CA1071997A - Transducer assembly, ultrasonic atomizer and fuel burner - Google Patents
Transducer assembly, ultrasonic atomizer and fuel burnerInfo
- Publication number
- CA1071997A CA1071997A CA290,308A CA290308A CA1071997A CA 1071997 A CA1071997 A CA 1071997A CA 290308 A CA290308 A CA 290308A CA 1071997 A CA1071997 A CA 1071997A
- Authority
- CA
- Canada
- Prior art keywords
- section
- transducer
- fuel
- dummy
- ultrasonic
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B17/00—Apparatus for spraying or atomising liquids or other fluent materials, not covered by the preceding groups
- B05B17/04—Apparatus for spraying or atomising liquids or other fluent materials, not covered by the preceding groups operating with special methods
- B05B17/06—Apparatus for spraying or atomising liquids or other fluent materials, not covered by the preceding groups operating with special methods using ultrasonic or other kinds of vibrations
- B05B17/0607—Apparatus for spraying or atomising liquids or other fluent materials, not covered by the preceding groups operating with special methods using ultrasonic or other kinds of vibrations generated by electrical means, e.g. piezoelectric transducers
- B05B17/0623—Apparatus for spraying or atomising liquids or other fluent materials, not covered by the preceding groups operating with special methods using ultrasonic or other kinds of vibrations generated by electrical means, e.g. piezoelectric transducers coupled with a vibrating horn
- B05B17/063—Apparatus for spraying or atomising liquids or other fluent materials, not covered by the preceding groups operating with special methods using ultrasonic or other kinds of vibrations generated by electrical means, e.g. piezoelectric transducers coupled with a vibrating horn having an internal channel for supplying the liquid or other fluent material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B17/00—Apparatus for spraying or atomising liquids or other fluent materials, not covered by the preceding groups
- B05B17/04—Apparatus for spraying or atomising liquids or other fluent materials, not covered by the preceding groups operating with special methods
- B05B17/06—Apparatus for spraying or atomising liquids or other fluent materials, not covered by the preceding groups operating with special methods using ultrasonic or other kinds of vibrations
- B05B17/0607—Apparatus for spraying or atomising liquids or other fluent materials, not covered by the preceding groups operating with special methods using ultrasonic or other kinds of vibrations generated by electrical means, e.g. piezoelectric transducers
- B05B17/0623—Apparatus for spraying or atomising liquids or other fluent materials, not covered by the preceding groups operating with special methods using ultrasonic or other kinds of vibrations generated by electrical means, e.g. piezoelectric transducers coupled with a vibrating horn
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B06—GENERATING OR TRANSMITTING MECHANICAL VIBRATIONS IN GENERAL
- B06B—METHODS OR APPARATUS FOR GENERATING OR TRANSMITTING MECHANICAL VIBRATIONS OF INFRASONIC, SONIC, OR ULTRASONIC FREQUENCY, e.g. FOR PERFORMING MECHANICAL WORK IN GENERAL
- B06B3/00—Methods or apparatus specially adapted for transmitting mechanical vibrations of infrasonic, sonic, or ultrasonic frequency
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23D—BURNERS
- F23D11/00—Burners using a direct spraying action of liquid droplets or vaporised liquid into the combustion space
- F23D11/34—Burners using a direct spraying action of liquid droplets or vaporised liquid into the combustion space by ultrasonic means or other kinds of vibrations
- F23D11/345—Burners using a direct spraying action of liquid droplets or vaporised liquid into the combustion space by ultrasonic means or other kinds of vibrations with vibrating atomiser surfaces
Abstract
ABSTRACT OF THE DISCLOSURE
A transducer assembly includes a first half wavelength double-dummy section having a pair of quarter wavelength ultrasonic horns and a driving element sandwiched therebetween. A second half wavelength stepped amplifying section extends from one end of the first section and has a theoretical reson-ant frequency equal to the actual resonant frequency of the first section.
When used as a liquid atomizer, the small diameter portion of the stepped am-plifying section has a flanged tip to provide an atomizing surface of increased area. To maintain efficiency, the length of the small diameter portion of the second section with a flange should be less than its length without a flange.
A decoupling sleeve within an axial liquid passageway eliminates premature atomization of the liquid before reaching the atomizing surface. In a fuel burner incorporating the atomizer, ignition electrode life is increased by locating the electrodes outside the normal flame envelope. During the ignition phase, drive power to the atomizer is increased to widen the spray envelope to the location of the electrodes. A variable orifice controls combustion air flow in accordance with fuel rate while maintaining constant lower speed.
Either three-step or continuous fuel rate modulation saves fuel and reduces pollution.
A transducer assembly includes a first half wavelength double-dummy section having a pair of quarter wavelength ultrasonic horns and a driving element sandwiched therebetween. A second half wavelength stepped amplifying section extends from one end of the first section and has a theoretical reson-ant frequency equal to the actual resonant frequency of the first section.
When used as a liquid atomizer, the small diameter portion of the stepped am-plifying section has a flanged tip to provide an atomizing surface of increased area. To maintain efficiency, the length of the small diameter portion of the second section with a flange should be less than its length without a flange.
A decoupling sleeve within an axial liquid passageway eliminates premature atomization of the liquid before reaching the atomizing surface. In a fuel burner incorporating the atomizer, ignition electrode life is increased by locating the electrodes outside the normal flame envelope. During the ignition phase, drive power to the atomizer is increased to widen the spray envelope to the location of the electrodes. A variable orifice controls combustion air flow in accordance with fuel rate while maintaining constant lower speed.
Either three-step or continuous fuel rate modulation saves fuel and reduces pollution.
Description
~ 97 The present invention relates to transducer assemblies and to apparatus employing same for achieving efficient combustion of fuels. ~n ex.arnple of same is found in the U. S. Patent to H. L. Berger, 3,861,852, issued 5. January 21, 1975.
When designing ultrasonic transducer assemblies such as those employed in apparatus for achieving combustion of fuels, a theoretical model for the ultrasonic horn is used in the developmental stage. The theoretical model is lO. that of a one dimensional transmission line.
In the actual operating environment, however, deviations from the theoretical model are introduced.
The deviations are due to, among other things: the finite dimensions of the sections of the horn setting up modes lS. other than longitudinal, e.g. expansion in a transverse direction; clamping means; sealing means; physical mismatch between component parts (planarity); etc.
The introduction of the deviation into the theo-retical model normally produces internal losses in the 20. transducer assembly and thus reduces Q, the mechanical merit factor.
The approach used in designing such prior art transducer assemblies so as to achieve maximum Q has been to: treat the entixe assembly as a theoretical structure;
25. choose the vibration fequency at which the structure is in resonance; provide an ultrasonic horn, according to a theoretical model whose si~e is such as to provide the resonance condition; and, utilize matexials and associated hardware such as fuel supply means~ clamp means r seals, 30. etc., of such type and so positioned as to minimi2e losses 3.
l~ig9~
inherent in the deviation from the theoretical model.
The prior art design approaches have failed to achieve maximum Q for a number of reasons: inappropriate design (deviations from the theoretical model); and, poor 5. acoustical coupling between the center electrode and the piezoelectric crystals of the driving element and between the driving element crystals and adjacent ultrasonic horn sections caused either by imperfect machining of'the crystals or by the presence of contaminants between the mating 10. surfaces.
A second problem associated with transducex assemblies of the type used in apparatus for achieving combustion of fuels is the non-uniform delivery of fuel to the atomizing surace with consequent non-uniform distri- ;
15. bution o fuel from same. It has been discovered that with such prior art assemblies, fuels which have low surface tension as, for example, hydrocarbon fuels, begin to atomize within the fuel passage leading to the atomizing surface.
This premature atomization createsbubbles within the fuel 20. passage. The bubbles eventually work their way to the atomizing surface, but their arrival at the atomizing surace results in a temporary interruption in uel flow to portions of the surface and, as a result, non-uniform distribution of fuel over the surface. The bubble remains 25. intact for a short period of time on the atomizing sur~ace and thus the surface area beneath the bubble during the interval is not wet with fuel.
A third problem associated with transducer assem-blies of the type used in apparatus for achieving 30. combustion of ~uels is that the fuel, once delivered to the 4' .. . .,.. . . , . . .... . . : . . : . .
~7~9~
atomizing surface, even if delivered uniformly, is not distributed or atomized from same uniformly. It has been discovered that one of the reasons for non-uniform distri-bution is the flexing action of the atomizing surface 5. itself, characteristic of the prior art structure~
A fourth problem associated w:ith prior art transducer assemblies is lack of efficiency. ~riefly stated, in an ultrasonic fuel atomizer a fi].m of fuel is injected at low pressure onto an atomizing surface and vibrated at 10. frequencies in excess of 20 kHz in a direction perpendicular to the atomizing surface. The rapid motion of the plane surface sets up capillary waves in the liquid film. When the amplitude of wave peaks excee~s that required for stability of the system, the liquid at the peak crests 15. breaks away in the form of droplets.
The smaller the droplet size the greater the fuel-air interface for a given volume of fuel. The increased fuel-air interface allows better utilization of primary combustion air resulting in low-excess air combustion, a 20. desirable feature from an efficiency standpoinb.
