WO1999024758A1 - Intelligent burner control system - Google Patents

Intelligent burner control system Download PDF

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Publication number
WO1999024758A1
WO1999024758A1 PCT/US1998/023681 US9823681W WO9924758A1 WO 1999024758 A1 WO1999024758 A1 WO 1999024758A1 US 9823681 W US9823681 W US 9823681W WO 9924758 A1 WO9924758 A1 WO 9924758A1
Authority
WO
WIPO (PCT)
Prior art keywords
communication network
flow
burner
module
coupled
Prior art date
Application number
PCT/US1998/023681
Other languages
French (fr)
Inventor
Albert W. Welz, Jr.
John D. Parker
Brenda J. Marchetti
Original Assignee
Maxon Corporation
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Maxon Corporation filed Critical Maxon Corporation
Priority to CA 2308496 priority Critical patent/CA2308496A1/en
Priority to EP98957638A priority patent/EP1036288A4/en
Publication of WO1999024758A1 publication Critical patent/WO1999024758A1/en

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N5/00—Systems for controlling combustion
    • F23N5/18—Systems for controlling combustion using detectors sensitive to rate of flow of air or fuel
    • F23N5/184—Systems for controlling combustion using detectors sensitive to rate of flow of air or fuel 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
    • F23N1/02—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
    • F23N5/00—Systems for controlling combustion
    • F23N5/18—Systems for controlling combustion using detectors sensitive to rate of flow of air or fuel
    • F23N2005/181—Systems for controlling combustion using detectors sensitive to rate of flow of air or fuel using detectors sensitive to rate of flow of air
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N5/00—Systems for controlling combustion
    • F23N5/18—Systems for controlling combustion using detectors sensitive to rate of flow of air or fuel
    • F23N2005/185—Systems for controlling combustion using detectors sensitive to rate of flow of air or fuel using detectors sensitive to rate of flow of fuel
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N2223/00—Signal processing; Details thereof
    • F23N2223/08—Microprocessor; Microcomputer
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N2233/00—Ventilators
    • F23N2233/06—Ventilators at the air intake
    • F23N2233/08—Ventilators at the air intake with variable speed
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N2235/00—Valves, nozzles or pumps
    • F23N2235/02—Air or combustion gas valves or dampers
    • F23N2235/06—Air or combustion gas valves or dampers at the air intake
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N2235/00—Valves, nozzles or pumps
    • F23N2235/12—Fuel valves
    • F23N2235/16—Fuel valves variable flow or proportional valves
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T137/00—Fluid handling
    • Y10T137/8158—With indicator, register, recorder, alarm or inspection means
    • Y10T137/8225—Position or extent of motion indicator
    • Y10T137/8242—Electrical

Definitions

  • the present invention relates to control systems and particularly to systems for controlling fluid flow More particularly, the present invention relates to electronic control systems for regulating flow of air and fuel for industrial burners
  • Industrial burners typically operate under varying conditions such as variable fuel and air supply pressures and temperatures, back pressure from the burner, humidity, fuel quality, etc
  • a control system that automatically compensates for changes in the burner operating environment will optimize burner performance over the changing conditions
  • a burner control system that provides improved precision in regulating the flow of air and fuel will allow for operation over a wider burner turndown and increase overall burner efficiency, resulting in reduced emissions over the entire operating range, as well as increasing reliability and burner operating life
  • an intelligent burner control apparatus for controlling the rate of a fluid flow in a burner system from a fluid supply to a burner
  • the burner system includes an electronic communication network
  • the apparatus includes a flow controller including a sensor and a communication module
  • the sensor is configured to be coupled between the fluid supply and the burner to measure the fluid flow rate
  • the communication module is configured to be coupled to the communication network to send a flow control signal
  • the flow controller is configured to determine the flow control signal based on the measured fluid flow rate
  • the apparatus also includes a flow regulator including a communication module and an actuator
  • the communication module of the flow regulator is configured to be coupled to the communication network to receive the flow control signal
  • the actuator is configured to be coupled between the fluid supply and the burner to control the fluid flow rate
  • the flow regulator is configured to command the actuator based on the flow control signal
  • the senor is a mass flow sensor, such as a thermal mass flow sensor
  • the actuator can include a variable speed blower, or a valve actuator coupled to a valve assembly, or both a variable speed blower and a valve actuator coupled to a valve assembly
  • the communication network can be a peer-to- peer communication network
  • the intelligent burner control apparatus further includes a brain module configured to be coupled to the communication network and to send a flow setpoint signal indicative of a desired fluid flow rate over the communication network
  • the flow controller module is configured to receive the flow setpoint signal and determine the flow control signal based on the measured flow rate and flow setpoint signal
  • the brain module can be configured to receive a firing rate signal and to determine the flow setpoint based on the firing rate signal
  • the brain module can monitor the rate of change in the firing rate signal from a process controller, and if the rate of change exceeds a predetermined threshold then the burner brain determines and sends a plurality of intermediate setpoints over the communication network
  • the intelligent burner control apparatus further includes a display module configured to be coupled to the communication network
  • the display module includes a display terminal and is configured to receive at least one display signal over the communication network
  • the display module provides an indication on the display terminal indicative of the display signal
  • the intelligent burner control apparatus can include a command module configured to be coupled to the communication network
  • the command module includes a user input device for sending at least one user command over the communication network
  • Fig 1 is a component block diagram showing modular flow measurement and actuator modules according to the present invention installed into air and gas pipe train components of a burner system, the flow and actuator modules communicating over a peer-to-peer communication network with a burner "brain" module within an interface panel module and a command and display module;
  • Fig. 2 is a block diagram similar to Fig. 1 showing the actuator module in the air pipe replaced by a variable speed air blower;
  • Fig. 3 is a conceptual diagram showing pressure and temperature environmental input parameters to a burner control system that regulates an air-fuel ratio output to the burner;
  • Fig. 4 is a system block diagram showing an industrial process control system that includes an air-fuel control system according to the present invention interposed between the pipe train components and a burner, and illustrating interfaces between a process controller and the air-fuel control system, an emissions monitoring component, a burner management and flame safeguard component, and process variables;
  • Fig. 5 is a network block diagram showing the modular components of the burner control system connected over the communication network, a PC user interface module for providing a gateway between the communication network and external systems such as a portable emissions gas analyzer or remote monitoring devices, and burner control signals to the interface panel module that includes the burner brain;
  • Fig. 6 is a schematic block diagram of the interface panel module including the burner brain module, showing relay switched discrete Input/Output, isolated analog inputs, and burner control system parameters conveyed over the communication network;
  • Fig. 7 is a schematic block diagram of the burner brain module showing isolated external Input/Output, direct internal Input/Output, regulated power, and a connection to the peer-to-peer communication network;
  • Fig. 8 is a block diagram of an intelligent flow controller including a thermal mass flow sensor configured with analog and serial interfaces, an interface board coupled to the mass flow sensor, and an Echelon LonWorksTM network control module coupled to the interface board for communication over the peer-to-peer network; and
