System and method for measuring fuel consumption and compensating for error in measurements

Abstract

A system and method for measuring fuel consumption and compensating for errors in measurements discloses a system (400) and method for measuring fuel consumption (416) of a machine (100) and compensating for errors in measurements. The system (400) comprises: a circuit (408); a liquid level sensor (202) located in the tank (110); a meter (404) in communication with the level sensor (202) and configured to display (418) a fuel level (204) in the tank (110); a resistor (406); an inclination sensor (410); a voltage sensing terminal (412); and a controller (402), the controller being provided with a volume lookup table (414), the volume lookup table containing irregular box (300) compensation data. The controller (402) is configured to: receive signals from the level sensor (202), the tilt sensor (410), the resistor (406), and the voltage sensing terminal (412); processing the signal and the volume lookup table (414) to measure the fuel consumption (416) of the machine (100) by compensating for errors caused by inclination and irregular box geometry (3D); and communicating the fuel consumption (416) to the display (418).

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a system for measuring fuel consumption, and more particularly to a system for measuring fuel consumption and compensating for errors in the measurement of fuel consumption. BACKGROUND

[0002] Machines known in the art, such as excavators, trucks, generator sets, and other types of mobile or stationary machines, have fuel tanks for storing fuel (e.g., gasoline or diesel). The fuel stored in these fuel tanks can be delivered via a fuel line and supplied to a prime mover for combustion and to power any operation associated with the machine. In some cases, these machines can operate in a stationary state (e.g., on a horizontal or inclined surface). In other cases, these machines can need to operate in a mobile state (e.g., on a horizontal or inclined surface). Regardless of the operating conditions, it can be prudent to monitor fuel consumption over time to efficiently manage fuel consumption and schedule refueling accordingly.

[0003] Determining the rate of fuel consumption and the volume of fuel remaining in a fuel tank of a machine that is dynamically changing due to various factors remains challenging, as both mobile and stationary machines typically operate under different operating conditions, such as load, terrain, surface gradient, and inclination, as well as different environmental conditions, such as temperature and humidity, all of which can significantly affect the rate of fuel consumption, making fuel consumption measurements difficult. Conventional fuel gauges alone cannot provide accurate measurements, resulting in errors in determining the volume of fuel remaining in the tank. Moreover, fuel can slosh around inside the tank due to movement of the machine or implement, introducing inaccuracies to the readings output by conventional designs and setups of fuel sensors, thus making it difficult to determine the exact amount of fuel remaining in the tank.

[0004] Furthermore, irregularly shaped tanks (e.g., irregular polyhedrons designed to accommodate any space constraints of the machine) can make it more difficult to accurately measure the volume of fuel remaining in the irregularly shaped tank, complicating fuel consumption measurements and calculations of fuel remaining. Additionally, irregular tank geometries can cause fuel to slosh around inside the tank, which can further negatively impact the accuracy of fuel level sensors and gauges. As described herein, “irregular tank geometry” refers to fuel tanks having non-standard shapes or structures, which can include complex curves, varying widths, or irregular surfaces. These non-conventional geometries make it difficult to accurately measure the volume of fuel in the tank, whether the machine is stationary or mobile, resulting in errors in measuring fuel consumption and fuel remaining in the tank. Therefore, there is a need for an accurate system for measuring fuel consumption to provide precise fuel consumption and fuel remaining calculations.

[0005] Others have attempted to develop systems for measuring fuel consumption in tanks with irregular geometries. For example, Korean patent application KR 20160120021 (hereinafter referred to as "Reference '021") discloses a fuel tank system for calculating fuel consumption, which includes a tank body, a detection unit, and a calculation unit. However, Reference '021 discloses that this fuel tank system measures fuel consumption in a tank body formed in a cuboid shape, and when fuel is stored in a tank with an irregular geometry, the system does not measure fuel or compensate for errors in the fuel measurement results. Reference '021 fails to provide a system for measuring fuel consumption that provides accurate fuel consumption and calculation for fuel remaining in a tank with an irregular geometry.

[0006] Therefore, there is a need for a system for measuring fuel consumption that can accurately measure dynamically changing fuel consumption rates and calculate the exact volume of fuel remaining in the fuel tank, especially when the tank has an irregular shape, in order to efficiently monitor fuel consumption and subsequently plan routine refueling of the tanks present on the machine. Summary of the Invention

