Magnetostrictive Probe Retrofit for Fuel Phase Separation Detection
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Solution Overview
Problem
Existing magnetostrictive probes in fuel storage tanks fail to detect phase separation between gasoline and ethanol mixtures due to the aqueous ethanol layer being less dense than water, leading to unsuitable fuel being pumped to dispensers.
Innovation Solution
A retrofit assembly with a fuel quality sensor and isolation sheath is integrated with a magnetostrictive probe, allowing for the detection of phase separation by providing a pathway for wiring and maintaining the operation of the product-level float, using an isolation sheath to carry wiring between the fuel quality sensor and the tank interface without exposing it to fuel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a water level float is used to detect the fuel-water interface, then the level of water in the storage tank can be determined, but the float cannot float on the phase separation interface because the aqueous ethanol layer is less dense than water
Solution Approach 1:
The invention changes the density parameter of the detection float by using a material with density between that of gasoline and aqueous ethanol (e.g., low-density polyethylene with density of 0.92-0.96 g/cm³). This allows the float to float on the phase separation interface rather than sinking to the water layer, enabling detection of phase separation when ethanol concentrations range from 5% to 85%.
2Measurement precision
If a fuel quality sensor is added to the magnetostrictive probe, then phase separation detection capability is improved, but the complexity of the probe assembly increases
Solution Approach 1:
The invention merges the fuel quality sensor with the existing magnetostrictive probe assembly by integrating it into the float structure. The sensor is positioned within the float housing, allowing it to share the same mounting infrastructure, wiring pathways, and data communication channels as the level measurement system, thereby reducing overall system complexity.
Solution Approach 2:
The float structure is designed to serve multiple functions: it provides buoyancy for level measurement, houses the fuel quality sensor, and acts as a mounting platform for both the magnetostrictive probe and the sensor. This multi-functional design eliminates the need for separate mounting structures and reduces the number of components required.
3Ease of operation
If wiring for the fuel quality sensor is routed through the probe shaft, then the sensor can be electrically connected, but the wiring may be exposed to fuel and cause degradation or safety issues
Solution Approach 1:
The invention introduces an isolation sheath as an intermediary barrier between the fuel and the wiring. This sheath is positioned within the probe shaft and provides a protective pathway for the wiring, allowing electrical connections to be made while preventing direct contact between the wiring and fuel, thereby eliminating degradation and safety concerns.
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
Enables accurate detection of phase separation, preventing unsuitable fuel mixtures from being pumped, ensuring compliance with environmental regulations and maintaining the integrity of fuel inventory reconciliation systems.
Implementation Method 1
a shaft extending through a tank interface into a fuel storage tank, and the shaft comprises a magnetostrictive element extending therealong
Implementation Method 2
Fuel quality sensors have been proposed to detect the onset and occurrence of phase separation. Such sensors are designed to determine the composition of the fuel mixture based on certain electrical characteristics such as capacitance
Implementation Method 3
An isolation sheath having a proximal end and a distal end is also provided. The isolation sheath is sized to be received over the fuel level probe shaft and extends between the fuel quality sensor and the tank interface
Data Source
AI summary
A retrofit assembly for installing a fuel quality sensor with a fuel level probe having a shaft extending through a tank interface into a fuel storage tank. The shaft, which comprises a magnetostrictive element extending therealong, is coupled with the fuel quality sensor. An isolation sheath is sized for receipt over the shaft and to extend between the fuel quality sensor and the tank interface. The sheath has a cross-sectional profile configured to define at least one passage between the sheath and the shaft when the sheath is received over the shaft. The passage(s) extend between a proximal end and a distal end of the sheath. Also provided is a product-level float comprising at least one product-level magnet for measuring the level of fuel in the fuel storage tank. The product-level float is configured to translate along the sheath with the level of fuel in the fuel storage tank.