Optical Hybrid Fuel Sensor with Resistive Wire for Safe Tank Communication

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Solution Overview

Problem

The installation of electrically conductive materials in fuel tanks poses challenges due to the risk of electrical discharges, and accurate fuel quantity measurement is hindered by the need for reliable and safe communication systems within the tank.

Innovation Solution

A system utilizing an optical hybrid fuel height sensor with a sealed connector and resistive non-metallic wire for electric power and data communications, including an optical signal out connection, to ensure safe and accurate fuel level monitoring across the fuel tank wall.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If electrically conductive materials are installed in fuel tanks for power and data communication, then communication functionality is enabled, but the risk of electrical discharge increases

Engineering Contradiction:

Improvecommunication functionalityVSAvoidelectrical discharge risk

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent replaces electrically conductive materials with optical fibers for data communication within the fuel tank. Optical fibers transmit data as light signals instead of electrical signals, eliminating the risk of electrical discharge while maintaining communication functionality. The optical hybrid fuel height sensor uses an optical transmitter to convert electrical signals to optical signals for transmission through the optical fiber.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces optical fibers as an intermediary medium between the fuel height sensor and external systems. The optical fiber acts as a mediator that carries information without conducting electricity, thus preventing electrical discharge while enabling data transmission. The sealed connector also serves as an intermediary that provides both electrical connection and sealing functionality.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If non-metallic conductive materials are used for shielding and anti-static applications, then electrical discharge risk is reduced, but measurement precision of fuel quantity deteriorates

Engineering Contradiction:

Improveelectrical discharge resistanceVSAvoidfuel quantity measurement

Core Design Contradiction:

Object-affected harmful factorsVSMeasurement precision

Solution Approach 1:

The patent replaces non-metallic conductive materials with optical fibers for data transmission. This substitution eliminates the interference that conductive materials cause to capacitive sensing while maintaining electrical discharge resistance. The optical fiber does not interact with the electrical fields used for fuel quantity measurement, thus preserving measurement precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Object-affected harmful factors

If resistive non-metallic wire is used for electric power connection, then electrical discharge risk is minimized, but power transmission efficiency decreases

Engineering Contradiction:

Improveelectrical discharge riskVSAvoidpower transmission efficiency

Core Design Contradiction:

Object-affected harmful factorsVSLoss of energy

Solution Approach 1:

The patent applies different material properties to different parts of the system: resistive non-metallic wire is used only for power transmission where it contacts fuel, providing local electrical discharge protection, while optical fiber is used for data communication where zero electrical discharge risk is required. This localized application optimizes both safety and efficiency.

Inventive Principle:

Principle #3Local quality

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 provides a safe and reliable method for electric power and data communication within the fuel tank, minimizing the risk of electrical discharges while enabling precise fuel quantity measurement and reporting.

Implementation Method 1

an optical transmitter configured to convert fuel height electrical signals to fuel height optical signals

Methodology Applied

Scientific EffectOptical transmission: Light

Implementation Method 2

The internal data communications connection includes an optical fiber that couples the optical transmitter and the sealed optical connector

Methodology Applied

Scientific EffectOptical fiber transmission: Optical Fibre

Implementation Method 3

the electric power connection includes a resistive non-metallic wire

Methodology Applied

Scientific EffectElectrical resistance: Electrical Resistance

Data Source

PatentUS11305884B2Electric power and data communications within a fuel tank and across a wall of the fuel tank using resistive non-metallic wire and an optical hybrid fuel height sensor

Publication Date: 2022.04.19 THE BOEING CO

AI summary

A system for power and data communications within a fuel tank and across a wall of the fuel tank includes an optical hybrid fuel height sensor and a sealed connector extending through a wall of the fuel tank. The system also includes an electric power connection between the optical hybrid fuel height sensor and the sealed connector. The electric power connection includes a resistive non-metallic wire. The system also includes a sealed optical connector extending through the wall of the fuel tank. The system further includes an internal data communications connection between the optical hybrid fuel height sensor and the sealed optical connector. The internal data communications connection includes an optical signal out connection.