U.S. patent application number 14/637679 was filed with the patent office on 2015-06-25 for fluid level measurement system and method.
The applicant listed for this patent is THERMO KING CORPORATION. Invention is credited to Randy Hochstein, Anthony J. McReynolds, Ashok Muralidhar, Russell L. Sanders.
Application Number | 20150177047 14/637679 |
Document ID | / |
Family ID | 44708025 |
Filed Date | 2015-06-25 |
United States Patent
Application |
20150177047 |
Kind Code |
A1 |
Sanders; Russell L. ; et
al. |
June 25, 2015 |
FLUID LEVEL MEASUREMENT SYSTEM AND METHOD
Abstract
A transport refrigeration system for a transportable temperature
controlled space includes a compressor, a condenser and an
evaporator fluidly connected to one another, an engine operatively
connected to the compressor, and a fuel tank assembly fluidly
connected to the engine. The fuel tank assembly includes a fuel
tank configured to contain the fuel, a fuel vapor and air, and an
ultrasonic fluid level sensor for sensing a level of fuel, the fuel
tank having a maximum fuel level. The fluid level sensor includes a
transducer having a ring period. The distance from the fluid level
sensor to the maximum fuel level is at least half the distance that
the sound travels through the fuel vapor and air during the ring
period of the transducer.
Inventors: |
Sanders; Russell L.;
(Minnetonka, MN) ; McReynolds; Anthony J.;
(Lonsdale, MN) ; Hochstein; Randy; (Plymouth,
MN) ; Muralidhar; Ashok; (Eagan, MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
THERMO KING CORPORATION |
Minneapolis |
MN |
US |
|
|
Family ID: |
44708025 |
Appl. No.: |
14/637679 |
Filed: |
March 4, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13078620 |
Apr 1, 2011 |
8997512 |
|
|
14637679 |
|
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|
61320033 |
Apr 1, 2010 |
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Current U.S.
Class: |
29/592.1 |
Current CPC
Class: |
G01F 23/2962 20130101;
G01F 23/2968 20130101; Y10T 29/49002 20150115 |
International
Class: |
G01F 23/296 20060101
G01F023/296 |
Claims
1-11. (canceled)
12. A method for positioning an ultrasonic fluid level sensor in a
tank assembly of a transport refrigeration system (TRS), the TRS
including a compressor, a condenser, and an evaporator fluidly
connected, an engine operatively connected to the compressor, a
tank containing a fluid, a fluid vapor, and air, wherein the fluid
level sensor includes a transducer having a ring period, the method
comprising: calculating a near field distance of the fluid level
sensor, wherein the near field distance is based on the speed of
sound through the fluid vapor during the ring period of the
transducer; determining a maximum fluid level in the tank; and
positioning the fluid level sensor at a distance from the maximum
fluid level that is greater than or equal to half the near field
distance, wherein the positioning includes directing the fluid
level sensor toward a surface of the fluid such that sound from the
fluid level sensor is reflected from the surface of the fluid.
13. The method of claim 12, wherein positioning the fluid level
sensor includes providing a spacer between the fluid level sensor
and the maximum fluid level.
14. The method of claim 12, wherein positioning the fluid level
sensor includes: providing a spacer adjacent the fluid level
sensor, the spacer extending into an interior of the tank assembly,
and providing fluid vapor and air inside the spacer for spacing a
surface of the fluid from the fluid level sensor.
15. The method of claim 12, wherein the near field distance is
calculated using the equation D.sub.nf=V.sub.sd*T.sub.t, where
D.sub.nf is the near field distance, V.sub.sd is the speed of sound
through the fluid vapor and air, and T.sub.t is the ring period of
the transducer.
16. The method of claim 12, wherein the fluid is fuel and the fluid
vapor is fuel vapor.
Description
RELATED APPLICATIONS
[0001] This application claims priority to co-pending U.S.
Provisional Patent Application No. 61/320,033 filed on Apr. 1,
2010, the entire content of which is incorporated herein by
reference.
BACKGROUND
[0002] The present invention relates to an apparatus and method for
making ultrasonic fluid level measurements in a transport
refrigeration application. Particularly, the invention relates to
the position of a fluid level sensor for detecting a fuel level in
a fuel tank associated with a transport temperature control
system.
