System and method for measuring, and compensating errors in measurements of, fuel consumption
Patent Information
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- CATERPILLAR INC
- Filing Date
- 2024-05-17
- Publication Date
- 2026-05-06
Smart Images
Figure US2024029829_02012025_PF_FP_ABST
Abstract
Description
[0001] Description
[0002] SYSTEM AND METHOD FOR MEASURING, AND COMPENSATING ERRORS IN MEASUREMENTS OF, FUEL CONSUMPTION
[0003] Technical Field
[0004] The present disclosure relates to a system for measuring fuel consumption, and more particularly relates to a system for measuring fuel consumption and compensating errors in the measurement of fuel consumption.
[0005] Background
[0006] Machines such as excavators, trucks, generator sets and other types of mobile or stationary machines known in the art have fuel tanks for storing fuel, for example, gasoline or diesel. The fuel stored in these fuel tanks may be routed via fuel lines and supplied to prime movers for combustion and powering any operations associated with the machine. In some cases, these machines may operate while being stationary, for example, on a horizontal or an inclined surface. In other cases, these machines may need to operate while moving, for example, on a horizontal or an inclined surface. Regardless of the operating condition, it may be prudent to monitor fuel consumption over time to efficiently manage fuel consumption and plan refueling accordingly.
[0007] Determining dynamically changing rates of fuel consumption and volumes of fuel remnant in fuel tanks of machines continues to remain challenging owing to a variety of factors as both mobile and stationary machines are often operated under different operating conditions such as loads, terrains, surface gradients and inclinations, and under different environmental conditions such as temperature and humidity that can significantly affect fuel consumption rates making fuel consumption measurements difficult. Conventional fuel gauges alone are incapable of providing precise measurements, thereby leading to errors in determining the volume of fuel remnant in the tank. Moreover, as fuel sloshes around in a tank due to machine or implement movement, inaccuracies are introduced into the readings output by conventional designs and setups of fuel sensors thus making it difficult to determine the exact amount of fuel remnant in the tank.
[0008] Moreover, irregularly shaped tanks for example, irregular polyhedrons designed to confirm with any space constraints of the machine can impart complexity to fuel consumption measurements and calculations of fuel remaining by making it harder to accurately measure the volume of fuel remnant in the irregularly shaped tank. Additionally, irregular tank geometries can cause fuel to slosh around inside the tank, which can further negatively affect the accuracy of fuel level sensors and gauges. As described herein, “irregular tank geometries” refers to fuel tanks that have a non-standard shape or structure, which may include complex curves, varying widths, or irregular surfaces. These unconventional geometries make it difficult to accurately measure the volume of fuel in the tank regardless of whether the machine is stationary or moving, leading to errors in measuring fuel consumption and the fuel remaining in the tank. Therefore, accurate systems for measuring fuel consumption are necessary to provide precise fuel consumption and remaining fuel calculations.
[0009] Others have attempted to develop systems for measuring fuel consumption of fuel stored in tanks with irregular geometries. For example, Korean Application KR 20160120021 (hereinafter referred to as “the ’021 reference”) discloses a fuel tank system for calculating fuel consumption having a tank body, a detection unit, and a calculation unit. However, the ’021 reference discloses that the fuel tank system measures fuel consumption in a tank body that is formed in a rectangular parallelepiped shape and does not measure fuel, or compensate for errors in measurement of fuel, when fuel is stored in tanks having irregular geometries. The ’021 reference fails to provide a system for measuring fuel consumption that provides precise fuel consumption and calculations for fuel that is remnant in tanks having irregular geometries.
[0010] Hence, there exists a need for a system for measuring fuel consumption that accurately measures the dynamically changing rate of fuel consumption and calculates an exact volume of fuel remnant in fuel tanks, esp. when the tank has an irregular shape, for efficient fuel consumption monitoring and subsequent planning of a refueling routine for the tank present on the machine.
[0011] Summary
[0012] In accordance with one aspect of the disclosure, a system for measuring fuel consumption of a fuel consumed by a prime mover from a tank in a machine is disclosed. The system comprises: an electrical circuit; a level sensor in the tank electrically connected to the electrical circuit, the level sensor is configured to output a fuel level signal indicative of a fuel level in the tank; a gauge electrically connected to the electrical circuit and in communication with the level sensor, the gauge is configured to display the fuel level in the tank; a resistor electrically connected to the electrical circuit; a tilt sensor on the machine configured to output a tilt signal indicative of inclination angles of the machine on an inclination; a voltage sense terminal electrically connected to the controller and an alternator, the voltage sense terminal is configured to output a voltage signal indicative of a system voltage of the machine; and a controller connected to the electrical circuit and in communication with the level sensor, the tilt sensor, the resistor, and the voltage sense terminal. The controller is provided with a volumetric look-up table having 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 sense terminal; process the fuel level signal, the tilt signal, the voltage signal, and the volumetric look-up table to measure the fuel consumption of the machine; and communicate the fuel consumption to the display.
