Measuring tank fluids and remote monitoring system

Abstract

A remote monitoring system that controls fluid level in fuel storage tanks of mining trucks includes a device that measures fluid level in fuel storage tanks of mining trucks resistant to rapid filling that protects a sensor inside the device, including a protective metallic tube; a level sensor arranged inside the protective metallic tube; and an anchorage system connected to the protective metallic tube with the tank allowing fluid communication inside the tank with fluid inside the protective metallic tube; antennas; Web server; remote means; and a power source.

Claims

1. A remote monitoring system that controls fluid level in fuel storage tanks of mining trucks comprising: a device that measures fluid level in fuel storage tanks of mining trucks resistant to rapid filling that protects a sensor inside the device, comprising: a protective metallic tube; a level sensor arranged inside the protective metallic tube; and an anchorage system connected to the protective metallic tube with the tank allowing fluid communication inside the tank with fluid inside the protective metallic tube; wherein the anchorage system comprises a packing, an exterior base mounted on the packing, a pressure dissipator located in the exterior base and attached to an interior base including stems that are expanded once the anchorage system is inserted into the tank, and the stems contact an interior surface of a tank wall; the exterior base is attached to the interior base by bolts bolted from outside the tank wall by holding the packing between the exterior base, the interior base and the tank wall; the inner base is a cylindrical metallic piece whose diameter is smaller than a perforation diameter in the tank, and has an inner orifice forming an inner diameter where stems are radially perpendicularly distributed; and the exterior base has a circular flat shape, with an outer diameter larger than a perforation diameter in the tank and has a circular inner orifice whose diameter is larger than an outer diameter of the pressure dissipator, and the exterior base has an inner bevel to accommodate the pressure dissipator and hold it into place; antennas; Web server; remote means; and a power source.

2. The system as recited in claim 1, wherein the antennas comprise a GPRS antenna and/or satellite GPS antenna through which collected data can be transmitted to the Web server.

3. The system as recited in claim 1, wherein remote means comprises computers, tablets or smartphones to monitor fluid levels with on line software.

4. The system as recited in claim 1, further comprising data line connection means that enable data transfer from the sensor to terminal.

5. The system as recited in claim 1, further comprising a main source and back-up battery, where the main source is supplied by a truck energy rack, leaving the back-up battery in the event there is a failure in the main system energization, where both power sources, the main source and back-up battery connect to a terminal connector.

6. The system as recited in claim 4, wherein the terminal in turn connects to the sensor by energy lines and also connects to telemetry and connectivity devices by energy transfer lines, thereby providing them with electrical current.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 illustrates a general chart of the remote monitoring system and how the different components are connected.

(2) FIG. 2 illustrates a general view of the fluid level measuring device that is comprised of a protective metallic tube formed by a level sensor and also shows the location of a protective metallic tube in a tank.

(3) FIG. 3A illustrates the upper anchorage system of the protective metallic tube and its connection to the tank.

(4) FIG. 3B illustrates more specifically the upper part of the protective metallic tube, level sensor, protection box and joining elbows.

(5) FIG. 4A illustrates the upper anchorage system and its connection to the tank.

(6) FIG. 4B illustrates the exterior part of the anchorage system including a packing, exterior base and pressure dissipator.

(7) FIG. 4C illustrates the interior part of the anchorage system including an interior base and holding stems.

(8) FIG. 5 illustrates a top plan view of the tank with the protective metallic tube mounted on the tank.

(9) FIG. 6 illustrates an elevated plan view of the interior part of the anchorage system shown in FIG. 4C.

(10) FIG. 7 illustrates a cross sectional view of the anchorage system, where both exterior and interior parts of the anchorage system are shown coupled to the tank wall.

(11) FIG. 8 illustrates a section of the pressure dissipator located in the exterior base showing more specifically the interior connection formed by the stems and the pressure dissipator located inside the anchorage system.