Going one step further, for a given fi~ed volume flow rate of fuel reaching the atomizing surface, the thinner the film, the more surface area will be involved in the atomizing process. This allows for greater atomizing ; 25. capacity. It has been discovered that prior art transducer assemblies have been lim.ited in this respect, however, due to the act that the fuel fed to the atomizing surface does not cover the entire surface before atomization occurs.
~dditionally the surface tension associated with smooth 30. metallic atomizing surfaces give rise to a tendency for not 5.
'' ~1~7:1997 wetting the entire surface.
According to one aspect of the present i:nvention there is provided a transducer assembly comprising the combination of: a first section includ-ing an ultrasonic horn and a driving element sandwiched therein, said first section having an empirically measured characteristic resonant frequency; and, a second section including a resonant section whos0 theoretical resonant -frequency matches the empirically measured frequency of said first section.
This aspect of the invention also provides a transducer assembly comprising the combination of: a first section including a front ultrasonic horn section having a flanged portion at one end thereof and a first fuel passage therethrough, a rear ultrasonic horn section having a flanged portion at one end thereof, a driving element comprising a pair of piezoelectric discs and an electrode positioned therebetween, said driving element sandwiched botweon the flanged portions of said horn sections, terminal means for feeding high frequency electrical energy to said electrode, delivery means for provid-ing fuel to said fuel passage, first and second gaskets surrounding said driv-ing element piezoelectric discs and positioned between said ~ront and rear horn sections and said terminal means, respectively, clamping means for com-pressing said sealing gaskets in sealing engagement about said driving element piezoelectric discs and for holding said horn section flanged portions in compression against said driving element, said clamping means including a mounting ring, said first section having an empirically measured characteris-tic resonant frequency; and, a second section including a large diameter segment of length A integrally formed with said first section front horn section, a small diameter segment of length B extending from said large diameter segment and having a rigid flanged tip of thickness C and an atomizing surface at said tip~ the interface between said l~rge diameter and small diameter segments con-stituting a step for ampliication of vibrating motion at said atomizing sur-~ace, a second :Euel passage extending through said second section, axially aligned and in communication with said first fuel passage for delivering fuel ~ - 6 -.
-1()'71997 to said atomizing surface, a decoupling sleeve mounted within said second fuel ;:
passage and extending up to said a~omizing surface, said second section having a theoretically resonant frequency matching the resonant ~r0quency of said first section. .
According to another aspect of the present invention there is provided a method of making a high efficiency piezoelectric ultransonic liquid atomizer comprising the steps of: designing a symmetrical double-dumlny ultra-sonic transducer comprising a central electrode disc and two opposed identical dummy sections, each section including a pie~oelectric element contiguous to a respective side of the electrode disc and a cylindrical element made of a metal having good sound transmission properties, the transducer being designed to have a theoretical natural frequency equal to a preselected ultrasonic frcquoncy; assembling an actual double-dummy transducer fabricated according to said dosign, the atual transducer including means for clamping the assembly together and means for mounting the transducer on a support structure; measur-ing the resoJIant frequency of said actual double-dummy transducer; designing a cylindrical amplitude amplification section made of the same metal as the cylindrical elements of the double-dummy transducer, the amplification section being designed to have a theoretical natural frequency equal to the measured natural frequency of said actual double-dun~ny transducer; and asseTnbling an actual plezoelectric ultrasonic liquid atomizer comprising a rear element identical to one of the dummy e:lements of said actua:L double dummy transducer, a front element having a cylindrical first section identical to the other dummy element of said actual double-dummy transducer and an integral second - section in accordance with the design of said amplification section.
In the accompanying drawings, which illustrate exemplary embodiments ~ :
of the present invention:
Figure 1 is a cross sectional view of a first section of a transducer assembLy;
Figure 2 is a cross sectional view of a second section of the trans-ducer assembly;
- 6a -.
~V~ 7 Fig. 3 is a cross sectional view of a complete novel transducer assembly of the present invention;
Fig. 4 is an enlarge~ cross sectional view of an alternate embodiment of a flanged atomizing tip with coated 5. atomizing surface;
Fig. 5 is an enlarged front view of an alternate embodiment of a flanged atomi~ing surface showing the atomizing surface with fuel channels;
Fig. 5A is a sectional view taken along the lines 10. 5A-5A of Fig. 5;
Fig. 6 is an enlarged partial sectional view of an alternate embodiment of a flanged atomizing tip with heating means for the atomizing tip;
Fig. 7 is an enlarged sectional view of an 15. ~lternate embodiment of a flanged atomizing surface showing the atomizing surface etched to increase surface area;
Fig. 8 is an enlarged sectional view af an alternate embodiment of a flanged atomizing tip with convex atomizing surface;
20. Fig. 9 is an enlarged sectional view of an alternate embodiment of a Elanged atomizing tip with a concave atomizing surface;
Fig. lO is a view partly in cross-section and partly in schematic of a fuel burner constructed in accord 25. ance with the teachings of the present invention for in-creasing the life o~ the ignition electrddes;
Fig. lOA is a sectional view of the forward end of a fuel burner with the ignition electrodes locatecl within the 1ame envelope momentarily during the ignition phase;
30. Fig. lOB is a sectional view similar to Fig. lOA
7.
':
~ 997 showing the ignition electrodes outside the flame envelope during the normal operating cycle;
Fig. 11 is a view partly in cross-section and partly in schematic of a fuel burner constructed in 5. accordance with the teachings of the present invention, including means for varying the flow rate of air through the burner;
Fig. 12 is a sectional view taken along the lines 12-12 of Fig. 11;
10. ~ig. 13 is a block diagram illustrating a control system for air flow rate varying means shown in Figs. 11 and 12;
Fig. 1~ is a block diagram of a three stage modulated mode of operation of an oil burner Eurnace utili-15. zing an ultrasonic transducer assembly; and, Fig. 15 is a block diagram of a solar panelsupplementary heating system employing continuous modulation.
One aspect of the present invention concerns itself with optimizing the shape of a transducer assembly, 20. for, among other things, maximum Q.
ReEerring to the drawing, in accordance with one as~ect of the invention the design O:e a transducer assembly is optimi~ed, for among other things, maximum Q, by constructing a first transducer assembly sec-tion comprising 25. a driving element and two identical horn sections (Fig.
1) such that the resulting structure ~orms a symmetric geometry with respect to the longitudinal axis. This first assembly section is referred to as a double-dummy ultrasonic horn. In the next operation the resonant fre~uency o~ the 30. first section is measured, and a second section is added 8.
~ 7 (Fig. 2) that includes an amplification step and an atomizing surface r and whose -theoretical resonant frequency matches the empirically measured frequency of the first section, thereby forming a complete transducer assembly (Fig. 3) 5- desiyned for maximum Q and for use in achieving efficient combustion of fuels.
Referring first to Fig. 1 the first section 11 of the novel transducer assembly is seen as including front 12A
and rear 13 ultrasonic horn sections and a driving element 10. 14 comprising a pair of pie~oelectric discs 15, 16 and an electrode ~not shown) positioned therebetween, excited by high frequency electrical energy fed thereto from a terminal 1~.
Driving element 14 is sandwiched between flanged 15. portions 19, 20 of horn sections 12A, 13 and securely clamped therein hy means of a clamping assembly that in-cludes a mounting ring 21 (for securing the assembly to other apparatus) and a plurality of assembly bolts 22 which pass through holes in terminal 18, flange sections 19 and 20 20~ into threaded openings in mounting ring 21. The assembly bolts 22 are electrically :isolated from the terminal 18 by means of insulators 23.
The first section 11 further includes a fuel tube 24 for introducing fuel into a channel within the transducer 25. assembly and a pair of sealing gaskets 26, 27 compressed between horn flange sections 19,20.
In a typical embodiment: the horn sections 12A, 13 and flange sections 19, 20 are preferably of good acoustic conducting material such as aluminum, titanium or magnesium;
30. or alloys thereof such as Ti-6~ -4V titanium-aluminum alloy, g 9~ -6061~T6 aluminum alloy, 7025 high strength aluminum alloy, AZ 61 magnesium allo~ and the like; the discs 15, 16 are of lead-zirconate-titanate such as those manufactured by Vernitron Corporation or of lithium miobate such as those 5. manufactured by Valtec Corporation; the electrode is of copper; the terminal 18, mounting ring 21, and assembly bolts 22 are of steel; the insulators 23 are of nylon, Teflon or some plastic with good electrical insulating properties; and, the sealing gaskets 26, 27 are of silicone 10. rubber.
The first section 11 is seen to have symmetric halE-wavelength ~eometry, yet it contains all the anamolous features of the transducer assembly, i.e. clamping at non-nodal planes, copper electrode, screw clamping and mounting 15. bracket. The properties of this first section are esta-blished and its characteristic frequency, for maximum Q, quantitatively measured. Typically the frequency is mea-sured and found to be 85KHZ. This completes the first step in the design of the transducer assembly.
