Note: Descriptions are shown in the official language in which they were submitted.
CA 02561120 2006-09-27
GAS FIREPLACE MONITORING AND CONTROL SYSTEM
Background of the Invention
Field of the Invention
The present invention generally relates to monitoring and control systems, and
more specifically relates to systems and methods for monitoring and control
systems heating
appliances such as fireplaces, stoves, and fireplace inserts.
Related Art
Gas, electric, and wood burning heating appliances such as fireplaces, stoves
and fireplace inserts are an efficient method for providing warmth and
creating the appeal of
a fire within a room. Fireplaces have become commonplace in today's building
trades for
both residential and commercial applications. Most new home construction
designs include at
least one, and often several fireplaces. Further, a significant number of
remodeling projects
are focused on fireplaces.
Most known heating appliances include some type of heat control system that
facilitates on/off control, the level of heat output, and possibly
thermostatic control. In the
case of a gas powered heating appliance such as a gas fireplace or stove, heat
generation is
controlled by altering the flow of gas to a burner via a gas valve.
Decorative heating appliances such as fireplaces and stoves typically include
a
combustion chamber of some type wherein heat is generated or simulated in the
form of a
flame, and the flame is viewable for aesthetic purposes. Many fireplaces and
stoves that burn
a gaseous substance rather than a solid fuel like wood or other fibrous
material attempt to
produce a flame or flame effect that simulates burning of a solid fuel.
Providing a flame
generated from gas can involve safety and maintenance issues different from
burning fibrous
products. A heating device that provides improved monitoring and control of a
gas flame is
desirable.
Summary of the Invention
The present invention generally relates to systems and methods for monitoring
and controlling heating appliances such as fireplaces, stove, and fireplace
inserts. The
disclosed embodiments illustrate example systems and methods for monitoring
and
controlling the burner and other features of a heating appliance, and
communicating the status
and conditions of the heating appliance with a remotely located computer
system. The status
CA 02561120 2006-09-27
or condition of the heating appliance can be indicated with a fault condition
signal. The fault
signal can indicate a priority level of the heating appliance condition.
One aspect of the invention relates to a monitoring and control system for use
with a heating appliance. The heating appliance includes a barner, a gas valve
configured to
control fuel flow to the burner, and an ignition system configured to ignite a
flame at the
burner. The system includes a sensor module, a computer system, a controller,
and a
communication system. The sensor module is configured to monitor the burner,
gas valve,
and ignition system and generate monitoring signals. The controller is
configured to generate
fault condition signals based on the monitoring signals. The communication
system is
configured to communicate the fault condition signals to the computer system,
wherein the
computer system is located remotely from the heating appliance. The computer
system is
configured to generate control signals in response to predetermined fault
condition signals.
The communication system is configured to communicate the control signals to
the controller
for control of at least one of the burner, gas valve, and ignition system.
Another aspect of the invention relates to a heating system that includes a
heating appliance and a monitoring and control system. The heating appliance
includes an
enclosure defining a combustion chamber, a burner position;,d in the
combustion chamber
and coupled to a source of combustible fuel, the burner being configured to
generate a flame,
a valve configured to control fuel flow to the burner, and an ignition system.
The monitoring
and control system includes a controller and a computer system. The controller
is configured
to control functions of at least one of the burner, valve, and ignition system
and generate fault
signals in response to predetermined conditions of at least one of the burner,
valve, and
ignition system. The computer system is positioned remotely from the heating
appliance and
is configured to receive the fault signals and generate control signals for
controlling functions
of at least one of the gas valve, ignition system, and burner.
A further aspect of the invention relates to a method of monitoring and
controlling features of a fireplace. The fireplace includes a sensor module, a
burner, and a
valve. The method includes monitoring with the sensor module a condition of
the burner,
communicating to a remotely located computer a fault condition based on the
monitored
burner condition, and shutting off the valve when a predetermined fault
condition is detected.
A still further aspect of the invention relates to a method of monitoring and
controlling performance of a heating appliance. The heating appliance includes
a combustion
chamber, a burner positioned in the combustion chamber, an ignition system, a
valve, a
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CA 02561120 2006-09-27
controller, and a plurality of sensors. The method includes the steps of
monitoring a status of
the burner, the ignition system, and the valve with the plurality of sensors,
controlling the
burner, the ignition system, and the valve with the controller in response to
the monitored
status, and communicating a fault signal between the controller and a remotely
located
computer in response to a predetermined monitored status.
