An Advanced Combustion Controller

Abstract

Abstract In the past ten years there have been significant advances in technologies that are relevant to improving gas-fire combustion controls for industrial applications. These technologies include sensors, electronics, and packaging. Sensors that can measure the constituents in the products of combustion (e.g., CO and O 2 ) can be made less expensive, more reliable, and require less effort in calibration and maintenance. The use of digital technology in the electronics area has substantially reduced the electronics cost while increasing its functional capability and reliability. Lower-cost fabrication and packaging techniques are available now because of the use of new materials and manufacturing processes. Combining these technologies can result in a combustion controller that is significantly lower in cost than existing devices and therefore applicable to a much wider range of applications. The work the Bailey Controls Company is performing on a new low cost combustion control ler is described. This work has been ongoing for the last two years and significant ad vances have been made. Two sensors, one for CO and the other O 2 , using the latest electrochemical and catalytic technologies, have been integrated into a sensor assembly designed for ease of installation and routine maintenance. The electronic assembly uses the latest microcontroller technologies to control sensor assembly conditions, process sensor signals, execute control algorithms, and send out signals to control actuators and recorders. The total design of the system is being implemented with manufacturing automation as a key criteria. The use of advanced materials and manufacturing processes are being evaluated to ensure a low cost device. To date, the feasibility of all critical components has been verified and a demonstra tion unit has been designed and fabricated. Initial test data is very encouraging. With our continued success, a product will be available which will allow for optimum combustion control on a wider range of applications. In addition, many end user cus tomers will be able to realize greater product utilization and improved product quality by having a better understanding of the environment in which their product is being treated.