Self-Calibrating Fuel Dispensing System Using Tank Level and Flow Data
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current fuel dispensing and metering systems require regular calibration and testing to maintain accuracy, leading to potential fines for under-dispensing and resulting in operators dispensing excess fuel to avoid penalties, thereby losing profits.
Innovation Solution
A self-calibrating method that logs outflow and inflow information, measures fluid levels, and derives a filled volume model for the tank to automatically adjust flow meters, ensuring accurate fuel dispensing without manual testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If regular manual calibration and testing are performed to maintain dispensing accuracy, then measurement precision is improved, but loss of time and productivity deteriorate due to system downtime and operational disruption
Solution Approach 1:
The system performs automatic self-calibration using the tank level sensor and flow meter data to generate a filled volume model, eliminating the need for manual calibration operations. The control system continuously monitors and adjusts dispensing parameters based on the model, enabling the system to maintain accuracy without human intervention or operational disruption.
Solution Approach 2:
The calibration process occurs continuously in the background without interrupting fuel dispensing operations. The control system continuously logs flow data and level measurements, continuously updates the filled volume model, and continuously adjusts dispensing parameters, maintaining both operational continuity and measurement precision.
2Productivity
If manual calibration is performed less frequently to reduce downtime, then productivity is improved, but measurement precision deteriorates as the system drifts from calibrated values
Solution Approach 1:
The system continuously updates the filled volume model by continuously logging flow meter data and tank level sensor data during normal operations. This continuous data collection and model updating ensures that calibration remains current without requiring system shutdowns, maintaining both productivity and precision simultaneously.
Solution Approach 2:
The control system continuously monitors the relationship between flow meter readings and actual fuel volume changes in the tank using the filled volume model. When discrepancies are detected, the system automatically adjusts dispensing parameters to maintain accuracy, providing continuous feedback-based correction without interrupting operations.
3Reliability
If excess fuel is dispensed to avoid fines for under-dispensing, then reliability of compliance is improved, but loss of substance deteriorates through lost profits from wasted fuel
Solution Approach 1:
The control system continuously compares flow meter measurements with actual fuel volume changes in the tank using the filled volume model. This real-time feedback enables precise tracking of actual fuel dispensed versus metered volume, allowing the system to maintain exact compliance with legal requirements without dispensing excess fuel, thereby eliminating profit loss while ensuring regulatory compliance.
Solution Approach 2:
The system replaces manual calibration and measurement methods with electronic sensors and automated control algorithms. The tank level sensor combined with the filled volume model provides precise digital measurement of actual fuel volume, substituting imprecise mechanical measurement systems that required manual calibration and led to compliance uncertainties and excess dispensing.
4Measurement precision
If frequent manual calibration is performed to maintain accuracy, then measurement precision is improved, but device complexity increases due to additional calibration equipment and procedures
Solution Approach 1:
The control system performs multiple functions using the same existing components: it controls fuel dispensing, logs flow data, monitors tank level, calculates the filled volume model, and performs automatic calibration adjustments. This multi-functionality eliminates the need for separate calibration equipment and procedures, maintaining measurement precision without increasing device complexity.
Solution Approach 2:
The system uses its own existing flow meters and tank level sensor to perform self-calibration, eliminating the need for external calibration equipment and manual procedures. The control system automatically generates the filled volume model and adjusts dispensing parameters using internally collected data, simplifying the overall system while maintaining accuracy.
Data Source
AI summary
Fluid level measurements for the shared tank and outflow information provided by calibrated flow meters corresponding to dispensing stations connected to the shared tank may be used to derive a filled volume model for the tank as a function of fluid level. Subsequently, a filled volume change for a shared tank over a selected time interval may be determined from pre-change and post-change fluid level measurements. The change in filled volume may be compared with the total fluid flow over the selected time interval as indicated by the flow meters of active dispensing stations. If the filled volume change for the tank is substantially different than the total fluid flow indicated by the flow meters, the flow meters may be collectively adjusted to provide a more accurate indication of the filled volume change in the shared tank.