U.S. patent application number 13/269093 was filed with the patent office on 2012-02-02 for system and method for testing fuel tank integrity.
This patent application is currently assigned to Environmental Systems Products Holdings Inc.. Invention is credited to Mark Davis, Michael Herzog, Arun R. Pandey, Valeri Maksimovich Shishkin, Gordon Ernest Smith, Charles Michael Sulik, Rex Graham Weedon.
Application Number | 20120024045 13/269093 |
Document ID | / |
Family ID | 34657036 |
Filed Date | 2012-02-02 |
United States Patent
Application |
20120024045 |
Kind Code |
A1 |
Herzog; Michael ; et
al. |
February 2, 2012 |
SYSTEM AND METHOD FOR TESTING FUEL TANK INTEGRITY
Abstract
The invention relates generally to a system and method for
testing fuel evaporative systems, and more particularly to a
stand-alone tank tester system (and method) for testing vehicle
fuel tank integrity. Furthermore, a self-contained calibration tank
with switchable leak sizes for calibrating the tank tester to
multiple leak sizes is provided. Constant flow and vacuum methods
for testing fuel tank integrity are also provided.
Inventors: |
Herzog; Michael; (Tucson,
AZ) ; Smith; Gordon Ernest; (Sandy, UT) ;
Sulik; Charles Michael; (Tucson, AZ) ; Pandey; Arun
R.; (Tucson, AZ) ; Shishkin; Valeri Maksimovich;
(Tucson, AZ) ; Weedon; Rex Graham; (Tucson,
AZ) ; Davis; Mark; (Tucson, AZ) |
Assignee: |
Environmental Systems Products
Holdings Inc.
East Granby
CT
|
Family ID: |
34657036 |
Appl. No.: |
13/269093 |
Filed: |
October 7, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11965113 |
Dec 27, 2007 |
8056397 |
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13269093 |
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|
11546300 |
Oct 12, 2006 |
7409852 |
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11965113 |
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10974677 |
Oct 28, 2004 |
7168297 |
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11546300 |
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60514745 |
Oct 28, 2003 |
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Current U.S.
Class: |
73/49.2 |
Current CPC
Class: |
G01M 3/3236 20130101;
F02M 25/08 20130101; G01F 17/00 20130101; F02M 37/20 20130101 |
Class at
Publication: |
73/49.2 |
International
Class: |
G01M 3/32 20060101
G01M003/32 |
Claims
1. A method for testing the integrity of a fuel tank, comprising:
applying a constant flow of gas to a fuel tank at a predetermined
flow rate; measuring a tank pressurization rate at which pressure
in the fuel tank increases; and calculating the size of a leak in
the fuel tank by: (i) storing an uncompromised pressurization rate
at which an uncompromised fuel tank would pressurize under the
predetermined flow rate; and (ii) comparing the tank pressurization
rate to the uncompromised pressurization rate, wherein the size of
a leak is proportional to the difference between the uncompromised
pressurization rate and the tank pressurization rate.
2. A method of testing the integrity of a fuel tank, comprising:
reducing pressure in a fuel tank to a predetermined pressure below
an ambient pressure; measuring a pressure ascension rate over a
predetermined period of time; and calculating the size of a leak
within the fuel tank by: (i) storing an uncompromised pressure
ascension rate at which an uncompromised fuel tank would ascend in
pressure when pressurized to the predetermined pressure level below
ambient pressure; and (ii) comparing the uncompromised pressure
ascension rate to the pressure ascension rate, wherein the size of
a leak is proportional to the difference between the uncompromised
pressure ascension rate and the pressure ascension rate.
3. A method for testing the integrity of a fuel tank, comprising:
applying a constant reduction of pressure below an ambient pressure
to a fuel tank at a predetermined rate; measuring a tank pressure
reduction rate at which a pressure in the fuel tank decreases;
calculating the size of a leak in the fuel tank by: (i) storing an
uncompromised pressure reduction rate at which an uncompromised
fuel tank would pressurize under the predetermined flow rate; and
(ii) comparing the tank pressure reduction rate to the
uncompromised pressure reduction rate, wherein the size of a leak
is proportional to the difference between the uncompromised
pressure reduction rate and the tank pressure reduction rate.
4. A method for testing the integrity of a fuel tank, comprising:
pressurizing a fuel tank that is connected to a cylinder by
applying a first predetermined force to a piston disposed within
the cylinder; ceasing movement of the piston in the cylinder when
pressure in the fuel tank exerts a second force equal to that of
the first force; and calculating a leak size in the fuel tank by:
(i) measuring movement of the piston in the cylinder over a
predetermined interval, wherein the movement of the piston in the
cylinder is proportional to the size of a leak in the fuel tank.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This Application is a divisional of U.S. patent application
Ser. No. 11/965,113, filed Dec. 27, 2007 (currently pending), which
is a divisional of U.S. patent application Ser. No. 11/546,300,
filed Oct. 12, 2006 (now U.S. Pat. No. 7,409,852 B2, issued Aug.
12, 2008), which is a divisional of U.S. patent application Ser.
No. 10/974,677, filed Oct. 28, 2004 (now U.S. Pat. No. 7,168,297
B2, issued Jan. 30, 2007), which claims priority to U.S.
Provisional Patent Application Ser. No. 60/514,745, filed Oct. 28,
2003, each of which are hereby incorporated herein by reference in
their entirety.
FIELD OF THE INVENTION
[0002] The invention relates generally to a system and method for
testing fuel evaporative systems, and more particularly to a
stand-alone tank tester system (and method) for testing vehicle
fuel tank integrity.
BACKGROUND OF THE INVENTION
[0003] The loss of fuel from a vehicle fuel tank (and associated
piping) through evaporation to the atmosphere may result in, among
other things, undesirable hydrocarbon pollution.
[0004] Accordingly, many systems and methods have been developed to
test the tank integrity of vehicle fuel systems, and to identify
vehicles that fail to comply with promulgated regulations and
mandated guidelines (regardless of whether they are on the federal,
state, or local level).
[0005] Unfortunately, many existing fuel tank integrity testing
systems can be expensive, cumbersome, and inconsistent. These and
other drawbacks exist.
SUMMARY OF THE INVENTION
[0006] The invention solving these and other problems relates to a
stand-alone tank tester system (and method) for testing vehicle
fuel tank (or fuel system) integrity.
[0007] According to an embodiment of the invention, a system is
provided for a tank tester. The tank tester may perform various
processes for testing fuel tank integrity, measurement of fuel tank
volume, measurement of fuel volume, measurement of vapor space,
measurement of fuel temperature, or other tests. The tank tester
may include a computer-implemented component ("computer
component"), a testing component, a housing, a calibration tank,
and/or other elements. In some embodiments, the tank tester may
perform various calibration and self-test procedures which may be
necessary for efficient and accurate execution of fuel tank
tests.
[0008] Computer Component
[0009] In one embodiment of the invention, the tank tester may
include a computer component. The computer component may include
various software elements and computer hardware such as, for
example, a processor board. The processor board may include a
processor which may be or include, for instance, any of the Intel
x86 PC/AT microprocessors or compatible processors such as those
available from Cyrix or AMD. The processor board may also include
one or more analog inputs with A/D converters that interface with
various sensors, one or more digital outputs to interface with one
or more solenoids, and other elements. The processor board may also
include one or more serial ports that may interface with additional
equipment such as, for example, Emissions Inspection Systems (EIS)
equipment, a modem, a real time clock, or other devices or
elements. The processor board may also include one or more memory
devices. The one or more memory devices may include flash erasable
programmable read-only-memory (FEPROM), a hard disk, or other data
suitable memory for data storage.
[0010] The computer component may also include a signal
conditioning board operatively connected to the processor board.
The signal conditioning board may, among other things, condition
electrical signals into and out from any sensors. The signal
conditioning board may include a DC/DC power supply. The signal
conditioning board may also include a pressure switch control for
releasing pressure from the testing component (described in detail
below) upon the existence of a predetermined pressure within the
testing component. The signal conditioning board may further
include one or more solenoid drivers for operating one or more
solenoids throughout the tank tester. One or more solenoids may be
utilized to operate various elements of the testing component
including switches, valves, or other elements.
[0011] The computer component may also include one or more sensors
operatively connected to the processor board and/or the signal
conditioning board. The one or more sensors may include pressure
transducers, temperature sensors, or other sensors for operation of
the tank tester.
[0012] The computer component may also include external memory
operatively connected to the processor board. The external memory
may include flash memory, a hard disk, or other suitable memory for
storing run-time programs, vehicle databases, testing lookup
tables, recent test results, or other data.
[0013] In one embodiment, the computer component may include or
host an operating application. The operating application may
include one or more software modules enabling the operation of, and
user interaction with, the tank tester. The operating application
may be based on any one of many computer programming languages such
as, for example, C, C++, or other programming language.
[0014] The operating application may include software for fuel tank
testing, inspection test procedures and criteria, security
measures, utilities, ancillary modules, or other software. The
features enabled may include, among other things, integrated
calibration and self test procedures, outside ambient temperature
measurement, internal tank tester pressure measurements, fuel tank
pressure measurements, evaporative tests, constant flow
determination of a tank leak, vapor space compensation, temperature
compensation, Reid Vapor Pressure (RVP) compensation, vacuum tank
integrity testing, hydrocarbon detection, constant pressure tank
integrity testing, use of vapor temperature for determination of
liquid fuel temperature, interface with an Emissions Inspections
System (EIS), or other features. One or more of the modules
comprising the operating application may be combined. For some
purposes, not all modules may be necessary.
[0015] In one embodiment, the operating application may also
include, or have access to, data look-up tables, and may use table
calls for fuel tank vapor space calculations, pass/fail decisions,
and/or other calculations and decisions. These tables may
compensate for temperature and RVP when making the vapor space
calculations, pass/fail determinations, or other calculations or
decisions. In addition, the operating application may write test
results and calibration test results to a record ("test
record").
[0016] In one embodiment, the computer component may include an
interface that enables one or more users to interact with the
operating application. The interface may comprise a graphical user
interface (GUI) presented to a user on a display device. A user may
interact with the operating application and the GUI via a user
input device.
[0017] The computer component may also include other elements for
the operation of the tank tester. As would be apparent to one
skilled in the art, other configurations for the computer component
may exist.
[0018] Testing Component
[0019] In one embodiment of the invention, the tank tester may
include a testing component. The testing component may include a
pressurized gas source, various pressure transducers, pressure
regulators, valves, orifices, pneumatic pluming elements, or other
elements for performing the operations of the tank tester described
herein.
[0020] In one embodiment, the pressurized gas source may contain or
produce pressurized gas for use in the tank tester. The pressurized
gas may comprise nitrogen, compressed air, or another gas. If the
tank tester uses nitrogen as a pressurizing gas, then the nitrogen
may be 98% pure. Other concentrations may be used. If the tank
tester uses compressed air as a pressurizing gas, an air filter
capable of removing harmful contaminants and moisture from the
compressed air may be included. This filter may ensure that no
contaminants enter the tank tester that could physically block any
orifice, or chemically contaminate the internal components of the
tester. The filter may be configured to filter down to 5-micron
size particles.
[0021] The pressurized gas source may be pneumatically connected to
the various pressure transducers, pressure regulators, valves,
orifices, or other elements included in the testing component of
the tank tester.
[0022] The testing element may also include an outlet hose. The
outlet hose may interface with a tank adaptor at one of its ends.
The tank adaptor may include any of a set of fuel filler neck
adaptors ("tank adaptors") that provide connectivity to various
vehicles.
[0023] According to an embodiment of the invention, the tank
adaptor, outlet hose, and any pneumatic conduit or gasket materials
may be comprised of material which may be pliable and impermeable
to some or all gasoline constituents including, for instance,
Methyl Tertiary Butyl Ether (MTBE), ethanol, and methanol. Material
exhibiting these properties is known in the art. Furthermore, the
tank adaptor, the outlet hose, and other elements within testing
component may be fitted with quick disconnect couplers that
facilitate easy and rapid connection and disconnection from the
vehicle.
[0024] Housing and Calibration Tank
[0025] In some embodiments of the invention, the tank tester may
include a housing that may enclose one or more components of the
tank tester. In other embodiments of the invention, the housing may
support one or more components of the tank tester. These components
may be supported either internally within the housing, externally
to the housing, or partially internal and partially external to the
housing. In another embodiment, the housing may comprise a custom
impact-resistant plastic enclosure with a carrying strap and/or
handle.
[0026] In one embodiment of the invention, a calibration tank may
be included with the tank tester. The calibration tank may form a
predetermined volume that may be pressurized. In some embodiments,
the calibration tank may be supported internally within the
housing. In some embodiments, the housing itself (or part of the
housing) may form the calibration tank. In one embodiment, the
calibration tank may include a bladder (not otherwise illustrated).
In some embodiments, the bladder may conform itself within the
housing. In another embodiment, the housing and/or the calibration
tank may include a blow-molded case (not otherwise illustrated)
with a volume that may be pressurized. As discussed above, the case
may be formed, machined, or molded to have any predetermined
volume.
[0027] The volume of the calibration tank may comprise one gallon,
two gallons, five gallons, ten gallons, or any other predetermined
volume. In some embodiments, this volume may be adjustable. The
calibration tank may serve as a component for performing various
calibration procedures (described in detail below) enabling
efficient and accurate operation of the tank tester.
