Concentric Tube Fuel Sensor Probe for Fracking Trucks
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Solution Overview
Problem
Fracking operations require continuous fuel supply to prevent equipment shutdowns, but existing technologies lack reliable and automated systems for maintaining optimal fuel levels in fracking truck tanks.
Innovation Solution
A refueling sensor probe with concentric metallic tubes and float switch assemblies that monitor fuel levels, controlling fuel supply to ensure continuous operation by detecting when the tank is full or empty, and automatically refilling as needed, with a fail-safe mechanism to prevent overfilling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual fuel monitoring and refilling is used, then device complexity is reduced, but reliability of continuous fuel supply deteriorates due to risk of human error and disruption
Solution Approach 1:
The fuel monitoring system automatically detects fuel levels using float switch assemblies and triggers refilling operations without human intervention. The sensor probe system serves itself by continuously monitoring and autonomously managing fuel supply, eliminating the need for manual checking and refilling while ensuring continuous operation of fracking equipment.
Solution Approach 2:
The float switch assemblies provide continuous feedback on fuel levels to the control system. When fuel reaches critical levels, the feedback signal automatically initiates refilling operations. This closed-loop feedback mechanism ensures reliable fuel supply by continuously adjusting refilling based on actual tank levels, preventing both fuel depletion and overflow.
2Productivity
If automated sensor probe system is implemented, then productivity is improved through continuous operation, but device complexity increases due to multiple sensors and control mechanisms
Solution Approach 1:
The sensor probe employs a nested concentric tube design where the inner tube contains float switch assemblies and the outer tube provides structural support and fuel flow pathways. This nesting arrangement consolidates multiple functional components into a single compact assembly, reducing the number of separate parts while maintaining automated monitoring and refilling capabilities for continuous productivity.
Solution Approach 2:
The sensor probe assembly performs multiple functions simultaneously: the concentric tubes provide both structural support and fuel flow channels, the float switches monitor fuel levels, and the integrated design enables both monitoring and automatic refilling. This multi-functionality reduces the need for separate systems while ensuring continuous fracking operation.
3Measurement precision
If float switch assemblies are used for fuel level detection, then measurement precision is improved, but device complexity increases due to multiple switches and wiring
Solution Approach 1:
The fuel level detection system is segmented into multiple float switch assemblies positioned at different heights within the tank. Each switch monitors a specific fuel level threshold, providing precise分段 detection. This segmentation allows accurate measurement of fuel levels at multiple points while keeping each individual switch simple and reliable.
Solution Approach 2:
The float switch assemblies are arranged vertically along the fuel tank height, adding a dimensional aspect to fuel level monitoring. Instead of a single point measurement, the vertical arrangement of switches provides precise measurement across the entire fuel column, enabling accurate detection of fuel levels at multiple elevations simultaneously.
4Loss of time
If continuous fuel monitoring is implemented, then loss of time is reduced by preventing equipment shutdown, but use of energy increases due to continuous sensor operation
Solution Approach 1:
The float switch assemblies operate periodically based on fuel level conditions rather than continuous active sensing. The switches are triggered only when fuel reaches specific levels, providing intermittent monitoring action. This periodic operation prevents equipment shutdown by detecting critical levels while consuming energy only when measurement or refilling action is required, not during continuous operation.
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 sensor probe maintains continuous fuel supply to fracking equipment, preventing disruptions and ensuring sustained operation by accurately monitoring and managing fuel levels within the truck's tank, enhancing operational efficiency and reliability.
Implementation Method 1
float switch assemblies that monitor fuel levels
Data Source
AI summary
This invention is a sensor probe, generally used in the oil fracking business, and includes structurally a pair of tube members, concentrically assembled, an inner housing tube, and an outer spout tube, affixed to a cap and adaptor, with the inner housing holding one or more sensors, to detect the level of fuel within the fuel tank of the fracking truck. The adaptor has a first aperture for attachment of the fuel line, for delivery of fuel in the space between the tube members, and the adaptor has a second aperture for connection of an electrical receptacle, for attachment with the electric lines leading from the various sensors, to the adaptor, for connection with a circuit line from a remote monitor.