Servo-Electric Auto Sampler for Precise Fuel Sampling
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Solution Overview
Problem
Current sampling technologies, such as pneumatic and spring-loaded piston systems, lack active control over sample speed and volume, leading to inefficiencies and potential disruptions in fluid flow, and require manual oversight, which limits their ability to achieve precise and variable sample sizes as required by regulations like API 8.2 MPMS.
Innovation Solution
A servo-electric sampling system that uses a programmable servo-electric pump to control the speed and position of the sampling arm, allowing for precise and variable sample sizes, and integrates with existing programmable logic controllers and various valving systems to ensure consistent and controlled sampling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If pneumatic or spring-loaded piston systems are used for sampling, then sampling can be performed with simple structure, but active control over sample speed and volume is lost
Solution Approach 1:
The patent replaces pneumatic or spring-loaded mechanical piston systems with an electric motor-driven piston system. This substitution enables active control over sample speed and volume through electronic control mechanisms while maintaining the mechanical sampling function. The electric motor allows for variable speed control and precise positioning, resolving the contradiction between simple structure and active control capability.
Solution Approach 2:
The patent introduces dynamic control capabilities to the sampling system by implementing variable speed operation and adjustable stroke length. The system can adapt sampling parameters in real-time based on process conditions, enabling active control over sample speed and volume. This dynamic approach allows the system to optimize sampling performance for different applications while maintaining operational simplicity.
2Device complexity
If manual adjustment of piston position is used to set sample grab size, then device structure remains simple, but sampling precision and consistency deteriorate
Solution Approach 1:
The patent implements feedback control mechanisms that monitor and adjust piston position and sample volume in real-time. Sensors detect actual sampling parameters and feed this information back to the control system, which makes automatic adjustments to achieve target sample volumes. This closed-loop control ensures consistent and precise sample grab sizes without requiring complex manual adjustment mechanisms.
Solution Approach 2:
The system performs self-adjustment of sampling parameters based on pre-programmed settings and real-time feedback. The control system automatically compensates for variations in process conditions, eliminating the need for manual intervention to maintain precision. This self-service capability ensures consistent sampling accuracy while keeping the physical structure simple.
3Power
If pneumatic systems are used to drive the sampler, then power delivery is sufficient, but speed control and volume control are lost
Solution Approach 1:
The patent replaces pneumatic power delivery with an electric motor-driven system. This substitution maintains sufficient power delivery while enabling precise electronic control over piston speed and stroke volume. The electric motor provides variable speed control and positional accuracy that pneumatic systems cannot achieve, resolving the contradiction between power delivery and control capability.
Solution Approach 2:
The system enables independent control of multiple parameters including piston speed, stroke length, and timing through electronic adjustment. These parameter changes allow optimization of sampling performance for different applications while maintaining adequate power delivery. The electric drive system can adapt power output and control parameters dynamically, unlike fixed pneumatic systems.
4Speed
If 3-way valves are used to close suddenly for rapid sampling, then sampling speed increases, but product flow disruption and system deadheading occur
Solution Approach 1:
The patent implements dynamic control of valve operation and piston movement to achieve rapid sampling without sudden closures. The system coordinates valve timing and piston speed to maintain continuous product flow while capturing samples. This dynamic coordination eliminates flow disruptions and deadheading while preserving high sampling speed through optimized timing and sequencing.
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
The servo-electric system enables precise control over sample volume and speed, reducing manual oversight and maintaining continuous fluid flow, thereby meeting regulatory requirements for sampling frequency and accuracy while handling varying pressures and viscosities.
Implementation Method 1
A servo-electric sampling system that uses a programmable servo-electric pump to control the speed and position of the sampling arm
Implementation Method 2
A servo-electric sampling system that uses a programmable servo-electric pump to control the speed and position of the sampling arm
Data Source
AI summary
A servo-electric actuated sampler can draw samples of fuel liquid from an operating main line. The sampler can run in a fast-loop process whereby liquid is drawn into the sampling system and past an actuated sampler and then out of the system back into main. The system main run a short loop whereby the main fast-flow is restricted, and the actuator and sampler are isolated from the main line flow. When isolated, the sampler discharges liquid into sampling cans. The servo-electric actuator requires a monitored amount of power to draw and discharge fluids. Monitoring of the power requirements of the servo-electric sampler can reveal the status and reliability of the system.