Tanker Fluid Level Measurement Using Custom Strap Charts
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Solution Overview
Problem
Current tanker truck fluid level measurement systems are inaccurate due to tank manufacturing variability, lack of practicality in using scales or flow meters, and inefficiencies in existing gauges and monitoring systems, necessitating a more precise and adaptable solution for fluid volume measurement and management.
Innovation Solution
A processor-based system with a level sensor and custom strap charts for each tank, correlating fluid level to volume, providing indicators for operators and automating flow control, and integrating geolocation for fluid transfer management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional level gauges and monitoring systems are used to measure fluid volume in tanker trucks, then the measurement process is simple and inexpensive, but the measurement precision is poor with volumes differing by 10-15% due to tank manufacturing variances
Solution Approach 1:
The system performs preliminary calibration by measuring the actual volume of each tank using a scale before deployment. This pre-measurement creates a custom strap chart for each tank that accounts for manufacturing variances, enabling accurate volume measurement without complex real-time calculations during fluid transfer operations
Solution Approach 2:
The system creates a digital copy (strap chart) of each tank's specific volume characteristics through preliminary measurement. This digital model captures the unique geometry and volume properties of each tank, allowing the system to accurately convert level measurements to volume readings without requiring physical measurement devices in the tank
2Measurement precision
If scales are used to measure fluid volume by weighing trucks empty and full, then measurement precision can be high, but the ease of operation is poor because it is impracticable to put a scale at every extraction site
Solution Approach 1:
The system performs the cumbersome weighing operation only once during an initial calibration phase at a scale facility. The resulting strap chart is then stored in the portable measurement system, eliminating the need for repeated scale usage at remote extraction sites while maintaining high measurement accuracy
Solution Approach 2:
The system replaces the need for physical scales at extraction sites with a digital model (strap chart) that was created from a single calibration weighing. This digital copy enables accurate volume measurement to be performed portably at any location using only a level sensor and the stored calibration data
3Measurement precision
If flow meters are used to measure the volume of liquid being placed in or removed from a tank, then measurement precision is improved, but the device complexity and cost increase significantly
Solution Approach 1:
The system replaces complex flow measurement devices with a simplified approach using a level sensor and a digital model (strap chart). The strap chart acts as a lookup table that converts simple level readings into accurate volume measurements, eliminating the need for sophisticated flow meters while maintaining measurement precision
Solution Approach 2:
The system replaces mechanical flow measurement mechanisms (flow meters) with an informational approach using electronic level sensing and computational lookup of pre-stored calibration data. This substitution eliminates moving parts and complex mechanical components while achieving equivalent or superior measurement accuracy
4Ease of manufacture
If tank manufacturing variability is accepted as inherent, then production costs are reduced, but measurement precision deteriorates because volumes vary by +/â3-5% even for tanks labeled the same container size
Solution Approach 1:
The system performs preliminary measurement of each tank's actual volume characteristics during or after manufacturing. This early calibration captures the unique properties of each tank before deployment, creating a custom strap chart that compensates for manufacturing variability without requiring tighter (more expensive) manufacturing tolerances
Solution Approach 2:
The system changes the measurement parameter from assuming a standard nominal volume to using the actual measured volume characteristics of each specific tank. By measuring and storing the unique volume-level relationship for each tank in its strap chart, the system adapts to manufacturing variations rather than fighting against them
Data Source
AI summary
A tank volume measurement system and method. The tank volume measurement system receives a tank identifier indicating which tank the level sensor is sensing, receives a tank level indication from a level sensor, correlates the tank level to a tank volume using a calibrated strapping chart, and outputs a volume indication to a user.