The above summary of the present invention is not intended to describe each
disclosed embodiment or every implementation of the present invention. The
Figures and the
detailed description that follow more particularly exemplify certain
embodiments of the
invention. While certain embodiments will be illustrated and describe
embodiments of the
invention, the invention is not limited to use in such embodiments.
Brief Description of the Drawings
The invention may be more completely understood in consideration of the
following detailed description of various embodiments of the invention in
connection with
the accompanying drawings, in which:
Figure 1 is a front perspective view of an example fireplace that includes
monitoring and control features according to principles of the present
invention;
Figure 2 is an exploded front perspective view of the assembly shown in
Figure 1;
Figure 3 is a further exploded front perspective view some of the
subassemblies shown in Figure 2;
Figure 4 is a schematic diagram illustrating an example system according to
the present invention;
Figure 5 is another schematic diagram illustrating another example system
according to the present invention;
Figure 6 is a schematic diagram illustrating features of an example control
system according to the present invention;
Figure 7 is a flow chart illustrating functionality of an example control
system
according to the present invention;
Figure 8 is a flow chart illustrating steps of an example method according to
the present invention; and
Figure 9 is a flow chart illustrating steps of another example method
according
to the present invention.
CA 02561120 2006-09-27
While the invention is amenable to various modifications and alternate forms,
specifics thereof have been shown by way of example and the drawings, and will
be
described in detail. It should be understood, however, that the intention is
not to limit the
invention to the particular embodiments described. On the contrary, the
intention is to cover
all modifications, equivalents, and alternatives falling within the spirit and
scope of the
invention.
Detailed Description of the Preferred Embodiment
The present invention generally relates systems and methods for monitoring
and controlling features of a heating appliance. Some example heating
appliance structures
with which the disclosed monitoring and control systems could be used include
universal
vent, horizontal/vertical vent, B-vent, and dual direct vented fireplaces, as
well as multisided
heating appliances having two or three glass panels as side panels, or in any
other unit used as
a gas, electric, or wood burning fireplace, stove or insert.
The monitoring and control systems of the present invention can provide
improved safety, reduced maintenance costs, and enhanced user control of the
heating
appliance. These monitoring and control systems can also provide improvements
in
troubleshooting a fireplace for maintenance problems either on-site or from a
remote
location, and can reduce overall incidents of unsafe conditions for the
heating appliance.
These monitoring and control systems can also provide a history of hours run
and/or
problems that have occurred in the past for the heating appliance. This
historical data can be
useful for many purposes such as evaluating total maintenance costs,
determining when
certain repair/maintenance should be performed, and to evaluate performance of
a plurality of
systems to determine core problems.
The example monitoring and control systems described herein include a
plurality of sensors and related functionality that provide monitoring of at
least the burner,
fuel valves, and ignition system of a heating appliance to ensure that those
features are
working properly. In the event any of those systems are monitored as not
functioning as
intended, a control system can automatically shut down and/or lock out some or
all functions
of the heating appliance. The example monitoring and control systems may also
include a
remotely located computer system that receives transmitted monitored and other
information
about the heating appliance. The computer system can be located remotely from
a living
space within which the heating appliance resides. In one example, the computer
system is
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CA 02561120 2006-09-27
located outside of a room within which the heating appliance resides. In
another example, the
computer system is located at least 1-100 miles away from a room within which
the heating
appliance resides.
The remotely located computer system may be capable of controlling some
features of the heating appliance via, for example, an analog or digital
control signal sent
through the controller at the heating appliance. The remotely located computer
system may
have other functionality that provides improved communication of information
related to the
heating appliance.
An example embodiment of the monitoring control system according to the
principles of the present invention is discussed with reference to a fireplace
10 shown in
Figures 1-3. Fireplace 10 includes an outer enclosure 12, a combustion chamber
enclosure 14,
a burner 16, an ignition assembly 18, a valve 20, a grate 22, and controller
24. The fireplace
10 may also include a blower 19, a light fixture 21, an air filter 23, a
pressure sensor 25, and a
scent generating device 27 (see Figure 2).