[0013] In accordance with another aspect of the disclosure, a machine is disclosed. The machine comprises a tank; a fuel in the tank; a prime mover configured to consume the fuel from the tank; a system for measuring fuel consumption of the fuel including: an electrical circuit; a level sensor in the tank electrically connected to the electrical circuit, the level sensor is configured to output a fuel level signal indicative of a fuel level in the tank; a gauge electrically connected to the electrical circuit and in communication with the level sensor, the gauge is configured to display the fuel level in the tank; a resistor electrically connected to the electrical circuit; a tilt sensor on the machine configured to output a tilt signal indicative of inclination angles of the machine on an inclination; a voltage sense terminal electrically connected to an alternator of the prime mover, the voltage sense terminal is configured to output a voltage signal indicative of a system voltage of the machine; a controller connected to the electrical circuit and in communication with the level sensor, the tilt sensor, the resistor, and the voltage sense terminal, the controller is provided with a volumetric look-up table having irregular tank compensation data and 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 sense terminal; process the fuel level signal, the tilt signal, the voltage signal, and the volumetric look-up table to measure the fuel consumption of the machine; and communicate the fuel consumption to the display.
[0014] In accordance with another aspect of the disclosure, a method for calculating fuel consumption of fuel consumed by a prime mover from a tank in a machine is disclosed. The method comprises: activating the prime mover of the machine; receiving a fuel level signal indicative of a fuel level in the tank, via a level sensor in the tank, and sending the fuel level signal to a controller in communication with the level sensor; receiving a resistance value from the level sensor, via a resistor, the resistor configured to convert the resistance value into a voltage value, and communicating a resistor signal indicative of the voltage value to the controller in communication with the resistor; receiving a voltage signal indicative of system voltage of the machine, via a voltage sense terminal connected to an alternator of the prime mover, and sending the voltage signal to the controller; receiving a tilt signal indicative of an inclination of the machine, via a tilt sensor on the machine, and sending the tilt signal to the controller in communication with the tilt sensor; processing the fuel level signal, the resistor signal, the voltage signal, the tilt signal, and a volumetric look-up table having irregular tank compensation data, via the controller, to calculate a fuel consumption of the machine, and sending measurements of fuel consumption to display in communication with the controller; and displaying the measurements of fuel consumption on the display.
[0015] These and other aspects and features of the present disclosure will be better understood upon reading the following detailed description when read in conjunction with the accompanying drawings.
[0016] Brief Description of the Drawings
[0017] FIG. 1 is a perspective view of a machine, according to an embodiment of the present disclosure.
[0018] FIG. 2 is a perspective view of a fuel tank for use in a machine, according to an embodiment of the present disclosure.
[0019] FIG. 3 is a perspective view of an irregular fuel tank, according to another embodiment of the present disclosure.
[0020] Fig. 4 is a schematic diagram of a system for measuring fuel consumption, according to an embodiment of the present disclosure.
[0021] FIG. 5 is a diagram of the fuel tank on an inclination, according to an embodiment of the present disclosure.
[0022] Fig. 6 is a volumetric chart of the tank of Fig. 3, according to an embodiment of the present disclosure.
[0023] FIG. 7 is a flow-chart of an operation of the system of Fig. 4 in a machine, according to an embodiment of the present disclosure.
[0024] FIG. 8 is a flow-chart of a method of determining fuel consumption in a machine, according to an embodiment of the present disclosure.
[0025] The figures depict one embodiment of the presented disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following discussion that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles described herein. Detailed Description
[0026] Referring now to the drawings, and with specific reference to the depicted example, a machine 100 is shown, illustrated as an exemplary excavator. Excavators are heavy mobile equipment designed to move earth material from the ground or landscape at a dig site in the construction and agricultural industries. While the following detailed description describes an exemplary aspect in connection with the excavator, it should be appreciated that the description applies equally to the use of the present disclosure in other mobile and stationary machines, including, but not limited to, generators, backhoes, front-end loaders, shovels, draglines, skid steers, wheel loaders, and tractors, as well.
[0027] Referring now to Fig. 1, the machine 100 comprises ground engaging elements 102, illustrated as continuous tracks, that support a frame 104. It should be contemplated that the ground engaging elements 102 may be any other type of ground engaging elements 102 such as, for example, wheels, etc. The machine 100 further includes a prime mover 106 coupled to an alternator 107 in the frame 104, a work implement 108 extending from the frame 104 for conducting work, such as, for example, excavating landscapes or otherwise moving earth, soil, or other material at a dig site. The frame 104 may have an upper swiveling body common with excavators and machines the agricultural and construction industries for conducting load-swing-dump operations. The prime mover 106 may be an engine such as a gasoline combustion engine, diesel combustions engine, or hydrogen combustion engine, as generally known in the arts. A fuel tank 110 may be provided in or on the frame 104 for storing fuel for the machine 100.