[0003] In a transport temperature control system application, a
temperature controlled space is transported over a road, rail, sea,
air or the like. As a result, fuel in a fuel tank for the
temperature control system is subjected to vibrations from
turbulence resulting from movement of the temperature controlled
space. Furthermore, periodic stopping and starting of the
temperature control system while the temperature controlled space
is in transit causes periodic electrical noise associated with
cranking of an engine that drives a compressor. Thus, the fluid
level sensor is simultaneously subjected to vibration noise and
electrical noise, which causes errors in the fluid level
reading.
SUMMARY
[0004] In one construction, the invention provides a transport
refrigeration system for a transportable temperature controlled
space. The transport refrigeration system includes a compressor, a
condenser and an evaporator fluidly connected to one another, an
engine operatively connected to the compressor, and a fuel tank
assembly fluidly connected to the engine. The fuel tank assembly is
subjected to vibrations from movement of the temperature controlled
space as the temperature controlled space is transported. The fuel
tank assembly includes a fuel tank configured to contain a fuel, a
fuel vapor and air, the fuel tank having a maximum fuel level. The
fuel tank assembly also includes an ultrasonic fluid level sensor
for sensing a level of fuel, the fluid level sensor coupled to the
fuel tank and positioned a distance from the maximum fuel level.
The fuel tank assembly also includes a power source electrically
connected to the fluid level sensor for powering the fluid level
sensor. The fluid level sensor includes a transducer having a ring
period, and the distance from the fluid level sensor to the maximum
fuel level is at least half the distance that the sound travels
through the fuel vapor and air during the ring period of the
transducer.
[0005] In another construction, the invention provides a transport
refrigeration system for a transportable temperature controlled
space. The transport refrigeration system includes a compressor, a
condenser and an evaporator fluidly connected to one another, an
engine operatively connected to the compressor, and a fuel tank
assembly fluidly connected to the engine. The fuel tank assembly is
subjected to vibrations from movement of the temperature controlled
space as the temperature controlled space is transported. The fuel
tank assembly includes a fuel tank configured to contain a fuel, a
fuel vapor and air, the fuel tank having a maximum fuel level and
an interior and an exterior. The fuel tank assembly also includes
an ultrasonic fluid level sensor for sensing a level of fuel, the
fluid level sensor coupled to the fuel tank and spaced from the
maximum fuel level, and a tubular spacer having a first end and a
second end and a length between the first end and the second end.
The first end is positioned adjacent the ultrasonic fluid level
sensor and the second end is positioned in communication with the
interior of the tank. The fluid level sensor includes a transducer
having a ring period, and the length of the spacer is at least half
the distance that the sound travels through the fuel vapor during
the ring period of the transducer.
[0006] In yet another construction, the invention provides a method
for positioning an ultrasonic fluid level sensor in a tank assembly
including a tank containing a fluid, a fluid vapor and air, wherein
the fluid level sensor includes a transducer having a ring period.
The method includes calculating a near field distance of the fluid
level sensor based on the speed of sound through the fluid vapor
and the ring period of the transducer, determining a maximum fluid
level in the tank, and positioning the fluid level sensor at a
distance from the maximum fluid level greater than or equal to half
the near field distance.
[0007] Other aspects of the invention will become apparent by
consideration of the detailed description and accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a schematic illustration of a fluid level
measurement system for a tank in accordance with the present
invention.
[0009] FIG. 2 is a plot of spacer height and near field distance
vs. ring time for the fluid level measurement system of FIG. 1.
[0010] FIG. 3 is a schematic diagram of a container power system
for powering the fluid level measurement system.
[0011] FIG. 4 is a schematic diagram of a trailer power system for
powering the fluid level measurement system.
[0012] FIG. 5 is an image of a tractor and trailer having the tank
of FIG. 1.
[0013] FIG. 6 is a schematic diagram of a temperature control
system for the trailer of FIG. 5.
[0014] FIG. 7 is a schematic illustration of another construction
of a fluid level measurement system for a tank in accordance with
the present invention.
DETAILED DESCRIPTION
[0015] Before any constructions of the invention are explained in
detail, it is to be understood that the invention is not limited in
its application to the details of construction and the arrangement
of components set forth in the following description or illustrated
in the following drawings. The invention is capable of other
constructions and of being practiced or of being carried out in
various ways.