[0028] Calibration
[0029] According to an embodiment of the invention, the tank tester
may include a calibration module. The calibration module may enable
calibration of the various elements of the tank tester. Calibration
may include one or more of the following processes: self-test of
inlet pressure, self-test of transducers, self-test of temperature
sensors, sensor check/zero with pressure disconnected, sensor
check/zero with pressure connected, system leak/decay check with no
tank, tank volume check with no leak, passing tank calibration,
failing tank calibration, or other process.
[0030] As mentioned above, the calibration module may utilize a
calibration tank that contains a known, predetermined volume (or
vapor space). In one embodiment, the calibration tank may include
switchable calibrated leak standards. For example, the calibration
tank may contain purposefully designed leaks of varying sizes, one
or more of which may be used to simulate fuel tank leaks of
differing degrees.
[0031] According to one embodiment, the calibration module may
utilize an internal clock to determine when calibration is due. As
an example, the calibration module may automatically lock out test
procedures on the tank tester every 72 hours pending a successful
completion of one or more calibration procedures. Other time
intervals may be used.
[0032] According to an embodiment, the calibration module may
perform a system test for the tank tester's overpressure function.
This system test monitors the tank tester's ability to disable the
tank tester in the event that over pressurization of a calibration
tank or fuel tank occurs. The tank tester may be capable of
resuming normal operation after the overpressure condition has been
eliminated and the tank tester successfully completes the
calibration procedure. For a failed overpressure test, the tank
tester may prevent further testing for a predetermined period of
time, but may allow subsequent attempts to successfully complete
calibration procedures, self-tests, or system tests.
[0033] Upon successful completion of a calibration procedure, the
calibration module may write the results to a calibration record
with the date and time. The calibration module may then start a
clock to time-out the next calibration due date and time according
to a predetermined time period. The new record may be recorded to
the calibration record. The data recorded in the calibration record
(regardless of failure or passage) may include Station ID (facility
conducting test), Tester ID (person conducting test), Calibration
ID (the specific calibration iteration), Date/Time of Calibration,
Software Version, Pressure Decay Results, Vapor Space Results,
Simulated Test Results, Overall Calibration Result, Calibration
Error, Date/Time of Next Calibration Due, or other data. To
calculate the next time due, the software may add the predetermined
time period to the current calibration date and time. Once
calibration has been successfully completed, the calibration module
may allow testing to occur.
[0034] If the tank tester fails any portion of a calibration test,
a user may be prompted to perform subsequent calibration procedures
or contact a designated service provider for repairs. According to
one embodiment, when service of the tank tester is required, the
tank tester may not allow further tank testing or manual mode
pressurization to be performed until full function has been
restored by an authorized or designated service representative.
[0035] Testing
[0036] Fuel Evaporative Test
[0037] According to an embodiment of the invention, the tank tester
may include a test module. The test module may be utilized to
conduct various fuel tank tests such as, for example, a fuel
evaporative test. A fuel evaporative test may be performed to
determine or calculate of the size of a hole in a fuel tank of
unknown volume.
[0038] During a fuel evaporative test, the tank tester may
pressurize a fuel tank. During pressurization, the tank tester may
determine if the maximum allowable fill time has been exceeded. If
the fuel tank cannot be pressurized to a predetermined pressure in
a predetermined amount of time, a gross leak may be present. If the
fuel tank passes the fill-time portion of the test (indicating no
gross leak), the test module may determine whether an otherwise
unacceptable leak exists in the fuel tank (i.e., pass or fail). In
accordance with this test, the tank tester may calculate the vapor
space within the fuel tank being tested.
[0039] Flow Method
[0040] In another embodiment of the invention, the test module of
the tank tester may perform a fuel evaporative test using a "flow
method." In this embodiment, the testing component of the tank
tester may have two filling paths: Fast Fill Flow and Slow Fill
Flow.
[0041] Using the Fast Fill Flow path, a fuel tank may be
pressurized to a predetermined pressure level such as, for example,
14'' H.sub.2O at a rate of approximately 8.5 standard liters per
minute (SLPM). Once the desired pressure is achieved, the tank
tester may switch to the Slow Fill Flow path. The Slow Fill Flow
path may have an orifice and a precision pressure regulator set to
a predetermined pressure level such as, for example, 14'' H.sub.2O.
The precision pressure regulator attempts to maintain a constant
pressure in the tank. If the tank has no leak, there will be no
flow. If the tank has a leak, the flow rate of gas required to keep
a constant pressure in the tank should be the flow rate of the
leak. Based on this flow rate and the pressure in the tank, the
size of the hole in the tank may be calculated and compared to a
calibration standard.
[0042] Once a hole size is determined by the constant flow method,
the tank may be allowed to leak down over a predetermine period.
Based on the pressure drop in the tank versus time, the volume of
the tank may be calculated. If the tank does not have any leaks,
the volume may be calculated based on the Fast Fill Flow time and
Fast Fill Flow rate.
[0043] Constant Flow Test
[0044] In another embodiment of the invention, the test module may
perform a constant flow test. The constant flow test may operate by
applying a constant flow of air to the fuel tank which may result
in a increasing pressure. By measuring the rate at which a pressure
corresponding to the pressure in the fuel tank increases, a
determination may be made as to the integrity of the fuel tank (or
fuel system). The pressure inside an un-compromised fuel tank would
increase at a greater rate than that inside a compromised fuel
tank. In some embodiments, the degree to which the fuel tank is
compromised may be determined by the rate at which the pressure
inside the fuel tank increases.
[0045] Leak Down
[0046] According to embodiment, the test module may test the
integrity of a fuel tank using a leak down test. In performing the
leak down test, the tank tester may pressurize the fuel tank to a
predetermined pressure. Once the predetermined pressure is reached,
a time interval elapses, and the pressure in the fuel tank is
measured. Successive time intervals and pressure measurements may
occur. If the pressure in the fuel tank remains approximately at
the predetermined pressure, the fuel tank (or fuel system) may not
be compromised (e.g., no leaks, or leaks within an accepted
tolerance). If the pressure in the fuel tank decreases, the fuel
tank (or fuel system) is most likely comprised (e.g., has a leak).
The tank tester may then perform calculations to determine the size
of the leak and whether the leak is acceptable (e.g.,
pass/fail).
[0047] Vacuum Testing
[0048] According to an embodiment of the invention, the test module
may determine the integrity of a fuel tank (or fuel system) using
vacuum testing. In one embodiment, vacuum testing may comprise
reducing pressure in a fuel tank to a predetermined pressure below
ambient pressure. Such a predetermined pressure may be achieved by
applying a vacuum to the fuel tank. Once the predetermined pressure
is reached, a pressure corresponding to the pressure in the fuel
tank is measured. If the pressure in the fuel tank remains
approximately at the predetermined pressure, the fuel tank (or fuel
system) may not be compromised (e.g., no leaks, or leaks within an
accepted tolerance). If the pressure in the fuel tank increases,
the fuel tank (or fuel system) may be comprised (e.g., has a leak).
The tank tester may then perform calculations to determine the size
of the leak and whether the leak is acceptable (e.g.,
pass/fail).
[0049] In another embodiment of the invention, vacuum testing may
include applying a continuous vacuum to a fuel tank which results
in a decreasing pressure inside the fuel tank. By measuring the
rate at which a pressure corresponding to the pressure in the fuel
tank decreases, a determination may be made as to the integrity of
the fuel tank (or fuel system). The pressure inside an
uncompromised fuel tank would decrease at a greater rate than that
inside a compromised fuel tank. In some embodiments, the degree to
which the fuel tank is compromised may be determined by the rate at
which the pressure inside the fuel tank decreases.
[0050] Mechanical Pressure
[0051] According to one aspect of the invention, the test module of
the tank tester may determine the integrity of the fuel tank (or
fuel system) by applying a constant, predetermined pressure to the
fuel tank via a mechanical device, such as a piston and cylinder. A
force may be applied to the piston commensurate with the desired
predetermined pressure to be applied to the fuel tank. Once a
predetermined pressure has been reached in the tank, the force
applied to the piston and the force corresponding to the pressure
in the fuel tank should be equal and opposite. If the fuel system
is uncompromised (e.g., no leaks), the piston should remain
stationary (or nearly so). If the fuel system is compromised (e.g.,
leaks), the piston should move. The degree to which the piston
moves is related to the degree to which the fuel system leaks. The
movement of the piston in the cylinder may be measured via various
well known mechanisms.
[0052] Manual Mode
[0053] In one embodiment of the invention, the tank tester may
include a manual-test module. The manual-test module may perform a
manual test sequence. In performing the manual test sequence a user
may first select the manual test mode, connect the tank tester to a
fuel tank, and initiate a manual test. The tank tester may then
pressurize the fuel tank to a predetermined pressure level such as,
for example, 14'' H.sub.2O. The tank tester may maintain that
pressure for a predetermined time period. During pressurization, a
user may take readings from the various sensors and transducers of
the tank tester for use in determining the various qualities of a
fuel tank being tested. At the end of the predetermined time
period, the tester may vent any remaining tank pressure.
[0054] Multiple Standards
[0055] The test module may utilize different predefined standards
for fuel tank tests. In one embodiment, a standard may be defined
as a leak that exceeds an equivalent size gap. For example, the
test module may base a pass/fail determination on a standard of a
0.020'' gap. Where a fuel evaporative system leak is less than or
equal to a 0.020'' diameter gap the test module may return a pass
determination. Accordingly, the test module may fail the fuel
evaporative system where the leak exceeds a 0.020'' diameter
gap.
[0056] Under a different standard such as, for instance, a 0.040''
diameter gap standard, the test module may pass a vehicle where the
fuel evaporative system leak is less than or equal to a 0.040''
diameter gap, and fail the fuel evaporative system where the leak
exceeds a 0.040'' diameter gap. The false pass error rate may be
less than .+-.5% and the false fail error rate may be less than
.+-.1%. Other pass/fail standards and error rates may be used. All
data pertinent to test standards may be stored in a file. This file
may contain any and all data and/or algorithms required to make the
Pass/Fail decision in the tank tester.
[0057] Calculations and Compensation
[0058] According to one aspect of the invention, the tank tester
may further comprise a data analysis module. The data analysis
module may, among other things, measure vapor space, temperature,
and Reid Vapor Pressure (RVP) within a fuel tank being tested, and
may compensate for these factors when making test calculations.
[0059] Temperature measurements may be taken by one or more
temperature sensors included in the tank tester. The temperature
sensors may be placed in various locations within the testing
component, and may be connected to a sensor or other element of the
computer component of the tank tester. Additionally, various
hardware and/or software components associated with the tank tester
may be used to determine liquid fuel temperature based on measured
vapor temperature. These temperature readings may be used in the
calculations made during the various tests performed by the tank
tester.
[0060] The tank tester may also include a barometric pressure
sensor that may enable measurement of the barometric pressure of
the testing environment in which the tank tester is being used. The
testing component may also include an ambient temperature sensor
that may enable measurement of the ambient temperature of the
testing environment. These measurements may also be used in the
calculations performed by the tank tester.
[0061] Reid Vapor Pressure (RVP) measurements may also be taken for
the fuel in a fuel tank. RVP corresponds to the pressure induced in
a closed volume (fuel tank) as a result of the liquid (fuel) in the
closed volume evaporating. To improve the accuracy of the tank
tester, the data analysis module may compensate for the RVP. In
order to compute RVP, the data analysis module may obtain the
following measurements or quantities: the volume of the fuel tank,
the volume of the liquid in the tank, a measure of the liquid's
tendency to evaporate, and the ambient temperature. With these
variables, the amount of pressure induced by the evaporative
effects of the fuel may determined.
[0062] In some embodiments of the invention, the RVP may be
measured directly by, for instance, releasing the pressure in the
fuel tank, resealing the fuel tank, allowing the closed system to
reach a steady state condition, and measuring the RVP at steady
state. Once the RVP is determined, the data analysis module may
compensate for RVP in its pressure measurements as would be
apparent.
[0063] In some embodiments, certain other measurements such as, for
example the volume of the fuel tank, the volume of fuel in a fuel
tank, the volume of vapor in the fuel tank, or other measurements,
may be used by the tank tester in making calculations. In some
embodiments, the volume of the fuel tank may be provided by the
manufacturer of the fuel tank or integrator of the fuel system
(e.g., an automobile manufacturer). In other embodiments, the
volume of the fuel tank may be measured. In some embodiments, the
volume of fuel may be measured. In other embodiments, the fuel tank
may be drained and a known volume of fuel may be dispensed into the
fuel tank. In some embodiments, the volume of the fuel tank and the
volume of the liquid (fuel) may be used to determine the volume of
vapor within the fuel tank. In other embodiments, the volume of the
vapor may be measured directly without obtaining the volume of the
fuel tank and/or the volume of the fuel.
[0064] Safety Measures
[0065] According to an embodiment of the invention, the tank tester
may be configured to determine an overpressure condition for either
an incoming supply pressure or a regulated test pressure. If at
anytime during a procedure (for example, a fuel evaporative test or
manual mode test) the tester inlet pressure from the air pressure
regulator exceeds 35 psi (or other predetermined value), the tank
tester may cease any test or procedure in progress. Tank tester
software may prevent the tank tester from performing a
pressurization of the fuel tank until any overpressure condition
has been corrected.