[0028] Now referring to Figs. 2-3 representing fuel tanks used in the machine 100. As depicted, Fig. 2 illustrates the fuel tank 110 as a uniform shape, according to one embodiment of the disclosure. Fig. 3 illustrates an irregular tank 300, according to another embodiment of the fuel tank 110. The fuel tank 110 and the irregular tank 300 may each contain an amount of fuel 200 and a level sensor 202 that provides an indication of a fuel level 204 remaining in the fuel tank 110 and / or irregular tank 300 (collectively “Fuel Tanks 110, 300”). The fuel 200 may be an oil, gasoline, diesel, hydrogen, or other fuel used as fuel, as generally known in the arts. As the prime mover 106 operates, the fuel level 204 in the Fuel Tanks 110, 300 decreases over time because the fuel 200 is consumed to power the prime mover 106. The level sensor 202 may communicate a fuel level signal via a first line 206 that indicates the level of fuel 200 in the Fuel Tanks 110, 300.
[0029] Now referring to Fig. 4, a schematic diagram of a system 400 for measuring fuel consumption is illustrated, according to an embodiment of the present disclosure. The system 400 for measuring fuel consumption comprises a controller 402, the level sensor 202, a gauge 404, a battery 405, a resistor 406, an electrical circuit 408, a tilt sensor 410, a voltage sense terminal 412, and a volumetric look-up table 414. The system 400 for measuring fuel consumption is configured to have the controller 402 receive inputs from the level sensor 202, the resistor 406, the tilt sensor 410, and the voltage sense terminal 412 and outputs a fuel consumption 416 in the form of a fuel consumption rate and fuel remaining in the Fuel Tanks 110, 300. The controller 402 may compensate for any measurements in the fuel consumption rate or fuel remaining by comparing the calculated measurements with the volumetric look-up table 414. The fuel consumption 416 may be a fuel level signal that communicates measurements of fuel consumption consisting of a fuel consumption rate in liters per hour, a low fuel level threshold, and / or the amount of fuel 200 remaining in the Fuel Tanks 110, 300. The fuel consumption 416 may be provided to a display 418 provided in the machine 100. The display 418 may be a CAN display, a display panel, or the like.
[0030] The level sensor 202 is provided in the Fuel Tanks 110, 300 to provide an indication of the fuel level 204. The level sensor 202 may be chosen from one of: a resistive-based float sensor, a voltage-based float sensor, a float switch, a capacitive level sensor, an ultrasonic level sensor, an optical level sensor, and a magnetic level sensor.
[0031] The level sensor 202 may be a fuel float sensor which may utilize a floatation device or float that moves up and down with the fuel level 204 in the Fuel Tanks 110, 300. As the level sensor 202 moves, it may communicate a fuel level signal to the controller 402 indicating the fuel level 204 over time. The level sensor 202 may also have digital interfaces that allow for integration with various monitoring and control systems in the machine 100.
[0032] In one embodiment, the level sensor 202 may be provided as a resistance-based float sensor, which operates based on changes in resistance for changes in the fuel level 204. The resistance-based float sensor also consists of 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 resistance element can be a variable resistor or a fixed resistor with a resistance value specific to the level sensor 202. By measuring the resistance of the resistive element, the fuel level 204 can be determined. As the level sensor 202 moves, it changes the contact area or position of the resistive element, which, in turn, changes the resistance level. This resistance change is then measured to provide a resistance signal that corresponds to the fuel level 204 and may be communicated to the controller 402. The resistance value may then be converted into a voltage level signal that can be measured by the controller 402.
[0033] The gauge 404 may be an analog gauge configured to display realtime monitoring of the fuel level 204 in the Fuel Tanks 110, 300. The gauge 404 is electrically connected to the electrical circuit 408, as well as the level sensor 202, the controller 402, the resistor 406. The gauge 404 may be configured to measure the rate of consumption, amount, or contents of the fuel 200 in the Fuel Tanks 110, 300 and provided with a visual display to display such information to an operator, as generally known in the arts. The gauge 404 may be connected to the battery 405 for power, as generally known in the arts.