  • Fig 9 is a block diagram of an intelligent valve actuator for regulating fluid flow including an Echelon NeuronTM processor having application code and data stored in a flash memory and a network interface for communicating over the network, the flow regulation module configured for autonomous closed-loop control of a valve via a stepping motor command output and an encoded valve position feedback input
  • FIG. 1 An intelligent burner control system 10 in accordance with the present invention having flow controller modules 12, 14 and valve actuator modules 16, 18 coupled to an air pipe 20 and gas pipe 22 of a pipe train assembly of a burner 24 is shown in Fig 1
  • the flow controller modules 12, 14 and valve actuator modules 16, 18 communicate with a command and display module 26 and interface panel module 28 over a peer-to-peer communication network 30 as best shown in Fig 5
  • Valve actuator modules 16, 18 are coupled to valves 88, 90 respectively to regulate the flow of air and fuel in pipes 20, 22
  • the interface panel module 28 includes a "brain" module 32 that cooperates with the flow controller modules 12, 14 and valve actuator modules 16, 18 to provide precise regulation of the flow of air 34 and gas 36 to burner 24
  • intelligent burner control system 10 provides intelligent, modular components to compensate automatically for changes in environmental parameters over the complete operating range of the burner For example, by providing flow controller modules 12, 14 that perform closed loop control based on fluid flow mass rate, burner control system 10 automatically compensates for changes in fluid pressures and temperatures without needing to monitor these parameters
  • burner control system 10 provides for operation over changing conditions, resulting in a wide burner turndown ratio that allows for reduced emissions and increased efficiency and reliability
  • Modular burner control system 10 can be used to replace part or all of the air-fuel ratio control system in a burner control system, allowing for both a turnkey approach to installation as well as incorporation into existing designs
  • the use of intelligent components coupled to communication network 30 further provides the abi ty to monitor or to manage the control system remotely
  • the modular architecture simplifies installation, modification, and operation of burner control system 10
  • the intelligent modules 12, 14, 16, 18, 26, 32 provide a turnkey approach for air-fuel ratio control for burners that integrates easily into a conventional combustion control system
  • the modular architecture based on a peer-to-peer communication network 30 enables the control functions to be distributed throughout the networked components to provide maximum flexibility, reduced network complexity, increased precision, and increased system reliability
  • the modular architecture allows for replacement of valve actuator module 16 and valve 88 in air pipe 20 with a variable speed blower 38 as shown in Fig 2, without requiring modifications to the remaining modular components 12, 14, 18, 26, 32 within burner control system 10
  • variable speed blower 38 can be combined with valve actuator module 16 and valve 88 to achieve more precise control of air flow over a wider range of operating conditions than is possible by using either variable speed blower 38 or valve actuator module 16 and valve 88 alone
  • the burner control system 10 of the present invention can be configured to achieve desired burner performance while automatically compensating for a variety of operating conditions
  • flow controllers 12, 14 are configured to measure mass flow directly and provide control signals to valve actuators 16, 18 so that burner control system 10 reacts automatically to variations in gas pressures 21, air pressures 23, back pressure 25, and air and gas temperatures 27, 29 in pipes 20, 22 to determine an air-fuel ratio 31
  • the modular, micro-processor based architecture further contemplates integrating additional sensor data into the control system, such as providing humidity and fuel sensor data directly to burner brain 32 which then the valve actuator modules 16, 18 for use in adjusting the air-fuel ratio 31 to burner 24 based on these inputs
  • Burner control system 10 also provides the ability to predict the emissions from burner 24, for example based on input parameters such as air and fuel mass flow
  • the emission characteristics for burner 24, such as NO x and CO emissions can be experimentally determined as a function of and fuel mass flow Character
  • the expected NO x and CO emissions output from an operational burner 24 thus characterized can then be determined by software within any module coupled to the network, such as burner brain module 32, by using the actual air and fuel mass flow rates measured by flow controller modules 12, 14 in conjunction with the predetermined characteristic emissions curves.
  • This predictive emissions capability can be used to complement, verify, or replace actual emissions monitoring to assist in compliance with various federal, state, and local environmental regulations.
  • Elements of a typical industrial heating system 40 incorporating burner control system 10 for air and fuel control are shown in the block diagram of Fig. 4.
  • Heating system 40 illustratively includes the burner control system 10 coupled to burner 24, pipe train 42, and a process controller 44.
  • Process controller 44 can be a distributed control system computer, a programmable logic controller, an application specific universal digital controller, or the like, and manages one or more process variables 48, such as oven temperature, Process controller 44 is also coupled to an emissions monitoring system 46 which can monitor emissions continuously or on a sampled basis.
  • Process controller 44 provides a firing rate signal 52 to burner control system 10, where firing rate signal 52 represents a percentage of firing rate for burner 24.
  • Firing rate is illustratively an analog signal where firing rate is proportional to signal current, but any analog or digital signal could be used to command firing rate.
  • the command signal from process controller 44 to burner control system 10 can be any parameter indicative of desired burner 24 performance.
  • Burner control system 10 controls the air and fuel flow rates to burner 24 to achieve the firing rate commanded by process controller 44.
  • Process controller 44 is illustratively coupled to burner brain 32 through an analog firing rate signal 52, but that other interfaces such as a serial Input/Output interface or communication over network 30 is contemplated.
  • a burner management and flame safeguard element 50 is coupled to process controller 44 and contains monitoring and control logic to light burner 24 and to shutdown burner 24 if it detects an absence of a flame or if commanded by process controller 44. Burner management and flame safeguard element 50 is further coupled to pipe train 42, which contains various permissive interlocks required for safe starting and operation of burner 24 Burner management and flame safeguard element 50 also monitors parameters such as high and low gas pressure, low air pressure, high process temperatures, and the like Process controller 44 provides the firing rate signal 52 to interface panel module 28 of burner control system 10 as shown in Fig 5 Interface panel module 28 provides burner status information to process controller 44 Burner brain module 32 within interface panel module 28 then translates firing rate signal 52 into an air flow setpoint and a fuel flow setpoint using software based on known performance characteristics of burner 24 Burner brain module 32 transmits the air and fuel flow setpoints to air flow and gas flow controller modules 12, 14 respectively over the peer- to-peer communication network 30 Air and gas flow controller modules 12, 14 in turn measure the air and gas mass flow rates and determine valve position commands that
  • variable speed blower 38 replaces air valve actuator module 16 for controlling air flow 34 to burner 24
  • air flow controller module 12 will provide a blower frequency setpoint to produce the appropriate flow
  • Variable speed blower 38 can be used in conjunction with air valve actuator module 16, in which case air flow controller module 12 will command a blower frequency setpoint slightly higher than necessary to produce the desired flow rate and will command air valve actuator module 16 to trim the air flow to achieve the desired flow rate
  • This primary- secondary control approach allows air flow controller module 12 to maintain valve actuator module 16 in a configuration that maximizes precision
  • the air flow rate can be varied so that a butterfly valve can operate as a secondary trim around its peak precision orientation of forty-five degrees
  • the air flow can be varied by primary air flow regulator, for example, variable speed blower 38, to maximize the precision characteristics of any type of secondary flow regulator used as secondary trim
  • Any suitable mechanism can be used for the primary control of air flow rate, such as another type of valve mechanism instead of variable speed blower 38