20. Referring to Fig. 2, another half-wave section 29 is added to the first section 11. The section 29 is seen as including a large diameter segment 12B, a small diameter segment 30 so as to form an amplification step 31, a flanged tip 32 with atomizing surface 33, a central passage 34 for 25. delivering ~uel to the atomizing surface 33 and internally mounted decoupling sleeve 35. The decoupling sleeve is a substance such as Teflon which does not couple well acous-tically to the fuel hole.
It will be observed by those skilled in the 30. art that this section contains fe~ anamolies since it is a 10~
~ 97 pure theoretical structure as well. Its characteristic frequency for maximum Q is computed and selec~ed so as to match that of the first section ll.
In order to complete the design, the two sections 5. ll and 29 are formed integrally so as to yield a transducer assembly (Fig. 3) optimized for maximum Q and for use in achieving efftcient combustion of fuels.
Prior art transducer assemblies used for ultrasonic atomization of fuel have, in the past, typically employed a lO. flanged tip 32 with atomization surface 33. The presence of the flanged tip with its atomization surface 33 increases atomization capabilities due to increased atomizing surface area.
The addition of such flange has been at the 15. expense of atomizer efficiency.
Referring to Fig. 2, let A s length of horn front section 12B, B = length of small diameter segment 30 and C
thickness of flanged tip section 32.
In prior art assemblies that do not use a flange, 20. ~ = l since they are both quarter wave length sections.
In prior art assemblies utilizing a flange A , l.
3-~C
It has been determined that maintaining the ratio at l, even after addition of the flange, is inefficient and 25. reduces power transfer, but by maintaining the ratio BAc ~ 1 efficiency levels can be maintained at pre-flange addition levels. Thus, for example, if D3 = diameter of flange section 32 D2 = diameter of small diameter segment 30 for 30~ D = 1.53 11.
.. , . . . .. , .. . ~
~J~99'~
A ~-~C (Without ~lange) = A - 1 and~B~c (with flange~ - 1.12 and the efficiency levels achieved with the flange match -those of the assembly with the flange.
5. The foregoing analysis applies to assemblies of aluminum, titanium, magnesium and previously mentioned alloys, and assumes that for both mate:rials the velocity of sound in same is approximately the same. For other materials with different velocities of sound the ratio BA+c will 10. differ, but always be greater than 1.
The long-term reliability of the device is dra-matically enhanced by sealing the discs 15 since fuel contamination is no longer possible. The space between the clamping flange sections 19, 20 is filled with a silicone 15. rubber compound as by sealing gaskets 26, 27. In the past, fuel creepage onto the faces of the discs 15, 16 has caused degradation of same and has resulted in poor long-term atomizer performance. The phenomenon causes a loss in mechanical coupling between elements of the horn. The 20. gaskets 26, 27 solve the problem and atomizer performance is not affected by the added mass as has been confirmed by before and after measurement of impedance, operating frequency and flange displacement. The slightly higher internal heating caused by sealing the discs 15 does not 25. reduce the atomizer's useful life since internal temperatures are still well below the maximum operating temperature for piezoelectric crystals. The gaskets 26, 27 are of a com-pressible material and have an inner periphery conforming to but initially slightly greater than the outer circumference 30. of the discs 15, 16. Upon clamping the inner periphery of 12.
~O'Yi~9~
gaskets 26, 27 come into light contact with the outer circumference of the discs 15, 16.
Another aspect o the present invention is the elimination of prema-ture atomization of fuel in the fuel 5. passage leading to the atomizing surface. As noted pre-viously, in prior art structures the fuel can begin to atomize within the fuel passage leading to ~he atomizing surface. This premature atomization creates voids within the fuel passage at the fuel-wall interface which leads to 10. the formation of bubbles within the fuel passage. The bubbles eventually work their way to the atomizing surface, but their arrival at the atomizing surface results in a temporary interruption in fuel flow to a portion of the surface and as a result, non-unifQrm distribution of euel 15. over the surface. The bubble remains intact for a short period of time on the atomizing surface and thus the surface area beneath the bubble during that interval is not wet with fuel. The net effect of this non-uniform and constantly varying distribution of fuel on the surface is a spatially 20. unstable spray of fuel, a condition which leads to unstable combustion.
The foregoing problem is eliminated by the pro-vision of a decoupling sleeve 35 within the fuel passage 34 that extends up to, say within 1/32 of an inch of the 25. atomizing surface 33. The sleeve is typically made of plastic and press fit into passage 34 extending inwardly to large diameter segment 12B. The ~ifference in acoustical transmitting properties between the material of the sleeve 35 and the horn section 29 is such -that the vibrating motion 30. of section 29 is not imparted to the fuel within the fuel 13.
10~9~
passage 34 encompassed by the sleeve 35.
Still another object of the pxesent invention is achieving uniform atomization from the atomizing surface of an ultrasonic fuel atomizer.
5. It has been discovered that the non-uniform distribution or atomization is due in part to the fact that the atomizer tip flexes du~ing vibration and that the non-uniform distribution is decreased when the flange face or atomizing surface 33 moves as a rigid plane. The atomizing 10. surface will move as a rigid plane by increasing the thickness of the flanged tip 32 such that the tip 32 and surace 33 remain rlgid during vibration. In a typical embodiment tip 32 is 0.050" thick~
A Eurther aspect of the present invention is `~
15. achieving greater atomizing capacity.~ As noted above, it has been discovered that prior art transducer assemblies have been limited in this respect due to the fact that the fuel fed to the atomizing surface does not cover the entire surface before atomization occurs. Additionally the 20. surface tension normally associated with smooth metallic atomizing surfaces gives rise to a bendency for not wetting the entire surface.
The aforementioned prior art difficulties are overcome in accordance with the teachings of the present 25. invention by reducing surface tension at the fuel-atomizing surface interface thereby permitting the fuel when fed to the atomizing surface to flow more readily over the atomizing surface and b~ the provision of means for more evenl~ distributing fuel over the atomizing sur~ace.
30. In accordance with one embodiment and referring to 1~ . ', ':
Fig. 4, surface tension at the fuel-atomizing surface is reduced by coating the atomizing su:rface with a substance that reduces surface tension. Fig. ~ depicts the flanged tip 32 as having an atomizing surface 33 with a thin coating 5. 41 thereon. Examples of such materials are Teflon, polyvinyl chloride, polyesters and polycarbonates.
In accordance with anothex embodiment and referring to Fig. 5, the ability of fuel to reach the outer - edges is increased by the provision of preferred paths or 10. channels 42 in the atomizing surface 33. The inclusion of channels in the atomizing surface which extend to the periphery of the flanged tip promotes flow of fuel over the entire atomizing surface. Thus for A given quantity of fuel, the result is A thin Eilm over substantialLy the 15. entir~e atomizing surface instead of a somewhat thicker film cent~red about the central fuel passage.
In accordance with another embodiment and with reference to Fig. 6 heating means 43 are provided to heat the atomizing surface during operation to temperatures on 20. the order of up to 150 F. The heat reduces the viscosity of the fuel alld promotes easier wetting of the surface, In accordance with another embodiment and with reference to Fig. 7, the atomizing surface is etched as at 44, by sand-blasting, thereby greatly increasing surface 25. area and reducing film thickness for a given quantity of fuel.
The geometrical contour of the flanged atomizing surface influences the spray pattern and density of particles developed by atomization. Thus, for example, a planar face atomizing surface 33 such as depicted in Figs. 2-7 will 15.
~ 9'~
generate a particular pattern and density~ If the surface is made to be convex, as shown at 33' in Fig. 8, the spray pattern is wider and there are fewer particles per unit of cross-sectional area than with a planar surface. A concave 5. surface 33" such as that depicted in Fig. 9 narrows the spray pattern and density of particles is greater than with a planar surface. Different spray patterns may be required depending on the application.
Turning attention now from the transducer assembly 10. ~ se to a fuel burner, a recurring problem is the short life of the ignition electrodes. These electrodes provide the spark for initiating the ignition of the fuel/air mi~ture within the 1ame cone. Once ignition occurs, however, the electrodes e~tend into the Elame envelope 15. resu~ting rom ignition and this constant exposure to high intensity heat during the firing cycles leads to rapid deterioration of the electrodes and frequent replacement of same.
In accordance with another aspect of the present 20. invention, the aforementioned prior art difficulty has been greatly diminished by locating the ignition electrodes outside the normal flame envelope, but increasing the drive power to the atomizer electrodes during the ignition phase.
This has the effect of increasing the angle of the spray 25. envelope considerably, bringing the ignition electrodes ~-within the space occupied by the fuel/air mixture and result-ing flame envelope. As soon as ignition is accomplished the anglie of the spray envelope is returned to its normal running mode by decreasing drive power to the atomizer 30. electrodes such that the ignition electrodes are located 16.
~.:
,. ~ . , ''' `' ' ' '. ' outside the normal flame envelope.
