Optical Sensor for Sealed Gas Meter Automation
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Solution Overview
Problem
Existing gas meter reading systems struggle to provide automated reading capabilities for sealed mechanical gas meters, such as tin case meters, due to their sealed and ferrous metal construction, which prevents non-invasive measurement and compliance with regulatory requirements for accurate consumer billing and leak detection.
Innovation Solution
A non-invasive optical sensor system is retrofitted to the meter's window, using a translucent base and cap member with a light emitting diode and CMOS sensor to detect the rotation of the measurement dial, allowing for remote monitoring while maintaining the meter's seal and enabling manual reading, and a method for leak detection by comparing the dial's position before and after gas is turned back on.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a non-invasive optical sensor system is retrofitted to the meter's window, then automated remote reading capability is enabled, but the meter's sealed construction and ferrous metal housing block the optical signal and prevent measurement
Solution Approach 1:
The patent introduces an optical intermediary system consisting of a light source positioned inside the meter housing that illuminates the dial through the window. This internal light source acts as a mediator that bypasses the external optical path blocked by the ferrous metal housing, enabling the optical sensor to detect dial position without signal blocking.
Solution Approach 2:
Instead of attempting to read the dial from the external side through the metal housing (which blocks light), the patent inverts the approach by placing the light source inside the housing and having it illuminate the dial outward through the window. This reversal of the optical path direction allows automated reading while maintaining the sealed ferrous construction.
2Extent of automation
If the measuring mechanism is removed from the sealed meter for retrofitting, then automated reading equipment can be installed, but the sealed enclosure is breached and gas may leak into the atmosphere
Solution Approach 1:
The patent extracts only the essential reading function from the measurement mechanism itself. By using an optical sensor system that reads the dial position externally through the window, the invention eliminates the need to extract or modify the sealed measurement mechanism, thereby maintaining enclosure integrity while achieving automated reading.
Solution Approach 2:
The optical sensor system acts as an intermediary that interfaces with the sealed meter through the existing window opening. This mediator allows data extraction (dial position) without breaching the sealed enclosure, as the optical path passes through the window which is part of the sealed structure.
3Reliability
If manual dial reading is used, then the meter's sealed construction is maintained, but operational efficiency is reduced due to repeated trips and inability to read when no one is home
Solution Approach 1:
The automated optical reading system enables the meter to perform its own reading function without requiring external manual intervention. The system automatically detects dial position and transmits usage data, allowing utility personnel to retrieve readings remotely without needing to physically visit the meter location, thereby improving operational efficiency while maintaining sealed construction.
Solution Approach 2:
The patent replaces the manual mechanical reading process with an automated optical detection system. Instead of requiring personnel to visually read the dial during site visits, the optical sensor automatically detects dial position and communicates usage data, eliminating the need for repeated trips and improving productivity while preserving the sealed meter construction.
4Extent of automation
If automated reading devices are installed on sealed tin case meters, then remote monitoring is achieved, but compliance with regulatory requirements for accurate consumer billing and leak detection is compromised
Solution Approach 1:
The optical sensor system creates an accurate optical copy or image of the dial position, which is then processed to determine usage data. This optical copying mechanism faithfully reproduces the dial position information, ensuring measurement precision that complies with regulatory requirements for accurate consumer billing, while enabling remote monitoring through digital transmission of the copied data.
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 automated remote reading of sealed gas meters without breaching the seal, ensures accurate billing, and allows for compliance with industry and regulatory standards, while also facilitating leak detection using standard protocols.
Implementation Method 1
using a translucent base and cap member with a light emitting diode and CMOS sensor to detect the rotation of the measurement dial
Data Source
AI summary
A gas meter reading system is provided that allows automated meter reading capability to be incorporated with sealed mechanical type gas meters. The reading system is mounted to the window of the meter adjacent to the measurement dial. The reading system senses the rotation of the dial and provides data, such as a pulse, that may be recorded by an external source. A method of detecting for leaks with a gas meter having a reading system is also provided.