Robotic Surface Profiling for Non-Invasive Tank Calibration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for calibrating oil and gas storage tanks are inefficient, invasive, and costly, often requiring significant downtime and resulting in inaccurate volume measurements due to their invasive and destructive nature, which limits frequent calibration and leads to errors in volume transfer.
Innovation Solution
A robotic vehicle system equipped with distance sensors, inertial measurement units, and a control computing system that generates surface profiles by measuring movement and slope changes, allowing for non-invasive and rapid calibration of storage tanks without the need for external references or remote processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional calibration methods (manual strapping, optical techniques) are used, then calibration accuracy can be achieved, but tank downtime is significant and operation is disrupted
Solution Approach 1:
The patent replaces traditional mechanical calibration methods (manual strapping, physical reference lines) with an electromagnetic field-based system using magnets and magnetic sensors. This allows calibration to be performed without physical contact or disruption to the tank, enabling operation during calibration and eliminating downtime while maintaining accuracy through magnetic field measurements.
Solution Approach 2:
The patent introduces magnetic fields as an intermediary medium between the calibration system and the tank. By placing magnets on the tank exterior and measuring their positions with magnetic sensors on a profiling vehicle, the system indirectly measures tank dimensions without needing to access or disrupt the tank interior, thus maintaining operation during calibration.
2Measurement precision
If invasive calibration methods are used to access internal volume, then measurement can be performed, but the process becomes destructive and costly
Solution Approach 1:
The patent replaces invasive mechanical measurement methods with a non-contact magnetic field-based measurement system. Magnets are attached to the tank exterior at specific locations, and their positions are measured by magnetic sensors on a profiling vehicle that travels along the tank exterior. This eliminates the need to access, empty, or disrupt the tank interior, making the process non-destructive and cost-effective.
3Productivity
If calibration is performed infrequently due to high cost and downtime, then operational continuity is maintained, but volume measurement accuracy deteriorates
Solution Approach 1:
The patent replaces time-consuming mechanical calibration processes with a rapid magnetic field-based system that can be performed quickly without stopping tank operation. This enables frequent calibration (e.g., before each custody transfer operation) to maintain high measurement accuracy while preserving operational continuity, as the tank remains in service during calibration.
Solution Approach 2:
The patent enables continuous operation of the tank during the calibration process. The profiling vehicle travels along the exterior of the operating tank, measuring magnet positions without interrupting the tank's function. This allows calibration to be performed continuously or frequently without sacrificing productivity, maintaining both operational continuity and measurement accuracy.
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 quick, accurate, and cost-effective calibration of storage tanks, facilitating more frequent volume measurements and reducing errors, thereby improving operational efficiency and reducing downtime.
Implementation Method 1
one or more distance sensors are coupled to the robotic vehicle to measure a slope of the surface
Implementation Method 2
one or more wheel encoders housed within each wheel for measuring movement of the robotic vehicle when driven by the drive system
Implementation Method 3
one or more inertial measurement units. For example, the inertial measurement units can be an accelerometer or gyroscope
Data Source
AI summary
Disclosed herein are systems and methods for profiling a surface. In some embodiments, the systems and methods perform profiling using a robotic vehicle. The vehicle can include a drive system, one or more wheel encoders, and one or more distance sensors and/or inertial measurement units for capturing measurement data, such as the slope of the surface or the angle of the robotic vehicle relative to the surface or the gravity vector. A control computing system is included having one or more processors that execute instructions stored in software modules to process movement data. In some embodiments, the processed movement data determines a plurality of snapshots of the surface at different times and positions as the robotic vehicle traverses the surface. These snapshots are combined to generate a profile of the surface.