[0066] Additionally, if at anytime during a procedure, the fuel
tank pressure exceeds 28'' H.sub.2O gauge (or other predetermined
emergency pressure level), as measured by the tank tester, the tank
tester may open one or more valves and vent any remaining pressure
in the fuel tank. The tank tester may also prevent pressurization
of the fuel tank for any procedure until the problem has been
corrected. In some embodiments, a pressure switch may enable the
release of pressure from the testing component upon the detection
of the predetermined emergency pressure level. The pressure switch
may act as a back-up in the event that a pressure transducer (or
other element of the testing component) fails. According to one
embodiment, the pressure switch may be wired in series with one or
more valves within the testing component and may manipulate said
valves to prevent over-pressurization as a fail-safe measure.
[0067] At anytime during any test sequence, the test may be aborted
by the activation of an abort button operatively connected to the
computer component of the tank tester. The abort button may cause
the tester to immediately open a system relief valve, write the
"Tech. Abort" code to the Error field of the Test Record (or
otherwise record the aborted test), and subsequently return to a
main menu (discussed in detail below).
[0068] Software Updates
[0069] The tank tester may include a software update module. The
software update module may enable the software associated with the
tank tester (including the operating application and various
software modules) to be updated in a number of ways. Software
associated with the tank tester may be updated by a modem. For
example, a built-in modem may dial a 1-800 number, allow a query of
the tank tester for the software version, and update software
modules and databases as required. In another embodiment, the tank
tester may be connected to a phone line and a host may call the
tank tester to commence an update process.
[0070] In yet another embodiment, software may be updated using a
compact flash card or other memory storage device within the tank
tester, which may be removed from the tank tester, sent to a
service provider for reprogramming, and reintroduced into the tank
tester with updated software. Alternatively, memory storage devices
containing updated software may be sent to tank tester users as
replacements for older devices.
[0071] In another embodiment, software may be updated by connecting
the tank tester to a personal computer (or other computer). A user
may then connect to the Internet or other designated network and
link to a provider web page to download software updates. These
updates may then be communicated to and stored within the tank
tester. Alternatively, the tank tester may contain sufficient
computer hardware and/or software to connect to the Internet or
other network without the aid of an additional computer.
[0072] Menus
[0073] In one embodiment, the tank tester may include a main menu.
Any one or more of the following menu options may be displayed in
the main menu (or other menus) and may be facilitated by the tank
tester's software and/or hardware: (1) Fuel Evaporative Test, (2)
Diagnostic Manual Mode testing, (3) Calibration, (4) Self-test, (4)
Status Mode, (5) Software update, (6) Service mode, (7) QA State
Menu, or other options.
[0074] In one embodiment a Status Mode may display the following
information: testing station's license number (or other testing
station identification); next test record number; tester number;
date/time; loaded software version number; update software version
number; and tester lock out reason.
[0075] In one embodiment, a QA State Menu may provide access to
certain data stored on the tank tester. The QA State Menu may be
accessed via the tank tester's display device and user input
device, a separate computer (such as a laptop), or other device.
The QA State Menu may include a menu comprising one or more of the
following options: update config. tables, load software update,
download test records, download calibration records, lock-out
tester, or other options. The QA State Menu may be password
protected via a password protection module of the tank tester. The
password protection module may also be used to provide password
protection to any menu or feature of the invention described
herein.
[0076] System Communications
[0077] According to an embodiment, the tank tester may include a
communications module. The communications module may enable
standard RS232 communications protocols that may be used for
communication between an EIS and the tank tester. In addition, a
laptop computer (or other suitable device) using RS232
communications may be used for software and table updates for the
tank tester. Communications protocols as used herein may enable
users to perform one or more various functions including, for
example: updating operating software as deemed necessary; updating
tables for pass/fail standards; downloading test data from records
stored in the tank tester; downloading tank tester calibration
records stored in the tank tester; outputting pass/fail results to
the EIS; or communicating with other computers or a network of
computers. Furthermore, the communications module may perform
updates and other communications using a modem incorporated into
the tank tester. Protocols other than RS232 may be used.
[0078] According to an embodiment of the invention, the tank tester
may include a serial mode module for serial mode operation. Serial
mode operation may be two-fold. A first serial mode operation may
be for checkout and testing of production line tank testers and
repair of returned tank testers. A second serial mode operation may
be for integrating communication to EIS equipment. The
configuration of the serial port may, for instance, have a baud
rate fixed at 9600 baud. Other signaling rates may be used.
[0079] According to an embodiment, with the tank tester connected
to and communicating with an EIS, the tank tester may be powered by
a 12 VDC source limited to 0.5 amps supplied by the RS 232
communications port. Other configurations may be implemented.
Alternatively, the tank tester may be integrated with an EIS.
[0080] According to an embodiment, a development/service mode may
also be provided. The development/service mode may run an
evaporative test and show current pressure, temperature and flow
readings during the test and show results after the test is
finished. The development/service mode may also run a manual
service and test mode while displaying sensor readings solenoid or
valve status. Furthermore, the development mode may allow the
update of software, databases and tables in conjunction with or
apart from other features described herein.
[0081] Interlocking Tank Adaptor Safety Mechanism
[0082] In one embodiment, the tank adaptor of the tank tester
(which interfaces with and seals the tank tester to the fuel
system) may provide a closed system between the fuel system and the
tank tester. In some embodiments of the invention, the tank adaptor
may allow the tank tester to pressurize the fuel system, among
other things.
[0083] One drawback associated with pressurizing a fuel system may
arise when a fuel tank is full, or nearly full, of fuel. If the
pressure is not properly released, some fuel may spill or splash
out of the tank. According to one aspect of the invention, the tank
tester may include an interlock that prevents fuel from spilling,
splashing, or otherwise being released from the fuel system when it
is depressurized. This may be accomplished either at (or proximate
to) the tank adaptor alone, or in combination with various
functionality incorporated into the tank tester.
[0084] In some embodiments, the tank adaptor may be unable to be
physically removed from the fuel neck until pressure inside the
fuel tank returns to ambient pressure. For example, the tank
adaptor may incorporate or otherwise operate with an interlock that
prevents the tank adaptor from being removed from the fuel neck
until pressure inside the tank returns to ambient pressure.
[0085] In some embodiments, the tank adaptor may include a valve
(e.g., bleed valve, etc.) that releases the pressure in the fuel
system. In some embodiments, the valve may include an automated
valve that controls the return of ambient pressure to the fuel
tank.
[0086] Hydrocarbon Detector
[0087] In one embodiment, the tank tester may contain various
mechanical components, hardware components, and/or software
components (or modules, such as a hydrocarbon detection module)
that may enable the tank tester to detect fuel vapor that escapes
from the fuel system. To facilitate fuel vapor detection, a small
amount of pressure above ambient pressure may be applied to the
fuel system. This pressure may force any fuel vapor out of a
compromised fuel system. Such fuel vapor may be detected by a
detector incorporated into the tank tester such as, for example, a
gas analyzer or other detector capable of detecting hydrocarbons.
In addition to detecting whether fuel vapor may be leaking from the
fuel system, the detector may also be used to determine the
approximate location of the leak by, for example, using a probe
from the detector to identify areas with increased levels of
hydrocarbons. Devices suitable for hydrocarbon detection are known
to those skilled in the art.
[0088] Integrated Fuel Cap and Fuel Tank Testing
[0089] Currently, tank integrity and fuel cap tests may be
performed separately. According to one aspect of the invention, the
tank tester may be modified to contain sufficient devices, as well
as computer hardware and/or software to enable simultaneous
measurement of fuel cap leakage and fuel tank integrity.
[0090] These and other objects, features, and advantages of the
invention will be apparent through the detailed description of the
preferred embodiments and the drawings attached hereto. It is also
to be understood that both the foregoing general description and
the following detailed description are exemplary and not
restrictive of the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0091] FIG. 1 is a schematic diagram of a tank tester system,
according to an embodiment of the invention.
[0092] FIG. 2 is an exemplary illustration of various components
which may be utilized by a tank tester system, according to an
embodiment of the invention.
[0093] FIG. 3 is an exemplary illustration of various components
which may be utilized by a tank tester system, according to an
embodiment of the invention.
[0094] FIG. 4 is an exemplary illustration of various sensors and
plumbing components for use with a tank tester system, according to
an embodiment of the invention.
[0095] FIG. 5 is an exemplary illustration of various sensors and
plumbing components for use with a tank tester system, according to
an embodiment of the invention.
[0096] FIG. 6 is an exemplary flow chart of a calibration process,
according to an embodiment of the invention.
[0097] FIG. 7 is an exemplary flow chart of a calibration process,
according to an embodiment of the invention.
[0098] FIG. 8 is an exemplary flow chart of a calibration process,
according to an embodiment of the invention.
[0099] FIG. 9 is an exemplary flow chart of a self-test process,
according to an embodiment of the invention.
[0100] FIG. 10 is an exemplary flow chart of a fuel tank test
process, according to an embodiment of the invention.
[0101] FIG. 11 is a schematic diagram of a tank tester system,
according to an embodiment of the invention.
[0102] FIG. 12 is an exemplary flow chart of a manual mode test
process, according to an embodiment of the invention.
[0103] FIG. 13 is an exemplary flow chart of a password protection
process, according to an embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0104] According to an embodiment illustrated in FIG. 1, a system
100 is provided for a tank tester 101. Tank tester 101 may be used
to test the integrity of a fuel system 150, as described in greater
detail below. Fuel system 150 may include a fuel tank 140, a fuel
tank neck 143, fuel 145, and/or other elements. Fuel system 150 may
by a fuel system for a car, motorcycle, light-duty truck,
heavy-duty truck, or other motor vehicle. Tank tester 101 may
include a computer-implemented component 103 ("computer component
103"), a testing component 117, a housing 130, a calibration tank
135, and/or other elements.
[0105] Computer Component
[0106] In one embodiment, computer component 103 may include
various computer hardware and software elements such as, for
example, a processor 105. Processor 105 may be or include, for
instance, any of the Intel x86 PC/AT microprocessors or compatible
processors such as those available from Cyrix or AMD.
[0107] Computer component 103 may include an operating application
107. Operating application 107 may include one or more software
modules 109a-109n enabling the operation of, and user interaction
with, tank tester 101. Operating application 107 may be based on
any one of many computer programming languages such as, for
example, C, C++, or other programming language.
[0108] In particular, operating application 107 may include a data
analysis module, a test module, a calibration module, a self-test
module, a manual test module, a communications module, a serial
mode module, a software update module, a password protection
module, a hydrocarbon detection module, and/or other modules. The
features enabled may include, among other things, fuel tank
temperature measurement, fuel tank pressure measurements, tank
tester calibration procedures, fuel tank integrity tests, vapor
space compensation, temperature compensation, Reid Vapor Pressure
(RVP) compensation, hydrocarbon detection, interface with an
Emissions Inspections System (EIS), and other features. One or more
of the modules comprising operating application 107 may be
combined. For some purposes, not all modules may be necessary.
[0109] In one embodiment, operating application 107 may also
include, or have access to, data look-up tables, and may use table
calls for fuel tank vapor space calculations, pass/fail decisions,
and/or other calculations and decisions. These tables may
compensate for temperature and RVP when making the vapor space
calculations, pass/fail determinations, or other calculations or
decisions. In addition, operating application 107 may write test
results and calibration test results to a record ("test
record").
[0110] Computer component 103 may include one or more memory
devices 108. Memory device 108 may include, for instance, flash
erasable programmable read only memory (FEPROM), hard disk, or
other suitable memory for data storage. Memory device 108 may
enable the storage of test records or other results or error files.
Memory device 108 may also enable the storage of any data necessary
to perform the functions of tank tester 101 described herein.
[0111] According to an embodiment of the invention, one or more
users may access tank tester 101 and operating application 107
through an interface. The interface may comprise a graphical user
interface (GUI) 110 presented to a user on a display device 111.
The user may interact with operating application 107 and GUI 110
via a user input device 113. Display device 111 may be or include,
for instance, a display screen such as a 20'' by 4'' LCD screen. In
some embodiments, display device 111 may include other types of
known display screens.
[0112] In one embodiment, user input device 113 may be or include,
for instance, a 4 by 4 digital keypad with various keys. In another
embodiment, user input device 113 may include a combination of four
buttons to accommodate one or more of the following functions for
scrolling through and selecting items from menus displayed via
graphical user interface 110: (1) scroll up; (2) scroll down; (3)
select (or start); and (4) abort. Alternately, a rocker type switch
may be substituted to accommodate the scroll up and down function
thereby reducing the number of buttons to three. Other
configurations are possible. In some embodiments, user input device
113 may include other types of known input devices or
keyboards.
[0113] In one embodiment, display device 111 may enable interaction
with GUI 110 via various menus, with which a user may interact,
using user input device 113. Both display device 111 and user input
device 113 may be operatively connected to processor 105.
[0114] It should be understood that various software modules
109a-109n utilized to accomplish the functionalities described
herein may be maintained on one or more of processor 105, control
application 107, memory device 108, or other components of the
system. In other embodiments, as would be appreciated, the
functionalities described herein may be implemented in various
combinations of hardware and/or firmware, in addition to, or
instead of, software.
[0115] In one embodiment, tank tester 101 may also include an
outlet hose 121. Outlet hose 121 may include a section of pneumatic
conduit that may enable pneumatic connection between tank tester
101 and fuel system 150. One end of outlet hose 121 may terminate
in a tank adaptor 123. Tank adaptor 123 may be one of a set of fuel
tank filler neck adaptors that may interface with fuel neck 143,
regardless of the make or model of the vehicle of which fuel system
150 is a part.
[0116] In an embodiment of the invention illustrated in FIG. 2, an
exemplary configuration of computer component 103 may be provided
in a system 200. System 200 may include a processor board 201.