[0016] FIG. 1 illustrates a fluid level measurement system 10 for
use with a transport temperature control system 14 (FIGS. 3-6). The
fluid level measurement system 10 includes a fluid tank 18 for
containing a fluid 20 and a fluid vapor 21, such as a fuel tank
containing a fuel and fuel vapor, and a fluid level sensor 22
having a face 23. In the illustrated construction, the tank 18 is a
cylindrical diesel fuel tank coupled horizontally to a vehicle
(FIG. 5) such that a longitudinal axis thereof lies substantially
parallel to the ground. A spacer 26 is coupled with the tank 18
adjacent an opening in the tank 18 and extends from the top of the
tank 18. The spacer 26 is a tubular structure having a wall
extending axially from an outer surface of the tank 18 and having
first and second open free ends 26a, 26b, respectively. The sensor
22 is coupled with the spacer 26 and positioned coaxially with
respect to the spacer 26. The face 23 of the sensor 22 is
positioned adjacent the first free end 26a and the second free end
26b abuts the tank 18 and is in communication with an interior of
the tank 18.
[0017] In the illustrated construction, the fluid level sensor 22
is an ultrasonic fluid level sensor including a transducer that
emits a sound, by way of an initial vibration, in the direction of
a surface 30 of the fluid 20, preferably in a direction
perpendicular to the surface 30 of the fluid 20. The sound is
emitted from the sensor 22 at the face 23 of the sensor 22. The
sensor 22 includes a receiver that senses an echo of the initial
sound reflected off the surface 30 and records a time between
emitting the sound and receiving the echo. Based on the speed of
sound through the medium through which the sound travels, e.g., air
and fuel vapor 21, and the recorded time, a separation distance A
between the sensor 22 and the surface 30 of the fluid 20 is
calculated. The system 10 includes a fluid level algorithm that is
calibrated such that the distance A is associated with a fluid
level of the tank. The fluid level is displayed on a display
24.
[0018] The spacer 26 is sandwiched between the tank 18 and the
sensor 22 to provide a minimum separation distance B between the
sensor 22 and the surface 30 of the fluid 20 at a maximum fluid
level 28. The maximum fluid level 28 is a predetermined level that
the tank 18 is designed to hold and need not be the absolute
physical maximum of the tank 18. For example, a fuel-dispensing
nozzle typically shuts off automatically when the fuel reaches a
fluid level that is less than the physical maximum of the tank 18.
In this case, the maximum fluid level 28 is the level at which the
fuel-dispensing nozzle shuts off, and the fluid level algorithm is
calibrated to associate a reading of "FULL" with the maximum fluid
level 28. The tank 18 includes a fill neck (not shown) for
receiving the fuel-dispensing nozzle. The position of the fill neck
(e.g., height) on the cylindrical tank 18 can also define the
maximum fluid level 28. The minimum separation distance B occurs
when the fuel tank 18 is full and is the minimum distance necessary
to inhibit nondeterministic signals, which lead to erroneous fluid
level readings by the sensor 22, as will be described in greater
detail below. While the minimum separation distance B is constant
and unique to a particular configuration of the fluid level
measurement system 10, the separation distance A is variable
depending upon the level of the fluid 20.
[0019] The minimum separation distance B is equal to, or in some
constructions may be greater than, half the near field distance.
The near field distance is calculated using the equation
D.sub.nf=V.sub.sd*T.sub.t, where D.sub.nf is the near field
distance, V.sub.sd is the speed of sound through the medium through
which the sound travels, e.g., the fluid vapor 21 and air, and
T.sub.t is the ring period of the transducer. As described above,
the transducer emits the sound by way of an initial vibration;
however, the transducer continues to vibrate at a decreasing
magnitude after the initial vibration. The ring period is the time
for the vibrations of the transducer to settle, or decrease, below
a threshold of the sensor's receiver, i.e., to reach a magnitude of
vibration that the receiver of the sensor 22 can no longer detect.
In other words, the near field distance is equal to the distance
that the sound travels through the medium during the ring
period.
[0020] The fluid level measurement system 10 is configured based on
the near field distance such that the sensor 22 is positioned at a
distance from the surface 30 of the fluid 20 that is equal to or
greater than half the near field distance when the tank is full 22,
as indicated by the following equation:
B .gtoreq. V sd * T t 2 . ##EQU00001##
That is, the minimum separation distance B is equal to or greater
than half the near field distance.