[0007] According to one aspect of this disclosure, a system for measuring fuel consumption from a tank in a machine consumed by a prime mover is disclosed. The system includes: a circuit; a level sensor located in the tank and electrically connected to the circuit, the level sensor being configured to output a fuel level signal indicating the fuel level in the tank; an instrument electrically connected to the circuit and communicating with the level sensor, the instrument being configured to display the fuel level in the tank; a resistor connected to the circuit; a tilt sensor located on the machine and configured to output a tilt signal indicating the tilt angle of the machine at a tilt angle; a voltage sensing terminal electrically connected to a controller and an alternator, the voltage sensing terminal being configured to output a voltage signal indicating the system voltage of the machine; and a controller connected to the circuit and communicating with the level sensor, the tilt sensor, the resistor, and the voltage sensing terminal. The controller is provided with a volume lookup table containing irregular tank compensation data. The controller is configured to: receive the fuel level signal from the level sensor, the tilt signal from the tilt sensor, and the voltage signal from the voltage sensing terminal; process the fuel level signal, the tilt signal, the voltage signal, and the volume lookup table to measure the fuel consumption of the machine; and transmit the fuel consumption to the display.

[0008] According to another aspect of this disclosure, a machine is disclosed. The machine includes: a tank; fuel, the fuel being contained in the tank; a prime mover configured to consume the fuel from the tank; and a system for measuring fuel consumption, the system including: a circuit; a level sensor located in the tank and electrically connected to the circuit, the level sensor being configured to output a fuel level signal indicating the fuel level in the tank; an instrument electrically connected to the circuit and communicating with the level sensor, the instrument being configured to display the fuel level in the tank; a resistor connected to the circuit; a tilt sensor located on the machine and configured to output a tilt signal indicating the tilt angle of the machine at a tilt angle; and a voltage sensing terminal, the voltage... A sensing terminal is electrically connected to the alternator of the prime mover. The voltage sensing terminal is configured to output a voltage signal indicating the system voltage of the machine. A controller is connected to the circuit and communicates with the level sensor, the tilt sensor, the resistor, and the voltage sensing terminal. The controller is provided with a volume lookup table containing irregular box compensation data. The controller is configured to: receive the fuel level signal from the level sensor, the tilt signal from the tilt sensor, and the voltage signal from the voltage sensing terminal; process the fuel level signal, the tilt signal, the voltage signal, and the volume lookup table to measure the fuel consumption of the machine; and communicate the fuel consumption to the display.

[0009] According to another aspect of this disclosure, a method for calculating fuel consumption from a tank in a machine consumed by a prime mover is disclosed. The method includes: activating the prime mover of the machine; receiving a fuel level signal indicating the fuel level in the tank via a level sensor in the tank, and sending the fuel level signal to a controller communicating with the level sensor; receiving a resistance value from the level sensor via a resistor configured to convert the resistance value into a voltage value, and transmitting a resistor signal indicating the voltage value to the controller communicating with the resistor; receiving a voltage signal indicating the system voltage of the machine via a voltage sensing terminal of an alternator connected to the prime mover, and sending the voltage signal to the controller; receiving a tilt signal indicating the tilt angle of the machine via a tilt sensor on the machine, and sending the tilt signal to the controller communicating with the tilt sensor; processing the fuel level signal, the resistor signal, the voltage signal, the tilt signal, and a volume lookup table containing irregular tank compensation data via the controller to calculate the fuel consumption of the machine, and sending the fuel consumption measurement result to a display communicating with the controller; and displaying the fuel consumption measurement result on the display.

[0010] These and other aspects and features of this disclosure will be better understood when the following detailed description is read in conjunction with the accompanying drawings. Attached Figure Description

[0011] Figure 1 This is a perspective view of a machine according to an embodiment of the present disclosure.

[0012] Figure 2 This is a perspective view of a fuel tank for a machine according to an embodiment of the present disclosure.

[0013] Figure 3 This is a perspective view of an irregular fuel tank according to another embodiment of the present disclosure.

[0014] Figure 4 This is a schematic diagram of a system for measuring fuel consumption according to an embodiment of the present disclosure.

[0015] Figure 5 This is a diagram of a fuel tank at an angle according to an embodiment of the present disclosure.

[0016] Figure 6 According to embodiments of this disclosure Figure 3 Volume diagram of the container.

[0017] Figure 7 In a machine according to an embodiment of this disclosure Figure 4 The flowchart of the system operation.

[0018] Figure 8 This is a flowchart of a method for determining fuel consumption in a machine according to embodiments of the present disclosure.

[0019] The accompanying drawings depict one embodiment of the presented disclosure for illustrative purposes only. Those skilled in the art will readily recognize from the following discussion that alternative embodiments of the structures and methods shown herein can be employed without departing from the principles described herein. Detailed Implementation

[0020] Referring now to the accompanying drawings, and specifically to the illustrated example, a machine 100 is shown, exemplified as an exemplary excavator. An excavator is a heavy-duty mobile device designed for moving earth from the ground or terrain at excavation sites in the construction and agricultural industries. While the following detailed description describes exemplary aspects relating to an excavator, it should be understood that this description is equally applicable to the use of other mobile and stationary machines, including but not limited to generators, backhoe excavators, front-end loaders, shovels, cable-stayed loaders, skid steer loaders, wheel loaders, and tractors.