Processor board 201 may include a processor 203. Processor board
201 may also include, for instance, one or more analog inputs
205a-205n with A/D converters for interface with various sensors,
one or more digital outputs 207a-207n to interface with one or more
solenoids or other elements. Processor board 201 may also include
one or more serial ports 213a-213n which may interface with
additional equipment such as, for example, Emissions Inspection
Systems (EIS) equipment, a modem 216, a real time clock 215, or
other elements. Processor board 201 may also include one or more
memory devices 217. One or more memory devices 217 may include
FEPROM, a hard disk, or other suitable memory for storing data.
[0117] System 200 may also include a signal conditioning board 219
operatively connected to processor board 201. Signal conditioning
board 219 may, among other things, condition electrical signals
into and out from any sensors. Such signal conditioning may be
accomplished as would be apparent to one skilled in the art. Signal
conditioning board 219 may include a DC/DC power supply 223. Power
supply 223 may include a 12 volt 0.5 amp power supply, although
other voltages and amperages may be used. Signal conditioning board
219 may also include a pressure switch control 225 which may
release pressure from testing component 117 (FIG. 1) when a
predetermined pressure is reached within testing component 117.
Signal conditioning board 219 may also include one or more solenoid
drivers 227a-227n for operating one or more solenoids throughout
tank tester 101. One or more solenoids may be useful for the
operation of various elements of testing component 117 such as, for
example, switches, valves, or other elements.
[0118] System 200 may include tamper switch 229 operatively
connected to processor board 201 and/or signal conditioning board
219.
[0119] System 200 may include one or more sensors 231a-231n
operatively connected to processor board 201 and/or signal
conditioning board 219. One or more sensors 231a-231n may include
pressure transducers, temperature sensors, or other sensors for the
operation of tank tester 101.
[0120] System 200 may also include external memory 233 operatively
connected to processor board 201. External memory 233 may include
flash memory, a hard disk, or other suitable memory for storing run
time programs, vehicle databases, testing lookup tables, recent
test results, or other data.
[0121] Furthermore, computer component 103 may include a display
device 235 and a user input device 237 operatively connected to
processor board 201. Display device 235 and user input device 237
may be the same as, or similar to, display device 111 and user
input device 113 described above with reference to FIG. 1.
[0122] In an embodiment of the invention illustrated in FIG. 3, an
alternative configuration of computer component 103 may be provided
in a system 300. System 300 may include a processor board 301.
Processor board 301 may include a processor 303. Processor board
301 may also include, for instance, 50 pin compact flash memory
305, 512 kb (or other memory size) flash ROM 307, 512 kb (or other
memory size) SRAM 309, a battery 311, a real time clock 313, one or
more serial ports 315a-315n, a DB9 (or other format) connector 317,
a plug in modem card 319 which may include an RJ11 or similar
connector, a power input 321 and other elements.
[0123] System 300 may also include a signal conditioning board 323
operatively connected to processor board 301. System 300 may
include one or more solenoid drivers 325a-325n operatively
connected to processor boards 301 and/or signal conditioning board
323 which may enable the operation of one or more solenoids
throughout tank tester 101. System 300 may include a pressure
switch 327 operatively connected to processor board 301 and/or
signal conditioning board 323, which may enable the release of
pressure from testing component 117 (FIG. 1) upon the existence of
a predetermined pressure within testing component 117.
[0124] System 300 may also include one or more sensors 329a-329n
operatively connected to processor board 301 and/or signal
conditioning board 323. One or more sensors may include, for
instance, a inlet pressure sensor 329a, a flow pressure sensor
329b, a manifold pressure sensor 329c, a absolute pressure sensor
329d, a temperature sensor 329e, a solenoid power sensor 329, or
other sensors 329n.
[0125] Furthermore, system 300 may include a display device 331 and
a user input device 333 operatively connected to processor board
301. Display device 331 and user input device 333 may be the same
as, or similar to, display device 111 and user input device 113
described above with reference to FIG. 1.
[0126] Those having skill in the art will appreciate that the
aforementioned systems may work with various configurations.
Accordingly, more or less of the aforementioned system components
may be used and/or combined in various embodiments.
[0127] According to one embodiment, the power consumption by tank
tester 101 may be slightly less than 12 Volts, 0.5 Amps (6 Watts).
Other configurations may be implemented. In some embodiments, a 110
VAC wall pack transformer and connector to tank tester 101 may also
be provided.
[0128] Testing Component
[0129] According to an embodiment of the invention, tank tester 101
may include a testing component 117. Testing component 117 may
include various electronic sensor elements, electronic control
elements, and pneumatic pluming elements for performing the
operations of tank tester 101 described herein.
[0130] In an embodiment of the invention illustrated in FIG. 4, an
exemplary configuration of testing component 117 may be provided in
a system 400. System 400 may include a pressurized gas source 401.
Pressurized gas source 401 may contain and/or produce pressurized
gas for use in tank tester 101. Pressurized gas may include
nitrogen, compressed air, or other gas. If tank tester 101 uses
nitrogen as a pressurizing gas, the nitrogen may be 98% pure. Other
concentrations may be used. If tank tester 101 uses compressed air
as a pressurizing gas, an air filter capable of removing harmful
contaminants and moisture from the compressed air source may be
included. This filter may ensure that no contaminants enter tank
tester 101 that could physically block any orifice, or chemically
contaminate the internal components of tank tester 101. The filter
may comprise material known to one of skill in the art and may be
configured to filter down to 5-micron size particles.
[0131] Pressurized gas source 401 may reside outside a testing
component housing 403. In alternative embodiments, pressurized gas
source 401 may reside inside a testing component housing (or other
housing) or enclosures associated with tank tester 101.
[0132] Pressurized gas source 401 may be pneumatically connected to
an input filter 404. Input filter 404 may enable filtering of
particulates or contaminates from pressurized gas flowing from
pressurized gas source 401. Furthermore, a high pressure regulator
402 may be pneumatically connected to pressurized gas source 401 to
enable regulation of pressure into testing component 117. According
to an embodiment of the invention, pressure regulator 402 (and
other pressure regulators described herein) may enable a controlled
flow rate of between two and four liters per minute (LPM). Other
flow rates or ranges of flow rates may be achieved.
[0133] Pressurized gas source 401 may be pneumatically connected to
an inlet pressure transducer 405. Pneumatic connection may be
accomplished by pneumatic conduit which may comprise material known
to one skilled in the art, suitable to perform the various
functions and processes described herein. Inlet pressure transducer
405 may include an electronic sensor enabling the measurement and
communication of pressure levels to computer component 103. In one
embodiment, inlet pressure transducer 405 may sense pressure ranges
from 0-50 pounds per square inch (psi). Other pressure ranges may
be used. Inlet pressure transducer 405 may monitor the inlet
pressure levels of testing component 117 and communicate those
pressure levels to computer component 103. Computer component 103
may then take appropriate action. For example, if inlet pressure
levels exceed a predetermined level such as, for instance, 35 psi,
valves or other elements within testing component 117 may be
activated to correct the situation. According to an embodiment of
the invention, tank tester 101 may be configured to measure inlet
pressures of 0-35 psi within .+-.10% of point, and internal tank
tester pressures of 0''-28'' H.sub.2O .+-.5% of range. Other ranges
may be used.
[0134] Pressurized gas source 401 may also be pneumatically
connected to a first valve 406. First valve 406 may enable partial
or complete obstruction of gas flow through testing component 117.
First valve 406 may have a first end and a second end. In one
embodiment, an input filter 404 may be pneumatically connected
between pressurized gas source 401 and first valve 406. In some
embodiments, first valve 406 may be, include, or be controlled by,
a mechanism such as, for example, a solenoid driver or other
mechanism.
[0135] The second end of first valve 406 may be pneumatically
connected to pressure regulator 407. Pressure regulator 407 may
enable a specific flow rate of gas through testing component 117.
Pressure regulator 407 may be pneumatically connected to a second
valve 409. Second valve 409 may enable partial or complete
obstruction of gas flow through testing component 117. Second valve
409 may have a first end and a second end. In one embodiment, the
first end of second valve may be pneumatically connected to
pressure regulator 407. In some embodiments, second valve 409 may
be, include, or be controlled by a mechanism such as, for example,
a solenoid driver or other mechanism.
[0136] The second end of second valve 409 may be pneumatically
connected to an orifice 410. Orifice 410 may include a section of
pneumatic conduit of predetermined inner diameter through which gas
may flow. When open, orifice 410 may include an inner diameter of
0.023 centimeters. Other diameters may be used for orifice 410.
Orifice 410 may enable the controlled flow of gas through testing
component 117 and may be controlled by an electronic switch.
[0137] Orifice 410 may be pneumatically connected to air reservoir
411. Air reservoir 411 may include an enclosure in which gas may be
stored and/or through which gas may flow. In one embodiment, air
reservoir 411 may hold up to 0.34 liters of gas. In other
embodiments other volumes of gas may be held in air reservoir
411.
[0138] An outlet hose 413 may be pneumatically connected to air
reservoir 411. In alternative embodiments outlet hose 413 may be
connected directly to orifice 410, the second end of second valve
409 or other element of testing component 117. Outlet hose 413 may
have first and second ends. The first end of outlet hose 413 may be
pneumatically connected to air reservoir or other element of
testing component 117. The second end of outlet hose 413 may end in
tank adaptor 415. Tank adaptor 415 may include a set of fuel filler
neck adaptors that provide connectivity to various vehicles.
[0139] According to an embodiment of the invention, tank adaptor
415, outlet hose 413, and any pneumatic conduit or gasket materials
may be pliable and impermeable to some or all gasoline constituents
including, for instance, Methyl Tertiary Butyl Ether (MTBE),
ethanol, and methanol. Furthermore, tank adaptor 415, outlet hose
413, and other elements within testing component 117 may be fitted
with quick disconnect couplers that facilitate easy and rapid
connection and disconnection from the vehicle.
[0140] A differential transducer 417 may be pneumatically connected
between the second end of second valve 409 and orifice 410.
Differential transducer 417 may also be pneumatically connected to
air reservoir 411. Differential transducer 417 may include an
electronic sensor enabling the measurement and communication of
pressure levels to computer component 103. In one embodiment,
differential transducer 417 may sense pressure ranges from 0-14.5
psi. Other pressure ranges may be used. Differential transducer 417
may measure the pressure differential between a section of
pneumatic conduit prior to orifice 410 and air reservoir 411.
[0141] A reservoir pressure transducer 419 may be pneumatically
connected to air reservoir 411. Reservoir pressure transducer 419
may include an electronic sensor enabling the measurement and
communication of pressure levels in air reservoir 411 to computer
component 103. In one embodiment, reservoir pressure transducer 419
may sense pressure ranges from 0-40'' H.sub.2O. Other pressure
ranges may be used.
[0142] A third valve 421 may be pneumatically connected to air
reservoir 411. Third valve 421 may enable partial or complete
obstruction of gas flow through testing component 117. Third valve
421 may have a first end and a second end. In one embodiment, the
first end of third valve may be pneumatically connected to air
reservoir 411. In some embodiments, third valve 421 may be,
include, or be controlled by a mechanism such as, for example, a
solenoid driver or other mechanism.
[0143] The second end of third valve 421 may be pneumatically
connected to a vent outlet 423. Vent outlet 423 may enable the
outlet of gas from testing component 117. In some embodiments vent
outlet 423 may be pneumatically connected to a filter and/or an
outlet canister. For example, at the conclusion of a test,
compressed fuel tank fumes may vent through vent outlet 423 into a
charcoal canister. The remaining fuel tank fumes may be vented back
though tank tester 101's valves to an alternate outlet. Testing
component 117's alternate outlet may be routed out of a test
facility (e.g., a building or other environment) or into another
area/container. According to one embodiment, tank tester 101 may be
fully vented to a separate container such as, for instance, a
charcoal canister, that may be purged on a next (or other
subsequent) test cycle.
[0144] A check valve 425 may be pneumatically connected to air
reservoir 411. Check valve 425 may enable the release of gas to
prevent over-pressurization. Check valve 425 may operate to allow
such release upon a occurrence of a predetermined pressure level
within testing component 117 such as, for instance, 1 psi or other
predetermined pressure level ("cracking pressure"). Check valve 425
may have a first end and a second end. In one embodiment, the first
end of check valve 425 may be pneumatically connected to air
reservoir 411. In some embodiments, check valve 425 may be,
include, or be controlled by a mechanism such as, for example, a
solenoid driver or other mechanism. The second end of check valve
425 may be pneumatically connected to vent outlet 423.
[0145] A pressure switch 427 may be connected to testing component
117. Pressure switch 427 may include an electronic and/or
mechanical switch that may open one or more valves to release
pressure from testing component 117 upon the detection of a
predetermined pressure within tank tester 101 or a fuel system
being tested. A pressure switch 427 may act as a back-up in the
event that a pressure transducer (or other element of testing
component 117) fails. According to one embodiment, pressure switch
427 may be wired in series with one or more valves within testing
component 117, and may manipulate the valves to prevent
over-pressurization as a fail-safe measure.
[0146] A temperature sensor 429 may also be included in testing
component 117. Temperature sensor 429 may determine the temperature
of gas within testing unit 117 or a connected fuel system.
Temperature sensor 429 may be placed in various locations within
testing component 117 and may be connected to computer component
103. Testing component 117 may also include a barometric pressure
sensor 431 for detecting the barometric pressure of a testing
environment in which tank tester 101 is being used.