SYSTEM COMPONENTS

(12) 01 Main source 02 Back-up battery 03 Terminal 04 Satellite GPS antenna 05 GPRS antenna 06 Internet 07 Tank 08 Electronic devices energy line 09 Data line connection means 10 Web server 11 Server connection 12 Satellite 13 Cellular antenna 14 Remote means 15 Connector 16 Lower anchorage system 17 American joint 18 Elbow 19 Packing 20 Exterior base 21 Pressure dissipator 22 Bolts 23 Interior base 24 Stems 25 American joint 26 Elbow 27 Upper anchorage system 28 Connection tube 29 American joint 30 Elbow 31 Elbow 32 Elbow 33 Protection box 34 T-tube 35 American joint 36 Sensor 37 Protective metallic tube 38 Protection box 39 Plates

DETAILED DESCRIPTION

(13) I provide a device for measuring fluid level in fuel storage tanks of mining trucks, which is resistant to rapid filling and is comprised of: externally mounted sensor (36); protective metallic tube (37); anchorage system (16); and pressure dissipator (21).

(14) I also provide a remote monitoring system for controlling the fluid level in fuel storage tanks of mining trucks, which is comprised of:

(15) a device that measures fluid level in fuel storage tanks of mining trucks comprised of: externally mounted sensor (36); protective metallic tube (37); anchorage system (16); and pressure dissipator (21);

(16) antennas (04, 05);

(17) Web Server (10);

(18) remote means (14); and

(19) power source (01, 02).

(20) The device for measuring fluid level in fuel storage tanks of mining trucks comprises a sensor (36) located outside the fuel tank. The sensor is inside a high-strength protective metallic tube (37). The sensor is a level sensor that may be selected from the group of rheostatic, ultrasound or floating sensors. The preferred sensor is a rheostatic sensor. The sensor can be replaced by other sensors of different technology with no need of making great changes to the protection system.

(21) The device for measuring fluid level comprises an upper anchorage system (27) connected to an outlet at the top of the tank (07) and a lower anchorage system (16) connected to an outlet at the bottom of the rear wall of the tank (07). The sensor (36) communicates fluidly with the tank, keeping the same fluid level as the tank (07).

(22) The remote monitoring system comprises a device for measuring fluid level, formed by a sensor (36) that converts the fluid level into a voltage and, in turn, the voltage is converted into a hex string format traveling from a terminal (03) through satellite (12) or GPRS by Internet connection (06) that arrives to server (10). Then, through a Web platform, the end user has access, upon entering a password, to the fleet vehicle(s) through this Web platform, where alerts and actions can be programmed according to the fluid levels; this data management allows the end user to take actions and improve fleet productivity.

(23) As illustrated in FIG. 1, the remote monitoring system comprises a tank (07) formed by a protective metallic tube (37) externally attached to the tank (07) where the protective metallic tube has a level sensor (36) inside. The monitoring system also integrates telemetry and connectivity solutions by a GPRS antenna (05) and/or satellite GPS antenna (04) that enable transmission of collected data to a Web server (10) to have access to the information from remote means (14) such as computers, tablets or smartphones, to monitor fluid levels on line using appropriate software. Telemetry and connectivity devices are connected to a terminal (03) having a connector (15), which also connects to the protective metallic tube (37) by data line connection means (09) that enable data transference from the sensor to the terminal (03).

(24) The information transmitted by sensor (36) is sent through telemetry and connectivity devices by the GPRS antenna (05) or satellite GPS antenna (04) to Internet (06), and it then travels from there looking for the destination IP addressthat of the Web server (10). Information is stored and ordered according to the database(s) structure. This allows to access information from any remote means (14) with Internet access and Web browser.

(25) The system is powered by a main source (01) and back-up battery (02). The main source (1) is supplied by the truck's energy rack, leaving the back-up battery (2) in the event there is any failure in the main system energization. Both power sources, the main source (01) and back-up battery (02), connect to the terminal (03) connector (15). In turn, the terminal (03) connects to the sensor (36) by energy lines (08) and also connects to telemetry and connectivity (04, 05) devices by energy transference lines providing those elements with electrical current.

(26) FIG. 2 illustrates the device for measuring fluid levels, comprising a protective metallic tube (37), where the sensor (36) is mounted internally. The protective metallic tube (37) at its top outlet connects to a protection box (33), wherein the sensor (36) electronic connections are located. The protection box (33) is then connected to a second protection box (38) placed near the truck's energization rack between the energy connection lines (08) of the electronic devices and data lines connection means (09). Inside the protection box (38) there are the terminal (03), a satellite GPS antenna (04) and GPRS antenna (05).

(27) FIG. 3A illustrates the upper anchorage system (27) of the protective metallic tube joined to the tank (7), which comprises an American joint (25) and elbow (26).

(28) FIG. 3B shows the device for measuring fluid levels, where the upper part of the protective metallic tube (37) connects to a T-tube (34).