  • the interface control panel module 28 including burner brain module 32 is shown in detail in Fig 6
  • a 24 volt direct current power supply 56 is coupled to the alternating current power supply input 41 through a four amp circuit breaker 58 to provide power 45 to the module components and also for peer-to-peer communication network 30
  • Power supply 56 can be any suitable commercial power supply, and illustratively a five amp power supply is used for a burner control system requiring two amps, with the extra power capacity providing for improved reliability and higher temperature operations
  • a current shunt 60 provides a power supply monitor input 43 to burner brain module 32 for diagnostic purposes
  • Discrete Input/Output to and from interface panel module 28 is electrically isolated by use of relay banks 62, 64 Discrete input signals to burner brain module 32 are isolated by relay bank 62 and include blower on 47, interlocks proven 35, purge complete 49, and main valve on signals 51 Burner brain module 32 is also capable of receiving other spare input signals 53 to provide for added capacity Discrete outputs are isolated by a relay bank 64 and include burner enable 55, call for heat 57, and alarm signals 59 Burner brain module 32 similarly includes spare discrete and analog output signals 61, 63 to provide for additional capacity The firing rate analog signal 52 from process controller 44 is coupled through interface control panel 28 to burner brain module 32
  • Communication network 30 is illustratively a LonWorksTM peer-to-peer communication network from Echelon, although any suitable communications network can be used Communication network 30 and network system power bus share a four- conductor communication cable, one shielded twisted pair being used for power and another shielded twisted pair being used for communication, with both networks being appropriately terminated by termination filter 71 in interface panel module 28
  • Command and display module 26 is coupled to the peer-to-peer communication network 30 within panel module 28 to provide local monitoring and control functions
  • Command and display module 26 can display any of the parameters sent over network 30 by the intelligent modules 12, 14, 16, 18, 32, including values of external signals to the modules and internal parameters used by the modules
  • Module 26 can similarly command the various intelligent modules 12, 14, 16, 18, 32 to perform certain functions such as self-diagnostics, self-calibration, shut-down, etc Command and display module 26 can be coupled to communication network 30 at any location, and that more than one such module can be used
  • An optional network gateway module 54 can also be coupled to the peer-to-peer communication network within the interface panel 28 to provide an interface between the peer-to-peer communication network and an external network, for example through a standard telephone line 37, Ethernet transceiver 39, or the like Although network gateway module 54 is located in interface panel 28 it can also be located anywhere on communication network 30 Network gateway module 54 can be used, for example, to provide a remote command and display interface to burner control system 10
  • Burner brain 32 includes software for controlling air and fuel flows as a function of firing rate for the specific type of burner 24 and supplies the appropriate flow setpoints to the air and fuel flow controller modules 12, 14 over network 30
  • the software in burner brain 32 includes algorithms to ensure proper transformation of firing rate input commands to air and fuel setpoint output commands When a firing rate command input changes, burner brain 32 will determine intermediate firing rate step changes in the fuel setpoint command outputs to ensure that the proper air-fuel ratio is maintained as the controller modules 12, 14 command the actuator modules 16, 18 to achieve the new burner output
  • this approach allows burner brain 32 to achieve the most efficient rate of change in burner 24 output while maintaining a safe condition, that is, maintaining a proper air-fuel ratio during transition between commands
  • the burner control system 10 can automatically accommodate a variety of module configurations Burner brain 32 can be updated to accommodate changes in performance characteristics of other modules in the flow regulation system, for example by communicating performance characteristic information to burner brain 32 over communication network 30 or by providing modified software.
  • Burner brain 32 also monitors the discrete inputs and controls the discrete outputs to interface panel 28 discussed above
  • the blower on discrete input is used to signal burner brain 32 to command the optional variable speed blower to start.
  • the interlocks proven discrete input indicates that all permissive interlocks, such as low air pressure, low and high gas pressure, and excess temperature are within range for operating burner 24
  • the purge complete discrete input indicates that an external burner purge cycle has been completed and signals burner brain 32 to command an appropriate air flow setting to start burner 24.
  • the main valve on discrete input indicates that burner 24 is lit and under temperature control Burner brain 32 can also be configured to receive any or all of these inputs over communication network 30
  • the discrete outputs from burner brain 32 are coupled through 24 VDC relay drivers 74 Discrete outputs include a burner enable discrete output 33 used as an interlock by burner management and flame safeguard element 50 and a call for heat discrete output 57 to enable actuation of a main valve of burner 24 that is turned on by burner management and flame safeguard component 50 There is also an alarm discrete 59 that can be used for purposes such as turning on an indicator light (not shown) or can be coupled to process controller 44
  • burner brain 32 illustratively drives discrete outputs 33, 55, 57 directly, the invention contemplates sending these commands over network 30.
  • the status of all discrete outputs can also be communicated over communication network 30, as can the status of variables set or used within burner brain module 32.
  • Analog inputs to burner brain module 32 are electrically isolated by use of isolation amplifiers 66.
  • Analog inputs include firing rate 52, power supply current shunt voltage 65, and an optional process variable 67, which can be humidity, fuel quality, or any parameter that may affect performance of burner control system 10.
  • burner brain module 32 receives the analog firing rate signal 52 from process controller 44, burner brain 32 could receive a firing rate signal over communication network 30
  • Analog inputs are coupled from amplifiers 66 through a low pass filter 68 and analog-to-digital converter 70 to brain control module 72.
  • Discrete input blower on 47, interlocks proven 35, purge complete 49, main valve on 69, and spare inputs 53 are also coupled to brain module 32 through low-pass filter 68 via drivers 76.
  • Burner brain 32 can be configured to receive one or more process variables over network 30.
  • Control module 72 is an Echelon Neuron-based LonWorksTM control module, although it is understood that a module configured with any micro-processor, micro-controller or the like can be used.
  • the Echelon Neuron processor includes a communications processor (not shown) that performs all network-related functions for communicating over network 30 and is coupled to the Echelon LonWorksTM communication network.
  • a power supply circuit 77 for burner brain module 32 including a five volt regulator 87, a fifteen volt regulator 89, and a five volt isolated supply 91 is coupled to a filter 76 and provides filtered power including five volt direct current logic power 187, fifteen volt direct current power 189, and five volt direct current isolated power 191 for on-board use.
  • Burner brain module 32 further includes various status LED's 78, 79, 80 to indicate power status, service required, and control module board status.
  • Flow controller modules 12, 14 each include an Echelon LonWorksTM network control module 82 coupled to an interface board 84 as shown in Fig. 8. Similar to burner control module 32, flow controller modules 12, 14 also include a communications processor (not shown, but within LonWorksTM network control module 82) coupled to communication network 30 that performs all network-related functions for communicating over network 30.
  • Interface board 84 in flow controller modules 12, 14 is in turn coupled to a flow sensor 86 that illustratively is a thermal mass flow sensor. Any sensor from which mass flow rate can be derived is suitable, although the presently preferred embodiment uses a thermal mass flow sensor that provides an output signal directly indicative of flow rate.
  • Thermal mass flow sensor 86 is calibrated to provide a linear analog output of the flow rate through a pipe flow body (not shown) containing flow conditioning and having a known diameter. The system can also work with a calibrated non-linear signal from the flow sensor.
