Fuel Dispenser Temperature Conditioning and Recirculation Control
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Solution Overview
Problem
Fuel and diesel exhaust fluid dispensers face challenges with temperature-related issues, such as DEF crystallization and expansion causing damage, and liquid fuel volume inaccuracies due to temperature variations, which existing solutions do not adequately address, especially in environments where temperature compensation technologies like U.S. Pat. No. 5,557,084 may not be available.
Innovation Solution
A fluid dispenser system with a temperature conditioning subsystem, including heating and cooling devices, and a recirculation subsystem to maintain fluid temperature and prevent freezing, combined with a control system that manages fluid flow and measurement, ensuring accurate volume measurement and preventing component damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If DEF is stored in the dispenser at ambient temperature, then the dispenser structure remains simple, but DEF will crystallize and freeze causing damage to internal components
Solution Approach 1:
The system monitors and adjusts the temperature parameter of DEF storage to maintain it above the crystallization point (12°F). The control system activates heating when temperature drops below a threshold and deactivates when above a higher threshold, dynamically changing the thermal state to prevent crystallization while avoiding unnecessary energy consumption.
Solution Approach 2:
A temperature sensor continuously monitors the DEF temperature and provides feedback to the control system. The control system uses this feedback to automatically activate or deactivate the heater based on predefined temperature thresholds, creating a closed-loop control system that maintains reliability without requiring constant human intervention.
2Reliability
If a heater is mounted in the DEF dispenser cabinet, then DEF freezing is prevented, but energy consumption increases and safety risks arise from high power heating
Solution Approach 1:
Instead of continuously heating or using a high-power heater that constantly operates at maximum capacity, the system applies partial heating action only when and where needed. The heater is activated only when temperature drops below the threshold, and the system uses a 750W heater with intelligent control rather than excessive continuous heating, reducing overall energy consumption while maintaining reliability.
Solution Approach 2:
The system takes preliminary action by activating the heater before DEF actually freezes, when temperature first drops below the crystallization point. This preventive heating approach stops crystallization before it occurs, rather than attempting to thaw frozen DEF, thereby reducing the total energy required to maintain reliability.
3Measurement precision
If temperature compensation is implemented using thermometric probes and computation devices, then volumetric measurement accuracy is maintained, but device complexity and cost increase
Solution Approach 1:
The temperature sensor and flow measurement system are integrated into a unified control architecture. The control system combines temperature data from the thermometric probe with flow rate data from the flow meter, applying temperature compensation calculations to correct volumetric measurements. This merging of functions reduces overall system complexity compared to separate independent systems while maintaining measurement precision.
4Use of energy by moving object
If the dispenser operates at ambient temperature in cold environments, then energy consumption is low, but liquid fuel volume measurements become inaccurate due to thermal expansion/contraction
Solution Approach 1:
The system replaces physical temperature maintenance (heating to a fixed setpoint) with a computational approach. Temperature sensors monitor thermal conditions, and the control system applies mathematical compensation factors to flow measurements based on measured temperature deviations from a reference temperature. This substitution of mechanical temperature control with computational correction reduces energy consumption while maintaining measurement precision.
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 system effectively conditions fluids to prevent freezing and ensure accurate measurement, maintaining operational integrity and compliance with regulatory requirements by maintaining fluid at a consistent temperature, thus preventing damage and ensuring accurate dispensing.
Implementation Method 1
a temperature conditioning subsystem inline to the fluid flow path... including heating and cooling devices
Implementation Method 2
a temperature conditioning subsystem inline to the fluid flow path... including heating and cooling devices
Implementation Method 3
The recirculation subsystem comprises a recirculation pump, a bypass valve...
Data Source
AI summary
A fluid dispenser has a housing in which fluid flow control components are located and at least one fluid conduit completing first and second fluid flow paths between the at least one fluid storage tank and a nozzle coupled to the housing. The fluid dispenser also has a fluid flow meter located along said fluid flow path, a control system, and a recirculation subsystem. The recirculation subsystem has a bypass valve located along one of the first and second flow paths. The bypass valve is operative to prevent fluid communication between the first and second fluid flow paths when the fluid dispenser is in use and to allow fluid communication between the first and second fluid flow paths when the fluid dispenser is not in use. Methods of measuring the flow rate of a fluid in the fluid dispenser are also disclosed.