[0021] The spacer 26 is positioned vertically with respect to
gravity and is sized to provide a spacer height C such that the
sensor 22 and the surface 30 of the fluid 20 are separated by at
least half the near field distance when the tank 18 is full. FIG. 2
is a plot of the minimum required spacer height C and near field
distance vs. ring time, or ring period. In the illustrated
construction, the spacer height C is approximately equal to the
minimum separation distance B. The spacer height C depends on the
construction of the tank 18. In the illustrated construction, the
sensor 22 is employed with a diesel fuel tank 18 in which the
spacer 26 extends between the maximum fluid level 28 and the face
of the sensor 22, as can be seen in FIG. 1. In other constructions,
the sensor 22 may be employed with other types of tanks suited for
holding fluid in mobile applications. In some constructions, other
relationships between spacer height C and minimum separation
distance B are possible depending on the geometry of the tank 18.
In other constructions, a spacer is not necessary to provide a
sufficient minimum separation distance B between the sensor 22 and
the maximum fluid level 28.
[0022] In the illustrated construction of FIG. 1, the sensor 22 has
a ring period of 500 microseconds which corresponds to a near field
distance of approximately 6.5 inches. Therefore, the minimum
separation distance B is approximately 3.25 inches. Inherently, the
separation distance A is greater than half the near field distance
when the tank 18 is not full.
[0023] The fluid level measurement system 10 is preferably employed
with a transport temperature control system fuel tank 18, such as
for a truck, a trailer, a shipping container, a rail container, a
van or another transport vehicle that stores and/or carries goods
that must be maintained in a temperature controlled environment.
However, in other constructions, other types of tanks for other
applications may be used.
[0024] In one construction, illustrated in FIGS. 3 and 5, the fuel
tank 18 and fluid level measurement system 10 are coupled to a
transport vehicle 32 including a tractor 34 and trailer 38. As
shown in FIG. 5, the trailer 38 includes a frame 42 and an outer
wall 46 supported on the frame 42 for substantially enclosing a
temperature controlled load space 50. Doors 54 are supported on the
frame 42 for providing access to the load space 50. In some
constructions, the load space 50 can include a partition or an
internal wall for at least partially dividing the load space 50
into sub-compartments, including two or more load space zones, each
of which can be maintained at a different temperature or a
different humidity. A plurality of wheels 58 are provided on the
frame 42 to permit movement of the vehicle 32 across the ground. In
some constructions, wheels and/or rails for a railroad or a boat
vessel can be used for transporting temperature controlled
containers.
[0025] FIG. 6 illustrates one construction of a temperature control
system 14 that conditions the load space 50 of the trailer 38. The
temperature control system 14 includes a refrigeration circuit 62
having a compressor 66, a condenser 70, a receiver 74, an
evaporator 78 and an accumulator 82 connected in series, as is well
understood in the art. The refrigeration circuit 62 may also
include other components well known in the art, such as a three-way
switching valve 86 for switching between a heating mode and a
cooling mode. The temperature control system is fully described in
U.S. Pat. No. 6,367,269 titled "ELECTRONIC THROTTLING VALVE
DIAGNOSIS AND PREVENTATIVE SHUTDOWN CONTROL," assigned to the same
assignee as the present invention, the content of which is hereby
fully incorporated herein by reference.
[0026] The compressor 66 is operatively coupled to an engine 92. As
shown schematically in the construction of FIG. 3, the engine 92,
such as a diesel engine, is coupled to the compressor 66 by a
transmission 96 for driving the compressor 66. The fuel tank 18
supplies fuel to the engine 92 by way of a fuel line 102. FIG. 3
further illustrates a power source, such as a battery 98, for
powering the fluid level sensor 22, for powering a controller 104
for the temperature control system, and for powering an engine
starter 94 for starting the engine 92 when cooling or heating is
needed. Other components of the temperature control system 14 may
also be powered by the battery 98.
[0027] In other constructions, the engine 92 may include the
vehicle engine or a gasoline engine. Other arrangements are
possible and may be implemented, as desired. The fuel tank 18 may
supply fuel to one or more of the engines employed.
[0028] FIG. 4 illustrates another construction in which the fluid
level sensor 22 is employed with a temperature controlled transport
container 90. For shipments of perishable goods, the temperature
control system 14 may be employed to heat and/or cool the container
90. The transport container 90 may be transported by a variety of
modes, such as by railcar, barge and truck. While the transport
container 90 is stationary, such as while stored in a warehouse, on
a dock, or near an airport, an external source of power such as
utility electricity may be connected for powering the temperature
control system 14. If the container 90 is not provided with an
external power source, a generator set 91 may be provided to power
the temperature control unit 14. For example, when the container is
in transit by railcar, barge, or truck, the generator set 91 may be
necessary. The generator set 91 includes the engine 92 to drive an
alternator 93 which in turn provides electric power to the
temperature control system 14, specifically the compressor 66.