[0021] Now for reference Figure 1The machine 100 includes a ground engagement element 102 (exemplified as a continuous track) that supports a frame 104. It should be understood that the ground engagement element 102 can be any other type of ground engagement element 102, such as, for example, wheels. The machine 100 also includes: a prime mover 106 coupled to an alternator 107 in the frame 104; and a working implement 108 extending from the frame 104 to perform work, such as, for example, digging terrain or otherwise moving soil, earth, or other materials at the digging site. The frame 104 may have an upper slewing body, which is common to excavators and machines used in the agricultural and construction industries for performing "load-slew-unload" operations. As is well known in the art, the prime mover 106 can be an engine, such as a gasoline-fired engine, a diesel-fired engine, or a hydrogen-fired engine. A fuel tank 110 may be provided in or on the frame 104 for storing fuel for the machine 100.

[0022] Now for reference Figures 2-3 The fuel tank used in machine 100 is shown. As depicted, Figure 2 A fuel tank 110 with a regular shape according to one embodiment of the present disclosure is illustrated. Figure 3 An irregularly shaped tank 300 according to another embodiment of fuel tank 110 is illustrated. Fuel tank 110 and irregularly shaped fuel tank 300 may each contain a certain amount of fuel 200 and a level sensor 202 that provides an indication of the remaining fuel level 204 in fuel tank 110 and / or irregularly shaped fuel tank 300 (collectively, "fuel tanks 110, 300"). As is well known in the art, fuel 200 may be oil, gasoline, diesel, hydrogen, or other fuels used as fuel. When prime mover 106 is running, the fuel level 204 in fuel tanks 110, 300 decreases over time as fuel 200 is consumed to power prime mover 106. Level sensor 202 may transmit a fuel level signal via a first line 206 indicating the level of fuel 200 in fuel tanks 110, 300.

[0023] Now for reference Figure 4A schematic diagram illustrating a system 400 for measuring fuel consumption according to an embodiment of the present disclosure is shown. The system 400 for measuring fuel consumption includes: a controller 402, a level sensor 202, an instrument 404, a battery 405, a resistor 406, a circuit 408, a tilt sensor 410, a voltage sensing terminal 412, and a volume lookup table 414. The system 400 for measuring fuel consumption is configured such that the controller 402 receives inputs from the level sensor 202, the resistor 406, the tilt sensor 410, and the voltage sensing terminal 412, and outputs fuel consumption 416 in the form of fuel consumption rate and remaining fuel in fuel tanks 110, 300. The controller 402 can compensate for any measurement result of fuel consumption rate or remaining fuel by comparing the calculated measurement result with the volume lookup table 414. Fuel consumption 416 can be a fuel level signal that conveys the measurement results of fuel consumption, including fuel consumption rate in liters per hour, low fuel level threshold, and / or the amount of fuel 200 remaining in fuel tanks 110 and 300. Fuel consumption 416 can be provided to a display 418 installed in machine 100. Display 418 can be a CAN display or a display panel, etc.

[0024] A level sensor 202 is provided in fuel tanks 110 and 300 to provide indication of the fuel level 204. The level sensor 202 may be selected from the following: a resistive float sensor, a voltage float sensor, a float switch, a capacitive level sensor, an ultrasonic level sensor, an optical level sensor, and a magnetic level sensor.

[0025] The level sensor 202 may be a fuel float sensor, which utilizes a flotation device or float that moves up and down with the fuel level 204 in the fuel tanks 110 and 300. As the level sensor 202 moves, it transmits a fuel level signal indicating the fuel level 204 over time to the controller 402. The level sensor 202 may also have a digital interface that allows integration with various monitoring and control systems within the machine 100.

[0026] In one embodiment, the level sensor 202 may be provided as a resistive float sensor that operates based on the resistance change caused by a change in the fuel level 204. The resistive float sensor also includes a resistive element attached to the float. As the float rises or falls with the changing fuel level 204, the position of the resistive element changes. The resistive element may be made of a conductive material (such as a metal strip or wire) with a known resistance value. The resistive element may be a variable resistor or a fixed resistor with a resistance value specific to the level sensor 202. The fuel level 204 is determined by measuring the resistance of the resistive element. When the level sensor 202 moves, it changes the contact area or position of the resistive element, which in turn changes the resistance value. This resistance change is then measured to provide a resistance signal corresponding to the fuel level 204 and can be communicated to the controller 402. The resistance value can then be converted into a voltage level signal that can be measured by the controller 402.