[0147] In an embodiment of the invention illustrated in FIG. 5, an
alternative configuration of testing component 117 may be provided
in a system 500. System 500 may include a pressurized gas source
501. Pressurized gas source 501 may contain and/or produce
pressurized gas for use in tank tester 101. Pressurized gas source
501 may be pneumatically connected to input filter 504. Input
filter 504 may enable filtering of particulates or contaminates
from pressurized gas flowing from pressurized gas source 501.
Furthermore, a high pressure regulator 502 may be pneumatically
connected to pressurized gas source 501 to enable regulation of
pressure into testing component 117.
[0148] Pressurized gas source 501 may be pneumatically connected to
an inlet pressure transducer 505. Inlet pressure transducer 505 may
include an electronic sensor for measuring and communicating
pressure levels to computer component 103. In one embodiment, inlet
pressure transducer 505 may sense pressure ranges from 0-100 psi.
Other pressure ranges may be used.
[0149] Pressurized gas source 501 may also be pneumatically
connected to a first valve 507. First valve 507 may enable partial
or complete obstruction of gas flow through testing component 117.
First valve 507 may have a first end and a second end. In one
embodiment, the first end of first valve 507 may be pneumatically
connected to input filter 504 and/or pressurized gas source 501. A
temperature sensor 506 may be connected to a section of pneumatic
conduit between input filter 504, or pressurized gas source 501,
and first valve 507. Temperature sensor 506 may also be placed in
other areas of testing component 117. Temperature sensor 506 may
measure and communicate gas temperature to computer component 103.
In some embodiments, tank tester 101 may include an ambient
temperature sensor for measuring the temperature of a surrounding
testing environment.
[0150] The second end of first valve 507 may be pneumatically
connected to a first orifice 509. First orifice 509 may include a
section of pneumatic conduit of predetermined inner diameter
through which gas may flow. When open, first orifice 509 may
include an inner diameter of 0.024 centimeters. Other diameters may
be used. First orifice 509 may enable controlled flow of gas
through testing component 117 and may be controlled by an
electronic switch connected to computer component 103.
[0151] First orifice 509 may be pneumatically connected to manifold
transducer 511. Manifold transducer 511 may include an electronic
sensor for measuring and communicating pressure levels to computer
component 103. In one embodiment, manifold transducer 511 may sense
pressure ranges from 0-1.45 psi. Other pressure ranges may be
used.
[0152] First orifice 509 may be pneumatically connected to a
pressure switch 513. Pressure switch 513 may include an electronic
and/or mechanical switch that may enable the release of pressure
from testing component 117 via one or more valves upon the
detection of a predetermined pressure such as, for instance, 25''
H.sub.2O or other pressure level.
[0153] First orifice 509 may be pneumatically connected to outlet
filter 515. Outlet filter 515 may include an activated charcoal
filter or other filter for removing particulates and impurities
from gas traveling into an outlet hose 517. Outlet hose 517 may
have first and second ends. The first end of outlet hose 517 may be
pneumatically connected to outlet filter 515. In alternative
embodiments, the first end of outlet hose 517 may not be connected
to outlet filter 515, but may rather be connected to first orifice
509, to the second end of first valve 507, or to another element of
testing component 117. The second end of outlet hose 517 may
terminate in tank adaptor 519.
[0154] Pressurized gas source 501 may also be pneumatically
connected to a second valve 521. Second valve 521 may enable
partial or complete obstruction of gas flow through testing
component 117. Second valve 521 may have a first end and a second
end. In one embodiment, the first end of second valve 521 may be
pneumatically connected to input filter 504 and/or pressurized gas
source 501. In some embodiments, second valve 521 may be, include,
or be controlled by a mechanism such as, for example, a solenoid
driver or other mechanism.
[0155] The second end of second valve 521 may be pneumatically
connected to a second orifice 523. Second orifice 523 may include a
section of pneumatic conduit of predetermined inner diameter
through which gas may flow. When open, second orifice 523 may
include an inner diameter of 0.022 centimeters. Other diameters may
be used. Second orifice 523 may enable the controlled flow of gas
through testing component 117, and may be controlled by an
electronic switch connected to computer component 103.
[0156] Second orifice 523 may be pneumatically connected to a
pressure regulator 525. Pressure regulator 525 may enable the
controlled flow of gas through testing component 117. Pressure
regulator may be pneumatically connected to a section of pneumatic
conduit between first orifice 509 and outlet filter 515, or may be
otherwise pneumatically connected to outlet hose 517.
[0157] A differential transducer 527 may be pneumatically connected
to a section of pneumatic conduit located between the second end of
second valve 521 and second orifice 523. Differential transducer
527 may also be pneumatically connected to a section of pneumatic
conduit located between second orifice 523 and pressure regulator
525. Differential transducer 527 may include an electronic sensor
for measuring and communicating pressure levels to computer
component 103. In one embodiment, differential transducer 527 may
sense pressure ranges from 0-14.5 pounds per square inch (PSI).
Other pressure ranges may be used. Differential transducer 527 may
measure the pressure differential between a section of pneumatic
conduit on either side of second orifice 523.
[0158] A vent outlet 529 may be pneumatically connected to a
section of pneumatic conduit located between first valve 507 and
outlet hose 517. Vent outlet 529 may enable the outlet of pressure
and gas from testing component 117. In some embodiments vent outlet
may be pneumatically connected to a filter and/or an outlet
tank.
[0159] A check valve 531 may be pneumatically connected to testing
component 117. Check valve 531 may enable the release of pressure
from testing component 117 to prevent over-pressurization. Check
valve may operate to allow such a release upon reaching a
predetermined pressure level within testing component 117 such as,
for instance, 1 psi or other predetermined pressure level
("cracking pressure"). In some embodiments, check valve 531 may be,
include, or be controlled by a mechanism such as, for example, a
solenoid driver or other mechanism.
[0160] A relief valve 533 having first and second ends may be
pneumatically connected to testing component 117. The first end of
relief valve 533 may be pneumatically connected to a portion of
pneumatic conduit located between first valve 507 and outlet hose
517. The second end of relief valve 533 may be pneumatically
connected to vent outlet 529. Relief valve 533 may enable partial
or complete obstruction of gas flow through testing component
117.
[0161] Housing and Calibration Tank
[0162] According to an embodiment of the invention illustrated in
FIG. 1, tank tester 101 may include a housing 130. In one
embodiment of the invention, housing 130 may enclose one or more
components (e.g., 103, 117) of tank tester 101. In another
embodiment of the invention, housing 130 may support one or more
components of tank tester 101. These components may be supported
either internally within housing 130, externally to housing 130, or
partially internal and partially external to housing 130. In
another embodiment, housing 130 may comprise a custom
impact-resistant plastic enclosure with a carrying strap and/or
handle.
[0163] In one embodiment of the invention, a calibration tank 135
may be included in tank tester 101. Calibration tank 135 may form a
volume that may be pressurized. In some embodiments, housing 130
itself (or a portion thereof) may form calibration tank 135. In
these embodiments, housing 130 may be manufactured and assembled so
as to form a compartment having a predetermined volume that may be
pressurized. In various embodiments, the volume of calibration tank
135 may comprise one gallon, two gallons, five gallons, ten gallons
or any other predetermined volume. In some embodiments this volume
may be adjustable. Calibration tank 135 may also be constructed to
withstand an internal pressure of at least 20'' H.sub.2O. Other
pressure tolerances may be used. Furthermore, calibration tank 135
may be resistant to shock or other normal conditions present in an
automotive repair shop or other environment with no more than 1%
(or other percentage) deformation.
[0164] In one embodiment, calibration tank 135 may include a
bladder (not otherwise illustrated). In some embodiments, the
bladder may conform itself within housing 130. As discussed above,
the bladder may comprise any predetermined volume that may also be
pressurized.
[0165] In another embodiment, housing 130 and/or calibration tank
135 may include a blow-molded case (not otherwise illustrated)
having a predetermined volume that may be pressurized.
[0166] As discussed above, the case may be formed, machined, or
molded to have any predetermined volume.
[0167] Calibration
[0168] According to an embodiment of the invention, tank tester 101
may include a calibration module. The calibration module may be
utilized to calibrate various elements of tank tester 101.
Calibration may be used to adjust and confirm the consistency and
accuracy of tank tester 101's vapor space calculations, for various
test pass/fail determinations, or for other calculations.
Calibration may include, for example, pressurization of tank tester
101's internal components to check for leaks, calculation of a
known calibration tank volume, testing of a calibration tank
configured to pass, testing of a calibration tank configured to
fail, or other procedures. Calibration may also include various
self-tests of the tank tester 101's transducers, temperature
sensors, or other components.
[0169] According to one embodiment, the calibration module may
utilize an internal clock (e.g., real time clock 215 of FIG. 2) to
determine when calibration is due. As an example, the calibration
module may automatically lock out test procedures on tank tester
101 every 72 hours pending a successful completion of one or more
calibration procedures. Other time intervals may be used.
[0170] FIG. 6 illustrates an exemplary process 600, wherein the
calibration module of tank tester 101 may test the internal
integrity of testing component 117. This may be referred to herein
as "phase one" of tank tester 101's calibration procedure. In an
operation 601, an event may occur wherein automated calibration of
tank tester 101 is initiated. This event may include, the passage
of a predetermined amount of time, the completion of a
predetermined number of tests, user selection of a calibration
mode, or other event. In an operation 603, the display device 111
(FIG. 1) of tank tester 101 may display a prompt such as, for
example: "INSTALL CAL. ADAPTOR. PRESS START." As used herein,
"prompt" may include any message displayed to a user conveying
information regarding tank tester 101. In an operation 605, a user
may install a calibration adaptor to plug outlet hose 121 (FIG. 1)
of tank tester 101 thus enabling internal pressurization. Also, in
an operation 605, the calibration procedure may be commenced by a
user, for example, by the user pressing a start button that is
operatively connected to computer component 103 (FIG. 1) of tank
tester 101. After the calibration procedure is commenced in
operation 605, an operation 607 may occur, in which tank tester 101
may display the following prompt: "CALIBRATION SEQUENCE IN
PROGRESS." Other prompts conveying a similar message may be used.
In an operation 609, tank tester 101 may pressurize its internal
plumbing and external hose to 14'' H.sub.2O. Other pressure
thresholds may be used. In an operation 611, the pressurized gas
source may be turned off and one or more internal pressure sensors
(transducers) may monitor the internal pressure decay.
[0171] If, in an operation 613, the system pressure decay exceeds a
predetermined decay threshold such as, for example, 1'' H.sub.2O in
60 seconds, tank tester 101 may fail phase one of the calibration
test. In an operation 615, tank tester 101 may display a prompt
such as, for example: "PHASE ONE CAL FAILED." Other pressure decay
levels may be used to determine the failure of phase one
calibration. In an operation 617, tank tester 101 may vent any
remaining pressure in tank tester 101 to the atmosphere. In
operation 617 the calibration module may also lock out tank tester
101 and prevent it from performing other procedures until the
calibration procedure has been successfully completed. In an
operation 619, the calibration module may write "F" in a Pressure
Decay-Phase One Result field of a Calibration Record or otherwise
record the failure of phase one of the calibration procedure. In an
operation 621, tank tester 101 may display the following prompt:
"REMOVE CAL ADAPTOR" and return to the main menu of tank tester 101
(described in detail below). Other prompts conveying similar
messages may be used. If, in operation 613, tank tester 101 does
not exceed the predetermined pressure decay threshold, and thus
successfully completes phase one of the calibration procedure, tank
tester 101 may, in an operation 623, indicate passage of phase one
by displaying a prompt conveying such a message. In some
embodiments, the calibration module may then proceed to phase two
of the calibration procedure.
[0172] FIG. 7 illustrates exemplary process 700, in which the
calibration module of tank tester 101 may test and/or calibrate
tank tester 101's ability to determine the volume of a tank. This
may be referred to herein as "phase two" of tank tester 101's
calibration procedure and may be triggered by the successful
completion of phase one or other event.
[0173] In an operation 701, tank tester 101 may display a prompt
such as, for example: "CONNECT THE CAL TANK TO THE TESTER. TURN
CAL. LEAK SWITCH TO OFF." In an operation 703, a user may connect a
calibration tank to tank tester 101. In an operation 705, while
compensating for temperature, tank tester 101 may pressurize the
calibration tank to a predetermined pressure level such as, for
instance, 14'' H.sub.2O or other pressure level. Having the exact
volume of the calibration tank stored in memory, tank tester 101
may then, in an operation 707, calculate the volume of the
calibration tank. In an operation 709, tank tester 101 may then
compare the calculated volume of the calibration tank with the
calibration tank volume stored in memory. If, in an operation 711,
the calculated volume differs from the stored volume exceeding a
level of .+-.10% or other benchmark, tank tester 101 may fail phase
two of calibration, and in an operation 713, may display a prompt
such as, for example: "PHASE TWO CAL FAILED. DISCONNECT TESTER FROM
CAL TANK." In an operation 715, tank tester 101 may vent any
remaining pressure to the atmosphere and the calibration module may
lock out tank tester 101 to prevent further procedures until tank
tester 101 successfully passes the calibration procedure. In an
operation 717, the calibration module may write "F" in the Vapor
Space Calculation--Phase Two Result field of the Calibration Record
or otherwise record the failure of phase two calibration. In an
operation 719, tank tester 101 may return to the main menu.
[0174] If, in an operation 711, the calculated volume the
calibration tank does not differ from the stored volume of the
calibration tank exceeding exceed a level of +10% or other
benchmark, and thus successfully completes phase two of the
calibration procedure, tank tester 101 may, in an operation 721,
indicate passage of phase two by displaying a prompt conveying such
a message. In some embodiments, the calibration module may then
proceed to phase three of the calibration procedure.