(29) Laterally, the T-tube connects to an American joint (35), which also connects to elbows (30, 31, and 32) following the tank outline and lastly connects by an American joint (29) to a connection tube (28) and American joint (25) connected to the tank through an elbow (26) and by the upper anchorage system (27). The structure of above-mentioned elbows (30, 31, 32) respond to the geometry typical of a mining truck tank of certain make. Therefore, when installing the system in a tank of different geometry, components will change but the connection logic will be the samethat is, connecting the measurement device both in the upper and lower part of the tank to measure.

(30) The upper anchorage takes advantage of the breathers that are ready equipped in the mining truck, so it is simply an elbow (26) with a thread at one end.

(31) If the installation needs to be made in a tank that is not equipped with a factory output or breather, an equivalent anchorage system should be used in the lower anchorage system (16). The lower anchorage system is described below.

(32) FIG. 4A illustrates the lower part of the protective metallic tube connected to an American joint (17), which then connects to an elbow (18) connected to a lower anchorage system (16) externally connecting the protective metallic tube (37) with the tank (07). The lower connection allows for fluid connection inside the tank with the fluid inside the protective tube where the sensor is located. In this way, the fuel level inside the protective metallic tube, inside which there is the sensor (36), is the same as the level inside the tank (07), allowing the sensor (36) to obtain a reading based on the tank fuel level (07).

(33) FIG. 5 illustrates a top plan of the device for measuring fluid levels, where the connection of the protective metallic tube to the tank is represented. FIG. 5 illustrates an upper anchorage system (27), an elbow (26), an American joint (25), a connection tube (28), an elbow (30), and the protection box (33) as well. The upper connection to the tank allows air generated by the fluid entry to the conduit to travel to the tank upper part and pass freely through the fuel tank breather.

(34) The protective metallic tube (37) is made of steel, and the protective metallic tube size and the sensor (36) size internally depend on the features and size of the tank to be monitored.

(35) The protective metallic tube is made of steel, and the length of the sensor placed inside the protective metallic tube will depend on the tank dimensions, for example, the length of the sensor can vary between 1 m and 4 m, preferably between 1.5 to 3 m, and more preferably between 1.5 to 2 m.

(36) The lower anchorage system (16) shown more specifically in FIGS. 4B and 4C, comprises a packing (19), exterior base (20) mounted on the packing (19), and a pressure dissipator (21) located in the exterior base (20). The pressure dissipator (21) is internally attached to the elbow (18) (as shown in FIG. 4A), and to an interior base (23). The interior base (23) has stems (24) extending once the anchorage system is introduced into the tank interior and come into contact with the interior surface of the tank wall. The exterior base (20) is attached to the interior base (23) through bolts (22) bolted from the outside by holding the packing, exterior base (20), interior base (23) against the tank (07) wall.

(37) The lower anchorage system (16), shown more specifically in FIGS. 4B, 4C and 7, illustrates the exterior base (20). The exterior base (20) is a flat cylindrical metallic piece whose outer diameter is higher than the diameter of the perforation done in the tank (07). The exterior base (20) has a circular inner orifice whose diameter is bigger than the pressure dissipator outer diameter. There is a bevel and thread in the inner diameter of the exterior base (20). The bevel is used to accommodate the pressure dissipator (21). The thread is used to join the exterior base (20) with the elbow (18). The exterior base (20) also has several thread orifices that can be passed through by Parker bolts (22) joining the exterior base (20) with the interior base (23).

(38) The exterior base part that comes into contact with the tank wall (07) is mounted on a packing (19) to avoid fuel leaks from the tank interior.

(39) The interior base (23) is a cylindrical metallic piece whose diameter is smaller than the perforation diameter made in the tank lower part. The interior base (23) has an inner orifice forming an inner diameter and radially perpendicular stems (24). Stems have rivets on the side towards the piece center preventing the stems from detaching from the interior base (23). The interior base also has thread perforations through which Parker bolts (22) are introduced to connect the exterior base (20) with the interior base (23).

(40) The packing (19) has a flat circular shape and orifices through which bolts (22) are inserted. The outer diameter of the packing (19) is bigger than the perforation diameter made in the tank and has a circular inner orifice whose diameter is bigger than the pressure dissipator diameter.

