EP-4735840-A1 - SYSTEM AND METHOD FOR MEASURING, AND COMPENSATING ERRORS IN MEASUREMENTS OF, FUEL CONSUMPTION

EP4735840A1EP 4735840 A1EP4735840 A1EP 4735840A1EP-4735840-A1

Abstract

A system (400) and method for measuring and compensating errors in measurements of fuel consumption (416) of a machine (100) is disclosed. The system (400) comprises an electrical circuit (408), a level sensor (202) in a tank (110); a gauge (404) in communication with the level sensor (202) and configured to display (418) a fuel level (204) in the tank (110), a resistor (406), a tilt sensor (410), a voltage sense terminal (412), and a controller (402) provided with a volumetric look-up table (414) having irregular tank (300) compensation data. The controller (402) is configured to: receive signals from the level sensor (202), the tilt sensor (410), the resistor (406), and the voltage sense terminal (412); process the signals and the volumetric look-up table (414) to measure the fuel consumption (416) of the machine (100) by compensating errors caused by inclinations and irregular tank geometries (3D); and communicate the fuel consumption (416) to the display (418).

Inventors

ASHOKKUMAR, Kalaivani
THEKKEVAVANOOR, Swaran
GOMADAM, Sreekanth C.
SHERIFF, Omar

Assignees

Caterpillar, Inc.

Dates

Publication Date: 20260506
Application Date: 20240517

Claims (1)

Claims 1. A system (400) for measuring fuel consumption ( 16) and compensating errors in measurements of a fuel (200) consumed by a prime mover (106) from a tank (110) in a machine (100), the system (400) comprising: an electrical circuit (408); a level sensor (202) in the tank electrically connected to the electrical circuit (408), the level sensor (202) is configured to output a fuel level (204) signal indicative of a fuel level (204) in the tank (110); a gauge (404) electrically connected to the electrical circuit (408) and in communication with the level sensor (202), the gauge (404) is configured to display (418) the fuel level (204) in the tank; a resistor (406) electrically connected to the electrical circuit (408); a tilt sensor (410) on the machine (100) configured to output a tilt signal indicative of inclination (500) angles of the machine (100) on an inclination (500); a voltage sense terminal (412) electrically connected to an alternator (107), the voltage sense terminal (412) is configured to output a voltage signal indicative of a system (400) voltage of the machine (100); a controller (402) connected to the electrical circuit (408) and in communication with the level sensor (202), the tilt sensor (410), the resistor (406), and the voltage sense terminal (412), the controller (402) is provided with a volumetric look-up table (414) having irregular tank (300) compensation data and the controller (402) is configured to: receive the fuel level (204) signal from the level sensor (202), the tilt signal from the tilt sensor (410), and the voltage signal from the voltage sense terminal (412); process the fuel level (204) signal, the tilt signal, the voltage signal, and the volumetric look-up table (414) to measure the fuel consumption communicate the fuel consumption (416) to the display (418). 2. The system (400) of claim 1, wherein the fuel consumption (416) includes at least one of: fuel consumption (416) rates, fuel (200) volume remaining in the tank (110), and low fuel (200) levels. 3. The system (400) of claim 2, wherein: the level sensor (202) is chosen from one of: a resistive-based float sensor, a voltage-based float sensor, a float switch, and a capacitive level sensor (202); the gauge (404) is an analog gauge (404); the resistor (406) is chosen from one of: a pull-up resistor (406), a metal film resistor (406), a carbon film resistor (406), a carbon film pull-up resistor (406), and a metal film pull-up resistor (406); the voltage sense terminal (412) is chosen from one of: a power supply terminal, a voltage test point, a voltage regulator feedback, an integrated electrical circuit (408) pin, a voltage sense pin, a reference pin, and an alternator (107) R-terminal; and the tilt sensor (410) is chosen from one of: an inclinometer, a gradient sensor, a microelectromechanical inclinometer, an electrolytic tilt sensor (410), and a potentiometric inclinometers. 4. The system (400) of claim 3, wherein the fuel level (204) signal communicates a resistance value indicative of the fuel level (204) to the resistor (406), the resistor (406) is configured to convert the resistance value into a voltage value, and the resistor (406) communicates the voltage value to the controller (402) via a resistor (406) signal. 5. The system (400) of claim 3, wherein the resistor (406) is supplied by +5V from the controller (402). 6. The system (400) of claim 4, wherein: the irregular tank (300) compensation data includes a plurality of reference tanks having irregular tank geometries (3D) with at least one reference tank corresponding to the tank (110) in the machine (100), each reference tank including a plurality of volumetric analysis data for a plurality of fuel (200) levels in each reference tank from an empty condition to a full condition for a plurality of inclinations of the reference tank, the irregular tank (300) compensation data corresponds to values of the voltage value and the fuel (200) volume remaining; and the controller (402) is configured to: determine a geometry and a volume capacity of the tank (110); process the fuel level (204) signal, the resistor (406) signal, the tilt signal, the voltage signal to calculate the fuel consumption (416) of the machine (100); and compensate for measurement errors in the measurements of the fuel consumption (416) using the irregular tank (300) compensation data for changes in the fuel level (204) in the tank (110). 7. The system (400) of claim 3, wherein the tilt sensor (410) is mounted on a chassis of the machine (100). 8. The system (400) of claim 3, further comprising a telematics system (400) in communication with the controller (402), the telematics system (400) is configured to utilize a GPS technology and a wireless communication system (400) to track and report location, a speed, and the fuel consumption (416) data in real time of the machine (100). 9. A machine (100) compri sing : a tank (110); a fuel (200) in the tank (110); a prime mover (106) configured to consume the fuel (200) from the tank (110); the system (400) of claim 1. 10. The machine (100) of claim 9, the machine (100) further comprises a relay in communication with the controller (402), the controller (402) configured to activate and deactivate the machine (100) for a plurality of interval times. 11. A method for calculating fuel consumption (800) and compensating errors in measurements of fuel (200) consumed by a prime mover (106) from a tank (110) in a machine (100), the method comprising: activating the prime mover (106) of the machine (100); receiving a fuel level (204) signal indicative of a fuel level (204) in the tank (110), via a level sensor (202) in the tank (110), and sending the fuel level (204) signal to a controller (402) in communication with the level sensor (202); receiving a resistance value from the level sensor (202), via a resistor (406), the resistor (406) configured to convert the resistance value into a voltage value, and communicating a resistor (406) signal indicative of the voltage value to the controller (402) in communication with the resistor (406); receiving a voltage signal indicative of system (400) voltage of the machine (100), via a voltage sense terminal (412) connected to an alternator (107) of the prime mover (106), and sending the voltage signal to the controller (402); receiving a tilt signal indicative of an inclination (500) of the machine (100), via a tilt sensor (410) on the machine (100), and sending the tilt signal to the controller (402) in communication with the tilt sensor (410); processing the fuel level (204) signal, the resistor (406) signal, the voltage signal, the tilt signal, and a volumetric look-up table (414) having irregular tank (300) compensation data, via the controller (402), to calculate a fuel consumption (416) of the machine (100), and sending measurements of fuel consumption (416) to display (418) in communication with the controller (402); and displaying the measurements of the fuel consumption (416) on the display (418). 12. The method of claim 11, wherein the irregular tank (300) compensation data includes a plurality of reference tanks having irregular tank geometries (3D) with at least one reference tank corresponding to the tank (110) in the machine (100), each reference tank including a plurality of volumetric analysis data for a plurality of fuel (200) levels in each reference tank from an empty condition to a full condition at a plurality of inclinations, the plurality of volumetric analysis data provide corresponding values from the plurality of reference tanks to the voltage value of the resistor (406) indicative of a fuel (200) volume percentage remaining in the tank (110). 13. The method of claim 12, further comprising: tracking a location, a speed, and the fuel consumption (416) of the machine (100) via a telematics system (400) in communication with the controller (402), the telematics system (400) is configured to utilize a GPS technology system (400) and a wireless communication system (400); and reporting the location, the speed, and the measurements of the fuel consumption (416) of the machine (100) to a back-office system.