The outer enclosure 12 includes front and rear panels 40, 42, first and second
side panels 44, 46, and top and bottom panels 48, 50 that together define an
enclosure within
which the combustion chamber enclosure 14 can be positioned. First and second
wall
members 52, 54 shown in Figure l, which are attached to the outer enclosure
12, illustrate
that this particular fireplace structure can be positioned between two wall
members to provide
viewing of the fireplace interior from either the front or rear side of the
fireplace 10.
The combustion chamber enclosure 14 includes front and rear panels 56, 58,
top and bottom panels 60, 62, first and second side panels 64, 66, first and
second side
decorative panels 68, 70, and a bottom decorative panel 72. The plurality of
combustion
chamber enclosure panels define a combustion chamber 76 in which the burner 16
and grate
22 are positioned for viewing. The combustion chamber enclosure 14 may also
include a
mounting panel 74 that is configured for mounting some features of the
fireplace such as the
ignition assembly 18, valve 20, and controller 24.
The burner 16 includes a burner surface 80 having a plurality of apertures 82
formed in a pattern thereon. Each aperture provides for gas flow out of the
burner, wherein
the gas flow is ignited into a flame such that each aperture is associated
with a separate flame
member. Due to the close spacing of the apertures 82 on the burner sur face
80, the flames
extending from each aperture can merge to provide the appearance of a single
flame having a
shape corresponding to the pattern of apertures 82. Many different burner
structures can be
CA 02561120 2006-09-27
used with fireplace 10 in connection with the monitoring and control system
described in
further detail below.
The ignition assembly 18 includes a pilot flame nozzle 84, a spark-generating
probe 86 and ignition controls 88. The ignition controls 88 include a
controller that provides
S for spark generation in timed sequence with opening and closing of a pilot
flame valve
(described below) to ensure that a spark is generated only after the pilot
flame valve is
opened. The ignition controls 88 also include a sensor that determines the
presence of the
pilot flame. The ignition controls 88 can provide for a repeated cycle of
spark generation in
the event that the pilot flame is not generated within a predetermined time or
number of
sparks. An example ignition assembly is the PI ignition system model GM-6KA
produced by
DEXAN.
The valve 20 includes a main flame valve 76, a pilot flame valve 78 that are
combined together in a single valve housing. Each of the valves 76, 78 is
separately
controlled to regulate the flow of fuel to the burner 16 and pilot flame
nozzle 84. A fuel line
79 couples the valve 22 a source of fuel (not shown). An example valve 20 is
valve model no.
H3V produced by DEXAN.
The controller 24, while shown generically in Figure 3, may include a
plurality
of subcomponents that are mounted to, for example, a printed circuit board and
housed within
a housing. The controller 24 preferably includes a microprocessor such as the
ATMEGA48V
microprocessor produced by ATMEL CORPORATION of San Jose, CA, that has some
advantages such as, for example, its memory size, cost, power requirements,
interrupt mode
options, sleep mode options and its compatibility with the IPI ignition
system. The controller
24 may include other features as described below with reference to Figure 6.
The controller
24 is provided with hardwire or other communication capabilities to provide
communication
of control signals and monitored information between the burner 16, the
ignition assembly
18, valve 20, blower 19, light fixture 21, air filter 23, pressure sensor 25,
and scent generating
device 27 and the sensors described below.
The fireplace 10 includes a pilot flame sensor 26, a spark sensor 28, and a
main flame sensor 30. The pilot flame and spark sensors 26, 28 may be mounted
to a bracket
89 of the ignition assembly 18 so as to be positioned adjacent to the pilot
flame nozzle 84 and
the spark generating probe 86. Such a mounting would provide the proximity of
the sensors
necessary in order to provide accurate monitoring and assessment of the
existence of a pilot
flame and spark generation. The main flame sensor 30 may be positioned, for
example, on the
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CA 02561120 2006-09-27
burner surface 80, or otherwise mounted so as to be positioned adjacent to one
or more of the
apertures 82 where a main flame of a burner 16 exists. In some embodiments,
multiple main
flame sensors 30 may be positioned at various locations on or adjacent to the
burner surface
80 so as to monitor the presence of flames across different locations of the
burner surface,
which may relate to a complete ignition of the burner.