[0034] The resistor 406 may be one of a pull-up resistor, a metal film resistor, a carbon film resistor, a carbon film pull-up resistor, a metal film pull-up resistor. The resistor 406 may be electrically and / or communicably connected to the electrical circuit 408. The resistor 406 may be of a calculated value disposed in communication with the controller 402 via the first line 206. The resistor 406 may be supplied by +5V from the controller 402 and configured to convert resistance from the level sensor 202 to a voltage value and communicate the voltage value to the controller 402. The resistor 406 may be connected to the controller 402 with a logic that configured in a pull-up manner, where the resistor 406 may be connected between a high signal, such as +5 V inside the controller 402 and to a respective pin in the controller 402.
[0035] The voltage sense terminal 412 may be one of: a power supply terminal, a test point, a voltage sensing point, a voltage measurement point, a voltage regulator feedback, an integrated electrical circuit pin, a sense pin, a reference pin, and an alternator R-terminal. The voltage sense terminal 412 may be electrically connected to the alternator 107. The voltage sense terminal 412 may be also disposed in communication with the controller 402. The voltage sense terminal 412 is configured to detect voltages from the alternator 107 and send voltage measurements via the voltage signal to the controller 402. The voltage sense terminal 412 may be configured to provide DC voltage of the system 400 for measuring fuel consumption whenever the prime mover 106 is ON or activated. In one embodiment, the alternator R-terminal may be utilized as the voltage sense terminal 412 to send voltage signals to the controller 402 indicative of the voltage from the alternator 107, which can be used to measure electrical loads that indicate increased or decreased power consumption by the prime mover 106. Increasing and decreasing power consumption by the prime mover 106 affects the fuel consumption rate of the fuel 200 resulting in faster or slower changes in the fuel level 204.
[0036] The electrical circuit 408 may be a simple electrical circuit, as generally known in the arts. In one embodiment, the gauge 404, as an analog gauge, may be disposed in communication with the level sensor 202 via an end of the first line 206 of the electrical circuit 408. The controller 402 may be an electronic controller (ECM) disposed in communication with the first line 206 via a second line 420 to receive the fuel level signal and the resistor signal for fuel level changes of the level sensor 202. The level sensor 202 and the resistor 406 may be disposed in communication with the ECM via another end of the first line 206. The first line 206 and the second line 420 may be an electrical wire, as generally known in the art to connect to electrical circuits and other electrical components. The controller 402 may embody a single microprocessor or multiple microprocessors that include a means for controlling various operations in the machine 100. The microprocessors may be configured to perform the functions of the controller 402. The controller 402 may be embodied in a general machine microprocessor capable of controlling numerous machine functions. The controller 402 may include a memory, a secondary storage device, a processor, and any other components for running an application as well as storing the collection of data and the signals received.
[0037] Now referring to Fig. 5, the fuel tank 110 is shown on an inclination, according to one embodiment of the disclosure. The tilt sensor 410 may be provided on the frame 104, or a chassis of the machine 100, and used to measure an inclination angle 500 of the Fuel Tanks 110, 300 relative to the ground. The tilt sensor 410 may provide a tilt signal consisting of an output voltage value proportional or corresponding to the inclination angle 500. The tilt sensor 410 may be one of an inclinometer, a gradient sensor, microelectromechanical inclinometer, electrolytic tilt sensor, potentiometric inclinometers, inertial measurement units, and the like configured to measure an inclination or gradient of the machine 100 on the ground. The tilt sensor 410 may be configured to detect tilt in 2-axises, such as the x-axis or longitudinal axis of the machine and the y-axis or lateral axis of the machine so that the tilt or inclination of the Fuel Tanks 110, 300 is equivalent to the inclination of the machine 100.
[0038] The resistor signal from the resistor 406 and the tilt signal from the tilt sensor 410 may provide the controller with contemporaneous changes in the fuel level 204 and the inclination angle 500 of the Fuel Tanks 110, 300 to determine the fuel consumption 416 of the machine 100. When the prime mover 106 is operating, the fuel 200 is consumed thereby reducing the fuel level 204 and the fuel 200 remaining in the Fuel Tanks 110, 300. At the same time, the tilt sensor 410 may detect changes in the inclination angle 500 of the fuel tank 110 due to movements or changes in position of the machine 100.