[0175] FIG. 8 illustrates exemplary process 800, in which the
calibration module of tank tester 101 may test and/or calibrate
tank tester 101's ability to pass and fail tanks according to a
particular test. This may be known as "phase three" of tank tester
101's calibration procedure and may be triggered by the successful
completion of phase two or other event. In an operation 801, tank
tester 101 may display a prompt such as, for example: "SELECT PASS.
PRESS START." In an operation 803, a user may select "pass" from a
menu and may commence calibration by, for example pressing a start
button that is operatively connected to computer component 103
(FIG. 1). In an operation 805, tank tester 101 may undergo a
testing procedure such as, for example, a vapor leak test or other
testing procedure, using a calibration tank with the goal of
simulating a passing test. The integrity of the calibration tank
may be such that the calibration tank should pass the test. For
example, if the test were a vapor leak test, the calibration tank
may be configured such that no leaks (or insubstantial leaks) are
present. If, in an operation 807, tank tester 101 determines that
the calibration tank passes the test, tank tester 101 may, in an
operation 809, proceed to simulate a failed test of the same type.
In operation 809, tank tester 101 may display a prompt such as, for
example: "SELECT FAIL. PRESS START." In an operation 811, the user
may select "fail" from a menu and press the start button or other
button to begin the calibration.
[0176] In an operation 813, tank tester 101 may again utilize tank
tester 101's testing procedure, and tests the calibration tank. In
this instance the calibration tank may be configured such that it
should fail the test. If, in an operation 815, tank tester 101
fails the test tank, thus passing phase three of the calibration
procedure, tank tester 101 may display a prompt such as, for
example: "CAL PASSED. DISCONNECT CAL. TANK" in an operation
817.
[0177] If, in operation 807, tank tester 101 fails the test or, in
an operation 815, tank tester 101 passes the test, and thus fails
to properly identify the pass or fail conditions of the calibration
procedure, then, in an operation 819 tank tester 101 may vent any
remaining pressure to the atmosphere. In operation 819, the
calibration module may also lock out tank tester 101 and prevent it
from performing procedures or tests until tank tester 101
successfully passes the calibration procedure. In an operation 821,
the calibration module may write "F" in the Vapor Space
Calculation--Phase Two Result field of the Calibration Record or
otherwise record the failure of phase three calibration. In an
operation 823, tank tester 101 may return to the main menu and
display a prompt such as, for example: "PHASE 3 TESTER CAL
FAILED."
[0178] In one embodiment, the calibration module may utilize
switchable calibrated leak standards. To accomplish this, the
calibration tank may contain gaps of different sizes for different
standards. The use of these orifices may be controlled
automatically upon selection of a particular leak standard. For
example, if a 0.020'' standard is selected, a 0.016'' (pass) and
0.024'' (fail) gap may be used in conjunction with a calibration
tank for the pass/fail calibration of tank tester 101. If a 0.040''
standard is selected, a 0.035'' (pass) and 0.045'' (fail) gap may
be used in conjunction with the calibration tank for the pass/fail
calibration of tank tester 101. Other leak standards may be used.
Furthermore, if an "Off" position is selected, the calibration tank
may be sealed to create a sealed test container.
[0179] Upon successful completion of the calibration procedure, the
calibration module may write the results to the calibration record
with the date and time, and start a timer for the next calibration
due date and time. The new record may be recorded to the
calibration record. The data recorded in the calibration record
regardless of failure or passage may include Station ID (facility
conducting test), Tester ID (person conducting test), Calibration
ID (the specific calibration iteration), Date/Time of Calibration,
Software Version, Pressure Decay for Phase One, Vapor Space
calculated for Phase Two, Result of Phase 3, Overall Calibration
Result, Calibration Error, Date/Time of Next Calibration Due, or
other data. To calculate the next time due, the software may add
the predetermined time period to the current calibration date and
time.
[0180] FIG. 9 illustrates an exemplary process 900, wherein a
self-test module of tank tester 101 may perform a self-test. A
self-test may occur with a pressurized gas source connected to tank
tester 101, and may also occur with applicable outlet vents of tank
tester 101 open.
[0181] In an operation 901, a self-test may be initiated by, for
example, user selection of a self-test, initiation of a substantive
tank test, successful completion of other calibration procedures,
or other event. In an operation 903, tank tester 101 may display a
prompt such as, for example: "SELF TEST--PLEASE WAIT" while the
self-test module checks to verify that the calibration period has
not expired. If, in an operation 905, a predetermined calibration
period has expired, the self-test module may, in an operation 907,
display a prompt such as, for example: "CALIBRATION REQUIRED" and
return to the main menu.
[0182] If, in an operation 905, the predetermined calibration
period has not expired, the self-test module may begin a self-test
procedure in an operation 909. In operation 909, self-test module
may test whether tank tester 101's inlet pressure is within a
predetermined range while a known pressure is applied to tank
tester 101. If, in an operation 911, inlet pressure falls outside
the predetermined range, tank tester 101 may proceed to an
operation 913. In operation 913, tank tester 101 may determine the
number of times (within the present self-test) that inlet pressure
has been self-tested. If a predetermined number of inlet pressure
self-tests has not been exceeded, then tank tester 101 may proceed
to an operation 915, wherein tank tester 101 may display a prompt
such as, for example: "INLET PRESSURE ERROR--CHECK INLET SUPPLY
LINE." The self-test module may then return to operation 909 and
reinitiate the inlet pressure test. The self test module may then
proceed through operations 911 and 913. If, in operation 913, tank
tester 101 fails the inlet pressure self-test a second time (or
other predetermined number of times), tank tester 101 may, in an
operation 917, display a prompt such as, for example: "INLET
PRESSURE ERROR, CALL SERVICE." In an operation 919 the self-test
module may return to the main menu without setting a lockout and
may record the error.
[0183] If, in an operation 911, tank tester 101's inlet pressure
falls within the predetermined range, then the self-test module
may, in an operation 921, proceed to test whether tank tester 101's
pressure sensors (transducers) fall within a predetermined range.
To make this determination, sensor readings are taken while a known
pressure is applied to tank tester 101. If, in an operation 923,
the sensors fall outside an expected range, then tank tester 101
may, in an operation 925, display a prompt such as, for example:
"SENSOR ERROR--CALL SERVICE." Other prompts conveying similar
messages may be used. In an operation, 927, the self-test module
may return to the main menu without setting a lockout and may write
the error code Pressure Sensor Error to the test record in the
Error Code field, or otherwise record the error.
[0184] If, in an operation 923, tank tester 101's pressure sensors
fall within the predetermined range, the self-test module may
proceed, in an operation 929, to test whether tank tester 101's
temperature sensors fall within a predetermined range. This
determination may be made by taking temperature readings from the
temperature sensors while a known temperature is applied to tank
tester 101. If, in an operation 931, the temperature sensors fall
outside the predetermined range, then tank tester 101 may, in an
operation 933, display a prompt such as, for example: "TEMPERATURE
SENSOR ERROR--CALL SERVICE." In an operation 935, the self-testing
module may return to the Main Menu without setting a lockout and
may write the error code Temperature Sensor Error to the test
record in the Error Code field or otherwise record the error.
[0185] If, in operation 931, temperature sensors fall within the
predetermined range, the self-test module may, in an operation 937,
determine that the self test has been successfully completed and
may display a prompt conveying such a message.
[0186] According to an embodiment, the calibration module may
perform a system-test for tank tester 101's overpressure function.
This system-test monitors for tank tester 101's ability to disable
tank tester 101 in the event that over pressurize of a calibration
tank or fuel tank occurs. Tank tester 101 may be capable of
resuming normal operation after the overpressure condition has been
eliminated, and tank tester 101 successfully completes the
calibration procedure successfully. Upon failing the system-test,
tank tester 101 may prevent further testing with the device for a
predetermined period of time, but may allow subsequent attempts to
successfully complete calibration procedures, self tests or system
tests. Once calibration has been successfully completed, the
calibration module may allow testing to occur.
[0187] If tank tester 101 fails any portion of a calibration test,
a technician may be prompted to perform subsequent calibration
procedures or contact a designated service provider for repairs.
According to one embodiment, when service of tank tester 101 is
required, tank tester 101 may not allow further tank testing or
manual mode pressurization to be performed until full function has
been restored by an authorized or designated service
representative.
[0188] Although the calibration procedures described above may have
been described as occurring in a particular order ("phase one,"
"phase two," etc.), it should be understood that the aforementioned
calibration procedures, self-test procedures, and system test
procedures may be performed in any sequence. Any sequence of
calibration procedures, self-test procedures, and system test
procedures may be referred to as "calibration."
[0189] Testing
[0190] Fuel Evaporative Test
[0191] Once calibration have been performed, any number of tests,
measurements, and/or calculations may be performed. According to an
embodiment of the invention, tank tester 101 may include a test
module. The test module may enable tank tester 101 to conduct
various fuel tank tests such as, for example, a fuel evaporative
test. A fuel evaporative test may enable calculation of the size of
a leak in a fuel tank of unknown size.
[0192] FIG. 10 illustrates an exemplary process 1000, wherein a
test module of tank tester 101 may perform a fuel evaporative test.
In an operation 1001, fuel evaporative test may be selected from
the main menu or a fuel evaporative test may otherwise be
initiated. In an operation 1003, tank tester 101 may display a
prompt such as, for example: "CONNECT TO TANK, SEAL EVAP SYSTEM,
PRESS START." In an operation 1005, a user may then connect tank
tester 101 to a fuel tank to be tested, seal or otherwise prepare
all necessary systems, and commence the test. The user may commence
the test by, for example, pressing a start button that is
operatively connected to computer component 103 (FIG. 1).
[0193] In an operation 1007, tank tester 101 may pressurize the
fuel tank. During or after pressurization, tank tester 101 may
determine if the maximum allowable fill time has been exceeded. For
example, a gross leak may be indicated if the fuel tank cannot be
pressurized to 5'' H.sub.2O in the first 60 seconds of fill time.
If, in an operation 1009, the fill time has been exceeded, tank
tester 101 may proceed to an operation 1011. In operation 1011, the
test module may determine how many times operation 1007 has been
performed. If operation 1007 has not been performed more than a
predetermined number of times, then tank tester 101 may, in an
operation 1013, display a prompt such as, for example: "GROSS LEAK
DETECTED. CHECK ALL CONNECTIONS AND PRESS START." The test module
may then return to operation 1007 and reinitiate
pressurization.
[0194] The test module may then proceed through operations 1009 and
1011. If, in operation 1011, operation 1007 has been performed more
than the predetermined number of times, the test module may, in an
operation 1015, display a prompt such as, for example: "TEST
FAILED. TEST COMPLETE." Other prompts conveying similar messages
may be used. In an operation 1017, the test module may write a "G"
(for "gross leak") to the "Test Result" field of the Test Record or
otherwise record the failure and may then display a prompt such as,
for example: "UNSEAL EVAP SYSTEM. DISCONNECT TESTER." In an
operation 1019, tank tester 101 may monitor the fuel tank pressure
for 30 seconds (or other time period) after which, tank tester 101
may vent any remaining pressure from tank tester 101 and may return
to the main menu.
[0195] If, in an operation 1009, the fuel tank passes the fill-time
portion of the test (indicating no gross leak), the test module
may, in an operation 1021, determine whether an otherwise
unacceptable leak exists in the fuel tank (e.g., pass or fail) and
make vapor space calculations. In making such calculations, the
test module may compensate for temperature, Reid Vapor Pressure
(RVP), and vapor space (described in detail below). Temperature,
RVP, and vapor space compensation may be used to ensure accuracy of
pressure, volume, and leak measurements.
[0196] In operation 1021, the test module may write the ambient
temperature to the "Ambient Temp" field of the test record or
otherwise record the ambient temperature during the test. In
operation 1021, the test module may also write the calculated vapor
space results to the "Vapor Space" field of the test record or
otherwise record the vapor space results. If the fuel tank passes
the test, then, in operation 1021, the test module may write a "P"
to the Test Result field of the Test Record or otherwise record
passage of the test. In an operation 1023, tank tester 101 may
display a prompt such as, for example: "TEST PASSED. PRESS START TO
CONTINUE." Similar steps may be taken in the event of fuel tank
failure. In an operation 1025 the user may press the start button
or otherwise indicate readiness to disengage tank tester 101 from
the tested fuel system. In an operation 1027, tank tester 101 may
display a prompt such as, for example: "UNSEAL EVAP SYSTEM.
DISCONNECT TESTER." If tank tester 101 senses any pressure in the
fuel tank 10 seconds (or other predetermined amount of time) after
the last prompt, tank tester 101 may automatically vent the
remaining pressure from the tank and testing component 117 (FIG. 1)
to the atmosphere or other area. In an operation 1027, tank tester
101 may turn to the main menu.
[0197] Flow Method
[0198] In one embodiment of the invention, the test module of tank
tester 101 may perform a fuel evaporative test designed to
calculate the size of a hole in a subject tank using a "flow
method." In this embodiment, testing component 117 of tank tester
101 may have a "Fast Fill Flow" and "Slow Fill Flow" filling path.