A fireplace 10 may also include a particulate sensor 32, a temperature sensor
34, a gas sensor 36, and an airflow sensor 38 (see Figure 1). The particulate
sensor 32 is
configured to monitor the presence of particulates such as soot that build up
or are otherwise
present such as, for example, the burner surface 80, the pilot flame nozzle
84, the spark
generating probe 86, or on any of the sensors 26, 28, 30, etc. The presence of
particulates
such as soot may affect the performance of the fireplace features. Therefore,
the particulate
sensor 32 can generate a signal when the particulate is identified so that
maintenance or other
measures may be taken.
The temperature sensor 34 maybe mounted to any of a number of different
locations within the fireplace 10. The temperature sensor 34 may be mounted
to, for example,
a transparent glass panel of the fireplace so as to monitor the temperature of
the glass. In
another example, the temperature sensor may be mounted to the burner,
different features of
the ignition assembly 18, or the controllers so as to determine whether those
features are
maintaining a temperature that is within a predetermined temperature range.
The gas sensor 36 may be used to determine the presence of a gaseous fuel in
or around the fireplace 10. The determination of the presence of gas may be
particularly
useful at those times in which there should be no gas present. The gas sensor
can also be used
to determine the presence and flow of gaseous fuel within a fuel line, in the
valve, or in the
burner, for example.
The airflow sensor 38 may be used to monitor aspects of airflow in the
fireplace 10, such as, for example, the amount of airflow, the content of the
airflow (i.e.,
oxygen content or combustion products content), or the direction of airflow.
Other sensors in addition to or in combination with sensors 26, 28, 30, 32,
34,
36, 38 may be used to monitor and assess conditions of the blower 19, light
fixture 21, air
filter 23, pressure sensor 25, and scent generating device 27. Some example
conditions
monitored by such sensors include speed and power requirements of the blower
19, time of
use of the light fixture 21, air filter 23 and scent generating device 27, and
positive or
negative pressure or pressure gradients within the fireplace with the pressure
sensor 25.
CA 02561120 2006-09-27
The example sensors 26, 28, 30, 32, 34, 36, 38 represent some of the many
different types of sensors that can be used to monitor different functions and
conditions of the
fireplace 10. Each of these sensors may be configured to generate a signal
related to the
condition that they are monitoring. The signal can be sent to the controller
24 directly, for
example, via the ignition controls 88 such that the controller 24 acts as a
central database of
the monitored information. The controller 24 in turn can communicate the
information that is
delivered to it via the sensors 26, 28, 30, 32, 34, 36, 38 to anather device
such as remotely
located computer system (e.g., system 104 described below).
Figure 4 illustrates a relationship between a controller 100 that communicates
with a heating appliance 102. This communication may involve the input and
output of
signals relative to the controller 100 via a plurality of sensors and other
devices included in
the heating appliance 102. The controller I00 can communicate with the remote
computer
system 104 via any desired communication system. Some example communication
systems
include, for example, radial frequency (RF), infrared (IR), cellular,
satellite, ultrasound,
optics, drawn wire, or any other wireless or wired communication systems. One
example
digital means of communication includes the use of a modem wherein the
communication
signals between a controller 100 and remote computer system 104 are delivered
via a
telephone or cable wired communication network. Other example digital means of
communication include cellular and satellite means of communication. Some
example analog
means of communication include, for example, direct AC/DC and POT (plain old
telemetry)
systems.
Figure 5 provides a schematic illustration of the various components related
to
the controller 100, heating appliance 102 and remote computer system 104. The
heating
appliance 102 and ignition system 106, a main valve 108, temperature sensor
110, and a
particulate/soot sensor 112, a gas sensor 114, and an auxiliary system 116.
The ignition
system 106 includes ignition controls 120, a pilot flame valve 122, a pilot
flame sensor 124, a
spark generator 126, and a spark sensor 128. The ignition system features may
have at least
those capabilities described above related to the ignition assembly 18, valve
20, and sensors
26, 28.
The main valve 108 includes a main valve control 130, a burner flame 10
sensor 132, and a main flame valve 134. The main valve features may include at
least those
capabilities described above related to valve 20 and main flame sensor 30.
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The controller also communicates with the remote computer system 104,
wherein the remote computer system includes controls 140, a modem 142, and
memory 144.
As described above the modem 142 may be replaced with any desired
communication device
or system that provides communication with the computer system 104 when it is
at a location
remote from the controller 100.