[0039] The fuel level 204 may be affected when the inclination angle 500 changes when the machine 100 moves or otherwise operates. The inclination angle 500 thereby affects the fuel level 204 reading in irregular tank geometries. As the Fuel Tanks 110, 300 are tilted, the level sensor 202 changes positions within the Fuel Tanks 110, 300 from a first level 502 to a second level 504. The second level 504 may result in the level sensor 202 being situated higher than the first level 502 with the same amount of fuel 200 in the Fuel Tanks 110, 300, due to the inclination angle 500. The tilt sensor 410 is provided to compensate measurements of fuel consumption 416 for instances when the fuel level 204 changes due to the inclination angle 500 of the machine 100 on various gradients at work sites. By measuring these changes over time and compensating for situations when the Fuel Tanks 110, 300 are tilted, the fuel consumption 416 can be measured and displayed accurately on the display 418. For example, the fuel level 204 can be calculated from a non-inclined fuel level 506 when the machine 100 is on an inclination. The fuel level 204 can be calculated subtracting a level change delta 508 from the fuel level 204 at the second level 504 on the inclination angle 500 from the non-inclined fuel level at the first level 502 to determine the volume at the first level 502. The first level 502 equals the second level 504 minus the level change delta 508 with the same volume of fuel 200. The level change delta 508 can be determined by using the inclination angle 500 measured by the tilt sensor 410, as generally known in the arts. The volume of the fuel 200 in the Fuel Tanks 110, 300 can be calculated using the first level 502 multiplied by the volume of the Fuel Tanks 110, 300, as generally known in the arts.
[0040] Now referring to Fig. 6, a volumetric chart of the irregular tank 300 is illustrated, according to one embodiment of the disclosure. As changes in the fuel level 204 in the irregular tank 300 occur, the level sensor 202 changes positions within the irregular tank 300. The fuel level 204 in the irregular tank 300 may not necessarily provide a 1 : 1 measurement from the fuel level 204 to volume percentage left of fuel 200 remaining. For example, as shown in Fig. 6, when the level sensor 202 is positioned below 50% of the tank height, the volume of the fuel remaining in the tank is 50%. The volumetric analysis shown in Fig. 6 may be provided in the volumetric look-up table 414. The volumetric look-up table 414 may be provided as a dataset in the controller 402 for the Fuel Tanks 110, 300. The volumetric look-up table 414 may be provided with irregular tank compensation data having a plurality of reference tanks having irregular tank geometries, 3D fuel tank models comprising of different fuel volumes, and volumetric analysis data from an empty condition to a full condition in a plurality of inclination positions for irregular tank geometries. For example, the volumetric look-up table 414 may provide further volumetric analysis at various inclination conditions such as the fuel level 204 and remaining volume in the irregular tank 300 for inclinations at 15°, 30°, 45°, 60°, and the like. The volumetric analysis provided in the volumetric look-up table 414 may further include data consisting of the percent (%) fuel volume remaining that corresponds to the voltage of the level sensor 202 measured at the various inclination positions from an empty condition to a full condition in the Fuel Tanks 110, 300.
[0041] The controller 402 may calculate the inclination angle 500 of the machine 100 from the tilt signal received from the tilt sensor 410. Based on the inclination angle 500, the controller 402 calculates a volume compensation due to the inclination of the machine 100 on the ground, and provides the volume of the fuel 200 remaining in the Fuel Tanks 110, 300. The controller 402 calculates the inclination compensation required from the inclination angle 500 of the machine 100 to determine the actual fuel volume in the Fuel Tanks 110, 300. Additionally, the controller 402 is configured with the volumetric look-up table 414 for compensating any error in measuring the fuel consumption 416 due to the irregular tank geometry of the irregular tank 300. In one embodiment, when utilizing a resistance-based float sensor as the level sensor 202, the controller 402 may be configured to determine a float sensor voltage output which may also correspond to a 3D model tank or reference tank-derived volume provided by the volumetric look-up table 414 to measure an accurate fuel volume remaining in the irregular tank 300 at the inclination angle 500.
[0042] The volumetric look-up table 414 may be processed by the controller 402 with the irregular tank compensation data to compensate any errors in the measurements of fuel consumption 416 contemporaneously with processing the fuel level signal, the resistor signal, voltage signal, and the tilt signal by the controller 402. The controller 402 is configured to receive fuel level signals, resistor signals, voltage signals, and tilt signals from the level sensor 202, the resistor 406, the voltage sense terminal 412, and the tilt sensor 410, respectively, to determine: (1) the inclination angle 500 of the machinelOO via the tilt sensor 410; (2) the geometry of the Fuel Tanks 110, 300 to determine the Fuel Tanks 110, 300 volume capacity via the volumetric look-up table 414; (3) the operating time of the prime mover 106 via the voltage sense terminal 412; and (4) the fuel consumption 416 of the machine 100.
[0043] For example, when the irregular tank 300 is in a full condition of fuel 200, the level sensor 202 may provide a fuel level signal in voltage for the fuel level 204 such as 0.3 Volts which may correspond to, in the volumetric look-up table 414, a 100% volume capacity and 100% volume distribution of fuel 200 remaining in the irregular tank 300. Over time, the level sensor 202 may subsequently provide a new voltage reading and communicate a fuel level signal in volts of 1.5 Volts which may correspond to, in the volumetric look-up table 414, a 25% volume capacity and 35% volume distribution of fuel 200 remaining in the irregular tank 300.
