Wireless combustion/efficiency analyzer

• US 9,874,547 B2
• Filed: 08/29/2014
• Issued: 01/23/2018
• Est. Priority Date: 08/29/2014
• Status: Active Grant

• Current Assignee: Fluke Corporation (Fortive Corp.)
• Original Assignee: Fluke Corporation (Fortive Corp.)
• Inventors: Epperson, David L.
• Primary Examiner(s): Desta, Elias
• Application Number:
  US14/473,666
• Publication Number:
  US 20160061799A1
• Time in Patent Office: 1,243 Days
• CPC Class Codes: G01K 13/02 for measuring temperature of moving fluids or granular materials capable of flow
• CPC Class Codes: G01K 13/024 of moving gases
• CPC Class Codes: G01N 33/0032 using two or more different physical functioning modes
• CPC Class Codes: G01N 33/0062 concerning the measuring method or the display, e.g. intermittent measurement or digital display
• CPC Class Codes: G01N 33/0075 for multiple spatially distributed sensors, e.g. for environmental monitoring

Abstract

A technician uses a wireless apparatus and system to vary air or fuel in the burner to optimize efficiency and safety. A wireless remote sensor unit has a probe in a flue to draw a sample of combustion gas from the flue for gas sensors and a temperature sensor. The sensors generate analog signals of gas identity, concentration and temperature that are converted to digital signals by an A-to-D converter. A wireless transceiver sends digital signals to a hand held unit or central computer via wireless transmission. The hand held unit receives the digital signals and displays an analysis of the signals. The analysis may be performed by any one of the remote sensor unit, the hand held unit, or the central computer. The wireless unit also receives control signals for the hand held unit or the central computer.

Claims

1. A gas analyzer system comprising:

a plurality of remote sensor units attachable to one more flues;

a hand held unit in communication with the plurality of remote sensor units; and

a host computer in communications with the plurality of remote sensor units,

wherein each remote sensor unit comprises;

a housing;

an elongated sampling tube extending from the housing and configured to have one end pass through a wall of a flue into a bore of the flue;

a pump having an inlet and an outlet, the inlet disposed at the other end of the sampling tube for drawing a sample of cumbustion gas from the flue into the housing;

one or more gas sensors in fluid communication with the outlet of the pump, said one or more gas sensors configured to sense a presence of one or more gases in the combustion gas and to measure a concentration of the one or more gases in the combustion gas;

a temperature sensor for sensing a temperature of the sample of combustion gas; and

a wireless transceiver coupled to receive measurement data obtained by the one or more gas sensors and the temperature sensor for sending signals representative of temperature, types of gases, and concentrations of gases to both the hand held unit and the host computer and to receive control signals, from both the hand held unit and the host computer;

wherein the hand held unit comprises;

a wireless transceiver for receiving signals representative of temperature, types of gases, and concentrations of gases from the remote sensor units and for transmitting control signals to one or more of remote sensor units; and

a display that shows the temperature, types of gases, and concentrations of gases;

wherein circuitry and software disposed in one or both of the remote sensor units and the hand held unit, in operation, process output signals of the one or more gas sensors and the temperature sensor;

wherein the host computer comprises;

a wireless transceiver for receiving signals representative of temperature, types of gases, and concentrations of gases from the remote sensor units and for transmitting control signals to one or more of the remote sensor units;

a display that shows the temperature, types of gases, and concentration of gases; and

circuitry and software that, in operation, process signals received from the remote sensor units and send control signals to one or more of the remote sensor units; and

wherein at least one remote sensor unit wirelessly sends signals representative of temperature, types of gases, and concentration of gases in a flue to the hand held unit which allows a technician operating the hand held unit to make adjustments to a fuel intake and/or air intake of a burner coupled to the respective flue, and also wirelessly sends signals representative of temperature, types of gases, and concentration of gases in the flue to the host computer for review by an analyst reviewing combustion information in the respective flue and other flues that exhaust gas from other burners.

2. The system of claim 1, further comprising a filter disposed between the outlet of the pump and the one or more gas sensors.

3. The system of claim 1 wherein a remote sensor unit has one or more analog to digital converters for converting signals of the one or more gas sensors from analog signals to digital signals.