[0027] Instrument 404 may be an analog instrument configured to display real-time monitoring of the fuel level 204 in fuel tanks 110, 300. Instrument 404 is electrically connected to circuit 408 and to level sensor 202, controller 402, and resistor 406. Instrument 404 may be configured to measure the consumption rate, quantity, or content of fuel 200 in fuel tanks 110, 300, and is provided with a visual display to show such information to the operator as is well known in the art. As is well known in the art, instrument 404 may be connected to battery 405 for power.

[0028] Resistor 406 can be one of the following: a pull-up resistor, a metal film resistor, a carbon film resistor, a carbon film pull-up resistor, or a metal film pull-up resistor. Resistor 406 can be electrically and / or communicatively connected to circuit 408. Resistor 406 can have a calculated value and communicate with controller 402 via first line 206. Resistor 406 can be powered by +5V from controller 402 and is configured to convert the resistance from level sensor 202 into a voltage value and transmit that voltage value to controller 402. Resistor 406 can be connected to controller 402 using logic components configured in a pull-up manner, wherein resistor 406 can be connected between a high signal (such as +5V) inside controller 402 and a corresponding pin in controller 402.

[0029] Voltage sensing terminal 412 can be one of the following: a power supply terminal, a test point, a voltage sensing point, a voltage measurement point, a voltage regulator feedback, an integrated circuit pin, a sensing pin, a reference pin, and an alternator R terminal. Voltage sensing terminal 412 can be electrically connected to alternator 107. Voltage sensing terminal 412 can also be configured to communicate with controller 402. Voltage sensing terminal 412 is configured to detect the voltage from alternator 107 and send the voltage measurement result to controller 402 via a voltage signal. Voltage sensing terminal 412 can be configured to provide DC voltage to system 400 whenever prime mover 106 is turned on or activated to measure fuel consumption. In one embodiment, alternator R terminal can be used as voltage sensing terminal 412 to send a voltage signal to controller 402 indicating the voltage from alternator 107, which can be used to measure an electrical load indicating an increase or decrease in power consumption of prime mover 106. An increase or decrease in power consumption of prime mover 106 may affect the fuel consumption rate of fuel 200, causing fuel level 204 to change faster or slower.

[0030] As is well known in the art, circuit 408 may be a simple circuit. In one embodiment, instrument 404 (as an analog instrument) may communicate with level sensor 202 via the end of first line 206 of circuit 408. Controller 402 may be an electronic controller (ECM) configured to communicate with first line 206 via second line 420 to receive fuel level signals and resistor signals in response to changes in fuel level at level sensor 202. Level sensor 202 and resistor 406 may be configured to communicate with ECM via the other end of first line 206. As is well known in the art, first line 206 and second line 420 may be wires for connection to circuits and other electrical components. Controller 402 may be embodied as a single microprocessor or multiple microprocessors including components for controlling various operations in machine 100. The microprocessor may be configured to perform the functions of controller 402. Controller 402 may be embodied as a general-purpose machine microprocessor capable of controlling multiple machine functions. The controller 402 may include a memory, an auxiliary storage device, a processor, and any other components for running applications and storing a collection of received data and signals.

[0031] Now for reference Figure 5The diagram illustrates a fuel tank 110 at an angle of inclination according to an embodiment of the present disclosure. An inclination sensor 410 may be mounted on a frame 104 or the chassis of the machine 100 and is used to measure the inclination angle 500 of the fuel tanks 110, 300 relative to the ground. The inclination sensor 410 provides an inclination signal including an output voltage value proportional to or corresponding to the inclination angle 500. The inclination sensor 410 may be one of the following configured to measure the inclination or gradient of the machine 100 on the ground: an inclinometer, a gradient sensor, a microelectromechanical inclinometer, an electrolytic inclination sensor, a potentiometer inclinometer, and an inertial measurement unit, etc. The inclination sensor 410 may be configured to detect the inclination of two axes (such as the x-axis or longitudinal axis of the machine and the y-axis or transverse axis of the machine) such that the inclination or angle of inclination of the fuel tanks 110, 300 is equivalent to the angle of inclination of the machine 100.

[0032] The resistor signal from resistor 406 and the tilt signal from tilt sensor 410 provide the controller with simultaneous changes in the fuel level 204 and tilt angle 500 of fuel tanks 110 and 300 to determine the fuel consumption 416 of machine 100. When prime mover 106 is running, fuel 200 is consumed, thereby reducing the fuel level 204 and the remaining fuel 200 in fuel tanks 110 and 300. Simultaneously, tilt sensor 410 detects changes in the tilt angle 500 of fuel tank 110 caused by movement or positional changes of machine 100.