[0044] The display 418 may be provided in the machine 100 with an alerting buzzer or alarm feature. The display 418 may be communicably coupled to the controller 402, wherein the controller 402 issues control signals to: (1) indicate and display the fuel consumption 416 on the display 418; and (2) command the alerting buzzer to provide an audible alert if the fuel level 204 is in a low threshold condition, such as an indication of fuel 200 remaining is below 20% volume capacity in the Fuel Tanks 110, 300. The fuel consumption 416 may be displayed in liters per hour or another analogous consumption rate. The fuel consumption 416 may also be communicated via a wireless network to a back- office system to alert an owner or operator in a different location of the machine 100 that the fuel level 204 is low so the Fuel Tanks 110, 300 may be refueled and managed efficiently. Industrial Applicability
[0045] In operation, the present disclosure may find applicability in many industries including, but not limited to, the construction, earth-moving, mining, energy, and agricultural industries. Specifically, the systems, machines, and methods of the present disclosure may be used for detecting fuel consumption of operating machines including, but not limited to, generators, backhoes, front-end loaders, shovels, draglines, skid steers, wheel loaders, tractors, and similar machines as well. While the foregoing detailed description is made with specific reference to excavators, it is to be understood that its teachings may also be applied onto the other machines. The system 400 for measuring fuel consumption may be provided as a retrofit onto these other applications that require an operator for operation of machine work implements.
[0046] Now referring to Fig. 7, a flow-chart of an operation 700 of the system 400 for measuring fuel consumption in the machine 100 is illustrated, according to an embodiment of the present disclosure. In an operation 702, the machine 100 is activated or placed in a START condition, whereby the prime mover 106 is activated to begin consuming the fuel 200 from the Fuel Tanks 110, 300, as generally known in the arts. In an operation 704, the controller 402 and tilt sensor 410 are initialized or otherwise activated when the machine 100 is activated or placed in a Key-on condition for operation of the machine 100. The controller 402 and tilt sensor 410 may be initialized prior to, or contemporaneous with the start of operations by the machine 100.
[0047] In an operation 706, the controller 402 receives fuel level signal and tilt signal from the level sensor 202 and the tilt sensor 410, respectively. In an operation 708, the controller 402 calculates the fuel level 204 the received fuel level signal from the level sensor 202 and the inclination angle 500 received from the tilt sensor 410. The controller 402 may further conduct operation 708 utilizing the resistor signal from the resistor 406 and the irregular tank compensation data provided by the volumetric look-up table 414. In an operation 710, the volumetric look-up table 414 may be processed by the controller 402 to compensate for any errors in the measurements of the fuel level 204 on the inclination 500 using the irregular tank compensation data of volumetric analysis of fuel tanks with irregular tank geometries. In an operation 712, the fuel consumption 416 is calculated in volume over time such as liters per hour, or gallons per hour. In an operation 714, the voltage sense terminal 412 provides time stamp inputs to the controller 402 of the engine crank or the running time of the prime mover 106. The voltage sense terminal 412 may also provide a DC voltage of the system 400 for measuring fuel consumption when the prime mover 106 is activated or ON. The controller 402 may determine the actual running hours of the prime mover 106 by the received voltage signal from the voltage sense terminal 412. In an operation 716, the controller 402 communicates the fuel consumption 416 to the display 418 for displaying the fuel consumption 416 measurements. In an operation 718, the system 400 for measuring fuel consumption returns to operation 706 and continuously receives fuel level signals from the level sensor 202, resistor signals from the resistor 406, tilt signals from the tilt sensor 410, and voltage signals from the voltage sense terminal 412 to continuously calculate fuel consumption 416 during operation of the machine 100.
[0048] Now referring to Fig. 8, a method for calculating fuel consumption 800 of fuel consumed by the prime mover 106 from the Fuel Tanks 110, 300 of the machine 100, according to one embodiment of the disclosure. In a step 802, the prime mover 106 of the machine 100 is activated and begins consuming the fuel 200 from the Fuel Tanks 110, 300. In a step 804, the controller 402 receives a fuel level signal communicated by the level sensor 202 of changes of the fuel level 204 in the Fuel Tanks 110, 300. In step 804, the level sensor 202 may communicate the fuel level signal as a resistance value to the controller 402 and the resistor 406.
[0049] In a step 806, the resistor 406 receives the resistance value from the fuel level signal and converts the resistance value into a voltage value. In step 806, the resistor further communicates the voltage value to the controller 402 via the resistor signal. In a step 808, the voltage sense terminal 412 receives a voltage signal indicative of a system voltage of the machine 100 during operation or running time. The voltage sense terminal 412 sends the voltage signal to the controller 402 for communicating the voltage of the alternator 107. In a step 810, the tilt sensor 410 receives the tilt signal of the inclination angle 500 of the machine, and communicates the tilt signal to the controller 402 indicative of the gradient of the machine 100 on an inclined surface.