Referring now to Fig. 10, the fuel burner 50 is seen as including blast tube 51, a transducer assembly 52, ignition means including ignition electrodes 53, blower 54 5, for supplying air for combustion and for cooling the transducer assembly 52, air deflection means 55, flame cone 56, variable means 57 for supplying electric power, flame sensor 58, and pump means 59 for supplying fuel from a fuel tank 60 to the transducer assembly. The ignition 10. electrodes 53 are located between blast tube 51 and flame cone 56 and held by ceramic or porcelain insulators surrounded by high temperature asbestos material and near the atomizing surEace but at a suficient distance, typically 1/2 inch, to prevent arcing o~ the ignition spark to 15. the atomizer structure. During the ignition phase additional electrical power is swpplied by the power supply 57 to the input leads o~ the transduce~ assembly (greater voltage and current than during normal operation). Optionally, this can be accomplished automatically by programming the power 20. supp~y electronics such that prior to ignition the circuit supplies an excessive amount of power to the input leads of the transducer assembly apparatus. During the ignition phase the ignition electrodes are located within the flame ~ -envelope generated within the flame cone (Fig. 10A). Once 25. ignition has been established the flame sensor 58 sends a signal back to the power supply electronics switching the atomizer arive power to its normal operating mode, reducing the envelope of the flame and thus the ignition electrodes 53 found to be located outside the normal flame envelope 30. (Fig.l10B). This promotes longer ignition electrode life by .
. .
~ 997 virtue of the electrodes being kept at a cooler temperature during the normal operating cycle. The ignltion electrodes will not foul nor will they be oxidized by continuous heating.
5. An advantage to the use of an ultrasonic fuel atomizer is that one can vary the flow rate of fuel over a wide range. However, in order to implement a variable flow rate burner it is advantageous to have means to change the flow rate of combustion air through the burner combustion 10. tube 51. This can be done either by electrically controlling the blower motor speed or b~ providing a variable sized orifice for air ~low located in the air stream while main-taining a constant motor speed. With reference to Figs. 11-13 the latter method is preferred because only by this means 15. can the static pressure head of air within the burner be maintained in order ko develop turbulence necessary for proper combustion. This is implemented by an iris-type diaphragm 61 located within the combustion tube (Figs. 11 and 12) that is controlled electrically as shown in 20. Fig. 13.
The control of the iris diaphragm 61 is done electrically. For each fuel flow rate the amount of air is automatically adjusted by opening or closing the diaphragm until optimum burning conditions are sensed. The optimum 25. burning conditions are sensed by monitoring the CO2 level in the flue gas as at 62 from the furnace and feeding back data from that sensor to air control circuitry 63 for iris diaphragm 61 until a predetermined CO2 level, say 12.5 - 13%
CO2, is achieved.
30. In the prior art an oil burner will operate in a ':
18.
.: ~ . . . .
two stage mode, "off" and "on" and at a fixed fuel flow rate. It has been determined that such two stage operation suffers from a number of disadvantages. Firstly, it is uneconomical in the sense that it consumes more fuel than is 5. necessary and, secondly, it contributes to pollution. In the two stage operation when the system is turned from the off position to the on position or vice-versa, the firing is accompanied by generation of high volu~es of unburned hydrocarbons and carbon monoxide.
10. It has been determined that the aforementioned prior art difficulties may be eliminated and in accordance with the teachings of the present invention by going to a "three stage" modulated mode of operation.
The three stage mode, and with reference to Fig.
15. 1~ re~ers to a system in which there are three difEerent firin~ rates - high, low and off. For example, the three rates could typically be High - 0.60 gal./hr.
Low - 0.20 gal./hr.
20. Off - 0.00 gal./hr.
The high rate is called for by a duct or stack thermostat 71 in response to sensing a heat deficiency, just as is done in conventional heating systems with conventional thermostats. When the heat demand has been satisfied (as 25. determined by the thermostat setting) the system returns to the "low" ~iring rate via control valve 72 to furnace control assembly 73 in order to maintain system ductwork and -~
heat exchanger at an elevated temperature and to eliminate the draft losses occurring i~ the system were turned o-ff 30. completely as is the case in conventional heating systems.
''.
19 . .
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The operating cycle is between a high flow rate and a low flow rate, for example, 10 minutes at high firing rate, then 20 minutes at low, then 10 minutes more at highr etc. The time at high and low firing rates will vary with 5. demand for heat. This cycle allows ~or more efficient utilization of the furnace ~ince the system is already warm when the high part of the heating cycle begins, Moreover~
the firing rate for the high mode need not be as great as needed for a conventional cycle since the modulated system 10. will respond to the heat demand more quickly given the already warm conditions created during the low period.
The off part of the thre~ stage system would be used only during times of zero hea~ demand such as on days when outside temperature~ equal or exceed the inside tem~
15. peratures. This condition could he sensed by an external temperature sensor 74 ed into the system or could be manually controlled by the user.
In accordance with another aspect of the present invention, the transducer assembly of the present 20. invention can be used in an oil burner furnace system that employs continuous modulation.
With re~erence to Fig. 15 the firing rate o~ a system is allowed to vary continuously between some fixed ~ ;
upper and lower limits in response to an external control 25. signal supplied to the burner electronics as~ for example, in the solar panel supplementary heating system depicted. When the temperature of the hot water tank 81 is to be maintained abbve a minimum temperature To, the variable nature of the solar derived energy via pump 82 and solar 30. panel 83 requires that any solar energy deficit be made up 20.
9~
by the appropriate flux of heat from the oil burner assembly 84. This deficit, being variable, is sensed as at 85 and demands that the oil burner ~4 be able to fire at any possible rate within the desi~n limits of the system such 5. that the sum of the solar and oil burning heat delivered remains fixed at the required level. :
It should be obvious to those skilled in the art that while my invention has been illustrated for use in a burner suitable for burning fuel oil for heating a home it lO. may be used elsewhere to great advantage. It may be used, for example, in a burner for a mobil home where its low flow rate, typically less than one-half gallon per hour, and variable flow feature have obvious economic advantage. The invention may also be used for feeding fuel into internal 15. combustion or jet engines. The invention may also be used for atomization of other liquids such as water. While the invention has been particularly shown and descrihed :
with reference to the preferred embodiments thereof, it will :::
be understood by those skilled in the art that various : 20. changes in form and detail and omission may be made without departing from the sp.irit and scope of the invention. .~
25. . :
30.
When designing ultrasonic transducer assemblies such as those employed in apparatus for achieving combustion of fuels, a theoretical model for the ultrasonic horn is used in the developmental stage. The theoretical model is lO. that of a one dimensional transmission line.
In the actual operating environment, however, deviations from the theoretical model are introduced.
The deviations are due to, among other things: the finite dimensions of the sections of the horn setting up modes lS. other than longitudinal, e.g. expansion in a transverse direction; clamping means; sealing means; physical mismatch between component parts (planarity); etc.
The introduction of the deviation into the theo-retical model normally produces internal losses in the 20. transducer assembly and thus reduces Q, the mechanical merit factor.
The approach used in designing such prior art transducer assemblies so as to achieve maximum Q has been to: treat the entixe assembly as a theoretical structure;
25. choose the vibration fequency at which the structure is in resonance; provide an ultrasonic horn, according to a theoretical model whose si~e is such as to provide the resonance condition; and, utilize matexials and associated hardware such as fuel supply means~ clamp means r seals, 30. etc., of such type and so positioned as to minimi2e losses 3.
l~ig9~
inherent in the deviation from the theoretical model.
The prior art design approaches have failed to achieve maximum Q for a number of reasons: inappropriate design (deviations from the theoretical model); and, poor 5. acoustical coupling between the center electrode and the piezoelectric crystals of the driving element and between the driving element crystals and adjacent ultrasonic horn sections caused either by imperfect machining of'the crystals or by the presence of contaminants between the mating 10. surfaces.
A second problem associated with transducex assemblies of the type used in apparatus for achieving combustion of fuels is the non-uniform delivery of fuel to the atomizing surace with consequent non-uniform distri- ;
15. bution o fuel from same. It has been discovered that with such prior art assemblies, fuels which have low surface tension as, for example, hydrocarbon fuels, begin to atomize within the fuel passage leading to the atomizing surface.
This premature atomization createsbubbles within the fuel 20. passage. The bubbles eventually work their way to the atomizing surface, but their arrival at the atomizing surace results in a temporary interruption in uel flow to portions of the surface and, as a result, non-uniform distribution of fuel over the surface. The bubble remains 25. intact for a short period of time on the atomizing sur~ace and thus the surface area beneath the bubble during the interval is not wet with fuel.
A third problem associated with transducer assem-blies of the type used in apparatus for achieving 30. combustion of ~uels is that the fuel, once delivered to the 4' .. . .,.. . . , . . .... . . : . . : . .
~7~9~
atomizing surface, even if delivered uniformly, is not distributed or atomized from same uniformly. It has been discovered that one of the reasons for non-uniform distri-bution is the flexing action of the atomizing surface 5. itself, characteristic of the prior art structure~
A fourth problem associated w:ith prior art transducer assemblies is lack of efficiency. ~riefly stated, in an ultrasonic fuel atomizer a fi].m of fuel is injected at low pressure onto an atomizing surface and vibrated at 10. frequencies in excess of 20 kHz in a direction perpendicular to the atomizing surface. The rapid motion of the plane surface sets up capillary waves in the liquid film. When the amplitude of wave peaks excee~s that required for stability of the system, the liquid at the peak crests 15. breaks away in the form of droplets.