[0033] When machine 100 moves or otherwise operates, the tilt angle 500 changes, which may affect the fuel level 204. Therefore, the tilt angle 500 affects the fuel level 204 reading in irregular tank geometries. When fuel tanks 110 and 300 are tilted, the position of level sensor 202 within fuel tanks 110 and 300 changes from a first level 502 to a second level 504. Due to the tilt angle 500, when the amount of fuel 200 in fuel tanks 110 and 300 is the same, the second level 504 may cause the position of level sensor 202 to be higher than the first level 502. To compensate for the changes in fuel level 204 caused by the tilt angle 500 at various gradients in the workplace, a tilt sensor 410 is provided to compensate for the changes in fuel level 204 due to the tilt angle 500. By measuring these changes over time and compensating for the tilting of fuel tanks 110 and 300, fuel consumption 416 can be accurately measured and displayed on display 418. For example, when machine 100 is at an angle of inclination, fuel level 204 can be calculated based on non-inclination fuel level 506. Fuel level 204 can be calculated by subtracting the difference 508 between the non-inclination fuel level at first level 502 and the fuel level at second level 504 at an angle of inclination 500 from the non-inclination fuel level at first level 502, thus determining the volume at first level 502. First level 502 is equal to second level 504 minus the difference 508, assuming the same volume of fuel 200. As is well known in the art, the difference 508 can be determined using the angle of inclination 500 measured by tilt sensor 410. As is well known in the art, the volume of fuel 200 in fuel tanks 110, 300 can be calculated by multiplying first level 502 by the volume of fuel tanks 110, 300.

[0034] Now for reference Figure 6 A volume diagram of an irregularly shaped tank 300 according to one embodiment of the present disclosure is illustrated. When the fuel level 204 in the irregularly shaped tank 300 changes, the level sensor 202 changes its position within the irregularly shaped tank 300. The fuel level 204 in the irregularly shaped tank 300 does not necessarily provide a 1:1 measurement of the volume percentage from the fuel level 204 to the remaining fuel 200. For example, as... Figure 6 As shown, when the liquid level sensor 202 is below 50% of the tank height, the volume of fuel remaining in the tank is 50%. Figure 6 The volume analysis shown is available in volume lookup table 414.

[0035] Volume lookup table 414 can be provided as a dataset to controller 402 for fuel tanks 110 and 300. Volume lookup table 414 may provide irregular tank compensation data, which includes multiple reference tanks with irregular geometry, 3D fuel tank models including different fuel volumes, and volume analysis data of the irregular tank geometry from empty to full at multiple tilt positions. For example, volume lookup table 414 can provide further volume analysis under various tilt conditions, such as the fuel level 204 and remaining volume in irregular tank 300 at tilt angles of 15°, 30°, 45°, and 60°. The volume analysis provided in volume lookup table 414 may also include data consisting of the remaining fuel volume percentage (%), which corresponds to the voltage of the level sensor 202 measured at various tilt positions in fuel tanks 110 and 300 from empty to full.

[0036] The controller 402 calculates the tilt angle 500 of machine 100 based on the tilt signal received from the tilt sensor 410. Based on the tilt angle 500, the controller 402 calculates the volume compensation required due to the tilt of machine 100 on the ground and provides the volume 200 of the remaining fuel in fuel tanks 110, 300. The controller 402 calculates the tilt compensation required due to the tilt angle 500 of machine 100 to determine the actual fuel volume in fuel tanks 110, 300. Additionally, the controller 402 is configured with a volume lookup table 414 to compensate for errors in measuring fuel consumption 416 caused by the irregular geometry of the irregular box 300. In one embodiment, when a resistive float sensor is used as the level sensor 202, the controller 402 can be configured to determine the float sensor voltage output (which may also correspond to the volume derived from the 3D model box or reference box provided by the volume lookup table 414) to measure the accurate volume of remaining fuel in the irregular box 300 at an inclination angle of 500.

[0037] The controller 402 can process the volume lookup table 414 and irregular box compensation data to compensate for any errors in the measurement results of fuel consumption 416. The controller 402 can also process fuel level signals, resistor signals, voltage signals and tilt signals. The controller 402 is configured to receive fuel level signals, resistor signals, voltage signals and tilt signals from the level sensor 202, resistor 406, voltage sensing terminal 412 and tilt sensor 410 respectively to make the following determinations: (1) determining the tilt angle 500 of the machine 100 via the tilt sensor 410; (2) determining the geometry of the fuel tanks 110 and 300, thereby determining the volume of the fuel tanks 110 and 300 via the volume lookup table 414; (3) determining the operating time of the prime mover 106 via the voltage sensing terminal 412; and (4) determining the fuel consumption 416 of the machine 100.