The computer system 104 may be configured to automatically log all
information received from the controller 100. Based on the type and
priority/fault level of the
information received, the computer system 104 can perform different functions.
For
example, the information sent by controller 100 may be given status/fault
indicators related to
specific fireplace conditions. Upon receipt of the information by the remote
computer system
104, the system 104 can both log the information in memory 144 and generate
signals via the
controls 140 and deliver those control signals via a communication system or
network (e.g.,
the modem 142). In one example, the status/fault indicator for the information
transmitted by
controller 100 has a high priority representing, for example, the main flame
valve being
turned on, verification of spark generation, and a main flame sensor signal
representing that
no main flame is present even after repeated cycles of attempted ignition
(e.g., see Fault F1 in
Figure 7). Such a signal represents nonfunction of the fireplace burner, which
needs
immediate attention. In response to receiving this signal, the computer system
104 can log the
entry of the data with, for example, a date and time stamp along with the
status/fault
indicator, and generate a control signal via controls 140 that instructs the
controller 100 to
shut down the fireplace until maintenance can be performed. In some
embodiments, the
controller 100 may automatically shut down the fireplace in response to a high
priority
status/fault indicator before communicating the information to the remote
computer 104.
In other examples, wherein the status/fault indicator represents a low
priority,
the logged data saved in memory 144 can be reviewed on a periodic basis and
acted upon
either manually or automatically via the controls 140 and modem 142, In some
instances, the
computer system 104 can generate a notification signal that notifies, for
example, the
fireplace owner or maintenance personnel who can address the maintenance needs
of the
fireplace. In one example, the auxiliary system 115 may be configured to
monitor the usage
time of the fireplace and the controller 100 can generate and transmit a
signal to the remote
computer system 104 that indicates that regularly scheduled maintenance should
be
performed in view of the amount of usage time. In response to receiving this
signal, the
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CA 02561120 2006-09-27
computer system 104 can transmit a signal to the homeowner or to maintenance
personnel to
perform the necessary maintenance (e.g., changing a filter, cleaning, etc.).
Referring now to Figure 6, the controller 100 may include a CPU 150, a power
supply 152, a nonvolatile memory 154, a volatile memory, 156 input devices
158, output
devices 160, communications connection 162, digital-to-analog (D/A) converter
164, and an
analog-to-digital (A/D) converter 166. The CPU 150 can be any desired
processor such as a
microprocessor that provides processing and control of information gathered by
the controller
100.
The power supply may be, for example, a 5-volt do regulator that provides
power to the controller via, for example, nonregulated plug in do power
supply. The power
supply 152 may also include a backup power provided by, for example, some type
of
standard sized battery (e.g., D battery) that is either chargeable or
nonchargeable that
provides operation of the controller 100 for a specified number of hours in
the event the hard
wire power supply is disconnected.
The volatile and nonvolatile memory provides for the storage of various types
of information necessary to operate the controller 100 as well as storing
monitored
information and generate and receive control signals.
The input and output devices 158, 160 may include, for example, the modem
described above or any other communication system that can receive and
transmit signals via,
for example, the communication connection 162. The D/A and A/'D converters
164, 166 may
be used for communication between different types of sensors and devices
within the
fireplace as well as to convert different types of signals incoming via the
input device 158 or
outgoing via the output device 160.
A software code may be loaded into the controller memory and operated with
the CPU 150. The code preferably provides monitoring of the sensors to detect
the proper
sequence involved in igniting the fireplace and then to generate and transmit
data via the
communication connection with the remote computer system 104. The code must
also store
important information such as ignition history, fault status,
call/transmission status, and hours
of operation.
The software code may be structured similar to a state machine. When the
fireplace is turned off, the controller 100 is preferably operated in a low
power sleep mode
(first state), while checking the on/off switch periodically (e.g., every 100
ms to S00 ms).