4. The system of claim 3 wherein the remote sensor unit has circuitry and software that process the digital signals and provide the digital signals to the wireless transceiver of the remote sensor unit for transmission to the hand held unit.

5. The system of claim 3 wherein the hand held unit has circuitry and software that process the digital signals and provide the control signals to the wireless transceiver of the hand held unit for transmission to the remote sensor unit.

6. The system of claim 1 wherein the control signals include a control wake up signal, a control sleep signal, and a control signal to set one or more times for the remote sensor units to transmit signals representative of temperature, types of gases, and concentrations of gases.

7. A wireless sensor for analyzing gases, the wireless sensor comprising:

a housing;

an elongated sampling tube extending from the housing and configured to have one end pass through a wall of a flue into a bore of the flue;

a pump having an inlet and an outlet, the inlet disposed at the other end of the sampling tube for drawing a sample of combustion gas from the flue into the housing;

at least one sensor in fluid communication with the outlet of the pump for sensing a parameter of the sample of combustion gas, wherein the parameter includes at least one of temperature, types of gases, and concentrations of gases in the combustion gas; and

a wireless transceiver coupled to the at least one sensor for sending signals representative of the temperature, types of gases, and concentrations of gases to both a hand held unit and a host computer, and for receiving control signals from both the hand held unit and the host computer.

8. The wireless sensor for analyzing gases of claim 7 wherein the at least one sensor comprises one or more gas sensors in fluid communication with the outlet of the pump, said one or more gas sensors being configured to sense a presence of one or more gases in the combustion gas and to measure a concentration of one or more gases in the combustion gas.

9. The wireless sensor for analyzing gases of claim 7 wherein the at least one sensor comprises a temperature sensor for sensing the temperature of the sample of combustion gas.

10. The wireless sensor for analyzing gases of claim 8 wherein the at least one sensor comprises a temperature sensor for sensing the temperature of the sample of combustion gas.

11. The wireless sensor for analyzing gases of claim 7 wherein the sensor has circuitry and software for responding to control signals to wake up, to go to sleep, and to periodically transmit signals representative of temperature, types of gases and concentrations of gases.

12. A method for analyzing combustion gas in a flue, the method comprising:

providing, at each remote location of a plurality of remote locations, at least one gas sensor configured to sense a presence of one or more gases in a sample of combustion gas and to measure a concentration of the one or more gases in the combustion gas;

providing, at said plurality of remote locations at least one temperature sensor for sensing a temperature of the sample of combustion gas;

placing, at each remote location, one end of an elongated sampling tube into a bore of the flue;

pumping a sample of the combustion gas from the flue to the at least one gas sensor and the at least one temperature sensor; and

wirelessly sending signals representative of temperature, types of gases, and concentrations of gases to both a hand held unit and a host computer, and wirelessly receiving control signals from both the hand held unit and the host computer.

13. The method for analyzing combustion gas in a flue of claim 12, further comprising:

at both the hand held unit and the host computer, wirelessly receiving the signals representative of temperature, types of gases, and concentrations of gases and wirelessly transmitting control signals;

displaying the temperature, types of gases, and concentrations of gases at both the hand held unit and the host computer; and

generating control signals at both hand held unit and the host computer to operate the at least one gas sensor and the at least one temperature sensor at each remote location.

14. The method for analyzing combustion gas in a flue of claim 12, further comprising generating control signals to operate the at least one gas sensor and/or the at least one temperature sensor at each remote location to wake up, go to sleep, or periodically wirelessly transmit signals representative of temperature, types of gases, and concentrations of gases at one or more times.

15. The method for analyzing combustion gas in a flue of claim 12, further comprising:

continuously wirelessly sending signals representative of temperature, types of gases, and concentrations of gases in the flue, and wirelessly receiving control signals from the hand held unit which allows a technician operating the hand held unit makes adjustments to a fuel intake and/or air intake of a burner coupled to the respective flue; and

further wirelessly sending signals representative of temperature, types of gases, and concentrations of gases in the flue to the host computer for review by an analyst reviewing combustion information in the respective flue and other flues that exhaust gas from other burners.