  • Network control module 82 can lnterface with flow sensor 86 by any suitable communications protocol, such as a serial Input/Output interface
  • the flow controller modules 12, 14 are configured to conform to the NEMA4X rating to ensure reliable operation in the burner control system environment
  • flow sensors 86 are keyed in order to ensure proper alignment within the pipe flow body
  • Interface board 84 includes conditioning circuitry (not shown) to filter and digitize the analog Input/Output 73 to and from flow sensor 86 as well as handling serial Input/Output 75 for use by control module 82
  • Interface board 84 further includes power circuitry including filters 83, status LEDs, field connection wiring 81, network interface circuitry for coupling modules 12, 14 to communication network 30, and a serial Input/Output connection 85 to control module 82
  • Valve actuator modules 16, 18 are coupled to butterfly valves 88, 90 respectively to regulate the gas and air flows 34, 36 as shown in Fig 1
  • Any valve system could be used to regulate fluid flow in pipes 20, 22, and as discussed above the flow optionally can be regulated bv means of a variable speed blower 38
  • Variable speed blower 38 can be any device that adjustably increases the fluid flow rate, such as a turbine, pump, or the like
  • Valve actuator modules 16, 18 are each coupled to valves 88, 90 through a stepping motor 92 as shown in Fig 9 Stepping motor in turn is coupled to a planetary gear system (not shown) to provide precise rotational control of the position of valves 88, 90
  • the stepping motor is illustratively capable of driving 100 m-lb of torque and the planetary gear system has a 40 1 reduction ratio It is understood that the invention contemplates any coupling mechanism for driving valves 88, 90 with actuators 16, 18, however, such as alternative gear systems, e g , spur gears, or with any suitable electro-mechanical actuation design
  • valve actuator modules 16, 18 use Echelon Neuron-based LonWorksTM hardware, although any intelligent system capable of communicating with other modules over a communication network is contemplated
  • the control module 94 of actuator modules 16, 18 includes an Echelon Neuron processor 95 coupled to a network interface module 96 and a flash memory 97
  • Network interface module 96 is coupled to the peer-to-peer communication network 30
  • Neurons 95 in actuator modules 16, 18 execute software stored in flash memory 97 and internal memory (not shown) to perform closed loop control of valves 88, 90 based on control signals received from flow controller modules 12, 14 over communication network 30 and valve position feedback signals received from position feedback encoders 98 that are coupled to valves 88, 90
  • Each feedback encoder 98 is coupled to neuron 95 through an Input/Output conditioning circuit 99 that filters and digitizes the position signal Feedback encoders 98 are wiper pickups coupled to resistive encoder elements on the shaft of butterfly valves 88, 90 calibrated to 0 05 degree resolution, although any suitable valve position sensor design is contemplated
  • Stepping motor 92 is coupled to Neuron processor 95 through a motor drive circuit 100 and motor logic circuit 101 that conform the command from Neuron 95 to the electrical interface of motor 92
  • Each of the control modules 94 receives a valve position setpoint from one of flow controller modules 12, 14 over communication network 30, and each Neuron processor 95 performs closed-loop control of one of valves 88, 90 by commanding stepping motor 92 based on a valve- position feedback signal from encoder 98
  • Valve actuator modules 16, 18 also include power supply circuitry 102 that filters external power 45 for use by other components within the modules Modules 16, 18 further include a data acquisition circuit 103 coupled to Neuron processor 95 that allows for monitoring of internal signal parameters for safety and proper operation, such as motor drive current, as well as providing for communication of internal module signal values to communication network 30
  • the burner control system 10 provides a system for precise and efficient control of the air-fuel ratio to a burner 24
  • the modular architecture allows part of the system to be incorporated into an existing design for reduced application requirements For example, a flow controller and valve actuator pair could be retrofitted into an existing system to replace the fluid control element for a fluid supply pipe
  • the system could also be expanded to accommodate enhanced control, such as by using continuous emissions feedback in determining air and fuel setpoints
  • the intelligent, modular architecture allows for adaptation of the control system to accommodate changes in burner system, such as or modification to account for a new or changed burner characterization, by updating the software used within the modules Similarly, the burner control system can be optimized for a particular characteristic, such as

Abstract

An intelligent burner control apparatus (10) controls the rate of a fluid flow (34, 36) to a burner (24) in a system that includes an electronic communication network (30). A flow controller (12, 14) includes a communication module (82) and a sensor (86) to measure the fluid flow rate. The flow controller determines a flow control signal based on a measured fluid flow rate and the communication module sends the flow control signal over the network. A flow regulator (16, 18) includes a communication module (96) and an actuator (92) to control the fluid flow rate. The flow regulator commands the actuator based on the flow control signal received over the communication network.

Description

INTELLIGENT BURNER CONTROL SYSTEM
Background and Summary of the Invention
The present invention relates to control systems and particularly to systems for controlling fluid flow More particularly, the present invention relates to electronic control systems for regulating flow of air and fuel for industrial burners
Industrial burners typically operate under varying conditions such as variable fuel and air supply pressures and temperatures, back pressure from the burner, humidity, fuel quality, etc In comparison to a burner control system that is calibrated for a particular set of operating conditions, a control system that automatically compensates for changes in the burner operating environment will optimize burner performance over the changing conditions A burner control system that provides improved precision in regulating the flow of air and fuel will allow for operation over a wider burner turndown and increase overall burner efficiency, resulting in reduced emissions over the entire operating range, as well as increasing reliability and burner operating life
In accordance with the present invention, an intelligent burner control apparatus is provided for controlling the rate of a fluid flow in a burner system from a fluid supply to a burner The burner system includes an electronic communication network The apparatus includes a flow controller including a sensor and a communication module The sensor is configured to be coupled between the fluid supply and the burner to measure the fluid flow rate The communication module is configured to be coupled to the communication network to send a flow control signal The flow controller is configured to determine the flow control signal based on the measured fluid flow rate The apparatus also includes a flow regulator including a communication module and an actuator The communication module of the flow regulator is configured to be coupled to the communication network to receive the flow control signal The actuator is configured to be coupled between the fluid supply and the burner to control the fluid flow rate The flow regulator is configured to command the actuator based on the flow control signal
In preferred embodiments, the sensor is a mass flow sensor, such as a thermal mass flow sensor The actuator can include a variable speed blower, or a valve actuator coupled to a valve assembly, or both a variable speed blower and a valve actuator coupled to a valve assembly The communication network can be a peer-to- peer communication network
The intelligent burner control apparatus further includes a brain module configured to be coupled to the communication network and to send a flow setpoint signal indicative of a desired fluid flow rate over the communication network The flow controller module is configured to receive the flow setpoint signal and determine the flow control signal based on the measured flow rate and flow setpoint signal The brain module can be configured to receive a firing rate signal and to determine the flow setpoint based on the firing rate signal The brain module can monitor the rate of change in the firing rate signal from a process controller, and if the rate of change exceeds a predetermined threshold then the burner brain determines and sends a plurality of intermediate setpoints over the communication network
The intelligent burner control apparatus further includes a display module configured to be coupled to the communication network The display module includes a display terminal and is configured to receive at least one display signal over the communication network The display module provides an indication on the display terminal indicative of the display signal The intelligent burner control apparatus can include a command module configured to be coupled to the communication network The command module includes a user input device for sending at least one user command over the communication network
