Hydraulic Pump Empty Detection via Pressure Monitoring
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Solution Overview
Problem
Accurate detection of fluid levels in storage vessels, particularly for cryogenic fluids, is challenging due to inaccuracies in existing level sensors, leading to potential damage from continued pumping when the vessel is empty and issues in mobile applications where inertial forces affect fluid location.
Innovation Solution
An apparatus comprising a storage vessel with a process pump driven by a hydraulic drive system, a pressure sensor, and an electronic controller that monitors hydraulic fluid pressure to determine when the vessel is empty, stopping the pump and providing warnings for low fluid levels, using peak pressure measurements and cycle counting to ensure accurate detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If capacitance-type level sensors are used to measure cryogenic fluid levels, then level measurement is possible, but measurement precision deteriorates with errors of 20-25 percent and drift requiring periodic re-calibration
Solution Approach 1:
The patent replaces electrical level sensing systems (capacitance-type sensors) with a hydraulic pressure-based detection system. The hydraulic drive system's pressure characteristics are monitored to infer fluid level, eliminating the need for direct electrical contact with cryogenic fluids and avoiding sensor drift and calibration issues.
Solution Approach 2:
The patent introduces hydraulic fluid pressure as an intermediary parameter to indirectly measure fluid level. Instead of directly measuring level with inaccurate sensors, the system uses pressure sensor readings from the hydraulic system to infer when the storage vessel is empty, providing more reliable detection.
2Productivity
If the pump continues operating when the storage vessel is empty, then pumping action is maintained, but pump components suffer accelerated wear and damage
Solution Approach 1:
The patent implements a feedback control system where pressure sensor readings from the hydraulic drive system are continuously monitored by a controller. When the pressure characteristics indicate the storage vessel is empty, the controller automatically shuts down the pump, preventing damage while maintaining operational flexibility.
Solution Approach 2:
The system performs preliminary detection of empty vessel conditions through pressure monitoring before the pump can be damaged. By detecting the empty state in advance and shutting down proactively, the system prevents accelerated wear and damage to pump components.
3Adaptability or versatility
If mobile fuel tanks are used for vehicle fuel storage, then fuel transport is enabled, but inertial forces during vehicle movement shift fluid location making level detection inaccurate
Solution Approach 1:
The patent replaces mechanical/electrical level sensors that are affected by inertial forces with a hydraulic pressure-based detection system. The pressure sensor monitors hydraulic fluid pressure in the drive system, which reflects the actual fluid level regardless of vehicle movement or inertial effects.
Solution Approach 2:
The patent changes the measurement parameter from direct level position (which is affected by inertial forces) to hydraulic pressure (which is not affected by vehicle movement). This parameter transformation eliminates the measurement errors caused by mobile application inertial forces.
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 prevents pump damage by accurately determining when a storage vessel is empty, ensuring reliable operation and safe vehicle operation by preventing fuel depletion errors, even in mobile applications with cryogenic fluids.
Implementation Method 1
a pressure sensor for measuring hydraulic fluid pressure of the pressurized hydraulic fluid in the hydraulic drive system
Implementation Method 2
conduits for circulating and draining a pressurized hydraulic fluid to and from the hydraulic drive unit
Data Source
AI summary
An apparatus for delivering a process fluid comprises a storage vessel, a process pump for pumping the process fluid from the storage vessel, a hydraulic drive system comprising a hydraulic drive unit operatively connected to drive the process pump, a pressure sensor for measuring hydraulic fluid pressure of the pressurized hydraulic fluid in the hydraulic drive system, and, an electronic controller programmed to monitor a signal representative of hydraulic fluid pressure that is measured by the pressure sensor, process the signal to determine when the storage vessel is empty, and stop the process pump when the storage vessel is empty. The disclosed method relates to using the disclosed apparatus to measure hydraulic fluid pressure in the hydraulic drive system, process measured hydraulic fluid pressure to determine when the storage vessel is empty, and stop the process pump when the storage vessel is empty.