The smaller the droplet size the greater the fuel-air interface for a given volume of fuel. The increased fuel-air interface allows better utilization of primary combustion air resulting in low-excess air combustion, a 20. desirable feature from an efficiency standpoinb.
Going one step further, for a given fi~ed volume flow rate of fuel reaching the atomizing surface, the thinner the film, the more surface area will be involved in the atomizing process. This allows for greater atomizing ; 25. capacity. It has been discovered that prior art transducer assemblies have been lim.ited in this respect, however, due to the act that the fuel fed to the atomizing surface does not cover the entire surface before atomization occurs.
~dditionally the surface tension associated with smooth 30. metallic atomizing surfaces give rise to a tendency for not 5.
'' ~1~7:1997 wetting the entire surface.
According to one aspect of the present i:nvention there is provided a transducer assembly comprising the combination of: a first section includ-ing an ultrasonic horn and a driving element sandwiched therein, said first section having an empirically measured characteristic resonant frequency; and, a second section including a resonant section whos0 theoretical resonant -frequency matches the empirically measured frequency of said first section.
This aspect of the invention also provides a transducer assembly comprising the combination of: a first section including a front ultrasonic horn section having a flanged portion at one end thereof and a first fuel passage therethrough, a rear ultrasonic horn section having a flanged portion at one end thereof, a driving element comprising a pair of piezoelectric discs and an electrode positioned therebetween, said driving element sandwiched botweon the flanged portions of said horn sections, terminal means for feeding high frequency electrical energy to said electrode, delivery means for provid-ing fuel to said fuel passage, first and second gaskets surrounding said driv-ing element piezoelectric discs and positioned between said ~ront and rear horn sections and said terminal means, respectively, clamping means for com-pressing said sealing gaskets in sealing engagement about said driving element piezoelectric discs and for holding said horn section flanged portions in compression against said driving element, said clamping means including a mounting ring, said first section having an empirically measured characteris-tic resonant frequency; and, a second section including a large diameter segment of length A integrally formed with said first section front horn section, a small diameter segment of length B extending from said large diameter segment and having a rigid flanged tip of thickness C and an atomizing surface at said tip~ the interface between said l~rge diameter and small diameter segments con-stituting a step for ampliication of vibrating motion at said atomizing sur-~ace, a second :Euel passage extending through said second section, axially aligned and in communication with said first fuel passage for delivering fuel ~ - 6 -.
-1()'71997 to said atomizing surface, a decoupling sleeve mounted within said second fuel ;:
passage and extending up to said a~omizing surface, said second section having a theoretically resonant frequency matching the resonant ~r0quency of said first section. .
According to another aspect of the present invention there is provided a method of making a high efficiency piezoelectric ultransonic liquid atomizer comprising the steps of: designing a symmetrical double-dumlny ultra-sonic transducer comprising a central electrode disc and two opposed identical dummy sections, each section including a pie~oelectric element contiguous to a respective side of the electrode disc and a cylindrical element made of a metal having good sound transmission properties, the transducer being designed to have a theoretical natural frequency equal to a preselected ultrasonic frcquoncy; assembling an actual double-dummy transducer fabricated according to said dosign, the atual transducer including means for clamping the assembly together and means for mounting the transducer on a support structure; measur-ing the resoJIant frequency of said actual double-dummy transducer; designing a cylindrical amplitude amplification section made of the same metal as the cylindrical elements of the double-dummy transducer, the amplification section being designed to have a theoretical natural frequency equal to the measured natural frequency of said actual double-dun~ny transducer; and asseTnbling an actual plezoelectric ultrasonic liquid atomizer comprising a rear element identical to one of the dummy e:lements of said actua:L double dummy transducer, a front element having a cylindrical first section identical to the other dummy element of said actual double-dummy transducer and an integral second - section in accordance with the design of said amplification section.
In the accompanying drawings, which illustrate exemplary embodiments ~ :
of the present invention:
Figure 1 is a cross sectional view of a first section of a transducer assembLy;
Figure 2 is a cross sectional view of a second section of the trans-ducer assembly;
- 6a -.
~V~ 7 Fig. 3 is a cross sectional view of a complete novel transducer assembly of the present invention;
Fig. 4 is an enlarge~ cross sectional view of an alternate embodiment of a flanged atomizing tip with coated 5. atomizing surface;
Fig. 5 is an enlarged front view of an alternate embodiment of a flanged atomi~ing surface showing the atomizing surface with fuel channels;
Fig. 5A is a sectional view taken along the lines 10. 5A-5A of Fig. 5;
Fig. 6 is an enlarged partial sectional view of an alternate embodiment of a flanged atomizing tip with heating means for the atomizing tip;
Fig. 7 is an enlarged sectional view of an 15. ~lternate embodiment of a flanged atomizing surface showing the atomizing surface etched to increase surface area;
Fig. 8 is an enlarged sectional view af an alternate embodiment of a flanged atomizing tip with convex atomizing surface;
20. Fig. 9 is an enlarged sectional view of an alternate embodiment of a Elanged atomizing tip with a concave atomizing surface;
Fig. lO is a view partly in cross-section and partly in schematic of a fuel burner constructed in accord 25. ance with the teachings of the present invention for in-creasing the life o~ the ignition electrddes;
Fig. lOA is a sectional view of the forward end of a fuel burner with the ignition electrodes locatecl within the 1ame envelope momentarily during the ignition phase;
30. Fig. lOB is a sectional view similar to Fig. lOA
7.
':
~ 997 showing the ignition electrodes outside the flame envelope during the normal operating cycle;
Fig. 11 is a view partly in cross-section and partly in schematic of a fuel burner constructed in 5. accordance with the teachings of the present invention, including means for varying the flow rate of air through the burner;
Fig. 12 is a sectional view taken along the lines 12-12 of Fig. 11;
10. ~ig. 13 is a block diagram illustrating a control system for air flow rate varying means shown in Figs. 11 and 12;
Fig. 1~ is a block diagram of a three stage modulated mode of operation of an oil burner Eurnace utili-15. zing an ultrasonic transducer assembly; and, Fig. 15 is a block diagram of a solar panelsupplementary heating system employing continuous modulation.
One aspect of the present invention concerns itself with optimizing the shape of a transducer assembly, 20. for, among other things, maximum Q.
ReEerring to the drawing, in accordance with one as~ect of the invention the design O:e a transducer assembly is optimi~ed, for among other things, maximum Q, by constructing a first transducer assembly sec-tion comprising 25. a driving element and two identical horn sections (Fig.
1) such that the resulting structure ~orms a symmetric geometry with respect to the longitudinal axis. This first assembly section is referred to as a double-dummy ultrasonic horn. In the next operation the resonant fre~uency o~ the 30. first section is measured, and a second section is added 8.
~ 7 (Fig. 2) that includes an amplification step and an atomizing surface r and whose -theoretical resonant frequency matches the empirically measured frequency of the first section, thereby forming a complete transducer assembly (Fig. 3) 5- desiyned for maximum Q and for use in achieving efficient combustion of fuels.
Referring first to Fig. 1 the first section 11 of the novel transducer assembly is seen as including front 12A
and rear 13 ultrasonic horn sections and a driving element 10. 14 comprising a pair of pie~oelectric discs 15, 16 and an electrode ~not shown) positioned therebetween, excited by high frequency electrical energy fed thereto from a terminal 1~.
Driving element 14 is sandwiched between flanged 15. portions 19, 20 of horn sections 12A, 13 and securely clamped therein hy means of a clamping assembly that in-cludes a mounting ring 21 (for securing the assembly to other apparatus) and a plurality of assembly bolts 22 which pass through holes in terminal 18, flange sections 19 and 20 20~ into threaded openings in mounting ring 21. The assembly bolts 22 are electrically :isolated from the terminal 18 by means of insulators 23.
The first section 11 further includes a fuel tube 24 for introducing fuel into a channel within the transducer 25. assembly and a pair of sealing gaskets 26, 27 compressed between horn flange sections 19,20.
In a typical embodiment: the horn sections 12A, 13 and flange sections 19, 20 are preferably of good acoustic conducting material such as aluminum, titanium or magnesium;
30. or alloys thereof such as Ti-6~ -4V titanium-aluminum alloy, g 9~ -6061~T6 aluminum alloy, 7025 high strength aluminum alloy, AZ 61 magnesium allo~ and the like; the discs 15, 16 are of lead-zirconate-titanate such as those manufactured by Vernitron Corporation or of lithium miobate such as those 5. manufactured by Valtec Corporation; the electrode is of copper; the terminal 18, mounting ring 21, and assembly bolts 22 are of steel; the insulators 23 are of nylon, Teflon or some plastic with good electrical insulating properties; and, the sealing gaskets 26, 27 are of silicone 10. rubber.
The first section 11 is seen to have symmetric halE-wavelength ~eometry, yet it contains all the anamolous features of the transducer assembly, i.e. clamping at non-nodal planes, copper electrode, screw clamping and mounting 15. bracket. The properties of this first section are esta-blished and its characteristic frequency, for maximum Q, quantitatively measured. Typically the frequency is mea-sured and found to be 85KHZ. This completes the first step in the design of the transducer assembly.