[0050] In a step 812, the controller 402 processes the fuel level signal, the resistor signal, the power signal, the tilt signal, and the irregular tank compensation data of the volumetric look-up table 414 to measure the fuel consumption 416 of the machine 100. The controller 402 communicates the measurements of fuel consumption 416 to the display 418. In a step 814, the display 418 displays the measurements of fuel consumption 416 on the display 418.
[0051] The system 400 for measuring fuel consumption can be configured to prevent airlock in fuel lines by alerting the operators when the fuel level 204 is considered low. For example, when the fuel level 204 is less than 20% volume capacity in the Fuel Tanks 110, 300, the controller 402 may activate the audible buzzer or alert feature such as an alarm with a high volume (i.e. 90dB) and / or activating a flashing icon at fast repetition rates such as at least 2.5 Hz (greater than 1 / 16th of a second) to alert the owner / operator of the machine 100. If the machine 100 is not attended by the operator and the machine 100 remains in operation, the system 400 for measuring fuel consumption may be further connected via the controller 402 to other operational systems in the machine 100, such as a machine ignition control module to disable operation of the machine 100. The machine 100 may be disabled after a pre-determined period of time or controlled from a back- office system via an off-board network in communication with the controller 402, as generally known in the arts.
[0052] The system 400 for measuring fuel consumption may be integrated with other control systems, such as an engine control modules and a telematics systems, to optimize performance and promote efficient fuel consumption. Telematics systems may use GPS technology and wireless communications to track and report vehicle location, speed, and fuel consumption data in real time. The controller 402 may further relay information via a telematics device to record and process the system 400 for measuring fuel consumption data to the back-office for generating analytical reports for selected time periods for the fuel tank volume status and fuel consumption rates. Such reports may provide information regarding re-fueling and possible theft of the fuel from the Fuel Tanks 110, 300. The system 400 for measuring fuel consumption may include data logging capabilities that allows data of fuel consumption 416 measured to be stored and analyzed over time, providing insights into long-term fuel usage patterns and trends. The controller 402 can also be configured to distinguish between operator machine work shifts and non-work shift periods, especially during nighttime. The system 400 may be connected to a relay to power up the system at regular interval times, such as every 90 minutes, to monitor for fuel theft. From the foregoing, it can be seen that the technology disclosed herein has industrial applicability in a variety of settings such as, but not limited to agricultural, construction, and mining industries that utilize mobile and stationary machines such as automobiles, generators, excavators, backhoes, rope shovels, skid steers, wheel loaders, tractors, and similar machines having fuel tanks for fuel consumed by prime movers and engines.
Claims
Claims1. A system (400) for measuring fuel consumption ( 16) and compensating errors in measurements of a fuel (200) consumed by a prime mover (106) from a tank (110) in a machine (100), the system (400) comprising: an electrical circuit (408); a level sensor (202) in the tank electrically connected to the electrical circuit (408), the level sensor (202) is configured to output a fuel level (204) signal indicative of a fuel level (204) in the tank (110); a gauge (404) electrically connected to the electrical circuit (408) and in communication with the level sensor (202), the gauge (404) is configured to display (418) the fuel level (204) in the tank; a resistor (406) electrically connected to the electrical circuit (408); a tilt sensor (410) on the machine (100) configured to output a tilt signal indicative of inclination (500) angles of the machine (100) on an inclination (500); a voltage sense terminal (412) electrically connected to an alternator (107), the voltage sense terminal (412) is configured to output a voltage signal indicative of a system (400) voltage of the machine (100); a controller (402) connected to the electrical circuit (408) and in communication with the level sensor (202), the tilt sensor (410), the resistor (406), and the voltage sense terminal (412), the controller (402) is provided with a volumetric look-up table (414) having irregular tank (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 sense terminal (412); process the fuel level (204) signal, the tilt signal, the voltage signal, and the volumetric look-up table (414) to measure the fuel consumptioncommunicate the fuel consumption (416) to the display (418).
2. The system (400) of claim 1, wherein the fuel consumption (416) includes at least one of: fuel consumption (416) rates, fuel (200) volume remaining in the tank (110), and low fuel (200) levels.