Using the Fast Fill Flow path, the subject tank may be pressurized
to a predetermined pressure level such as, for example 14''
H.sub.2O at a rate of approximately 8.5 standard liters per minute
(SLPM). Once the desired pressure is realized, tank tester 101 may
switch to the Slow Fill Flow path. The Slow Fill Flow path may have
an orifice and precision pressure regulator set to a predetermined
pressure level such as, for example, 14'' H.sub.2O. The pressure
regulator attempts to maintain a constant pressure in the subject
tank. If the subject tank has no leak, there will be no flow. If
the subject tank has a leak, the flow rate of gas required to keep
a constant pressure in the subject tank should be the flow rate of
the leak. Based on this flow rate, and the pressure in the subject
tank, the size of the hole in the subject tank may be calculated
and compared to a calibrated standard.
[0199] Once a hole size is determined by the flow method, the tank
may be allowed to leak down over a certain period of time. Based on
the pressure drop in the tank versus time, the volume of the tank
may be calculated. If the tank does not have any leaks, the volume
may be calculated based on the Fast Fill Flow time and Fast Fill
Flow rate.
[0200] Constant Flow Test
[0201] In another embodiment of the invention, the test module of
tank tester 101 may perform a constant flow test. The constant flow
test may operate by applying a constant flow of gas to fuel tank
140 which results in a increasing pressure. By measuring the rate
at which a pressure corresponding to the pressure in fuel tank 140
increases, a determination is made as to the integrity of fuel tank
140 (or fuel system 150). The pressure inside an un-compromised
fuel tank would increase at a greater rate than that of a
compromised fuel tank. In some embodiments, the degree to which the
fuel tank is compromised may be determined by the rate at which the
pressure inside the fuel tank increases.
[0202] Leak Down
[0203] According one embodiment, the test module may determine the
integrity of a fuel tank using a leak down test. In performing a
leak down test, tank tester 101 may pressurize fuel tank 140 to a
predetermined pressure. Once the predetermined pressure is reached,
a time interval may elapse and a pressure corresponding to the
pressure in fuel tank 140 is measured. Successive time intervals
and pressure measurements may occur. If the pressure in fuel tank
140 remains approximately at the predetermined pressure, fuel tank
140 (or fuel system 150) may not be compromised (e.g., no leaks, or
leaks within an accepted tolerance). If the pressure in fuel tank
140 decreases, fuel tank 140 (or fuel system 150) may be comprised
(e.g., has a leak). Tank tester 101 may then perform calculations
to determine the size of the leak and whether the leak is
acceptable (e.g., pass/fail).
[0204] Vacuum Testing
[0205] In one embodiment, the test module of tank tester 101 may
determine the integrity of a fuel tank (or fuel system) using
vacuum testing. In one embodiment, vacuum testing may operate by
reducing pressure in fuel tank 140 to a predetermined pressure
below ambient pressure. Such a predetermined pressure may be
achieved by applying a vacuum to fuel system 150. The vacuum may be
applied by a suitable device such as, for example, a vacuum pump,
or other device known to one skilled in the art. Once the
predetermined pressure is reached, a pressure corresponding to the
pressure in fuel tank 140 is measured. If the pressure in fuel tank
140 remains at approximately the predetermined pressure, fuel tank
140 (or fuel system 150) may not be compromised (e.g., no leaks, or
leaks within an accepted tolerance). If the pressure in fuel tank
140 increases, fuel tank 140 (or fuel system 150) may be comprised
(e.g., has a leak). Tank tester 101 may then perform calculations
to determine the size of the leak and whether the leak is
acceptable (e.g., pass/fail).
[0206] In another embodiment, vacuum testing may operate by
applying a continuous vacuum to fuel tank 140 which results in a
decreasing pressure inside fuel tank 140. By measuring the rate at
which a pressure corresponding to the pressure in fuel tank 140
decreases, a determination may be made as to the integrity of fuel
tank 140 (or fuel system 150). The pressure inside an uncompromised
fuel tank would decrease at a greater rate than that inside a
compromised fuel tank. In some embodiments, the degree to which the
fuel tank is compromised may be determined by the rate at which the
pressure inside the fuel tank decreases.
[0207] Mechanical Pressure
[0208] According to one aspect of the invention illustrated in FIG.
11, the test module of a system 1100 may determine the integrity of
the fuel tank 140 (or fuel system 150) by applying a constant,
predetermined pressure to fuel tank 140 via a mechanical device,
such as a piston 162 and cylinder 160. A force may be applied to
piston 162 commensurate with the desired predetermined pressure to
be applied to fuel tank 150. The force may be applied to piston 162
by an electric or fuel based motor, by a hydraulic device, or by
another suitable device known to one skilled in the art. Once the
predetermined pressure is reached in the tank, the force applied to
piston 162 and the force corresponding to the pressure in fuel tank
140 should be equal and opposite. If fuel system 150 is
uncompromised (e.g., no leaks), piston 162 should remain stationary
(or nearly so). If fuel system 150 is compromised (e.g., leaks),
piston 162 should move. The degree to which piston 162 moves may be
related to the degree to which fuel system 150 leaks. The movement
of piston 162 in cylinder 160 may be measured via various well
known mechanisms.
[0209] Manual Mode
[0210] In one embodiment of the invention, tank tester 101 may
include a manual-test module. FIG. 12 illustrates an exemplary
process 1200, wherein a manual-test module of tank tester 101 may
perform manual test sequence. In an operation 1201, manual test
mode of tank tester 101 may be initiated. Initiation may occur upon
selection by a user or by other event. In an operation 1203, tank
tester 101 may display a prompt such as, for example: "PRESS START
TO BEGIN TEST." In an operation 1205, a user may commence the test
by, for example, pressing a start button that is operatively
connected to computer component 103 (FIG. 1). In an operation 1207
tank tester 101 may display a prompt such as, for example: "SEAL
EVAP SYSTEM. CONNECT TO TANK. PRESS START." In an operation 1209, a
user may connect tank tester 101 to a fuel tank, prepare the
system, and continue the test by, for example, pressing the start
button. In an operation 1211, tank tester 101 may pressurize the
fuel tank to 14'' of H.sub.2O (or other predetermined pressure
level) and maintain that pressure for no more than 10 minutes or
other predetermined amount of time. While in the Manual Mode
operation, tank tester 101 may display the following prompt:
"MANUAL MODE. TIME REMAINING: XX." The "XX" may represent the time
remaining on the predetermined amount of time and may count down as
the timer elapses. If the user re-initiates the test cycle by, for
example, pressing the start button prior to the expiration of the
predetermined time limit, tank tester 101 may restart the timer and
continue to pressurize the fuel evaporative system. This process
may be repeated until either the timer expires or the user aborts
the test by, for example, pressing an abort button that is
operatively connected to computer component 103. During
pressurization, a user may take readings from the various sensors
and transducers of tank tester 101 for use in determining the
various qualities of a fuel tank being tested. At the end of the
predetermined time period, in an operation 1213, tank tester 101
may vent any remaining tank pressure and display a prompt such as,
for example: "TEST COMPLETE. UNSEAL EVAP SYSTEM. DISCONNECT
TESTER." In an operation 1215, the manual-test module may return to
the main menu.
[0211] If at anytime during the manual mode sequence the testing
pressure applied to the fuel tank exceeds 28'' H.sub.2O (or other
predetermined pressure level), tank tester 101 may automatically
abort the manual operation, open the pressure vent, and display a
prompt such as, for example: "SYSTEM OVERPRESSURE. TEST ABORTED.
UNSEAL EVAP SYSTEM. DISCONNECT TESTER." Tank tester 101 may
subsequently lock out the fuel evaporative test and manual mode
operation until a successful calibration has been completed and
return to a main menu.
[0212] Additional Components
[0213] In some embodiments, tank tester 101 may also include one or
more devices (e.g., pliers/clamps) capable of pinching an outlet
hose or other pneumatic conduit to completely block vapor flow.
These devices may be used during various testing or calibration
procedures to block gas flow through tank tester 101. The devices
may apply sufficient pressure to substantially completely block any
flow while also leaving the conduit undamaged and serviceable. In
addition, the devices may be self-locking and capable of performing
approximately 5,000 clamping cycles.
[0214] In one embodiment, tank tester 101 may also include tapered
hose plugs that may plug vapor hose openings in the event that the
aforementioned pinching devices are incompatible with the vehicle
being tested. These hose plugs may be configured to fit 1/8 to 1/2
inch inner diameter hose in 1/8-inch increments. Other
configurations may be used. In lieu of specially designed plugs, a
set of plugs manufactured by Thexton, Part Number 312, or
equivalent may be substituted.
[0215] In one embodiment, tank tester 101 may also include a
calibration adaptor designed to plug the end of tank tester 101's
hose (that normally connects to a tank adaptor). This adaptor may
be used to plug tank tester 101's hose end during certain
calibration procedures as described above.
[0216] Multiple Standards
[0217] In one embodiment, the test module may enable the use of
different predefined standards for fuel tank tests. For example,
the test module may base a pass/fail determination on a standard on
a 0.020'' gap. Where a fuel evaporative system leak is less than or
equal to a 0.020'' diameter gap, the test module may return a pass
determination. Accordingly, the test module may fail the fuel
evaporative system where the leak exceeds a 0.020'' diameter
gap.
[0218] Under a different standard such as, for instance, a 0.040''
diameter orifice standard, the test module may pass a vehicle where
the fuel evaporative system leak is less than or equal to a 0.040''
diameter gap, and fail the fuel evaporative system where the leak
exceeds a 0.040'' diameter gap. The false pass error rate may be
less than .+-.5% and the false fail error rate may be less than
.+-.1%. Other pass/fail standards and error rates may be used. All
data pertinent to test standards may be stored in a file. This file
may include any or all data and/or algorithms required to make the
Pass/Fail decision in tank tester 101.
[0219] Calculations and Compensation
[0220] According to one aspect of the invention, tank tester 101
may contain a data analysis module. The data analysis module may,
among other things, measure vapor space, temperature, and Reid
Vapor Pressure (RVP) within a fuel tank being tested and may
compensate for these factors when making test calculations.
[0221] Temperature measurements may be taken by one or more
temperature sensors included in tank tester 101. The temperature
sensors may be placed in various places within the testing
component and may be connected to a sensor or other element of
computer component 103. Additionally, various hardware and software
components associated with tank tester 101 may be used to determine
liquid fuel temperature based on measured vapor temperature. These
temperature readings may be used in the calculations made during
the various tests performed by tank tester 101.
[0222] Tank tester 101 may include a barometric pressure sensor for
measuring the barometric pressure of the testing environment in
which tank tester 101 is being used. Tank tester 101 may also
include an ambient temperature sensor for measuring the ambient
temperature of the testing environment. These measurements may also
be used in the calculations performed by tank tester 101.
[0223] Referring back to FIG. 1, Reid Vapor Pressure (RVP)
measurements may be taken for a volume of fuel 145 in fuel tank
140. RVP corresponds to the pressure induced in a closed volume
(fuel tank 140) as a result of the evaporation of liquid (fuel 145)
in the closed volume. To improve the accuracy of tank tester 101,
the data analysis module may compensate for RVP. In order to
compute RVP, the data analysis module may obtain the following
measurements or quantities: the volume of fuel tank 140, the volume
of the liquid (fuel 145) in fuel tank 140, a measure of the
liquid's tendency to evaporate, and the ambient temperature of the
surrounding environment. With one or more of these variables, the
amount of pressure induced by the evaporative effects of the fuel
145 may be determined.
[0224] In some embodiments of the invention, RVP may be measured
directly by, for instance, releasing the pressure in fuel tank 140,
resealing fuel tank 140, allowing the closed system to reach a
steady state condition, and measuring RVP at steady state. Once RVP
is determined, the data analysis module may compensate for RVP in
pressure measurements as would be apparent.
[0225] In some embodiments, certain other measurements such as, for
example the volume of fuel tank 140, the volume of fuel 145 in fuel
tank 140, the volume of vapor in fuel tank 140, or other
measurements may be used by tank tester 101 in making calculations.
In some embodiments, the volume of fuel tank 140 may be provided by
the manufacturer of fuel tank 140 or integrator of fuel system 150
(e.g., automobile manufacturer). In other embodiments of the
invention, the volume of fuel tank 140 may be measured. In some
embodiments of the invention, the volume of fuel 145 in a fuel tank
140 may be measured. In other embodiments, fuel tank 140 may be
drained and a known volume of fuel 145 may be dispensed into fuel
tank 140. In some embodiments, the volume of fuel tank 140 and the
volume of fuel 145 may be used to determine the volume of vapor
within fuel tank 140. In other embodiments, the volume of the vapor
may be measured directly without obtaining the volume of fuel tank
140 and/or the volume of the fuel 145.
[0226] Safety Measures
[0227] According to an embodiment of the invention, tank tester 101
may be configured to determine an overpressure condition for either
an incoming supply pressure or a regulated test pressure. If at
anytime during a procedure (for example, a fuel evaporative test or
manual mode test) the tester inlet pressure from the air pressure
regulator exceeds 35 psi (or other predetermined value), tank
tester 101 may cease any test or procedure in progress. Tank tester
software may prevent tank tester 101 from performing a
pressurization of the fuel tank until any overpressure condition
has been corrected.
[0228] Additionally, if at anytime during a procedure the fuel tank
pressure exceeds 28'' H.sub.2O (or other predetermined pressure
level) as measured by tank tester 101, tank tester 101 may open one
or more valves and vent any remaining pressure in the fuel tank.
Tank tester 101 may also prevent pressurization of the fuel tank
for any procedure until the problem has been corrected.