[0038] For example, when the irregular tank 300 is full of fuel 200, the level sensor 202 can provide a fuel level signal 204 in the form of a voltage (such as 0.3 volts), which corresponds in the volume lookup table 414 to 100% volume and 100% volume distribution of the remaining fuel 200 in the irregular tank 300. Over time, the level sensor 202 can subsequently provide new voltage readings and convey a fuel level signal in the form of a voltage (1.5 volts), which corresponds in the volume lookup table 414 to 25% volume and 35% volume distribution of the remaining fuel 200 in the irregular tank 300.

[0039] The machine 100 may include a display 418 with an alert buzzer or alarm function. The display 418 is communicatively connected to a controller 402, which issues control signals to: (1) indicate and display fuel consumption 416 on the display 418; and (2) command the alert buzzer to issue an audible alert, such as an indication that the remaining fuel 200 in fuel tanks 110, 300 is below 20% of its capacity, if the fuel level 204 is at a low threshold. Fuel consumption 416 may be displayed in liters per hour or another similar consumption rate. Fuel consumption 416 may also be transmitted wirelessly to a back-end system to alert owners or operators located at locations different from the machine 100 to the low fuel level 204, facilitating refueling and efficient management of fuel tanks 110, 300.

[0040] Industry applicability

[0041] In practice, this disclosure is applicable to many industries, including but not limited to construction, earthmoving, mining, energy, and agriculture. Specifically, the systems, machines, and methods of this disclosure can be used to detect the fuel consumption of operating machinery, including but not limited to generators, backhoe excavators, front-end loaders, shovels, cable loaders, skid steer loaders, wheel loaders, tractors, and similar machines. Although the foregoing detailed description is specifically referenced to excavators, it should be understood that its teachings can also be applied to other machines. The system 400 for measuring fuel consumption can be provided as a retrofit device for these other applications requiring operator-operated machinery.

[0042] Now for reference Figure 7 A flowchart illustrating operation 700 of a system 400 for measuring fuel consumption of machine 100 according to an embodiment of the present disclosure is provided. As is well known in the art, in operation 702, machine 100 is activated or placed in a start-up state, thereby activating prime mover 106 to begin consuming fuel 200 from fuel tanks 110, 300. In operation 704, when machine 100 is activated or placed in a key-on state for operation of machine 100, controller 402 and tilt sensor 410 are initialized or otherwise activated. Controller 402 and tilt sensor 410 may be initialized before or simultaneously with the start of operation of machine 100.

[0043] In operation 706, controller 402 receives fuel level signals and tilt signals from level sensor 202 and tilt sensor 410, respectively. In operation 708, controller 402 calculates the fuel level signal 204 received from level sensor 202 and the tilt angle 500 received from tilt sensor 410. Controller 402 may further utilize resistor signals from resistor 406 and irregular box compensation data provided by volume lookup table 414 to perform operation 708. In operation 710, controller 402 may process volume lookup table 414 to compensate for any errors in the measurement of fuel level 204 at tilt angle 500 using irregular box compensation data from a volume analysis of a fuel tank with irregular box geometry. In operation 712, fuel consumption 416 is calculated in volume over time (e.g., liters per hour or gallons per hour). In operation 714, voltage sensing terminal 412 provides controller 402 with a timestamp input of the engine crankshaft or the operating time of prime mover 106. When the prime mover 106 is activated or turned on, the voltage sensing terminal 412 can also provide the DC voltage of the system 400 for measuring fuel consumption. The controller 402 can determine the actual operating hours of the prime mover 106 by the voltage signal received from the voltage sensing terminal 412. In operation 716, the controller 402 transmits the fuel consumption 416 to the display 418 to show the fuel consumption 416 measurement result. In operation 718, the system 400 for measuring fuel consumption returns to operation 706 and continuously receives the fuel level signal from the level sensor 202, the resistance signal from the resistor 406, the tilt signal from the tilt sensor 410, and the voltage signal from the voltage sensing terminal 412 to continuously calculate the fuel consumption 416 during the operation of the machine 100.

[0044] Now for reference Figure 8 According to one embodiment of this disclosure, a method for calculating fuel consumption 800 of fuel consumed by prime mover 106 from fuel tanks 110, 300 of machine 100 is provided. In step 802, prime mover 106 of machine 100 is activated and begins consuming fuel 200 from fuel tanks 110, 300. In step 804, controller 402 receives a fuel level signal, transmitted by level sensor 202, indicating a change in fuel level 204 in fuel tanks 110, 300. In step 804, level sensor 202 may transmit the fuel level signal as a resistance value to controller 402 and resistor 406.

[0045] In step 806, resistor 406 receives a resistance value from the fuel level signal and converts the resistance value into a voltage value. In step 806, the resistor further transmits the voltage value to controller 402 via a resistor signal. In step 808, voltage sensing terminal 412 receives a voltage signal indicating the system voltage of machine 100 during operation. Voltage sensing terminal 412 sends the voltage signal to controller 402 to convey the voltage of alternator 107. In step 810, tilt sensor 410 receives a tilt signal of the machine's tilt angle 500 and transmits a signal indicating the gradient of machine 100 on the tilted surface to controller 402.