When the controller detects that the on/off switch has been turned to the "on"
position, the
CA 02561120 2006-09-27
controller goes into a second state wherein it watches for an indication via
the ignition system
that the main flame valve has been opened. When the controller determines that
the main
flame valve has been opened, this indicates that the ignition controller has
sensed that the
pilot flame has been ignited and is present so that it is appropriate to turn
on the main flame
valve. Once the main flame valve has been opened, the controller enters a
third state in which
the controller will monitor the presence of the main flame via the main flame
sensors. If the
main flame is not observed within a predetermined amount of time, the
controller 100 may be
configured to shut down the fireplace automatically and send a signal to the
remote computer
system. The remote computer system may in turn generate a control signal that
is sent back to
the controller 100 for shutting down the fireplace. In this scenario, it may
be likely that the
fireplace is disabled until it can be serviced to determine a reason why the
main flame was
not generated within the proper time period given the occurrence of all the
sequence of steps
needed to ignite the main flame.
The condition in which the main flame is not detected within the
predetermined time can be referred to as a default or fault detection. 'This
is just one of
several fault conditions that may occur and be determined by the controller
100. Other
example faults with less high importance include a determination that no pilot
flame is
generated after a predetermined time from when a spark is generated and the
pilot flame has
been turned on. Another fault relates to observance of, for example, debris,
soot or
particulates at various locations in the fireplace at the time of ignition. A
yet further fault
relates to the scheduled maintenance timer being tripped in response to a
certain amount of
usage of the fireplace. Figure 7 illustrates in schematic fashion various
functions that may
occur in response to sensors S1-S4 monitoring information that results in
faults F1-F4.
Once a fault has been detected by the controller 100, a signal can be sent
with
that specific fault indicator to the remote computer, to the user, to
maintenance personnel, or
to all three. When the controller transmits this information about the fault,
it may also send
concurrently the serial number of the fireplace and other relevant information
such as the date
and time, the number of hours since the last maintenance was performed, etc.
The following is an example of how communication occurs between a
controller and a remotely located computer when using an analog communication
system:
Example 1
1. A fault is tripped on the controller by the fireplace actions.
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CA 02561120 2006-09-27
2. The controller checks the telephone line to see if it is being used, and if
so waits a set amount of time after it is not used before dialing.
3. If/when the line is not in use, the controller performs any action
necessary to reach an outside line.
4. The controller then dials the designated phone number to reach the
remotely located computer system.
S. The receiving computer system picks up and waits for ready to send
code from the fireplace controller.
6. The receiving computer system hears a "ready to send" code and
transmits "ready to receive" code.
7. After hearing the ready to receive code, the fireplace controller sends
the serial number with a coded signal indicating the fault code and
other information about the fireplace.
8. When the transmission of information is completed, the fireplace
controller will then wait until it hears the received successfully code
from the receiving computer system. If the sequence makes it to this
point but the fireplace controller does not hear the received
successfully code, it must wait a predetermined time period and
continue the sequence until the information is received
successfully at the remote location.
9. After the fireplace controller receives the proper indication that the
information has been transmitted, the lines on both ends are hung up.
10. The receiving computer system logs the information on, for example, a
Microsoft Excel spreadsheet for viewing at the remote location.
11. The remote located computer system can automatically generate
responsive signals to be sent to the fireplace controller, maintenance
personnel, or the fireplace owner via, for example, a telephone
transmission, an e-mail message, etc.
Table 1 (see below) lists some possible detectable faults along with their
intended purpose, whether or not the fault should result in a forced shut down
of a system,
whether or not new sensors are needed over time, and an example hardware for
use in
detecting the fault. These example faults can be determined using one or more
of the example
sensors described with reference to Figure 5.
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TABLE I-Possible Detectable Faults
Forced New Sensor
Fault Purpose Shut Needed Detection
down
Main Flame UV sensor or 2-3
Detection Safety yes yes probes similar
to pilot
circuit
Malfunctioning Circuit using FETs
Pilot Circuit connected to IPI
Safety yes no sensing probe -
white
wire
Ignition Time Inductive switch
on
Out Safety yes no spark line - orange
wire
Soot Detection Two leads in a
finger
weaved layout to
detect
Appearance no yes voltage transferred
between them
Hour Meter Uses clock inside
microcontroller
and
Maintenance no no fireplace switch
- brown
wire
Overheating Thermistor used
to
Safety yes yes detect heat outside
of
box
Tamper Watch lines and
sensors
Detection Safety no no already connected
for
unexpected activity
Non-Use Hour Separate internal
Meter Maintenance no no counter to count
hours
between uses
Gas DetectionSafety yes yes Sensor on bottom
of
fireplace (more
useful
LP but maybe not
for
practical)
Figures 8 and 9 illustrate some example method steps related to monitoring
and controlling operation of a fireplace. Figure 8 illustrates the steps of
monitoring with
sensors the condition of a burner flame, a pilot flame, and a spark generation
in the fireplace.