20. Referring to Fig. 2, another half-wave section 29 is added to the first section 11. The section 29 is seen as including a large diameter segment 12B, a small diameter segment 30 so as to form an amplification step 31, a flanged tip 32 with atomizing surface 33, a central passage 34 for 25. delivering ~uel to the atomizing surface 33 and internally mounted decoupling sleeve 35. The decoupling sleeve is a substance such as Teflon which does not couple well acous-tically to the fuel hole.
It will be observed by those skilled in the 30. art that this section contains fe~ anamolies since it is a 10~
~ 97 pure theoretical structure as well. Its characteristic frequency for maximum Q is computed and selec~ed so as to match that of the first section ll.
In order to complete the design, the two sections 5. ll and 29 are formed integrally so as to yield a transducer assembly (Fig. 3) optimized for maximum Q and for use in achieving efftcient combustion of fuels.
Prior art transducer assemblies used for ultrasonic atomization of fuel have, in the past, typically employed a lO. flanged tip 32 with atomization surface 33. The presence of the flanged tip with its atomization surface 33 increases atomization capabilities due to increased atomizing surface area.
The addition of such flange has been at the 15. expense of atomizer efficiency.
Referring to Fig. 2, let A s length of horn front section 12B, B = length of small diameter segment 30 and C
thickness of flanged tip section 32.
In prior art assemblies that do not use a flange, 20. ~ = l since they are both quarter wave length sections.
In prior art assemblies utilizing a flange A , l.
3-~C
It has been determined that maintaining the ratio at l, even after addition of the flange, is inefficient and 25. reduces power transfer, but by maintaining the ratio BAc ~ 1 efficiency levels can be maintained at pre-flange addition levels. Thus, for example, if D3 = diameter of flange section 32 D2 = diameter of small diameter segment 30 for 30~ D = 1.53 11.
.. , . . . .. , .. . ~
~J~99'~
A ~-~C (Without ~lange) = A - 1 and~B~c (with flange~ - 1.12 and the efficiency levels achieved with the flange match -those of the assembly with the flange.
5. The foregoing analysis applies to assemblies of aluminum, titanium, magnesium and previously mentioned alloys, and assumes that for both mate:rials the velocity of sound in same is approximately the same. For other materials with different velocities of sound the ratio BA+c will 10. differ, but always be greater than 1.
The long-term reliability of the device is dra-matically enhanced by sealing the discs 15 since fuel contamination is no longer possible. The space between the clamping flange sections 19, 20 is filled with a silicone 15. rubber compound as by sealing gaskets 26, 27. In the past, fuel creepage onto the faces of the discs 15, 16 has caused degradation of same and has resulted in poor long-term atomizer performance. The phenomenon causes a loss in mechanical coupling between elements of the horn. The 20. gaskets 26, 27 solve the problem and atomizer performance is not affected by the added mass as has been confirmed by before and after measurement of impedance, operating frequency and flange displacement. The slightly higher internal heating caused by sealing the discs 15 does not 25. reduce the atomizer's useful life since internal temperatures are still well below the maximum operating temperature for piezoelectric crystals. The gaskets 26, 27 are of a com-pressible material and have an inner periphery conforming to but initially slightly greater than the outer circumference 30. of the discs 15, 16. Upon clamping the inner periphery of 12.
~O'Yi~9~
gaskets 26, 27 come into light contact with the outer circumference of the discs 15, 16.
Another aspect o the present invention is the elimination of prema-ture atomization of fuel in the fuel 5. passage leading to the atomizing surface. As noted pre-viously, in prior art structures the fuel can begin to atomize within the fuel passage leading to ~he atomizing surface. This premature atomization creates voids within the fuel passage at the fuel-wall interface which leads to 10. the formation of bubbles within the fuel passage. The bubbles eventually work their way to the atomizing surface, but their arrival at the atomizing surface results in a temporary interruption in fuel flow to a portion of the surface and as a result, non-unifQrm distribution of euel 15. over the surface. The bubble remains intact for a short period of time on the atomizing surface and thus the surface area beneath the bubble during that interval is not wet with fuel. The net effect of this non-uniform and constantly varying distribution of fuel on the surface is a spatially 20. unstable spray of fuel, a condition which leads to unstable combustion.
The foregoing problem is eliminated by the pro-vision of a decoupling sleeve 35 within the fuel passage 34 that extends up to, say within 1/32 of an inch of the 25. atomizing surface 33. The sleeve is typically made of plastic and press fit into passage 34 extending inwardly to large diameter segment 12B. The ~ifference in acoustical transmitting properties between the material of the sleeve 35 and the horn section 29 is such -that the vibrating motion 30. of section 29 is not imparted to the fuel within the fuel 13.
10~9~
passage 34 encompassed by the sleeve 35.
Still another object of the pxesent invention is achieving uniform atomization from the atomizing surface of an ultrasonic fuel atomizer.
5. It has been discovered that the non-uniform distribution or atomization is due in part to the fact that the atomizer tip flexes du~ing vibration and that the non-uniform distribution is decreased when the flange face or atomizing surface 33 moves as a rigid plane. The atomizing 10. surface will move as a rigid plane by increasing the thickness of the flanged tip 32 such that the tip 32 and surace 33 remain rlgid during vibration. In a typical embodiment tip 32 is 0.050" thick~
A Eurther aspect of the present invention is `~
15. achieving greater atomizing capacity.~ As noted above, it has been discovered that prior art transducer assemblies have been limited in this respect due to the fact that the fuel fed to the atomizing surface does not cover the entire surface before atomization occurs. Additionally the 20. surface tension normally associated with smooth metallic atomizing surfaces gives rise to a bendency for not wetting the entire surface.
The aforementioned prior art difficulties are overcome in accordance with the teachings of the present 25. invention by reducing surface tension at the fuel-atomizing surface interface thereby permitting the fuel when fed to the atomizing surface to flow more readily over the atomizing surface and b~ the provision of means for more evenl~ distributing fuel over the atomizing sur~ace.
30. In accordance with one embodiment and referring to 1~ . ', ':
Fig. 4, surface tension at the fuel-atomizing surface is reduced by coating the atomizing su:rface with a substance that reduces surface tension. Fig. ~ depicts the flanged tip 32 as having an atomizing surface 33 with a thin coating 5. 41 thereon. Examples of such materials are Teflon, polyvinyl chloride, polyesters and polycarbonates.
In accordance with anothex embodiment and referring to Fig. 5, the ability of fuel to reach the outer - edges is increased by the provision of preferred paths or 10. channels 42 in the atomizing surface 33. The inclusion of channels in the atomizing surface which extend to the periphery of the flanged tip promotes flow of fuel over the entire atomizing surface. Thus for A given quantity of fuel, the result is A thin Eilm over substantialLy the 15. entir~e atomizing surface instead of a somewhat thicker film cent~red about the central fuel passage.
In accordance with another embodiment and with reference to Fig. 6 heating means 43 are provided to heat the atomizing surface during operation to temperatures on 20. the order of up to 150 F. The heat reduces the viscosity of the fuel alld promotes easier wetting of the surface, In accordance with another embodiment and with reference to Fig. 7, the atomizing surface is etched as at 44, by sand-blasting, thereby greatly increasing surface 25. area and reducing film thickness for a given quantity of fuel.
The geometrical contour of the flanged atomizing surface influences the spray pattern and density of particles developed by atomization. Thus, for example, a planar face atomizing surface 33 such as depicted in Figs. 2-7 will 15.
~ 9'~
generate a particular pattern and density~ If the surface is made to be convex, as shown at 33' in Fig. 8, the spray pattern is wider and there are fewer particles per unit of cross-sectional area than with a planar surface. A concave 5. surface 33" such as that depicted in Fig. 9 narrows the spray pattern and density of particles is greater than with a planar surface. Different spray patterns may be required depending on the application.
Turning attention now from the transducer assembly 10. ~ se to a fuel burner, a recurring problem is the short life of the ignition electrodes. These electrodes provide the spark for initiating the ignition of the fuel/air mi~ture within the 1ame cone. Once ignition occurs, however, the electrodes e~tend into the Elame envelope 15. resu~ting rom ignition and this constant exposure to high intensity heat during the firing cycles leads to rapid deterioration of the electrodes and frequent replacement of same.
In accordance with another aspect of the present 20. invention, the aforementioned prior art difficulty has been greatly diminished by locating the ignition electrodes outside the normal flame envelope, but increasing the drive power to the atomizer electrodes during the ignition phase.
This has the effect of increasing the angle of the spray 25. envelope considerably, bringing the ignition electrodes ~-within the space occupied by the fuel/air mixture and result-ing flame envelope. As soon as ignition is accomplished the anglie of the spray envelope is returned to its normal running mode by decreasing drive power to the atomizer 30. electrodes such that the ignition electrodes are located 16.
~.:
,. ~ . , ''' `' ' ' '. ' outside the normal flame envelope.
