
  • the method of the invention based on voltage measurements, is not based on measurement of the ionisation current and is therefore less affected by problems arising from wear and ageing of the electrodes.
  • Another advantage is linked to the speed with which the response to the voltage signal applied to the electrode is obtained, which renders the method extremely rapid compared with the known solutions.
  • a further advantage resides in the fact that the electrode used in the method of the invention makes it possible to use quite low voltage potentials. This property makes the electrode less costly compared with the traditionally proposed solutions.
  • a further advantage is that the method of the invention advantageously provides for the use of a single electrode for applying the voltage signal in the flame and receiving the response signal.
  • a system for controlling and regulating combustion, for the burner 1, operating with the method of the invention provides for example the following operating phases, with reference to the graph of Figure 6 , where the abscissa expresses the number of revolutions (n) of the fan, the ordinates of the upper quadrant express the current (I) of actuation of the modulating gas valve, and the ordinates of the lower quadrant express the flow rate (Q) of gas delivered (correlated with the power need).
  • the curves C, C' of regulation of the above-mentioned parameters are typically preset in the control circuit, as illustrated in the diagram.
  • a number of revolutions n1 and a current I1 correspond to a need Q1.
  • the control circuit associates the current value 12 with the modulator.
  • ⁇ ob target air number
  • the effective air number ( ⁇ stim ) is calculated using the method described above, and a comparison is made between ⁇ ob and ⁇ stim , making the appropriate corrections to the parameters - current I - or - number of revolutions n - in order to obtain an air number essentially coincident with the target air number.
  • the current to the modulator is altered, for example by increasing it to the value I2'.
  • the operating curve C is further updated for the air number equal to the target air number, and thus becomes the curve C'.
  • the updating of the regulation curve may for example be performed by accumulating a certain number of correction points and calculating the regression curve that correlates with them, said curve becoming the new regulation curve.
  • the regulation system described above represents simply a non-limitative example for the application of the combustion monitoring and control system of the invention. It is understood that by this method it is possible to provide specific logics for controlling and regulating the burner according to the respective operating and system needs, said logics providing for a comparison between a target air number, optimal for combustion, and the air number calculated by the method of the invention.
  • the invention therefore achieves the proposed aims, overcoming the limitations pointed out with respect to the prior art, demonstrating the advantages described with respect to the known solutions.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Control Of Combustion (AREA)
  • Regulation And Control Of Combustion (AREA)
EP16181377.9A 2015-07-28 2016-07-27 Verfahren und system zur überwachung und regelung der verbrennung in gasbrennern Active EP3124866B1 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
ITUB2015A002534A ITUB20152534A1 (it) 2015-07-28 2015-07-28 Metodo per il monitoraggio e controllo della combustione in apparecchi bruciatori a gas combustibile e sistema di controllo della combustione operante in accordo con tale metodo

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EP3124866A1 true EP3124866A1 (de) 2017-02-01
EP3124866B1 EP3124866B1 (de) 2018-01-24

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EP (1) EP3124866B1 (de)
ES (1) ES2663912T3 (de)
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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102017204030A1 (de) 2016-09-02 2018-03-08 Robert Bosch Gmbh Verfahren zum Erfassen eines Alterungszustands eines Heizsystems sowie eine Steuereinheit und ein Heizsystem
US20190162408A1 (en) * 2017-11-30 2019-05-30 Brunswick Corporation Systems and Methods for Avoiding Harmonic Modes of Gas Burners
US11441772B2 (en) 2018-07-19 2022-09-13 Brunswick Corporation Forced-draft pre-mix burner device
US11608983B2 (en) 2020-12-02 2023-03-21 Brunswick Corporation Gas burner systems and methods for calibrating gas burner systems
US11940147B2 (en) 2022-06-09 2024-03-26 Brunswick Corporation Blown air heating system

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5899683A (en) * 1996-05-09 1999-05-04 Stiebel Eltron Gmbh & Co. Kg Process and device for operating a gas burner
US5971745A (en) * 1995-11-13 1999-10-26 Gas Research Institute Flame ionization control apparatus and method
WO2013117516A1 (en) * 2012-02-09 2013-08-15 Sit La Precisa S.P.A. Con Socio Unico A method for controlling a burner of a boiler and a control system operating according to this method
WO2014049502A1 (en) * 2012-09-27 2014-04-03 Sit La Precisa S.P.A. Con Socio Unico Method for monitoring and controlling combustion in fuel gas burner apparatus, and combustion control system operating in accordance with said method

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5971745A (en) * 1995-11-13 1999-10-26 Gas Research Institute Flame ionization control apparatus and method
US5899683A (en) * 1996-05-09 1999-05-04 Stiebel Eltron Gmbh & Co. Kg Process and device for operating a gas burner
WO2013117516A1 (en) * 2012-02-09 2013-08-15 Sit La Precisa S.P.A. Con Socio Unico A method for controlling a burner of a boiler and a control system operating according to this method
WO2014049502A1 (en) * 2012-09-27 2014-04-03 Sit La Precisa S.P.A. Con Socio Unico Method for monitoring and controlling combustion in fuel gas burner apparatus, and combustion control system operating in accordance with said method

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102017204030A1 (de) 2016-09-02 2018-03-08 Robert Bosch Gmbh Verfahren zum Erfassen eines Alterungszustands eines Heizsystems sowie eine Steuereinheit und ein Heizsystem
US20190162408A1 (en) * 2017-11-30 2019-05-30 Brunswick Corporation Systems and Methods for Avoiding Harmonic Modes of Gas Burners
EP3492812A3 (de) * 2017-11-30 2019-08-21 Brunswick Corporation System und verfahren zur vermeidung harmonischer moden von gasbrennern
US10718518B2 (en) 2017-11-30 2020-07-21 Brunswick Corporation Systems and methods for avoiding harmonic modes of gas burners
EP3757456A1 (de) * 2017-11-30 2020-12-30 Brunswick Corporation System und verfahren zur vermeidung harmonischer moden von gasbrennern
US11608984B1 (en) 2017-11-30 2023-03-21 Brunswick Corporation Systems for avoiding harmonic modes of gas burners
US11441772B2 (en) 2018-07-19 2022-09-13 Brunswick Corporation Forced-draft pre-mix burner device
US11608983B2 (en) 2020-12-02 2023-03-21 Brunswick Corporation Gas burner systems and methods for calibrating gas burner systems
US11940147B2 (en) 2022-06-09 2024-03-26 Brunswick Corporation Blown air heating system

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Publication number Publication date
ITUB20152534A1 (it) 2017-01-28
EP3124866B1 (de) 2018-01-24
ES2663912T3 (es) 2018-04-17

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