Thus, the engine 92 is operatively connected to the compressor 66.
The alternator 93 also provides electric power to the fluid level
sensor 22.
[0029] FIG. 7 illustrates another construction of a fluid level
measurement system 110 having an internal spacer 126. Elements of
this construction that are similar to the construction of FIG. 1
are given similar reference numerals. The internal spacer 126 is
positioned vertically with respect to gravity. The internal spacer
126 provides the minimum separation distance B between the face 23
of the sensor 22 and a maximum fluid level 128 of the fluid within
the internal spacer 126, which is lower than the maximum fluid
level 28 of the tank 16, by trapping an air/vapor bubble 121 inside
the spacer 126 to push the maximum fluid level 128 inside the
spacer 126 away from the face of the sensor 23, much like
submerging a cup upside down in water. The internal spacer 126 is a
tubular structure having a wall extending axially and having first
and second open free ends 126a, 126b, respectively. The face 23 of
the sensor 22 is positioned adjacent the first free end 126a and
the second free end 126b is in communication with the interior of
the tank 18.
[0030] The height C of the internal spacer 126 is at least equal to
the minimum required spacer height shown in FIG. 2, as discussed
above, and is preferably greater than the minimum required spacer
height to account for possible tilting of the tank 18 or sloshing
of the fluid within the internal spacer 126. If the tank 18 and
internal spacer 126 are tilted or if sloshing occurs, the air/vapor
bubble 121 may escape from the internal spacer 126, raising the
level 128 closer to the level 28. Therefore, the actual height C of
the internal spacer 126 is preferably greater than the minimum
required spacer height C. For example, if the ring time of the
transducer is 350 microseconds, the minimum spacer height C is
approximately 2.4 inches, as plotted in FIG. 2. The actual height
of the internal spacer may be chosen to be 3.5 or 4 inches to
reduce the chance of air/vapor escaping. Thus, similar to the
construction described in FIG. 1, the minimum separation distance B
is equal to or greater than half the near field distance. In some
constructions, the internal spacer 126 may include a flange for
inhibiting the air/vapor bubble 121 from escaping.
[0031] In operation, the fluid level sensor 22 is powered by the
same power source that provides power to the temperature control
system 14. In the construction of FIG. 4, a generator set 91
provides power to the fluid level sensor 22 and the temperature
control system 14. In the construction of FIG. 3, a battery
provides power to the fluid level sensor 22 and the engine starter
94, which starts the engine 92 to drive the compressor 66 of the
temperature control system 14. In other constructions, other types
of suitable power sources may be employed.
[0032] The output power, oscillator frequency, and analog circuitry
of the fluid level sensor 22 depend on a constant input voltage.
During startup of the compressor 66 of the temperature control
system 14, which occurs as needed while the trailer 38 or container
90 is in transit, the power source 98, 91 is subjected to a heavy
load, e.g., cranking, causing the voltage supply to the fluid level
sensor 22 to droop and be unstable (e.g., power supply noise).
[0033] While the trailer 28 or container 90 is in transit,
vibrations from movement over the road or rail, or other
turbulence, causes vibrations in the surface 30 of the fluid 20.
The combination of power supply noise and vibration noise in the
fluid surface 30, simultaneously, may result in a nondeterministic
signal. A nondeterministic signal introduced to the fluid level
algorithm results in multiple possible fluid levels being computed,
causing glitches in the fluid level measurement, such as rapid
changes in the fluid level reading in a short period of time, e.g.,
more than 4% in less than 10 seconds, when the algorithm selects
the wrong fluid level out of the possible fluid levels.
[0034] When the sensor 22 is spaced from the surface 30 of the
fluid 20 by at least half the near field distance, the
nondeterministic signal is inhibited and glitches are avoided.
Thus, the fluid level measurement system 10, 110 is configured such
that the sensor 22 is spaced from the maximum fluid level 28, 128
of the tank 18 by at least half the near field distance such that
the sensor 22 is spaced from the fluid surface 30 by a distance
greater than half the near field distance when the tank 18 is not
full. The spacer 26, 126 is sized accordingly to provide the
necessary minimum separation distance B.
[0035] Thus, the invention provides, among other things, a fluid
level sensor spaced from a maximum fluid level of the tank by a
distance greater than or equal to half the near field distance of
the sensor.
* * * * *