Referring now to Fig. 10, the fuel burner 50 is seen as including blast tube 51, a transducer assembly 52, ignition means including ignition electrodes 53, blower 54 5, for supplying air for combustion and for cooling the transducer assembly 52, air deflection means 55, flame cone 56, variable means 57 for supplying electric power, flame sensor 58, and pump means 59 for supplying fuel from a fuel tank 60 to the transducer assembly. The ignition 10. electrodes 53 are located between blast tube 51 and flame cone 56 and held by ceramic or porcelain insulators surrounded by high temperature asbestos material and near the atomizing surEace but at a suficient distance, typically 1/2 inch, to prevent arcing o~ the ignition spark to 15. the atomizer structure. During the ignition phase additional electrical power is swpplied by the power supply 57 to the input leads o~ the transduce~ assembly (greater voltage and current than during normal operation). Optionally, this can be accomplished automatically by programming the power 20. supp~y electronics such that prior to ignition the circuit supplies an excessive amount of power to the input leads of the transducer assembly apparatus. During the ignition phase the ignition electrodes are located within the flame ~ -envelope generated within the flame cone (Fig. 10A). Once 25. ignition has been established the flame sensor 58 sends a signal back to the power supply electronics switching the atomizer arive power to its normal operating mode, reducing the envelope of the flame and thus the ignition electrodes 53 found to be located outside the normal flame envelope 30. (Fig.l10B). This promotes longer ignition electrode life by .
. .
~ 997 virtue of the electrodes being kept at a cooler temperature during the normal operating cycle. The ignltion electrodes will not foul nor will they be oxidized by continuous heating.
5. An advantage to the use of an ultrasonic fuel atomizer is that one can vary the flow rate of fuel over a wide range. However, in order to implement a variable flow rate burner it is advantageous to have means to change the flow rate of combustion air through the burner combustion 10. tube 51. This can be done either by electrically controlling the blower motor speed or b~ providing a variable sized orifice for air ~low located in the air stream while main-taining a constant motor speed. With reference to Figs. 11-13 the latter method is preferred because only by this means 15. can the static pressure head of air within the burner be maintained in order ko develop turbulence necessary for proper combustion. This is implemented by an iris-type diaphragm 61 located within the combustion tube (Figs. 11 and 12) that is controlled electrically as shown in 20. Fig. 13.
The control of the iris diaphragm 61 is done electrically. For each fuel flow rate the amount of air is automatically adjusted by opening or closing the diaphragm until optimum burning conditions are sensed. The optimum 25. burning conditions are sensed by monitoring the CO2 level in the flue gas as at 62 from the furnace and feeding back data from that sensor to air control circuitry 63 for iris diaphragm 61 until a predetermined CO2 level, say 12.5 - 13%
CO2, is achieved.
30. In the prior art an oil burner will operate in a ':
18.
.: ~ . . . .
two stage mode, "off" and "on" and at a fixed fuel flow rate. It has been determined that such two stage operation suffers from a number of disadvantages. Firstly, it is uneconomical in the sense that it consumes more fuel than is 5. necessary and, secondly, it contributes to pollution. In the two stage operation when the system is turned from the off position to the on position or vice-versa, the firing is accompanied by generation of high volu~es of unburned hydrocarbons and carbon monoxide.
10. It has been determined that the aforementioned prior art difficulties may be eliminated and in accordance with the teachings of the present invention by going to a "three stage" modulated mode of operation.
The three stage mode, and with reference to Fig.
15. 1~ re~ers to a system in which there are three difEerent firin~ rates - high, low and off. For example, the three rates could typically be High - 0.60 gal./hr.
Low - 0.20 gal./hr.
20. Off - 0.00 gal./hr.
The high rate is called for by a duct or stack thermostat 71 in response to sensing a heat deficiency, just as is done in conventional heating systems with conventional thermostats. When the heat demand has been satisfied (as 25. determined by the thermostat setting) the system returns to the "low" ~iring rate via control valve 72 to furnace control assembly 73 in order to maintain system ductwork and -~
heat exchanger at an elevated temperature and to eliminate the draft losses occurring i~ the system were turned o-ff 30. completely as is the case in conventional heating systems.
''.
19 . .
:lV~g~
The operating cycle is between a high flow rate and a low flow rate, for example, 10 minutes at high firing rate, then 20 minutes at low, then 10 minutes more at highr etc. The time at high and low firing rates will vary with 5. demand for heat. This cycle allows ~or more efficient utilization of the furnace ~ince the system is already warm when the high part of the heating cycle begins, Moreover~
the firing rate for the high mode need not be as great as needed for a conventional cycle since the modulated system 10. will respond to the heat demand more quickly given the already warm conditions created during the low period.
The off part of the thre~ stage system would be used only during times of zero hea~ demand such as on days when outside temperature~ equal or exceed the inside tem~
15. peratures. This condition could he sensed by an external temperature sensor 74 ed into the system or could be manually controlled by the user.
In accordance with another aspect of the present invention, the transducer assembly of the present 20. invention can be used in an oil burner furnace system that employs continuous modulation.
With re~erence to Fig. 15 the firing rate o~ a system is allowed to vary continuously between some fixed ~ ;
upper and lower limits in response to an external control 25. signal supplied to the burner electronics as~ for example, in the solar panel supplementary heating system depicted. When the temperature of the hot water tank 81 is to be maintained abbve a minimum temperature To, the variable nature of the solar derived energy via pump 82 and solar 30. panel 83 requires that any solar energy deficit be made up 20.
9~
by the appropriate flux of heat from the oil burner assembly 84. This deficit, being variable, is sensed as at 85 and demands that the oil burner ~4 be able to fire at any possible rate within the desi~n limits of the system such 5. that the sum of the solar and oil burning heat delivered remains fixed at the required level. :
It should be obvious to those skilled in the art that while my invention has been illustrated for use in a burner suitable for burning fuel oil for heating a home it lO. may be used elsewhere to great advantage. It may be used, for example, in a burner for a mobil home where its low flow rate, typically less than one-half gallon per hour, and variable flow feature have obvious economic advantage. The invention may also be used for feeding fuel into internal 15. combustion or jet engines. The invention may also be used for atomization of other liquids such as water. While the invention has been particularly shown and descrihed :
with reference to the preferred embodiments thereof, it will :::
be understood by those skilled in the art that various : 20. changes in form and detail and omission may be made without departing from the sp.irit and scope of the invention. .~
25. . :
30.
Claims (10)
1. A transducer assembly comprising the com-bination of:
a first section including an ultrasonic horn and a driving element sandwiched therein, said first section having an empirically measured characteristic resonant frequency; and, a second section including a resonant section whose theoretical resonant frequency matches the empirically measured frequency of said first section.
a first section including an ultrasonic horn and a driving element sandwiched therein, said first section having an empirically measured characteristic resonant frequency; and, a second section including a resonant section whose theoretical resonant frequency matches the empirically measured frequency of said first section.
2. A transducer assembly comprising the combination of:
a first section including a front ultrasonic horn section having a flanged portion at one end thereof and a first fuel passage there-through, a rear ultrasonic horn section having a flanged portion at one end thereof, a driving element comprising a pair of piezo-electric discs and an electrode positioned therebetween, said driving element sandwiched between the flanged portions of said horn sections, terminal means for feeding high frequency electrical energy to said electrode, delivery means for providing fuel to said fuel passage, first and second gaskets surrounding said driving element piezoelectric discs and positioned between said front and rear horn sections and said terminal means, respectively, clamping means for compressing said sealing gaskets in sealing engagement about said driving element piezoelectric discs and for holding said horn section flanged portions in compression against said driving element, said clamping means including a mounting ring, said first section having an empirically measured characteristic resonant frequency; and, a second section including a large diameter segment of length A integrally formed with said first section front horn section, a small diameter segment of length B extending from said large diameter segment and having a rigid flanged tip of thickness C and an atomizing surface at said tip, the interface between said large diameter and small diameter segments constituting a step for amplification of vibrating motion at said atomizing surface, a second fuel passage extending through said second section, axially aligned and in communication with said first fuel passage for delivering fuel to said atomizing surface, a decoupling sleeve mounted within said second fuel passage and extending up to said atomizing surface, said second section having a theoretically resonant frequency matching the resonant frequency of said first section.
a first section including a front ultrasonic horn section having a flanged portion at one end thereof and a first fuel passage there-through, a rear ultrasonic horn section having a flanged portion at one end thereof, a driving element comprising a pair of piezo-electric discs and an electrode positioned therebetween, said driving element sandwiched between the flanged portions of said horn sections, terminal means for feeding high frequency electrical energy to said electrode, delivery means for providing fuel to said fuel passage, first and second gaskets surrounding said driving element piezoelectric discs and positioned between said front and rear horn sections and said terminal means, respectively, clamping means for compressing said sealing gaskets in sealing engagement about said driving element piezoelectric discs and for holding said horn section flanged portions in compression against said driving element, said clamping means including a mounting ring, said first section having an empirically measured characteristic resonant frequency; and, a second section including a large diameter segment of length A integrally formed with said first section front horn section, a small diameter segment of length B extending from said large diameter segment and having a rigid flanged tip of thickness C and an atomizing surface at said tip, the interface between said large diameter and small diameter segments constituting a step for amplification of vibrating motion at said atomizing surface, a second fuel passage extending through said second section, axially aligned and in communication with said first fuel passage for delivering fuel to said atomizing surface, a decoupling sleeve mounted within said second fuel passage and extending up to said atomizing surface, said second section having a theoretically resonant frequency matching the resonant frequency of said first section.
