LPG Tank Fill Control via Telemetry and Flow Feedback
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Solution Overview
Problem
The existing method for filling LPG tanks relies on the 'spit valve' and is prone to accidental and costly spills, lacking precise control over filling levels.
Innovation Solution
A system comprising a telemetry unit installed on the LPG tank and a flow controller on the filling vehicle, which communicate to provide real-time level indications and control the filling process, ensuring the LPG tank is filled to a predetermined level without overfilling, using proximity sensors and data authentication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the spit valve method is used for filling LPG tank, then the filling process is simple to operate, but the filling precision is poor and overfilling cannot be prevented
Solution Approach 1:
The patent implements a feedback control system where the telemetry unit continuously monitors the LPG tank fill level and transmits real-time data to the flow controller. The flow controller adjusts the filling rate based on this feedback, reducing the fill rate as the tank approaches the target level to prevent overfilling while maintaining operational simplicity.
Solution Approach 2:
The patent replaces the mechanical spit valve method with an electronic control system comprising telemetry unit, flow controller, and level sensors. This substitution enables precise electronic monitoring and control of fill levels, eliminating the imprecision of visual observation of vapor clouds while maintaining ease of operation through automated control.
2Device complexity
If the spit valve method is used for filling LPG tank, then the device complexity is low, but the reliability is poor due to potential accidental spills
Solution Approach 1:
The feedback control system continuously monitors fill level and automatically adjusts the filling process, preventing accidental spills by stopping filling at the predetermined level. The system provides multiple layers of safety including real-time monitoring, automated control, and alarm systems that enhance reliability without significantly increasing device complexity.
Solution Approach 2:
The system enables the filling process to self-regulate through automated control. The telemetry unit and flow controller work together to automatically monitor, control, and stop the filling process based on real-time level data, eliminating the need for constant manual intervention and reducing the risk of human error while maintaining operational simplicity.
3Manufacturing precision
If real-time level monitoring is implemented, then the filling precision is improved, but the device complexity increases due to additional sensors and communication systems
Solution Approach 1:
The telemetry unit serves multiple functions including level monitoring, data transmission, and communication with the flow controller. The flow controller also performs multiple roles such as receiving data, processing control logic, and adjusting the filling rate. This multi-functionality reduces the need for separate dedicated components, thereby improving precision while limiting the increase in device complexity.
4Reliability
If automated flow control is used, then the filling safety is improved by preventing overfilling, but the ease of operation is reduced due to authentication requirements
Solution Approach 1:
The authentication process is performed in advance before the filling operation begins. The telemetry unit and flow controller exchange authentication data and establish secure communication beforehand, so that during the actual filling process, the system operates automatically without requiring continuous manual authentication, thus maintaining both safety and operational convenience.
Data Source
AI summary
A method and a system are disclosed for filling an LPG tank equipped with a spit valve and a fill assembly, the method comprising providing an indication of a level in the LPG tank upon detection of a filling vehicle in a vicinity of the LPG tank, the filling vehicle having a filling hose; initiating a filling of the LPG tank once the filling hose is connected to the fill assembly of the LPG tank; determining when a current level reaches a given level in the LPG tank and stopping the providing of the LPG to the LPG tank once the current level reaches the given level in the LPG tank.