The method also includes communicating information about the monitored
conditions to
remotely located computer and shutting off a gas supply to the fireplace when
a
predetermined monitored condition exists. The method still further includes
generating
control signals and alarms/reports with the remotely located computer system.
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Figure 9 relates to a method that includes providing a heating appliance
having
a combustion chamber, a burner, a pilot flame system, an ignition system, a
valve, a
controller, and a plurality of sensors. The method also includes a status of
the burner, the
pilot flame system, the ignition system, and the valve with the plurality of
sensors. The
method also includes controlling the burner, the pilot flame system, the
ignition system and
the valve in response to the monitored status, and communicating between the
controller and
a remotely located computer system in response to a predetermined monitored
status.
Functional Options
The monitoring and control system described herein can provide a more
definite safety/worry free fireplace operation. The following potential
options, some of which
are discussed above, can further enhance the overall functionality of the
system.
1. Set hour Service Call. This feature could provide a service call when
the fireplace reaches a certain number of hours of operation logged, it
makes a call to get a "check-up."
2. Wireless Phone Jack. This feature could be provided in order to make
retrofitting easier, a wireless system could be used either to modulate
the signal over the AC power lines, or to transmit the signal via radio
frequencies (RF) to a module that is located at a phone j ack.
3. Glass Temperature Sensor. This feature could be used to detect
whether there is a higher temperature on the glass than it's rating.
4. Gas Line Pressure Sensor. This feature could be used to ensure that
the gas line has a high enough pressure for the fireplace to operate
properly.
5. Multiple Call/Contact Option. This feature could be used to place
multiple calls concurrently (e.g., a dealer/manufacturer, the fireplace
owner, or maintenance personnel). As an added feature, additional
numbers or contact instructions could be added (cell number, email,
text message, etc.).
6. Combustible Gas Detector. This feature could be used to detect no
gas before sparking on a fireplace.
7. Tamper Detection. This feature could provide additional sensors or
switches to indicate whether the glass has been off the fireplace, phone
14
CA 02561120 2006-09-27
line has been disconnected, or any other areas to watch that would
indicate the system has been changed by someone who does not have
the ability to reset the history.
The system may include a connector for future "add-on sensors" that can go to
different ports of the microcontroller such as I/O's, A/D or D/A converter
lines. The system
may also include the capability (e.g., via a serial port) for a service
technician to retrieve the
history of the fireplaces actions and/or problems from the microcontroller or
communication
transmission. Such capability may also include the possibility for future
upgrades in code and
a possibility of talking with another microcontroller that could be in an
"added-on" device in
the future.
The system may use LEDs as status indicators on the fireplace, at other
locations in close proximity to the fireplace, or at the remote computer
location. These visual
indicators may be turned off or removed according to user preferences.
The examples provided above with reference to the attached Figures focus on
gas burning decorative heating appliances such as fireplaces, stove, and
fireplace inserts. The
systems and methods described above could be modified to provide the same or
similar
functions for other types of decorative heating appliances such as, for
example, electric, wood
burner, and pellet fireplaces, stove and fireplace inserts. While such
alternative heating
appliances may not include a valve or the type of ignition system required for
ignition of a
gaseous fuel, such alternative heating appliances may include different types
of ignition
systems and heat sources that can be monitored and controlled with the
assistance of sensors,
as well as blowers, light fixtures, air filters, scent generating devices and
other features that
can be monitored and controlled.
In other example embodiments, the system may include sensors that monitor
the fuel supply associated with the decorative heating appliance. For example,
a sensor or
other monitoring device may be used to monitor a pellet supply level for a
pellet stove or
fireplace, or a liquid propane (LP) supply level for a LP gas fireplace.
The present invention should not be considered limited to the particular
examples or materials described above, but rather should be understood to
cover all aspects
of the invention as fairly set out in the attached claims. Various
modifications, equivalent
processes, as well as numerous structures to which the present invention may
be applicable
will be readily apparent to those of skill in the art to which the present
invention is directed
upon review of the instant specification.