3. The system (400) of claim 2, wherein: the level sensor (202) is chosen from one of: a resistive-based float sensor, a voltage-based float sensor, a float switch, and a capacitive level sensor (202); the gauge (404) is an analog gauge (404); the resistor (406) is chosen from one of: a pull-up resistor (406), a metal film resistor (406), a carbon film resistor (406), a carbon film pull-up resistor (406), and a metal film pull-up resistor (406); the voltage sense terminal (412) is chosen from one of: a power supply terminal, a voltage test point, a voltage regulator feedback, an integrated electrical circuit (408) pin, a voltage sense pin, a reference pin, and an alternator (107) R-terminal; and the tilt sensor (410) is chosen from one of: an inclinometer, a gradient sensor, a microelectromechanical inclinometer, an electrolytic tilt sensor (410), and a potentiometric inclinometers.
4. The system (400) of claim 3, wherein the fuel level (204) signal communicates a resistance value indicative of the fuel level (204) to the resistor (406), the resistor (406) is configured to convert the resistance value into a voltage value, and the resistor (406) communicates the voltage value to the controller (402) via a resistor (406) signal.
5. The system (400) of claim 3, wherein the resistor (406) is supplied by +5V from the controller (402).
6. The system (400) of claim 4, wherein: the irregular tank (300) compensation data includes a plurality of reference tanks having irregular tank geometries (3D) with at least one reference tank corresponding to the tank (110) in the machine (100), each reference tank including a plurality of volumetric analysis data for a plurality of fuel (200) levels in each reference tank from an empty condition to a full condition for a plurality of inclinations of the reference tank, the irregular tank (300) compensation data corresponds to values of the voltage value and the fuel (200) volume remaining; and the controller (402) is configured to: determine a geometry and a volume capacity of the tank (110); process the fuel level (204) signal, the resistor (406) signal, the tilt signal, the voltage signal to calculate the fuel consumption (416) of the machine (100); and compensate for measurement errors in the measurements of the fuel consumption (416) using the irregular tank (300) compensation data for changes in the fuel level (204) in the tank (110).
7. The system (400) of claim 3, wherein the tilt sensor (410) is mounted on a chassis of the machine (100).
8. The system (400) of claim 3, further comprising a telematics system (400) in communication with the controller (402), the telematics system (400) is configured to utilize a GPS technology and a wireless communication system (400) to track and report location, a speed, and the fuel consumption (416) data in real time of the machine (100).
9. A machine (100) compri sing : a tank (110); a fuel (200) in the tank (110);a prime mover (106) configured to consume the fuel (200) from the tank (110); the system (400) of claim 1.
10. The machine (100) of claim 9, the machine (100) further comprises a relay in communication with the controller (402), the controller (402) configured to activate and deactivate the machine (100) for a plurality of interval times.
11. A method for calculating fuel consumption (800) and compensating errors in measurements of fuel (200) consumed by a prime mover(106) from a tank (110) in a machine (100), the method comprising: activating the prime mover (106) of the machine (100); receiving a fuel level (204) signal indicative of a fuel level (204) in the tank (110), via a level sensor (202) in the tank (110), and sending the fuel level (204) signal to a controller (402) in communication with the level sensor (202); receiving a resistance value from the level sensor (202), via a resistor (406), the resistor (406) configured to convert the resistance value into a voltage value, and communicating a resistor (406) signal indicative of the voltage value to the controller (402) in communication with the resistor (406); receiving a voltage signal indicative of system (400) voltage of the machine (100), via a voltage sense terminal (412) connected to an alternator(107) of the prime mover (106), and sending the voltage signal to the controller (402); receiving a tilt signal indicative of an inclination (500) of the machine (100), via a tilt sensor (410) on the machine (100), and sending the tilt signal to the controller (402) in communication with the tilt sensor (410); processing the fuel level (204) signal, the resistor (406) signal, the voltage signal, the tilt signal, and a volumetric look-up table (414) having irregular tank (300) compensation data, via the controller (402), to calculate afuel consumption (416) of the machine (100), and sending measurements of fuel consumption (416) to display (418) in communication with the controller (402); and displaying the measurements of the fuel consumption (416) on the display (418).
12. The method of claim 11, wherein the irregular tank (300) compensation data includes a plurality of reference tanks having irregular tank geometries (3D) with at least one reference tank corresponding to the tank (110) in the machine (100), each reference tank including a plurality of volumetric analysis data for a plurality of fuel (200) levels in each reference tank from an empty condition to a full condition at a plurality of inclinations, the plurality of volumetric analysis data provide corresponding values from the plurality of reference tanks to the voltage value of the resistor (406) indicative of a fuel (200) volume percentage remaining in the tank (110).
13. The method of claim 12, further comprising: tracking a location, a speed, and the fuel consumption (416) of the machine (100) via a telematics system (400) in communication with the controller (402), the telematics system (400) is configured to utilize a GPS technology system (400) and a wireless communication system (400); and reporting the location, the speed, and the measurements of the fuel consumption (416) of the machine (100) to a back-office system.