Constant Efficiency Controller
A system and controller where the pressure of the air is continuously monitored or read at a designated exhaust point and adjustments made to the flow of the air and gas to keep the efficiency of the appliance at a maximum to control the appliance (or the burner for an appliance) within specifications as dictated by the customer or consumer rather than training the user.
This application claims priority to and the benefit of U.S. Provisional Patent Application No. 62/140,153, filed on Mar. 30, 2015, the entire contents of which are hereby incorporated by reference.
TECHNICAL FIELDThe subject matter relates to a controller for heating operations.
BACKGROUNDIn the present invention pressure of the manifold gas pressure and the vacuum air pressure are continuously monitored or read at a designated exhaust point and makes adjustments to the flow of the air and gas to keep the efficiency of the appliance at a maximum to control the appliance (or the burner for an appliance) rather than training the user.
The subject invention also provides a method that helps eliminate repetitive, unnecessary, and sometimes harmful switching of the speed of the fan. As the switching of the motor speed may cause damage to various electrical components, such as relays and transistors, the method serves to prevent optimum switching of the fan to run at an optimum speed. The method also promotes proper operation of burner at its optimum state.
Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
Referring to the Figures, a controller 10 in a system 20 is shown herein. This controller 10 is designed to provide a uniform output heat pattern as called for in a specific environment to have a constant efficiency of a burner (ideal for an operating point). The efficiency of the burner is determined by customer or consumer specifications and is tested, as shown in
The controller 10 is designed, as shown in
Once this stage is reached, the derived gas pressure target is fed into the gas pressure specification 118 to generate a digital instruction in the PID controller 119 to control the valve 120. A sensor 122 is used at the output of the valve 120 to feed information back to the A/D input 124 into a gas pressure monitor 126 for the valve, where the monitor 126 feeds back into the PID controller 119.
In operation, the system and controller controls a gas modulating valve 200 (
The circuit 10 shown can provide a number of advantages. The components of the circuit 10 are preferably supported by one or more printed circuit boards. The printed circuit board 215 (
The present invention has been described herein in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the invention are possible in light of the above teachings.
Claims
1. A circuit for a heating appliance comprising
- A fuel source;
- At least one fuel passageway;
- A valve to control pressure of the fuel in said passageway;
- At least one air passageway;
- A fan having a motor to create air pressure in the passageway;
- A fuel pressure sensor on the fuel passageway;
- An air pressure sensor on the air passageway;
- A controller in communication with said fan motor and said valve;
- A testing device to determine a target fuel pressure and a target air pressure at optimum performance specifications provided by the manufacturer of the appliance;
- A comparator to compare the fuel pressure and air pressure during operation of the heating appliance and determine any variance with the target fuel pressure or target air pressure as determined by the testing device;
- A signal generator in communication with said comparator and said controller to indicate a signal to the controller if the comparator find variance with the target fuel pressure and air pressure from optimum performance specifications;
- Wherein the controller adjusts the fan speed and the fuel pressure in response to any variance of the target fuel pressure and target air pressure from optimum performance specifications.
2. A method for maintaining the efficiency of a burner, having a fan driven by a motor having a speed control for the motor, comprising the steps of:
- Deriving an internal air pressure target;
- Sensing combustion air pressure;
- Sensing burner gas pressure;
- Comparing the air pressure and burner gas pressure to the air pressure target; and
- Controlling fan speed to match the internal air pressure target by control of the motor speed.
3. A method for maintaining the efficiency of a burner used in an appliance, having a controller, passageways for combustion air and burner gas, at least one fan having a motor to control the speed of the fan by the controller, and air pressure sensors for combustion air pressure and burner gas pressure, comprising the steps of:
- Obtaining optimum performance specifications of the appliance;
- Testing the appliance to determine the combustion air pressure and burner gas pressure at optimum performance of the appliance to determine a target control parameter;
- Input the target control parameter into the controller;
- Comparing the air vacuum pressure from the sensors to the target control parameter;
- Sending a signal to the controller to generate a digital instruction to the controller to control the gas valve;
- Sensing burner gas pressure;
- Changing the speed of the fan motor if the signal indicates a variance from optimum performance to return to target control parameter relating to motor speed;
- Changing the position of the gas valve if the signal indicates a variance from optimum performance to return to target control parameter relating to burner gas pressure; and
- Further monitoring and changing as needed for further optimum efficiency performance of the appliance.
Type: Application
Filed: Mar 30, 2016
Publication Date: Oct 6, 2016
Inventors: John James Schlachter (Leonard, MI), Mark Geoffrey Masen (Leonard, MI), Frank P. Mimick (Watauga, TX), Nicholas Roth Hanawalt (Detroit, MI), Lynn E. Cooper (North Richland Hills, TX)
Application Number: 15/085,536