Grid Sensor Array for Tank Inventory Tracking
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Solution Overview
Problem
Current tank cylinder inventory management systems for industrial gases lack efficient monitoring and reporting of used tanks at end-user locations, leading to suboptimal inventory control and delivery optimization.
Innovation Solution
A tank grid system with weight sensors or proximity sensors on a pad that reports tank presence or absence to a local server, which is connected to a remote server for tracking usage and optimizing replacement deliveries, utilizing a network of sensors and servers to manage inventory and route replacements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inventory tracking methods are used, then system complexity is reduced, but measurement precision and productivity deteriorate due to lack of real-time monitoring
Solution Approach 1:
The system divides the tank storage area into a grid pattern with multiple discrete sensor locations. Each sensor independently monitors a specific grid position, allowing the system to track individual tank presence and movement. This segmentation enables precise inventory monitoring while maintaining manageable system complexity through modular sensor deployment.
Solution Approach 2:
The sensor array serves multiple functions: detecting tank presence, determining tank location, monitoring tank movement, and providing real-time inventory status. By making the sensor system multi-functional, the patent eliminates the need for separate monitoring systems, thereby improving measurement precision without proportionally increasing device complexity.
2Productivity
If sophisticated software algorithms are implemented, then productivity is improved through optimization, but device complexity increases due to complex inventory management systems
Solution Approach 1:
The sensor array continuously provides real-time feedback on tank inventory status to the management system. This feedback mechanism enables automated decision-making for delivery optimization without requiring complex manual intervention. The system uses sensor data to automatically track tank usage, generate replacement orders, and optimize delivery routes, improving productivity while keeping the management system relatively simple.
Solution Approach 2:
The inventory management system automatically monitors tank status, detects when tanks need replacement, and initiates ordering processes without human intervention. This self-service capability allows the system to optimize deliveries and manage inventory autonomously, improving productivity while minimizing the complexity of manual management procedures.
3Measurement precision
If RFID tags and optical sensors are used, then measurement precision is improved for tank identification, but device complexity and cost increase
Solution Approach 1:
The patent replaces complex electronic identification systems (RFID tags, optical sensors) with simpler mechanical weight-based detection. The sensor array uses weight sensors to detect tank presence and movement, providing sufficient identification accuracy for inventory management without the complexity and cost of electronic tagging systems. This mechanical approach maintains measurement precision for inventory tracking while reducing device complexity.
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
This solution enables accurate monitoring of tank usage, optimizing replacement deliveries and improving inventory management by providing real-time data for tank management and supply software, facilitating efficient tracking and procurement of replacement tanks.
Implementation Method 1
tanks on separate weight sensors that are part of a signaling system. Sensors can detect tank weight
Implementation Method 2
Sensors can detect tank weight or, alternatively tank proximity to a sensor
Data Source
AI summary
A tank inventory signaling apparatus that has gas cylinder tanks stored on a pad having an array of spots to mark tank placement. Tanks are placed directly over the spots in a grid of rows and columns. Sensors below each spot act as weight or proximity sensors indicating the presence or absence of a tank. The sensors are connected to logic that monitors the state of all sensors. Tank inventory is inferred by changes of state of the sensor grid since it is necessary to change sensor state to remove a tank. Sensor states are reported to a remote server having associated tank management and supply software and route management software. In this manner, local tank usage can be tracked at remote locations for resupply of tanks and delivery of replacement tanks can be optimized.