(41) The interior base (23) has a flat circular shape and orifices through which bolts (22) are inserted from the exterior base. The outer diameter of the interior base (23) is slightly smaller than the perforation diameter made in the tank to introduce the base. The interior base (23) has a circular inner orifice whose diameter is bigger than the pressure dissipator outer diameter.

(42) The interior base (23) has stems (24) inside that are alternated with the thread perforations through which bolts are inserted. Stems are used to support securely the pressure dissipator that is accommodated inside the interior base.

(43) Once the anchorage device is assembled, the exterior base (20), packing and interior base (23) are assembled by inserting bolts (22). The anchorage device is inserted in the tank and the stems (24) of the interior base (23) extend and allow for the interior base to be firmly secured inside the tank, securing the anchorage device. The anchorage device is then fitted to the tank. The pressure dissipator is inserted by the inner orifice formed by the inner diameter of the exterior base, packing and interior base. When the pressure dissipator passes through the interior base, it is fitted internally avoiding stem return. In this way, the anchorage device position is secured. Each of the stems has rivets at both ends ensuring that they are not detached from their position.

(44) Bolts (22) pass through the exterior base and the rubber packing, securing the interior base.

(45) The anchorage device can be assembled outside the tank, and its installation only requires an orifice in the tank to insert the interior base (23). Installation of the lower anchorage device requires just one orifice. That is, neither additional orifices nor welding are required. A tank breather is used to install the upper anchorage system. If the tank is not equipped with a breather, an orifice should be drilled in the tank to install the upper anchorage system.

(46) The anchorage device is assembled externally and, once assembled, pieces are fitted into position in the tank. Once assembled, the device is inserted in the tank and the pressure dissipator is inserted into the bevel formed in the exterior base inner ring; then, the elbow (18) is fitted perpendicularly and bolts are tightened to secure the elbow (18), which is fitted to the protective tube (37), where the sensor is located.

(47) The pressure dissipator (21) comprises some plates (39) or covers, allowing the dissipator to generate a pressure drop during fuel filling. This prevents the fuel level from raising to the sensor interior violently, avoiding potential damages to the sensor (36). The plates (39) or covers to the interior of the pressure dissipator have a screen with orifices or grillwork that allows reducing the speed at which the fuel enters the protective metallic tubewhere the sensor is located.

(48) The pressure dissipator (21) has the following functions:

(49) a) reduces the flow rate generated by the pressure filling system, reducing the fuel pressure that impacts on the system, and ensuring zero damages to the sensor;

(50) b) ensures the interior base (23) stems (24) are kept extended, avoiding their movement towards the center. As a result, the anchorage system is remained still and the sensor structure is not at risk; and

(51) c) the pressure dissipator serves as a filter and settling tank, thereby preventing intrusion of particles and residues into the protective metallic tube and their arrival at the sensor. The pressure dissipator plates (39) avoid the passing of particles bigger than the orifice diameter. For example, plates will avoid the passing of particles bigger than 4 mm, if the dissipator plate orifices are 4 mm in diameter.

(52) The pressure dissipator (21) extends the sensor life and ensures the proper operation of the sensor after each tank filling. It also allows saving in system maintenance. The pressure dissipator (21) comprises plates (39) or covers at each side. These plates (39) are formed by a drilled frame, where orifice diameters vary from 1 to 10 mm; preferably, from 3 to 5 mm, and more preferably, 4 mm. The thickness of the plate (39) varies from 1 to 5 mm, where the preferably thickness is 2 mm. When fuel makes an impact on the first dissipator plate, the plate reduces the fuel pressure inside the dissipator, assuring that the fuel arrives passively at the sensor to avoid damage.

(53) On the other hand, passing of fluid generates air inside the tank, the air travels to the top of the tank and is released freely through a breather located at the top of the fuel tank.

(54) The lower or upper anchorage system can be installed in any type of fuel tank. For example, the anchorage system can be installed in a round, oval-shaped, square or rectangular tank, without the need for big perforations in the tank. In this way, the anchorage system installation does not put at risk the structural strength of the tank.

(55) The pressure dissipator (21) is made up of a hollow cylindrical metallic piece similar to a tube, having a bevel at one end that allows attaching it to the lower anchorage system interior (16). This piece has plates (39) or covers at both ends with 4 mm perforations. These plates could be replaced by grills or plates or covers perforated with different diameters depending on the intended use of the system.