Additional features of the invention will become apparent to those skilled in the art upon consideration of the following detailed description of preferred embodiments exemplifying the best mode of carrying out the invention as presently perceived
Brief Description of the Drawings
The detailed description particularly refers to the accompanying figures in which Fig 1 is a component block diagram showing modular flow measurement and actuator modules according to the present invention installed into air and gas pipe train components of a burner system, the flow and actuator modules communicating over a peer-to-peer communication network with a burner "brain" module within an interface panel module and a command and display module;
Fig. 2 is a block diagram similar to Fig. 1 showing the actuator module in the air pipe replaced by a variable speed air blower; Fig. 3 is a conceptual diagram showing pressure and temperature environmental input parameters to a burner control system that regulates an air-fuel ratio output to the burner;
Fig. 4 is a system block diagram showing an industrial process control system that includes an air-fuel control system according to the present invention interposed between the pipe train components and a burner, and illustrating interfaces between a process controller and the air-fuel control system, an emissions monitoring component, a burner management and flame safeguard component, and process variables;
Fig. 5 is a network block diagram showing the modular components of the burner control system connected over the communication network, a PC user interface module for providing a gateway between the communication network and external systems such as a portable emissions gas analyzer or remote monitoring devices, and burner control signals to the interface panel module that includes the burner brain; Fig. 6 is a schematic block diagram of the interface panel module including the burner brain module, showing relay switched discrete Input/Output, isolated analog inputs, and burner control system parameters conveyed over the communication network;
Fig. 7 is a schematic block diagram of the burner brain module showing isolated external Input/Output, direct internal Input/Output, regulated power, and a connection to the peer-to-peer communication network;
Fig. 8 is a block diagram of an intelligent flow controller including a thermal mass flow sensor configured with analog and serial interfaces, an interface board coupled to the mass flow sensor, and an Echelon LonWorks™ network control module coupled to the interface board for communication over the peer-to-peer network; and Fig 9 is a block diagram of an intelligent valve actuator for regulating fluid flow including an Echelon Neuron™ processor having application code and data stored in a flash memory and a network interface for communicating over the network, the flow regulation module configured for autonomous closed-loop control of a valve via a stepping motor command output and an encoded valve position feedback input
Detailed Description
An intelligent burner control system 10 in accordance with the present invention having flow controller modules 12, 14 and valve actuator modules 16, 18 coupled to an air pipe 20 and gas pipe 22 of a pipe train assembly of a burner 24 is shown in Fig 1 The flow controller modules 12, 14 and valve actuator modules 16, 18 communicate with a command and display module 26 and interface panel module 28 over a peer-to-peer communication network 30 as best shown in Fig 5 Valve actuator modules 16, 18 are coupled to valves 88, 90 respectively to regulate the flow of air and fuel in pipes 20, 22 The interface panel module 28 includes a "brain" module 32 that cooperates with the flow controller modules 12, 14 and valve actuator modules 16, 18 to provide precise regulation of the flow of air 34 and gas 36 to burner 24
In order to improve burner efficiency and reduce burner emissions, intelligent burner control system 10 provides intelligent, modular components to compensate automatically for changes in environmental parameters over the complete operating range of the burner For example, by providing flow controller modules 12, 14 that perform closed loop control based on fluid flow mass rate, burner control system 10 automatically compensates for changes in fluid pressures and temperatures without needing to monitor these parameters By providing high-precision modular components, burner control system 10 provides for operation over changing conditions, resulting in a wide burner turndown ratio that allows for reduced emissions and increased efficiency and reliability
Modular burner control system 10 can be used to replace part or all of the air-fuel ratio control system in a burner control system, allowing for both a turnkey approach to installation as well as incorporation into existing designs The use of intelligent components coupled to communication network 30 further provides the abi ty to monitor or to manage the control system remotely The modular architecture simplifies installation, modification, and operation of burner control system 10
The intelligent modules 12, 14, 16, 18, 26, 32 provide a turnkey approach for air-fuel ratio control for burners that integrates easily into a conventional combustion control system The modular architecture based on a peer-to-peer communication network 30 enables the control functions to be distributed throughout the networked components to provide maximum flexibility, reduced network complexity, increased precision, and increased system reliability For example, the modular architecture allows for replacement of valve actuator module 16 and valve 88 in air pipe 20 with a variable speed blower 38 as shown in Fig 2, without requiring modifications to the remaining modular components 12, 14, 18, 26, 32 within burner control system 10 Similarly, as discussed in more detail below, variable speed blower 38 can be combined with valve actuator module 16 and valve 88 to achieve more precise control of air flow over a wider range of operating conditions than is possible by using either variable speed blower 38 or valve actuator module 16 and valve 88 alone
By using intelligent, micro-processor based modules to perform closed- loop control using mass flow rates of the air and fuel supplies to the burner, the burner control system 10 of the present invention can be configured to achieve desired burner performance while automatically compensating for a variety of operating conditions For example, flow controllers 12, 14 are configured to measure mass flow directly and provide control signals to valve actuators 16, 18 so that burner control system 10 reacts automatically to variations in gas pressures 21, air pressures 23, back pressure 25, and air and gas temperatures 27, 29 in pipes 20, 22 to determine an air-fuel ratio 31 See Fig 3 The modular, micro-processor based architecture further contemplates integrating additional sensor data into the control system, such as providing humidity and fuel sensor data directly to burner brain 32 which then the valve actuator modules 16, 18 for use in adjusting the air-fuel ratio 31 to burner 24 based on these inputs Burner control system 10 also provides the ability to predict the emissions from burner 24, for example based on input parameters such as air and fuel mass flow The emission characteristics for burner 24, such as NOx and CO emissions, can be experimentally determined as a function of and fuel mass flow Characteristic curves of burner emission performance based on air and fuel mass flow can then be generated. The expected NOx and CO emissions output from an operational burner 24 thus characterized can then be determined by software within any module coupled to the network, such as burner brain module 32, by using the actual air and fuel mass flow rates measured by flow controller modules 12, 14 in conjunction with the predetermined characteristic emissions curves. This predictive emissions capability can be used to complement, verify, or replace actual emissions monitoring to assist in compliance with various federal, state, and local environmental regulations. Elements of a typical industrial heating system 40 incorporating burner control system 10 for air and fuel control are shown in the block diagram of Fig. 4. Heating system 40 illustratively includes the burner control system 10 coupled to burner 24, pipe train 42, and a process controller 44. Process controller 44 can be a distributed control system computer, a programmable logic controller, an application specific universal digital controller, or the like, and manages one or more process variables 48, such as oven temperature, Process controller 44 is also coupled to an emissions monitoring system 46 which can monitor emissions continuously or on a sampled basis.
Process controller 44 provides a firing rate signal 52 to burner control system 10, where firing rate signal 52 represents a percentage of firing rate for burner 24. Firing rate is illustratively an analog signal where firing rate is proportional to signal current, but any analog or digital signal could be used to command firing rate. The command signal from process controller 44 to burner control system 10 can be any parameter indicative of desired burner 24 performance. Burner control system 10 controls the air and fuel flow rates to burner 24 to achieve the firing rate commanded by process controller 44. Process controller 44 is illustratively coupled to burner brain 32 through an analog firing rate signal 52, but that other interfaces such as a serial Input/Output interface or communication over network 30 is contemplated.