3. The invention defined by Claim 2 wherein .
4. In an ultrasonic atomizer including a transducer assembly according to Claim 1, with said second section including a large diameter segment of length A, a small diameter segment of length B extending from said large diameter segment and a displacement antinode at its free end comprising a flanged tip of thickness C, the improvement wherein .
5. In an ultrasonic atomizer including a transducer assembly according to Claim 1, with said second section having a flanged tip at one end compris-ing an atomizing surface, said flange being of a material of sufficient thick-ness to move as a rigid plane during vibration.
6. A method of making a high efficiency piezoelectric ultrasonic liquid atomizer comprising the steps of designing a symmetrical double-dummy ultrasonic transducer comprising a central electrode disc and two opposed identical dummy sections, each section including a piezoelectric element contiguous to a respective side of the electrode disc and a cylindrical element made of a metal having good sound transmission properties, the transducer being designed to have a theoretical natural frequency equal to a preselected ultrasonic frequency;
assembling an actual double-dummy transducer fabricated according to said design, the actual transducer including means for clamping the assembly to-gether and means for mounting the transducer on a support structure;
measuring the resonant frequency of said actual double-dummy transducer;
designing a cylindrical amplitude amplification section made of the same metal as the cylindrical elements of the double-dummy transducer, the amplifi-cation section being designed to have a theoretical natural frequency equal to the measured natural frequency of said actual double-dummy transducer; and assembling an actual piezoelectric ultrasonic liquid atomizer comprising a rear element identical to one of the dummy elements of said actual double-dummy transducer, a front element having a cylindrical first section identical to the other dummy element of said actual double-dummy transducer and an inte-gral second section in accordance with the design of said amplification section.
assembling an actual double-dummy transducer fabricated according to said design, the actual transducer including means for clamping the assembly to-gether and means for mounting the transducer on a support structure;
measuring the resonant frequency of said actual double-dummy transducer;
designing a cylindrical amplitude amplification section made of the same metal as the cylindrical elements of the double-dummy transducer, the amplifi-cation section being designed to have a theoretical natural frequency equal to the measured natural frequency of said actual double-dummy transducer; and assembling an actual piezoelectric ultrasonic liquid atomizer comprising a rear element identical to one of the dummy elements of said actual double-dummy transducer, a front element having a cylindrical first section identical to the other dummy element of said actual double-dummy transducer and an inte-gral second section in accordance with the design of said amplification section.
7. The method of Claim 6 wherein each of the cylindrical elements of the designed double-dummy transducer has an integral flange on one end con-tiguous to the respective piezoelectric element, and the means for clamping the actual double-dummy assembly together comprises a plurality of bolts extending between said flanges.
8. The method of Claim 6 wherein the amplification section is designed with a flanged tip for providing an increased atomizing surface, the thickness of the flange being sufficient to prevent significant flexure at the designed natural frequency of the amplification section.
9. The method of Claim 8 wherein the other of the cylindrical elements of the actual double-dummy transducer includes an axial passageway for deliver-ing liquid to the outer face of the element.
10. The method of Claim 9 wherein the front element of the actual liquid atomizer includes an axial passageway for delivering liquid to the outer face of the amplifying section.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA336,571A CA1090694A (en) | 1976-11-08 | 1979-09-28 | Transducer assembly, ultrasonic atomizer and fuel burner |
| CA336,572A CA1090695A (en) | 1976-11-08 | 1979-09-28 | Transducer assembly, ultrasonic atomizer and fuel burner |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US05/739,812 US4153201A (en) | 1976-11-08 | 1976-11-08 | Transducer assembly, ultrasonic atomizer and fuel burner |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1071997A true CA1071997A (en) | 1980-02-19 |
Family
ID=24973876
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA290,308A Expired CA1071997A (en) | 1976-11-08 | 1977-11-07 | Transducer assembly, ultrasonic atomizer and fuel burner |
Country Status (21)
| Country | Link |
|---|---|
| US (1) | US4153201A (en) |
| JP (2) | JPS5816082B2 (en) |
| AT (1) | AT383509B (en) |
| BE (1) | BE860540A (en) |
| CA (1) | CA1071997A (en) |
| CH (1) | CH627097A5 (en) |
| DE (1) | DE2749859A1 (en) |
| DK (1) | DK150229C (en) |
| ES (1) | ES463976A1 (en) |
| FI (1) | FI773325A (en) |
| FR (1) | FR2386226A1 (en) |
| GB (3) | GB1595716A (en) |
| IE (1) | IE46066B1 (en) |
| IT (1) | IT1090915B (en) |
| LU (1) | LU78476A1 (en) |
| MX (1) | MX148756A (en) |
| NL (1) | NL186796C (en) |
| NO (1) | NO148826C (en) |
| PT (1) | PT67246B (en) |
| SE (1) | SE434348B (en) |
| ZA (1) | ZA776376B (en) |
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- 1977-10-25 IE IE2169/7A patent/IE46066B1/en not_active IP Right Cessation
- 1977-10-26 DK DK475677A patent/DK150229C/en not_active IP Right Cessation
- 1977-10-26 ZA ZA00776376A patent/ZA776376B/en unknown
- 1977-11-03 GB GB19543/80A patent/GB1595716A/en not_active Expired
- 1977-11-03 GB GB45799/77A patent/GB1595715A/en not_active Expired
- 1977-11-03 GB GB19544/80A patent/GB1595717A/en not_active Expired
- 1977-11-07 CH CH1351177A patent/CH627097A5/de not_active IP Right Cessation
- 1977-11-07 NO NO773808A patent/NO148826C/en unknown
- 1977-11-07 CA CA290,308A patent/CA1071997A/en not_active Expired
- 1977-11-07 IT IT51701/77A patent/IT1090915B/en active
- 1977-11-07 FR FR7733420A patent/FR2386226A1/en active Granted
- 1977-11-07 FI FI773325A patent/FI773325A/en not_active Application Discontinuation
- 1977-11-07 BE BE182395A patent/BE860540A/en not_active IP Right Cessation
- 1977-11-07 NL NLAANVRAGE7712249,A patent/NL186796C/en not_active IP Right Cessation
- 1977-11-07 SE SE7712563A patent/SE434348B/en not_active IP Right Cessation
- 1977-11-08 AT AT0797277A patent/AT383509B/en not_active IP Right Cessation
- 1977-11-08 ES ES463976A patent/ES463976A1/en not_active Expired
- 1977-11-08 JP JP52134010A patent/JPS5816082B2/en not_active Expired
- 1977-11-08 DE DE19772749859 patent/DE2749859A1/en active Granted
- 1977-11-08 MX MX171240A patent/MX148756A/en unknown
- 1977-11-08 PT PT67246A patent/PT67246B/en unknown
- 1977-11-08 LU LU78476A patent/LU78476A1/xx unknown
-
1982
- 1982-11-19 JP JP57203535A patent/JPS5892480A/en active Pending
Also Published As
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| SE7712563L (en) | 1978-05-09 |
| ZA776376B (en) | 1978-10-25 |
| GB1595715A (en) | 1981-08-19 |
| ES463976A1 (en) | 1980-12-16 |
| PT67246A (en) | 1977-12-01 |
| NL186796B (en) | 1990-10-01 |
| IE46066B1 (en) | 1983-02-09 |
| NL186796C (en) | 1991-03-01 |
| FI773325A (en) | 1978-05-09 |
| IE46066L (en) | 1979-05-08 |
| DK150229B (en) | 1987-01-12 |
| FR2386226A1 (en) | 1978-10-27 |
| CH627097A5 (en) | 1981-12-31 |
| JPS5816082B2 (en) | 1983-03-29 |
| LU78476A1 (en) | 1978-03-14 |
| DK150229C (en) | 1987-09-28 |
| SE434348B (en) | 1984-07-23 |
| DE2749859C2 (en) | 1988-08-11 |
| US4153201A (en) | 1979-05-08 |
| BE860540A (en) | 1978-05-08 |
| DE2749859A1 (en) | 1979-05-10 |
| GB1595716A (en) | 1981-08-19 |
| NO148826C (en) | 1983-12-21 |
| JPS5359929A (en) | 1978-05-30 |
| PT67246B (en) | 1979-04-16 |
| NO773808L (en) | 1978-05-09 |
| IT1090915B (en) | 1985-06-26 |
| FR2386226B1 (en) | 1985-05-03 |
| JPS5892480A (en) | 1983-06-01 |
| NO148826B (en) | 1983-09-12 |
| AT383509B (en) | 1987-07-10 |
| MX148756A (en) | 1983-06-14 |
| NL7712249A (en) | 1978-05-10 |
| DK475677A (en) | 1978-05-09 |
| GB1595717A (en) | 1981-08-19 |
| ATA797277A (en) | 1986-12-15 |
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