(56) As explained herein, the pressure dissipator is a key component of the measuring device since it allows for the system operation and provides security and low maintenance, which extends the device and sensor life.

(57) The remote monitoring system comprises a main battery (01) connected to a terminal (03) through a 30-pin connector (15) of the terminal (03) by using the positive continuous pin number 29 (it may range from 9 to 32 DVC) and the pin number 30 to negative or ground. The back-up battery (02) is powered by the external ports of the 5-12 connector (15) pins. The work embodiment is defined according to the planning file. Satellite GPS antenna (04) connects to terminal (03). Satellite GPS antenna (04) must be aligned and directed to communication satellites. GPRS (05) antenna connects to the terminal (03) using the terminal (03) RP SMA connector. The terminal (03) has a 30-pin green connector (15). The same pins powering the connectors (15) are used to power the sensor. Likewise, from the connector, data is sent to and received by the sensor (36) using data line connection means (09) with the connection pattern RS 485.

(58) Data is sent to the sensor through pins TX, pin 2, EIA 485 line A, and data is received by pins RX, pin 3 EIA 485 line B. Information transmitted by the sensor (36) is sent by satellite with coordinates. Likewise, GPRS data is sent through the GPRS antenna (05) to the closest cellular antenna station (13), or they are sent by satellite, so sensor data is sent to Internet (06) and then travel looking for the destination IP address, which is that of the Web server (10). Information is stored and ordered according to the database(s) structure. This allows to access information from any remote means (14) with Internet access and Web browser.

(59) The protection box (38) contains the satellite module and its corresponding antennas, a satellite GPS antenna (04) and GPRS antenna (05). The protection box (33) is placed outside the fuel tank on its top. This box contains the sensor (36) electronic connections. To install the protection box (33), the box base must be drilled to install fixing bolts that will support the box, and the metallic hose carrying the energy to the truck connection rack must be fixed with plastic cable ties. Eye terminals must be installed in each power line; then, check if the terminal receives energy through the power LED and verify the voltage received using a tester.

(60) Assembly and Installation Procedure

(61) Assembly and installation procedure is divided into three stages:

(62) 1. Preliminary Procedures

(63) a. Empty the fuel tank and check if it is completely empty. b. Remove the tank breather plugs (07). c. Fill the tank (07) with water to the perforation level.
2. Lower anchorage system (16) a. Drill an orifice that is 1 mm bigger than the interior base (23) diameter. Then, drain the water from the tank (07) and wait until the tank is completely dry to proceed. b. After that, assemble the exterior base (20) with the packing (19) and interior base (23) using the Parker bolts (22) to join them (see FIGS. 4B, 4C). a. Previously assembled part is positioned in front of the tank perforation inserting the interior base (23) into the tank. b. Once the part is positioned inside the tank, stems (24) are extended outwards so they can make contact with the tank interior wall (see FIG. 8). c. With stems extended, the pressure dissipator (24) is inserted into the lower connection system (16), which, as explained in the description, attaches the stems (24) and lower connection system (16) to the tank. d. Then, tighten the Parker bolts until the entire bodyformed by parts 19, 20, 21, 22, 23, 24is securely fitted to the tank (07). e. Once this part is definitely fixed, connect elbow (18), which has a thread at one end, to the exterior base (20) at the end with the thread (see FIG. 7). f. Upon installation of the lower anchorage system (16), you can connect the remaining part, including mainly the protective metallic tube (37), sensor (36) and upper anchorage system (27).
3. Assembly and Installation of Upper System a. Center elbow (18) and connect the protective metallic tube (37). b. Fix and press the protective metallic tube (36). c. Insert sensor (36) into the protective metallic tube, inserting the sealing rubber and fixing it with high-strength silicone. d. Connect T-tube (34) and fix its lateral output next to the tank (07). e. At the T-tube output (34), attach the American joint (35) and the fix the elbows (30, 31, 32) until they are connected to the tank breather (07). f. Fix the protection box (33) on the top of the T-tube (34) wherein sensor (36) electronic connections are secured. g. Install terminal (03), satellite GPS antenna (04) and GPRS antenna (05) inside the protection box (38) and make appropriate electronic connections. h. Connect sensor (36) with terminal (03) using the data line connecting means (09). i. Power sensor (36) and the devices installed in the protection box (38) using the electronic devices power line (08). j. Check if the program receives the module signal by sending and receiving test messages. k. Check if the program receives the module signal by sending and receiving test messages.