A burner management and flame safeguard element 50 is coupled to process controller 44 and contains monitoring and control logic to light burner 24 and to shutdown burner 24 if it detects an absence of a flame or if commanded by process controller 44. Burner management and flame safeguard element 50 is further coupled to pipe train 42, which contains various permissive interlocks required for safe starting and operation of burner 24 Burner management and flame safeguard element 50 also monitors parameters such as high and low gas pressure, low air pressure, high process temperatures, and the like Process controller 44 provides the firing rate signal 52 to interface panel module 28 of burner control system 10 as shown in Fig 5 Interface panel module 28 provides burner status information to process controller 44 Burner brain module 32 within interface panel module 28 then translates firing rate signal 52 into an air flow setpoint and a fuel flow setpoint using software based on known performance characteristics of burner 24 Burner brain module 32 transmits the air and fuel flow setpoints to air flow and gas flow controller modules 12, 14 respectively over the peer- to-peer communication network 30 Air and gas flow controller modules 12, 14 in turn measure the air and gas mass flow rates and determine valve position commands that are sent over network 30 to air and gas valve actuator modules 16, 18 Air and gas flow controller modules thus automatically compensate for variations in pressure and temperature by performing closed-loop control of valve position based directly on mass flow rate Similarly, air and gas valve actuator modules 16, 18 automatically compensate for changing environmental parameters, including mechanical factors such as hysteπsis in valves 88, 90, by performing closed-loop control based on measured valve position to drive valves 88, 90 to the commanded positions
When variable speed blower 38 replaces air valve actuator module 16 for controlling air flow 34 to burner 24, air flow controller module 12 will provide a blower frequency setpoint to produce the appropriate flow Variable speed blower 38 can be used in conjunction with air valve actuator module 16, in which case air flow controller module 12 will command a blower frequency setpoint slightly higher than necessary to produce the desired flow rate and will command air valve actuator module 16 to trim the air flow to achieve the desired flow rate This primary- secondary control approach allows air flow controller module 12 to maintain valve actuator module 16 in a configuration that maximizes precision For example, the air flow rate can be varied so that a butterfly valve can operate as a secondary trim around its peak precision orientation of forty-five degrees The air flow can be varied by primary air flow regulator, for example, variable speed blower 38, to maximize the precision characteristics of any type of secondary flow regulator used as secondary trim Any suitable mechanism can be used for the primary control of air flow rate, such as another type of valve mechanism instead of variable speed blower 38
The interface control panel module 28 including burner brain module 32 is shown in detail in Fig 6 A 24 volt direct current power supply 56 is coupled to the alternating current power supply input 41 through a four amp circuit breaker 58 to provide power 45 to the module components and also for peer-to-peer communication network 30 Power supply 56 can be any suitable commercial power supply, and illustratively a five amp power supply is used for a burner control system requiring two amps, with the extra power capacity providing for improved reliability and higher temperature operations A current shunt 60 provides a power supply monitor input 43 to burner brain module 32 for diagnostic purposes
Discrete Input/Output to and from interface panel module 28 is electrically isolated by use of relay banks 62, 64 Discrete input signals to burner brain module 32 are isolated by relay bank 62 and include blower on 47, interlocks proven 35, purge complete 49, and main valve on signals 51 Burner brain module 32 is also capable of receiving other spare input signals 53 to provide for added capacity Discrete outputs are isolated by a relay bank 64 and include burner enable 55, call for heat 57, and alarm signals 59 Burner brain module 32 similarly includes spare discrete and analog output signals 61, 63 to provide for additional capacity The firing rate analog signal 52 from process controller 44 is coupled through interface control panel 28 to burner brain module 32
Communication network 30 is illustratively a LonWorks™ peer-to-peer communication network from Echelon, although any suitable communications network can be used Communication network 30 and network system power bus share a four- conductor communication cable, one shielded twisted pair being used for power and another shielded twisted pair being used for communication, with both networks being appropriately terminated by termination filter 71 in interface panel module 28 Command and display module 26 is coupled to the peer-to-peer communication network 30 within panel module 28 to provide local monitoring and control functions Command and display module 26 can display any of the parameters sent over network 30 by the intelligent modules 12, 14, 16, 18, 32, including values of external signals to the modules and internal parameters used by the modules Module 26 can similarly command the various intelligent modules 12, 14, 16, 18, 32 to perform certain functions such as self-diagnostics, self-calibration, shut-down, etc Command and display module 26 can be coupled to communication network 30 at any location, and that more than one such module can be used
An optional network gateway module 54 can also be coupled to the peer-to-peer communication network within the interface panel 28 to provide an interface between the peer-to-peer communication network and an external network, for example through a standard telephone line 37, Ethernet transceiver 39, or the like Although network gateway module 54 is located in interface panel 28 it can also be located anywhere on communication network 30 Network gateway module 54 can be used, for example, to provide a remote command and display interface to burner control system 10
Details of burner brain module 32 are shown in Fig 7 Burner brain 32 includes software for controlling air and fuel flows as a function of firing rate for the specific type of burner 24 and supplies the appropriate flow setpoints to the air and fuel flow controller modules 12, 14 over network 30
The software in burner brain 32 includes algorithms to ensure proper transformation of firing rate input commands to air and fuel setpoint output commands When a firing rate command input changes, burner brain 32 will determine intermediate firing rate step changes in the fuel setpoint command outputs to ensure that the proper air-fuel ratio is maintained as the controller modules 12, 14 command the actuator modules 16, 18 to achieve the new burner output By having knowledge of the air and fuel flow regulation performance, that is, the flow controller and valve actuator modules, this approach allows burner brain 32 to achieve the most efficient rate of change in burner 24 output while maintaining a safe condition, that is, maintaining a proper air-fuel ratio during transition between commands By including predefined knowledge of performance characteristics of various flow controller, valve actuator, and variable speed blower modules in burner brain 32, the burner control system 10 can automatically accommodate a variety of module configurations Burner brain 32 can be updated to accommodate changes in performance characteristics of other modules in the flow regulation system, for example by communicating performance characteristic information to burner brain 32 over communication network 30 or by providing modified software.
Burner brain 32 also monitors the discrete inputs and controls the discrete outputs to interface panel 28 discussed above The blower on discrete input is used to signal burner brain 32 to command the optional variable speed blower to start. The interlocks proven discrete input indicates that all permissive interlocks, such as low air pressure, low and high gas pressure, and excess temperature are within range for operating burner 24 The purge complete discrete input indicates that an external burner purge cycle has been completed and signals burner brain 32 to command an appropriate air flow setting to start burner 24. The main valve on discrete input indicates that burner 24 is lit and under temperature control Burner brain 32 can also be configured to receive any or all of these inputs over communication network 30
The discrete outputs from burner brain 32 are coupled through 24 VDC relay drivers 74 Discrete outputs include a burner enable discrete output 33 used as an interlock by burner management and flame safeguard element 50 and a call for heat discrete output 57 to enable actuation of a main valve of burner 24 that is turned on by burner management and flame safeguard component 50 There is also an alarm discrete 59 that can be used for purposes such as turning on an indicator light (not shown) or can be coupled to process controller 44 Although burner brain 32 illustratively drives discrete outputs 33, 55, 57 directly, the invention contemplates sending these commands over network 30. The status of all discrete outputs can also be communicated over communication network 30, as can the status of variables set or used within burner brain module 32.
External analog inputs to burner brain module 32 are electrically isolated by use of isolation amplifiers 66. Analog inputs include firing rate 52, power supply current shunt voltage 65, and an optional process variable 67, which can be humidity, fuel quality, or any parameter that may affect performance of burner control system 10. Although in an illustrative embodiment burner brain module 32 receives the analog firing rate signal 52 from process controller 44, burner brain 32 could receive a firing rate signal over communication network 30 Analog inputs are coupled from amplifiers 66 through a low pass filter 68 and analog-to-digital converter 70 to brain control module 72. Discrete input blower on 47, interlocks proven 35, purge complete 49, main valve on 69, and spare inputs 53 are also coupled to brain module 32 through low-pass filter 68 via drivers 76. Burner brain 32 can be configured to receive one or more process variables over network 30.