[0046] In step 812, controller 402 processes the fuel level signal, resistor signal, power signal, tilt signal, and irregular box compensation data from volume lookup table 414 to measure the fuel consumption 416 of machine 100. Controller 402 transmits the fuel consumption 416 measurement result to display 418. In step 814, display 418 displays the fuel consumption 416 measurement result.

[0047] The system 400 for measuring fuel consumption can be configured to prevent airlock in the fuel line by alerting the operator when the fuel level 204 is considered low. For example, when the fuel level 204 in fuel tanks 110, 300 is below 20% of its capacity, the controller 402 can activate an audible buzzer or alert function (such as a high-volume alarm (i.e., 90 dB)) and / or activate a flashing icon at a rapid repetition frequency such as at least 2.5 Hz (greater than 1 / 16 second) to alert the owner / operator of machine 100. If machine 100 is unattended and continues to operate, the system 400 for measuring fuel consumption can be further connected via the controller 402 to other operating systems in machine 100, such as the machine ignition control module, to disable the operation of machine 100. As is well known in the art, machine 100 can be disabled after a predetermined period of time or controlled from a background system via an external network communicating with the controller 402.

[0048] The system 400 for measuring fuel consumption can be integrated with other control systems, such as engine control modules and telematics systems, to optimize performance and promote efficient fuel consumption. The telematics system can use GPS technology and wireless communication to track and report vehicle location, speed, and fuel consumption data in real time. The controller 402 can also further transmit information to a background unit via a telematics device for recording and processing data from the system 400 for measuring fuel consumption, thereby generating analytical reports on fuel tank volume status and fuel consumption rate for selected time periods. Such reports can provide information on fuel replenishment and potential theft of fuel in fuel tanks 110 and 300. The system 400 for measuring fuel consumption may include data logging capabilities that allow the storage and analysis of measured fuel consumption data 416 over time, providing insights into long-term fuel usage patterns and trends. The controller 402 can also be configured to differentiate between operator machine shifts and non-shift periods, especially at night. The system 400 can be connected to a relay to energize the system at regular intervals, such as every 90 minutes, to monitor for fuel theft.

[0049] As can be seen from the foregoing, the technology disclosed herein is applicable to various industries, such as, but not limited to, agriculture, construction, and mining, which employ mobile and stationary machinery, such as automobiles, generators, excavators, backhoe excavators, rope shovels, skid steer loaders, wheel loaders, tractors, and similar machines with fuel tanks to provide fuel consumed by prime movers and engines.

Claims

1. A system (400) for measuring fuel consumption (416) of fuel (200) consumed by a prime mover (106) from a tank (110) in a machine (100) and compensating for errors in the measurement results, the system (400) comprising: Circuit (408); A level sensor (202) is located in the tank and electrically connected to the circuit (408), and the level sensor (202) is configured to output a fuel level (204) signal indicating the fuel level (204) in the tank (110); An instrument (404) is electrically connected to the circuit (408) and communicates with the level sensor (202). The instrument (404) is configured to display (418) the fuel level (204) in the tank. Resistor (406), the resistor being electrically connected to the circuit (408); A tilt sensor (410) is located on the machine (100) and is configured to output a tilt signal indicating the tilt angle (500) of the machine (100) at a tilt angle (500); A voltage sensing terminal (412) is electrically connected to an alternator (107) and is configured to output a voltage signal indicating the system (400) voltage of the machine (100); A controller (402), connected to the circuit (408) and communicating with the level sensor (202), the tilt sensor (410), the resistor (406), and the voltage sensing terminal (412), is provided with a volume lookup table (414) containing irregular box (300) compensation data, and the controller (402) is configured to: Receive the fuel level (204) signal from the level sensor (202), the tilt signal from the tilt sensor (410), and the voltage signal from the voltage sensing terminal (412); The fuel level (204) signal, the tilt signal, the voltage signal, and the volume lookup table (414) are processed to measure the fuel consumption (416) of the machine (100); and The fuel consumption (416) is communicated to the display (418).

2. The system (400) according to claim 1, wherein the fuel consumption (416) includes at least one of the following: fuel consumption (416) rate, remaining fuel (200) volume in the tank (110) and low fuel (200) level.

