Modular Backpressure Sensor for On-Site Fuel Nozzle Repair
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Solution Overview
Problem
Current fuel nozzles for large construction and mining vehicles require frequent rebuilding due to wear, necessitating costly and inconvenient trips to specialized rebuild centers, and often lack on-site repair and calibration capabilities, as well as protection from incidental damage.
Innovation Solution
A modular backpressure sensor system that allows for on-site removal, repair, and calibration of the pressure sensing component, featuring a pressure sensing chamber with a biasing member and retainer, enabling quick rebuilding and adaptation to various fuel receiver diameters, and includes a kit with tools and replacement parts for maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the entire nozzle is returned to a rebuild center for complete disassembly and reassembly, then the nozzle can be repaired and tested, but the process is costly, time-consuming, and requires specialized equipment that is not available on-site
Solution Approach 1:
The nozzle is divided into modular sections with the pressure sensing component as a separate, removable module. This allows the sensing component to be replaced independently without disassembling the entire nozzle, enabling on-site repairs without requiring full nozzle disassembly and reassembly at specialized centers.
Solution Approach 2:
The pressure sensing component is extracted as a separate replaceable module from the nozzle assembly. This extraction allows the component to be removed and replaced independently in the field, eliminating the need to ship the entire nozzle to a rebuild center for routine maintenance.
2Productivity
If complete back up sets of nozzles are kept on hand for use while a first set is being rebuilt, then operational continuity is maintained, but inventory costs and storage requirements increase
Solution Approach 1:
By segmenting the nozzle into modular components with replaceable sensing modules, the system reduces the need for complete backup nozzle sets. Only the small sensing module needs to be replaced rather than the entire nozzle, significantly reducing inventory requirements while maintaining operational continuity.
3Reliability
If the pressure sensing component is subjected to frequent wear and requires rebuilding after every few months or weeks, then reliability is maintained, but the frequency of repairs and associated costs increase
Solution Approach 1:
The pressure sensing component is extracted as a separate module that can be quickly replaced in the field. This allows operators to replace worn sensing components without waiting for scheduled rebuilds at specialized centers, reducing downtime and maintaining reliability while decreasing the frequency of formal repair operations.
4Adaptability or versatility
If rubber bumpers are removed from the end of the fuel nozzle to fit newer fuel receivers, then compatibility is achieved, but physical protection from incidental damage is lost
Solution Approach 1:
The nozzle is segmented into modular components where the sensing module can be independently replaced. This modular approach allows the main nozzle body to retain protective features like rubber bumpers while accommodating different fuel receiver types through the interchangeable sensing modules, maintaining both protection and adaptability.
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 on-site rebuilding of fuel nozzles, reducing shipping and handling costs, enhancing safety by preventing fuel-soaked nozzles from being transported, and providing a cost-effective solution for maintaining fuel delivery systems with improved durability and adaptability.
Implementation Method 1
Most fuel nozzles, in current use, incorporate either a spring biased piston or diaphragm to sense the change in back pressure of the fuel flowing through the nozzle. The change in back pressure causes the nozzle to shut off when the pressure reaches a pre-set pressure.
Implementation Method 2
A biasing member reacts to pressure on the pressure response member
Data Source
AI summary
An apparatus, system, and means are disclosed for a modular backpressure sensor configured for use with a fluid delivery nozzle. The modular backpressure sensor may be installed and removed using simple tools and may optionally include an activator handle attachment. The system may optionally include a protective end plug for the fluid delivery nozzle.