Method of forming a burner assembly

Abstract

A method of forming a burner assembly includes capturing at least one feature of a burner with an imaging system, determining a location of a fireball based on the feature, moving the burner to an aligned position relative to a header or reflector based on the location of the fireball, and securing the burner in the aligned position.

1 . A method of forming a burner assembly, comprising: 
 capturing at least one feature of a burner with an imaging system;    determining a location of a fireball based on said at least one feature;    moving said burner to an aligned position relative to a reference point based on said location of said fireball; and    securing said burner in said aligned position.    
   
   
       2 . The method of  claim 1 , wherein capturing said at least one feature includes identifying at least one of a feature of a glass tube of said burner, a feature of an electrode, a gap between electrodes, and a shape of a central portion of said burner.  
   
   
       3 . The method of  claim 1 , wherein determining a location of said fireball includes capturing a plurality of profile views of said burner.  
   
   
       4 . The method of  claim 3 , wherein capturing said plurality of profile view includes capturing a plurality of orthogonal profile views of said burner.  
   
   
       5 . The method of  claim 3 , wherein capturing a plurality of profile views of said burner includes capturing images with first and second imaging devices.  
   
   
       6 . The method of  claim 5 , wherein said capturing said images with said first and second imaging devices includes at least one of capturing an optical image, capturing an x-ray image, and capturing a thermal image.  
   
   
       7 . The method of  claim 5 , wherein capturing image with said first and second imaging devices includes capturing a first orthogonal view of said burner and capturing a second orthogonal view directed to said second imaging device by a mirror.  
   
   
       8 . The method of  claim 5 , and further comprising providing rear illumination for each of said first and second imaging devices.  
   
   
       9 . The method of  claim 1 , and further comprising the step of determining a proper location of said burner relative to a reflector.  
   
   
       10 . The method of  claim 1 , wherein securing said burner to said header includes tacking said burner to said header with an adhesive.  
   
   
       11 . The method of  claim 1 , wherein moving said header to an aligned position relative to burner includes controlling an orientation of said burner by rotating said burner relative to three axes and translating said header parallel to said three axes.  
   
   
       12 . The method of  claim 11 , wherein rotating said burner relative to said three axes includes controlling a fixture, a Goniometer, and a rotational stage and translating said header comprises translating a reference fixture assembly coupled to a robotic arm.  
   
   
       13 . A system for forming a burner assembly, comprising: 
 a burner fixture assembly;    a reference fixture assembly,    a first imaging device, said first imaging device being configured to capture a first profile view of a burner;    a second imaging device, said second imaging device being configured to capture a second profile view of said burner; and    a processor coupled to said first imaging device and said second imaging device, said processor being configured to estimate a location of a fireball based on said first and second views.    
   
   
       14 . The system of  claim 13 , wherein said processor is configured to estimate a location of a fireball of a burner based on features identified in said first and second views.  
   
   
       15 . The system of  claim 13 , wherein said processor is configured to calculate an alignment and orientation a header relative to said burner based on said location of said fireball.  
   
   
       16 . The system of  claim 13 , wherein said processor is configured to control movements of said burner fixture assembly and said reference fixture assembly to align said header relative to said burner.  
   
   
       17 . The system of  claim 13 , wherein said burner fixture assembly includes a rotational fixture, a Goniometer, and a rotational stage.  
   
   
       18 . The system of  claim 13 , and further comprising a mirror configured to direct light from said burner to said second imaging device.  
   
   
       19 . The system of  claim 13 , wherein said processor includes an image processing module and a movement control module.  
   
   
       20 . The system of  claim 13 , and further comprising a first and second light sources, said first and second light sources being configured to provide rear illumination for said first and second imaging devices.  
   
   
       21 . The system of  claim 13 , wherein said first and second imaging devices include at least two of a group include an optical imaging device, an x-ray image device, and a thermal imaging device.  
   
   
       22 . A system, comprising: 
 means for capturing an image of a burner;    means for identifying at least one feature of said burner in said image; and    means for determining an alignment and orientation of said burner relative to a header based on said at least one feature.    
   
   
       23 . The system of  claim 22 , and further comprising means for moving said header and burner based on said alignment and orientation.  
   
   
       24 . The system of  claim 22 , and further comprising means for illuminating said burner.  
   
   
       25 . A method of forming a lamp assembly, comprising: 
 placing a fireball of a representative burner near a focal point of a representative reflector;    placing a representative surface at a known location relative to said burner;    capturing features of said representative burner;    establishing a position and orientation of said representative surface relative to said features; said position and orientation comprising a representative alignment;    capturing features of an individual burner; and    aligning said individual burner to an individual surface in a position and orientation corresponding to said representative alignment while said burner is in a non-operating state.    
   
   
       26 . The method of  claim 25 , wherein aligning said individual burner to said individual surface includes aligning said individual burner to a header.  
   
   
       27 . The method of  claim 25 , wherein capturing features of said individual burner includes performing an imaging operation.  
   
   
       28 . The method of  claim 25 , and further comprising securing said individual burner to said individual burner.