Automated DEF Refill System with Electric Sensor and Valve
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Solution Overview
Problem
Manual refilling of diesel exhaust fluid (DEF) in diesel engines is labor-intensive, time-consuming, and prone to contamination and human error, especially in environments like oil and gas operations, where it increases operational costs and introduces dirt and contaminants into the systems.
Innovation Solution
An automated DEF refilling system featuring a supply tank, a supply line, and a DEF flow control device with an electric fluid sensor and motorized ball valve that controls the flow of DEF, powered by a battery, which senses the fluid level and automatically refills the tank without manual intervention, using either a gravity-fed or pump-based system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual refilling is used, then the system is simple and easy to operate, but it increases labor intensity, time consumption, and contamination risk
Solution Approach 1:
The DEF refilling system performs refilling operations automatically without manual intervention. The sensor detects DEF levels and triggers the pump to transfer fluid from the supply tank to the DEF tank, eliminating the need for operators to manually refill and reducing time consumption.
Solution Approach 2:
The patent replaces manual mechanical refilling operations with an automated electromechanical system. The pump, controlled by electronic sensors and circuitry, substitutes for manual pumping operations, reducing both time consumption and labor intensity.
2Device complexity
If manual refilling is used, then the device complexity is low, but it increases contamination and dirt introduction
Solution Approach 1:
The automated system minimizes human interaction with the DEF tanks and refilling process. By having the system self-monitor and self-refill, the exposure of tank openings and DEF fluid to environmental contaminants is significantly reduced compared to manual refilling operations.
Solution Approach 2:
The patent introduces an automated pump and control system as an intermediary between the supply tank and DEF tank. This intermediary system enables controlled, clean transfer of DEF fluid without direct human handling, reducing contamination risk despite increased device complexity.
3Device complexity
If manual refilling is used, then the system is simple, but it introduces human error in refilling frequency and procedure
Solution Approach 1:
The system incorporates sensors that continuously monitor DEF fluid levels and provide feedback to the control circuitry. When the fluid level drops below a threshold, the system automatically activates the pump to refill, ensuring consistent and reliable operation without human error. The feedback loop maintains reliable DEF supply by continuously monitoring and responding to fluid levels.
4Productivity
If automated refilling is implemented, then labor intensity and time consumption are reduced, but device complexity increases
Solution Approach 1:
The automated DEF refilling system performs monitoring and refilling operations autonomously, significantly improving productivity by eliminating manual labor. The sensor-controlled pump system handles the entire refilling process automatically, trading increased device complexity for substantial productivity gains.
Solution Approach 2:
The patent replaces manual refilling operations with an automated electromechanical system comprising sensors, control circuitry, and an electric pump. This substitution increases device complexity but dramatically improves productivity by eliminating manual labor and reducing refilling time.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The automated system reduces labor and time associated with manual refilling, minimizes contamination, and ensures consistent and accurate refilling, creating a cleaner environment and reducing operational costs by eliminating human error.
Implementation Method 1
an electric fluid sensor disposed in a sensor housing and having a shaft extending into the DEF tank, the shaft having a slot such that the electric fluid sensor senses DEF when the slot is submerged
Implementation Method 2
a valve actuator operable to move the valve between the open position and the closed position
Implementation Method 3
a battery configured to power the control circuity, the valve actuator, and the electric fluid sensor
Implementation Method 4
the supply tank is positioned on a deck of a frame raised to a higher elevation than an inlet of the DEF tank
Data Source
AI summary
An automated diesel exhaust fluid (DEF) system and method for refilling DEF. The automated DEF system provides DEF refilling after an initial setup and without manual intervention. The automated DEF system includes a electric DEF flow control device that controls the flow of DEF. The electric DEF flow control device may include control circuitry, an electrics enclosure that encloses the control circuity, an electric fluid sensor, a valve, a beacon light, a status light, a button, a threaded swivel connection, and a mandrel on the inside of the threaded swivel connection.