[0229] At anytime during a test sequence, the test may be aborted
by the activation of an abort button that is operatively connected
to computer component 103 (FIG. 1). The abort button may cause tank
tester 101 to immediately open a system relief valve, write the
"Tech. Abort" code to the Error field of the Test Record (or
otherwise record the aborted test), and subsequently return tank
tester 101 to the main menu.
[0230] Software Updates
[0231] A tank tester 101 may include a software update module. The
software update module may enable software associated with tank
tester 101 (including the operating application and various
software modules) to be updated in a number of ways.
[0232] Software associated with tank tester 101 may be updated by a
modem. For example, a built-in modem may dial a 1-800 number, allow
a query of tank tester 101 for the software version, and update
software modules and databases as required. In another embodiment,
tank tester 101 may be connected to a phone line and a host may
call tank tester 101 to commence an update process.
[0233] In yet another embodiment, software may be updated using a
compact flash card or other memory storage device within tank
tester 101. Such a device may be removed from tank tester 101, sent
to a service provider for reprogramming, and reintroduced into tank
tester 101 with updated software. Alternatively, memory storage
devices containing updated software may be sent to tank tester
users as replacements for older devices.
[0234] In another embodiment, software may be updated by connecting
tank tester 101 to a personal computer (or other computer). A user
may then connect to the Internet (or other designated network) and
link to a provider web page to download software updates. These
updates may then be communicated to (and/or stored within) tank
tester 101. Alternatively, tank tester 101 may contain sufficient
computer hardware and/or software to connect to the Internet or
other network without the aid of an additional computer.
[0235] Menus
[0236] In one embodiment, tank tester 101 may include a main menu.
In various embodiments, any one or more of the following menu
options may be displayed in the main menu or other menus and may be
facilitated by tank tester 101's software and/or hardware: (1) Fuel
Evaporative Test, (2) Diagnostic Manual Mode testing, (3)
Calibration, (4) Self-test, (4) Status Mode, (5) Software update,
(6) Service mode, (7) QA State Menu, or other options.
[0237] In one embodiment, a Status Mode may display the following
information: testing station's license number (or other testing
station identification); next test record number; tester number;
date/time; loaded software version number; update software version
number; and tester lock out reason.
[0238] The testing station license number of an entity using tank
tester 101 may include a license number issued by a state
automotive authority or other authority. Other station
identification may be used. Station identification may be entered
into tank tester 101 during initial operation or startup. In one
embodiment, station identification may consist of eight characters.
In one embodiment, the first two characters of the identification
number may be alphas followed by six digits. Other identification
number formats may be used.
[0239] Tank tester 101 may assign each test a consecutive number
(test record number). The number may be written in a Test Record
Number field of the test record or otherwise recorded. In one
embodiment, this field may be numeric and have a length of six
digits. Furthermore, each tank tester 101 may have a unique serial
number which may be recorded in the test record.
[0240] Using an internal clock, tank tester 101 may assign a
date/time stamp to each valid test. A valid test may, in certain
embodiments, consist of a completed fuel evaporative test with a
pass/fail result recorded to the test record. The time may also
change to coincide with changes from standard time in a particular
time zone to daylight savings time. In addition, tank tester 101
may compensate for leap year. In one embodiment, the date and time
may be formatted as follows: mmddyyyy_hhmm. The hour stamp may use
the 24-hour clock format. The date/time may be written to the Test
Date/Time field of the test record or otherwise recorded.
[0241] The loaded software version number may contain the version
number in current use by tank tester 101. The loaded software
version number may be written to the Loaded Software Version Number
field of the test record or otherwise recorded. This field may be
populated in the test record for every valid test.
[0242] The update software version number may contain the version
number of update software that is currently loaded but not being
used by tank tester 101. The update software version number may be
recorded into a field of the test record. This field of the test
record may be populated if tank tester 101 has update software
loaded. At a predetermined date, the software of tank tester 101
may be updated, and the old software may be discarded. After the
update software version turns into the loaded software version, the
update software version number field may be blank.
[0243] If tank tester 101 has been locked out, then one of the
following reasons (or other reasons) may be displayed on the status
page: clock failure, sensor failure, QA/State tester lockout, or
calibration failure.
[0244] In one embodiment, a QA State Menu may provide access to
certain data stored on tank tester 101. The QA State Menu may be
accessed via tank tester 101's display device and user input
device, a separate computer (such as a laptop), or other device.
The QA State Menu may require a password. In one embodiment, the
password may consist of a six character, case sensitive
alphanumeric and may change daily. The access code algorithm may be
supplied by a service provider or system administrator. Other
configurations may be implemented.
[0245] The QA State Menu may consist of a menu including one or
more of the following options: update config. tables, load software
update, download test records, download calibration records,
lock-out tester, or other options.
[0246] FIG. 13 illustrates an exemplary process 1300, wherein the
QA State Menu (or other password protected area) of tank tester 101
may be accessed. In an operation 1301, the QA State Menu may be
selected. In an operation 1303, tank tester 101 may display a
prompt such as, for example: "ENTER PASSWORD." In an operation
1305, a user may enter a password. While entering the password,
tank tester 101's display device may display only X's or other
indicators on the screen. In an operation 1307, a password
protection module may verify the password. If, in an operation
1309, the password is incorrect, the software may proceed to an
operation 1311. In an operation 1311, the password protection
module may determine if the number of times a password has been
entered ("password try") exceeds a predetermined allowable number.
If, in an operation 1311, the number of password tries does not
exceed the allowable number, tank tester 101 may, in an operation
1313 display a prompt such as, for example: "PASSWORD INCORRECT.
REENTER PASSWORD." The password protection module may then return
to operation 1305 wherein the user may enter a password. The
password protection module may proceed through operations 1307,
1309, and 1311. If, in an operation 1311, the number of password
tries exceed the allowable number, the password protection module
may, in an operation 1315, return to the main menu and record a
password error to the test record or otherwise record the error. In
operation 1315 the password protection module may also record the
date and time of the error to the test record.
[0247] If, in operation 1309, the password is correct, then the
password protection module may (in an operation 1317) display the
QA State Menu which may contain one or more of the following
options: update config. tables, load software update, download test
records, download calibration records, lock-out tester, or other
option. In some embodiments, the QA State Menu, or other menu, may
enable update of tank tester 101's internal clock.
[0248] The password protection module is described above for use in
conjunction with the QA State Menu. The password protection module
may, however, be used to provide password protection to any menu or
feature of the invention described herein.
[0249] If the update config. tables option is selected form the QA
State Menu, the software update module may enable the update of the
testing parameter in a Config. Table (or other location) as
necessary to improve accuracy or compliance with mandated
guidelines. If the load software update option is selected, a
connected computer may communicate with tank tester 101 to load an
updated software version into tank tester 101's memory for
activation at a later date. If the download test records option is
selected, a user may access test records and download some or all
records to a connected computer. The download may be stored in a
unique file on the connected computer identified by Tester ID and
Station ID. The process may not delete any records from tank tester
101. If the download calibration records option is selected, a user
may access a calibration record and download all records to a
connected computer. The download may be stored in a unique file on
the connected computer identified by Tester ID and Station ID. The
process may not delete any records from tank tester 101. If the
lockout tester option is selected, a user may send a lock out code
to tank tester 101 that prevents tank tester 101 from performing
tests or other procedures. In one embodiment, calibration and or
self-tests may not be locked out by selection of the tester lockout
option.
[0250] Test Record
[0251] According to an embodiment, tank tester 101 may record test
results and related data to a test record. The test record may
include multiple fields containing various types of test data such
as, for example test start year, test start month, test start day,
test start hour, test start minute, test start second, vehicle
year, vehicle make, vehicle model, head space, ambient temp,
pressure increase/decrease, test result (pass, fail, abort, etc),
abort code, date of last calibration, software version number,
and/or other data.
[0252] According to an embodiment, a test record may be read from
tank tester 101 by sending a command with four data bytes in the
range of 0000 to 9999 (or other range). Tank tester 101 may respond
with the data for the selected tank test results as follows:
TABLE-US-00001 <STX><echoed command><command data
(status bytes) XXXXrr...rr><chesksum><ETX> .fwdarw.
where XXXX is the record number (as requested) .fwdarw. rr...rr is
the test record data (see above) or all zeros if no such record has
been collected
Other processing alternatives may be implemented.
[0253] System Communications
[0254] According to an embodiment, tank tester 101 may include a
communications module. The communications module may enable
standard RS232 communications protocols that may be used for
communication between an EIS and tank tester 101. In addition, a
laptop computer (or other suitable device) using RS232
communications may be used for software and table updates for tank
tester 101. Communications protocols as used herein may enable
users to perform one or more various functions including, for
example: updating operating software as deemed necessary; updating
tables for pass/fail standards; downloading test data from records
stored in tank tester 101; downloading tester calibration records
stored in tank tester 101; outputting pass/fail results to the EIS;
communication with other computers or a network; or other function.
Furthermore, the communications module may perform updates and
other communications using a modem incorporated into tank tester
101. Protocols other than RS232 may be used.
[0255] According to an embodiment, tank tester 101 may include a
serial mode module for serial mode operation. Serial mode operation
may be two-fold. A first serial mode operation may be for checkout
and testing of production line tank testers and repair of returned
tank testers. A second serial mode operation may be for integrating
communication to EIS equipment. The configuration of the serial
port may, for instance, have a baud rate fixed at 9600 baud. Other
signaling rates may be used.
[0256] According to an embodiment, when connected to and
communicating with an EIS, tank tester 101 may be powered by a 12
VDC source limited to 0.5 amps supplied by the RS 232
communications port. Other configurations may be implemented.
Alternatively, tank tester 101 may be integrated with an EIS.
[0257] According to an embodiment, a service mode may also be
provided. The development/service mode may run an evaporative test
and show current pressure, temperature and flow readings during the
test and show results after the test is finished. The service mode
may also run a manual service and test mode while displaying sensor
readings solenoid or valve status. Furthermore, the development
mode may allow the update of software, databases and tables in
conjunction with or apart from other features described herein.
[0258] Interlocking Tank Adaptor Safety Mechanism.
[0259] According to embodiment, the tank adaptor of tank tester 101
(e.g., tank adaptor 415 in FIG. 4 or tank adaptor 519 of FIG. 5)
may provide a closed system between fuel system 150 and tank tester
101. In some embodiments of the invention, tank adaptor 121 may
enable tank tester 101 to pressurize fuel system 150, among other
things.
[0260] One drawback associated with pressurizing fuel system 150
may arise in the event that fuel tank 140 is full, or nearly so, of
fuel 145. If the pressure is not properly released, some fuel 145
may spill or splash out of the tank. According to one aspect of the
invention, tank tester 101 may include an interlock that prevents
fuel from spilling, splashing or other being released from fuel
system 150 when it is depressurized. This may be accomplished
either at or proximate to tank adaptor 121 alone or in conjunction
with various functionality incorporated into tank tester 101.
[0261] In some embodiments of the invention, tank adaptor 121 may
be unable to be physically removed from fuel neck 143 until
pressure inside fuel tank 140 returns to ambient pressure. In some
embodiments, tank adaptor 121 may incorporate or otherwise operate
with an interlock that prevents tank adaptor 121 from being removed
from fuel neck 143 until the pressure returns to ambient pressure
(i.e., the pressure of the testing environment).
[0262] In some embodiments, tank adaptor 121 may include a valve
(e.g., bleed valve, etc.) that releases the pressure in fuel system
150. In some embodiments, tank tester 101 may include the valve
(such as the relief valves described in FIGS. 4 and 5). Other
embodiments may incorporate the valve elsewhere as would be
apparent. In some embodiments, tank tester 101 may include an
automated valve that controls the return of ambient pressure to
fuel tank 140.
[0263] In one embodiment, a kit containing various tank adaptors
may be provided with tank tester 101. These adaptors may be
designed to fit a majority of vehicles' fuel tank filler necks. In
case none of the adaptors fit, a universal tank adaptor may be
provided. These adaptors may be made using materials that may be
pliable and impermeable to all gasoline constituents. These
adaptors may also be made using non-conductive material to prevent
sparks.
[0264] Hydrocarbon Detector
[0265] According to one aspect of the invention, tank tester 101
may contain various mechanical components, hardware components,
and/or software components (or modules, such as a hydrocarbon
detection module) that may enable tank tester 101 to detect fuel
vapor that escapes from fuel system 150. To facilitate fuel vapor
detection, a small amount of pressure above ambient pressure may be
applied to fuel system 150. This pressure may tend to force any
fuel vapor out of a compromised fuel system 150. Such fuel vapor
may be detected by a detector incorporated into tank tester 101
such as, for example, a gas analyzer or other detector capable of
detecting hydrocarbons. In addition to detecting whether fuel vapor
may be leaking from fuel system 150, the detector may also be used
to determine the approximate location of the leak by, for example,
using a probe from the detector to identify areas with increased
levels of hydrocarbons. Devices suitable for hydrocarbon detection
are known to those skilled in the art.
[0266] Integrated Fuel Cap and Fuel Tank Testing
[0267] Currently, tank integrity and fuel cap tests may be
performed separately. According to one aspect of the invention,
tank tester 101 may be modified to contain sufficient devices, as
well as computer hardware and/or software to enable simultaneous
measurement of fuel cap leakage and fuel tank integrity.
[0268] Other embodiments, uses and advantages of the invention will
be apparent to those skilled in the art from consideration of the
specification and practice of the invention disclosed herein. The
specification should be considered exemplary only, and the scope of
the invention is accordingly intended to be limited only by the
following claims.
* * * * *