3. The system (400) according to claim 2, wherein: The liquid level sensor (202) is selected from the following: a resistive float sensor, a voltage float sensor, a float switch, and a capacitive liquid level sensor (202). The instrument (404) is an analog instrument (404). The resistor (406) is selected from the following: pull-up resistor (406), metal film resistor (406), carbon film resistor (406), carbon film pull-up resistor (406), and metal film pull-up resistor (406). The voltage sensing terminal (412) is selected from one of the following: a power supply terminal, a voltage test point, a voltage regulator feedback, an integrated circuit (408) pin, a voltage sensing pin, a reference pin, and an alternator (107) R terminal; and The tilt sensor (410) is selected from the following: inclinometer, gradient sensor, microelectromechanical inclinometer, electrolytic tilt sensor (410), and potentiometer inclinometer.

4. The system (400) of claim 3, wherein the fuel level (204) signal conveys a resistance value indicating the fuel level (204) to the resistor (406), the resistor (406) being configured to convert the resistance value into a voltage value, and the resistor (406) conveying the voltage value to the controller (402) via the resistor (406) signal.

5. The system (400) of claim 3, wherein the resistor (406) is powered by +5V from the controller (402).

6. The system (400) according to claim 4, wherein: The irregular box (300) compensation data includes multiple reference boxes having irregular box geometry (3D), wherein at least one reference box corresponds to the box (110) in the machine (100), each reference box including multiple volumetric analysis data of multiple fuel (200) levels from empty to full in each reference box for multiple tilt angles of the reference box, the irregular box (300) compensation data corresponding to the voltage value and the remaining fuel (200) volume; and The controller (402) is configured to: Determine the geometry and volume of the box (110); The fuel level (204) signal, the resistor (406) signal, the tilt signal, and the voltage signal are processed to calculate the fuel consumption (416) of the machine (100); and The measurement error in the measurement result of the fuel consumption (416) is compensated using the compensation data of the irregular box (300) for the change of the fuel level (204) in the box (110).

7. The system (400) according to claim 3, wherein the tilt sensor (410) is mounted on the chassis of the machine (100).

8. The system (400) of claim 3, further comprising a telematics system (400) communicating with the controller (402), the telematics system (400) being configured to use GPS technology and a wireless communication system (400) to track and report the location, speed and fuel consumption (416) data of the machine (100) in real time.

9. A machine (100), said machine comprising: Box (110); Fuel (200), the fuel being contained in the tank (110); Prime mover (106), which is configured to consume the fuel (200) from the tank (110). The system (400) according to claim 1.

10. The machine (100) of claim 9, further comprising a relay communicating with the controller (402), the controller (402) being configured to activate and deactivate the machine (100) at multiple time intervals.

11. A method for calculating fuel consumption (800) of fuel (200) consumed by a prime mover (106) from a tank (110) in a machine (100) and compensating for errors in the measurement results, the method comprising: The prime mover (106) of the machine (100) is activated. The fuel level (204) signal, which indicates the fuel level (204) in the tank (110), is received via the level sensor (202) in the tank (110), and the fuel level (204) signal is sent to the controller (402) which communicates with the level sensor (202). A resistance value is received from the level sensor (202) via a resistor (406), the resistor (406) being configured to convert the resistance value into a voltage value and to transmit a resistor (406) signal indicating the voltage value to the controller (402) communicating with the resistor (406). The voltage signal indicating the system (400) voltage of the machine (100) is received via the voltage sensing terminal (412) of the alternator (107) connected to the prime mover (106), and the voltage signal is sent to the controller (402). The tilt signal indicating the tilt degree (500) of the machine (100) is received via the tilt sensor (410) on the machine (100), and the tilt signal is sent to the controller (402) which communicates with the tilt sensor (410). The controller (402) processes the fuel level (204) signal, the resistor (406) signal, the voltage signal, the tilt signal, and a volume lookup table (414) containing compensation data for the irregular box (300) to calculate the fuel consumption (416) of the machine (100), and sends the measurement result of the fuel consumption (416) to a display (418) communicating with the controller (402); and The measurement result of the fuel consumption (416) is displayed on the display (418).

12. The method of claim 11, wherein the irregular box (300) compensation data comprises a plurality of reference boxes having an irregular box geometry (3D), wherein at least one reference box corresponds to the box (110) in the machine (100), each reference box comprising a plurality of volumetric analysis data for a plurality of fuel (200) levels in each reference box from empty to full at a plurality of tilt angles, the plurality of volumetric analysis data providing values ​​from the plurality of reference boxes corresponding to the voltage value of the resistor (406), the corresponding values ​​indicating the remaining fuel (200) volume percentage in the box (110).

13. The method according to claim 12, further comprising: The location, speed and fuel consumption (416) of the machine (100) are tracked via a telematics system (400) that communicates with the controller (402). The telematics system (400) is configured to utilize a GPS technology system (400) and a wireless communication system (400). as well as The measurement results of the machine's (100) position, speed, and fuel consumption (416) are reported to the background system.

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