Control module 72 is an Echelon Neuron-based LonWorks™ control module, although it is understood that a module configured with any micro-processor, micro-controller or the like can be used. The Echelon Neuron processor includes a communications processor (not shown) that performs all network-related functions for communicating over network 30 and is coupled to the Echelon LonWorks™ communication network. A power supply circuit 77 for burner brain module 32 including a five volt regulator 87, a fifteen volt regulator 89, and a five volt isolated supply 91 is coupled to a filter 76 and provides filtered power including five volt direct current logic power 187, fifteen volt direct current power 189, and five volt direct current isolated power 191 for on-board use. A twenty-four volt monitor signal 104, a fifteen volt monitor signal 105, and an ambient temperature signal 106 coupled to low pass filter 68 are also provided as inputs to control module 72. Burner brain module 32 further includes various status LED's 78, 79, 80 to indicate power status, service required, and control module board status.
Flow controller modules 12, 14 each include an Echelon LonWorks™ network control module 82 coupled to an interface board 84 as shown in Fig. 8. Similar to burner control module 32, flow controller modules 12, 14 also include a communications processor (not shown, but within LonWorks™ network control module 82) coupled to communication network 30 that performs all network-related functions for communicating over network 30.
Interface board 84 in flow controller modules 12, 14 is in turn coupled to a flow sensor 86 that illustratively is a thermal mass flow sensor. Any sensor from which mass flow rate can be derived is suitable, although the presently preferred embodiment uses a thermal mass flow sensor that provides an output signal directly indicative of flow rate. Thermal mass flow sensor 86 is calibrated to provide a linear analog output of the flow rate through a pipe flow body (not shown) containing flow conditioning and having a known diameter. The system can also work with a calibrated non-linear signal from the flow sensor. Network control module 82 can lnterface with flow sensor 86 by any suitable communications protocol, such as a serial Input/Output interface
The flow controller modules 12, 14 are configured to conform to the NEMA4X rating to ensure reliable operation in the burner control system environment In order to ensure precise flow measurement and control, flow sensors 86 are keyed in order to ensure proper alignment within the pipe flow body
Interface board 84 includes conditioning circuitry (not shown) to filter and digitize the analog Input/Output 73 to and from flow sensor 86 as well as handling serial Input/Output 75 for use by control module 82 Interface board 84 further includes power circuitry including filters 83, status LEDs, field connection wiring 81, network interface circuitry for coupling modules 12, 14 to communication network 30, and a serial Input/Output connection 85 to control module 82
Valve actuator modules 16, 18 are coupled to butterfly valves 88, 90 respectively to regulate the gas and air flows 34, 36 as shown in Fig 1 Any valve system could be used to regulate fluid flow in pipes 20, 22, and as discussed above the flow optionally can be regulated bv means of a variable speed blower 38 Variable speed blower 38 can be any device that adjustably increases the fluid flow rate, such as a turbine, pump, or the like
Valve actuator modules 16, 18 are each coupled to valves 88, 90 through a stepping motor 92 as shown in Fig 9 Stepping motor in turn is coupled to a planetary gear system (not shown) to provide precise rotational control of the position of valves 88, 90 The stepping motor is illustratively capable of driving 100 m-lb of torque and the planetary gear system has a 40 1 reduction ratio It is understood that the invention contemplates any coupling mechanism for driving valves 88, 90 with actuators 16, 18, however, such as alternative gear systems, e g , spur gears, or with any suitable electro-mechanical actuation design
Like the burner brain 32 and flow controller 12, 14 modules, valve actuator modules 16, 18 use Echelon Neuron-based LonWorks™ hardware, although any intelligent system capable of communicating with other modules over a communication network is contemplated The control module 94 of actuator modules 16, 18 includes an Echelon Neuron processor 95 coupled to a network interface module 96 and a flash memory 97 Network interface module 96 is coupled to the peer-to-peer communication network 30
Neurons 95 in actuator modules 16, 18 execute software stored in flash memory 97 and internal memory (not shown) to perform closed loop control of valves 88, 90 based on control signals received from flow controller modules 12, 14 over communication network 30 and valve position feedback signals received from position feedback encoders 98 that are coupled to valves 88, 90 Each feedback encoder 98 is coupled to neuron 95 through an Input/Output conditioning circuit 99 that filters and digitizes the position signal Feedback encoders 98 are wiper pickups coupled to resistive encoder elements on the shaft of butterfly valves 88, 90 calibrated to 0 05 degree resolution, although any suitable valve position sensor design is contemplated
Stepping motor 92 is coupled to Neuron processor 95 through a motor drive circuit 100 and motor logic circuit 101 that conform the command from Neuron 95 to the electrical interface of motor 92 Each of the control modules 94 receives a valve position setpoint from one of flow controller modules 12, 14 over communication network 30, and each Neuron processor 95 performs closed-loop control of one of valves 88, 90 by commanding stepping motor 92 based on a valve- position feedback signal from encoder 98
Valve actuator modules 16, 18 also include power supply circuitry 102 that filters external power 45 for use by other components within the modules Modules 16, 18 further include a data acquisition circuit 103 coupled to Neuron processor 95 that allows for monitoring of internal signal parameters for safety and proper operation, such as motor drive current, as well as providing for communication of internal module signal values to communication network 30 The burner control system 10 provides a system for precise and efficient control of the air-fuel ratio to a burner 24 The modular architecture allows part of the system to be incorporated into an existing design for reduced application requirements For example, a flow controller and valve actuator pair could be retrofitted into an existing system to replace the fluid control element for a fluid supply pipe The system could also be expanded to accommodate enhanced control, such as by using continuous emissions feedback in determining air and fuel setpoints The intelligent, modular architecture allows for adaptation of the control system to accommodate changes in burner system, such as or modification to account for a new or changed burner characterization, by updating the software used within the modules Similarly, the burner control system can be optimized for a particular characteristic, such as emissions reduction, again by software within one or more of the modules By including a characterization of burner emissions performance burner control system 10 provides the ability to predict emissions from an operational burner Furthermore, the ability of the system to provide external and internal operating parameters to the communications network enhances the ability to monitor and optimize the system The network-based, modular architecture of the present invention enhances the ability to expand the burner control system 10, such as by adding an additional processor to network 30 to increase the computational capacity Similarly, additional intelligent sensors can readily be attached to network 30, such as an optical flame sensor, to provide further control, diagnostic or safety features Moreover, the network-based architecture improves the system diagnostic capability, such as the ability to isolate and correct a defective valve actuator 16, 18 or valve 88, 90 based on the ability to monitor signals and control modules over network 30 The use of modular components based on a standard communication network and protocol such as Echelon LonWorks™ further provides for increased expandability and reduced cost Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of the present invention as described and defined in the following claims

Claims

CLAIMS:
1. An intelligent burner control apparatus for controlling the rate of a fluid flow in a burner system from a fluid supply to a burner, the burner system including an electronic communication network, the apparatus comprising a flow controller including a sensor and a communication module, the sensor being configured to be coupled between the fluid supply and the burner to measure the fluid flow rate, the communication module being configured to be coupled to the communication network to send a flow control signal, and the flow controller being configured to determine the flow control signal based on the measured fluid flow rate; and a flow regulator including a communication module and an actuator, the communication module being configured to be coupled to the communication network to receive the flow control signal, the actuator being configured to be coupled between the fluid supply and the burner to control the fluid flow rate, and the flow regulator being configured to command the actuator based on the flow control signal.
