Mechanical Fuel Distribution Manifold for Automated Refueling
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Solution Overview
Problem
Existing refueling systems for continuously operating vehicles, such as those at fracking sites, are inefficient and pose safety hazards due to the need for manual refueling and the use of electrical sensors, which can cause spark risks and depressurize fuel lines, reducing responsiveness.
Innovation Solution
A fuel distribution system with a distribution manifold, control valves, tank valve assemblies, and a controller that manages fuel flow sequentially to multiple vehicles, incorporating pressure and temperature sensors, and a pump with a flow meter to ensure safe and efficient refueling without electrical sensors, using mechanical valves and a control circuit to monitor and adjust fuel delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If electrical sensors are used to monitor fuel levels in each truck, then automatic refueling can be achieved, but spark risk increases and fuel line depressurization occurs
Solution Approach 1:
The patent replaces electrical sensors with mechanical float valves that use buoyancy principles to detect fuel levels. The float valve assembly includes a float that rises with fuel level, mechanically actuating a valve mechanism to close when the tank is full, eliminating electrical components and their associated spark risks entirely.
Solution Approach 2:
The float valve assembly is designed to automatically detect when a tank is full and close the valve without requiring external electrical signals or personnel intervention. The mechanical float mechanism self-actuates based on fuel level, providing autonomous refueling control while maintaining fuel line pressure.
2Extent of automation
If electrical sensors and control systems are installed in each truck, then automated fuel distribution is enabled, but device complexity increases
Solution Approach 1:
The patent extracts and removes electrical sensors and complex control electronics from the fuel distribution system. Instead of using electrical sensors in each truck, the system uses a centralized mechanical float valve assembly that communicates fuel level through pure mechanical means, significantly simplifying the overall system architecture.
Solution Approach 2:
The float valve assembly serves multiple functions simultaneously: it detects fuel level, controls valve closure, and maintains fuel line pressure all through a single mechanical mechanism. This multi-functionality eliminates the need for separate electrical sensors, control circuits, and pressure monitoring systems in each vehicle.
3Extent of automation
If fuel lines are depressurized to enable sensor operation, then electrical sensors can function, but fuel line responsiveness decreases
Solution Approach 1:
By replacing electrical sensors with a mechanical float valve that operates based on buoyancy and mechanical actuation, the system maintains full fuel line pressure throughout operation. The float valve closes mechanically when the tank is full without requiring pressure drops or electrical signals, preserving fuel line responsiveness.
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 ensures efficient, safe, and automated refueling of multiple vehicles by reducing personnel risks, minimizing downtime, and maintaining fuel line pressure, while providing real-time monitoring and alerts for potential issues.
Implementation Method 1
Each tank valve assembly includes a float valve mechanism that automatically shuts off fuel flow when the tank reaches a predetermined fill level
Implementation Method 2
A pump is operable to draw fuel from the fuel source and deliver the fuel to the distribution manifold
Implementation Method 3
The controller is adapted to receive a pressure measurement from the pressure sensor wherein the controller is further configured to close the at least one of the plurality of control valves and open a different control valve when the pressure measurement is greater predetermined amount indicating the tank valve is closed
Data Source
AI summary
A system and method for delivering fuel to a plurality of vehicles comprising a distribution manifold having a plurality of outlets, said distribution manifold in fluidic communication with a fuel source, each of said plurality of outlets having an associated control valve for controlling fluid flow therethrough and a plurality of tank valve assemblies in fluidic communication with one of said plurality of fuel lines each located at an inlet to a tank of one of said plurality of vehicles, each of said tank valve assembly being operable to shut off flow of fuel therethrough when said tank is filled to a predetermined level. The system further comprises a plurality of fuel lines, each of said plurality of fuel lines extending between an outlet of said distribution manifold and a tank valve assembly and a controller operably coupled to said plurality of control valves wherein said adapted to sequentially open at least one of said plurality of control valves at a time.