Terminal Tractor Auxiliary LPG Cylinder Refill System
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Solution Overview
Problem
Existing LPG-powered terminal tractors experience downtime due to the need for refilling their primary fuel tank, which can disrupt high-throughput operations in cross-docking and logistics, as they lack auxiliary fueling options for immediate refueling.
Innovation Solution
A system with one or more portable, removable LPG cylinders and a controller-sensor-pump configuration that refills the primary tank when its fuel level falls below a predetermined level, allowing for on-demand fueling and minimizing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If a single primary LPG tank is used in the tractor, then the fuel storage capacity is sufficient for extended operation, but the tractor experiences downtime when the tank needs refilling
Solution Approach 1:
The fuel storage system is segmented into a primary LPG tank and multiple auxiliary portable LPG cylinders. The primary tank provides main fuel storage while auxiliary cylinders can be quickly swapped when depleted, eliminating refueling downtime and maintaining continuous operation.
Solution Approach 2:
Auxiliary LPG cylinders are pre-filled and kept ready for immediate use. When the primary tank needs refilling, pre-filled auxiliary cylinders can be quickly connected to the fuel system, allowing the tractor to maintain operation without waiting for refueling.
2Productivity
If a large primary LPG tank is installed, then refueling frequency is reduced, but the tractor cannot perform immediate refueling during operation
Solution Approach 1:
The fuel system is divided into a primary tank and multiple auxiliary cylinders, allowing the system to function as a large-capacity system when auxiliary cylinders are full, and providing flexibility to swap auxiliary cylinders when needed, thus maintaining both productivity and adaptability.
Solution Approach 2:
The fueling system is designed to accept multiple types of fuel sources - the primary LPG tank and multiple auxiliary portable LPG cylinders - all connecting to the same fuel delivery system. This multi-functionality allows the tractor to adapt to different fueling scenarios and maintain high productivity regardless of fuel availability.
3Reliability
If auxiliary LPG cylinders are added to the tractor, then refueling flexibility and continuous operation are improved, but the device complexity increases
Solution Approach 1:
The fuel system is segmented into modular components - a primary tank and multiple identical auxiliary cylinders. Each auxiliary cylinder is a self-contained unit that connects to the existing fuel delivery system through standardized interfaces, adding reliability through redundancy while keeping the increase in complexity manageable through modularity.
Solution Approach 2:
The system includes sensors that automatically detect when auxiliary cylinders need replacement and can automatically initiate the refueling process from available auxiliary cylinders, reducing the need for manual intervention and simplifying operation despite the added system complexity.
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
Enhances operational efficiency by enabling continuous operation through tank swapping, reducing downtime and maintaining high throughput in logistics and cross-docking operations.
Implementation Method 1
A controller interfaced to a sensor and a pump is operative to pump fuel from the auxiliary LPG cylinder and into the fuel line to refill the primary LPG tank
Data Source
AI summary
A vehicle such as a terminal or yard tractor used for freight spotting is provided with one or more individual, portable LPG cylinders of the type used by forklifts facilitating tank swapping on an as-needed basis for reduced downtime. Each auxiliary cylinder is a portable, removable and replaceable cylinder having a fuel capacity less than that of the vehicle's primary tank. A controller interfaced to a sensor and a pump is operative to pump fuel from the auxiliary LPG cylinder and into the fuel line to refill the primary LPG tank when the fuel level of the primary tank falls below a predetermined level. The invention may be factory-installed onto the vehicle, or may be provided as a kit enabling an existing vehicle to be retrofitted with the auxiliary LPG cylinder(s).