2. The apparatus of claim 1, wherein the sensor is a mass flow sensor.
3. The apparatus of claim 2, wherein the mass flow sensor is a thermal mass flow sensor.
4. The apparatus of claim 1, wherein the actuator includes a valve actuator coupled to a valve assembly.
5. The apparatus of claim 1, wherein the actuator includes a variable speed blower. 6. The apparatus of claim 5, wherein the actuator further includes a valve actuator coupled to a valve assembly.
7. The apparatus of claim 1, wherein the communication network is a peer-to-peer communication network.
8. The apparatus of claim 1, further comprising a brain module configured to be coupled to the communication network and send a flow setpoint signal indicative of a desired fluid flow rate over the communication network, and wherein the flow controller module is configured to receive the flow setpoint signal and determine the flow control signal based on the measured flow rate and flow setpoint signal
9 The apparatus of claim 8, wherein the brain module is configured to receive a firing rate signal and the flow setpoint is determined based on the firing rate signal
10 The apparatus of claim 9, wherein the brain module monitors the rate of change in the firing rate signal, and if the rate of change exceeds a predetermined threshold then the burner brain determines and sends a plurality of intermediate setpoints over the communication network 1 1 The apparatus of claim 9, wherein the brain module is configured to receive the firing rate signal over the communication network 12 The apparatus of claim 8, wherein the brain module is configured to receive at least one process variable and the flow setpoint is determined based on the process variable 13 The apparatus of claim 12, wherein the at least one process variable is received over the communication network
14 The apparatus of claim 12, wherein the at least one process variable includes a humidity signal
15 The apparatus of claim 12, wherein the at least one process variable includes a fluid quality signal
16 The apparatus of claim 12, wherein the at least one process variable includes a process temperature signal
17 The apparatus of claim 8, wherein the brain module is configured to receive at least one burner status signal 18 The apparatus of claim 17, wherein the at least one burner status signal is received over the communication network
19 The apparatus of claim 8, wherein the brain module is configured to send at least one burner command signal
20 The apparatus of claim 19, wherein the at least one burner command signal is sent over the communication network
21 The apparatus of claim 1, further comprising a display module configured to be coupled to the communication network, the display module including a display terminal, the display module being configured to receive at least one display signal over the communication network and provide an indication on the display terminal indicative of the at least one display signal.
22. The apparatus of claim 1, further comprising a command module configured to be coupled to the communication network, the command module including a user input device for sending at least one user command over the communication network.
23. The apparatus of claim 1, further comprising a gateway module configured to be coupled to the communication network, the gateway module providing an interface between the communication network and a second communication network for sending at least one signal between the communication network and the second communication network.
24. The apparatus of claim 23, wherein the gateway module is configured to send at least one display signal from the communication network to the second communication network.
25. The apparatus of claim 23, wherein the gateway module is configured to send at least one command to the communication network from the second communication network.
26. An intelligent burner control apparatus for controlling the rate of air and fuel flow to a burner in a burner system including an electronic communication network, the apparatus comprising a brain module configured to be coupled to the communication network, the brain module configured to determine air and fuel flow setpoint signals indicative of desired air and fuel flow rates and send the air and fuel setpoint signals over the communication network.
27. The apparatus of claim 26, wherein the communication network is a peer-to-peer communication network.
28. The apparatus of claim 26, wherein the brain module is configured to receive a firing rate signal and determine the air and fuel flow setpoint signals based on the firing rate signal. 29 The apparatus of claim 26, wherein the brain module includes a burner performance characterization and determines the air and fuel flow setpoint signals based on the burner characterization
30 The apparatus of claim 26, wherein the brain module includes a burner emission characterization and determines at least one expected burner emission output based on the burner emission characterization and the air and fuel flow setpoint signals
31 The apparatus of claim 30, wherein the at least one expected burner emission output includes nitrogen oxide compound emissions 32 The apparatus of claim 26, further comprising an air flow controller and a fuel flow controller configured to be coupled to the communication network and control air and fuel flow based on the air and fuel setpoint signals
33 The apparatus of claim 32, further comprising an air flow regulator and a fuel flow regulator configured to be coupled to the communication network and regulate air and fuel flow based on signals from the air and fuel flow controllers
34 The apparatus of claim 26, further comprising a command module configured to be coupled to the communication network and send at least one command to the brain module over the communication network 35 The apparatus of claim 26, further comprising a display module configured to be coupled to the communication network and display at least one signal from the brain module over the communication network
36 The apparatus of claim 26, further comprising a gateway module configured to be coupled to the communication network, the gateway module providing an interface between the communication network and a second communication network for sending at least one signal between the communication network and the second communication network
37 An intelligent burner control apparatus for controlling the rate of air and fuel flow to a burner from air and fuel supplies in a burner system including an electronic communication network, the apparatus comprising a brain module configured to be coupled to the communication network, the brain module configured to receive a firing rate signal and send air and fuel flow setpoint signals indicative of desired air and fuel flow rates over the . communication network; air and fuel flow controllers including a sensor and a communication module, the sensors being configured to be coupled between the air and fuel supplies and the burner to measure the air and fuel flow rates, the communication modules being configured to be coupled to the communication network to send air and fuel flow control signals, and the flow controllers being configured to determine the flow control signals based on the measured air and fuel flow rates and the air and fuel flow setpoint signals; air and fuel flow regulators including a communication module and an actuator, the communication modules being configured to be coupled to the communication network to receive the air and fuel flow control signals, the actuators being configured to be coupled between the air and fuel supplies and the burner to control the air and fuel flow rates, and the flow regulators being configured to command the actuators based on the air and fuel flow control signals; a command module configured to be coupled to the communication network, the command module including a user input device for sending at least one user command over the communication network; and a display module configured to be coupled to the communication network, the display module including a display terminal, the display module being configured to receive at least one display signal over the communication network and provide an indication on the display terminal indicative of the at least one display signal.
38. The apparatus of claim 37, wherein the communication network is a peer-to-peer communication network.
39. The apparatus of claim 37, further comprising a gateway module configured to be coupled to the communication network, the gateway module providing an interface between the communication network and a second communication network so that at least one signal can be sent between the communication network and the second communication network.
40. An apparatus for controlling a fluid flow through a passageway to a desired flow rate comprising a first flow controller configured to be coupled to a communication network and command a first flow rate, the first fluid flow rate being higher than the desired flow rate; a first flow regulator configured to be coupled to the passageway and regulate the fluid flow to the first flow rate based on the command from the first fluid flow controller; a second flow controller configured to be coupled to the communication network and command the desired flow rate; and a second flow regulator configured to be coupled to the passageway downstream of the first flow regulator and regulate the fluid flow based on the command from the second flow controller.
41. The apparatus of claim 40 wherein the second fluid flow regulator has a first operating range having a first operating precision and a second operating range having a second operating precision relatively higher than the first operating precision, and the first fluid flow regulator controls the flow rate so that the second fluid flow regulator operates in the second operating range.
42. The apparatus of claim 41 wherein the first fluid flow regulator includes a variable speed blower and the second fluid flow regulator includes a valve actuator coupled to a valve. 43. The apparatus of claim 42, wherein the valve is a butterfly valve moveable between about zero and about ninety degrees, and the variable speed blower is configured to regulate the flow rate so that the desired flow rate is achieved with the butterfly valve at about forty-five degrees.
PCT/US1998/023681 1997-11-07 1998-11-06 Intelligent burner control system WO1999024758A1 (en)

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US5997280A (en) 1999-12-07
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EP1036288A4 (en) 2001-02-28
US6247919B1 (en) 2001-06-19

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