Description

Description SYSTEM AND METHOD FOR MEASURING, AND COMPENSATING ERRORS IN MEASUREMENTS OF, FUEL CONSUMPTION Technical Field The present disclosure relates to a system for measuring fuel consumption, and more particularly relates to a system for measuring fuel consumption and compensating errors in the measurement of fuel consumption. Background Machines such as excavators, trucks, generator sets and other types of mobile or stationary machines known in the art have fuel tanks for storing fuel, for example, gasoline or diesel. The fuel stored in these fuel tanks may be routed via fuel lines and supplied to prime movers for combustion and powering any operations associated with the machine. In some cases, these machines may operate while being stationary, for example, on a horizontal or an inclined surface. In other cases, these machines may need to operate while moving, for example, on a horizontal or an inclined surface. Regardless of the operating condition, it may be prudent to monitor fuel consumption over time to efficiently manage fuel consumption and plan refueling accordingly. Determining dynamically changing rates of fuel consumption and volumes of fuel remnant in fuel tanks of machines continues to remain challenging owing to a variety of factors as both mobile and stationary machines are often operated under different operating conditions such as loads, terrains, surface gradients and inclinations, and under different environmental conditions such as temperature and humidity that can significantly affect fuel consumption rates making fuel consumption measurements difficult. Conventional fuel gauges alone are incapable of providing precise measurements, thereby leading to errors in determining the volume of fuel remnant in the tank. Moreover, as fuel sloshes around in a tank due to machine or implement movement, inaccuracies are introduced into the readings output by conventional designs and setups of fuel sensors thus making it difficult to determine the exact amount of fuel remnant in the tank. Moreover, irregularly shaped tanks for example, irregular polyhedrons designed to confirm with any space constraints of the machine can impart complexity to fuel consumption measurements and calculations of fuel remaining by making it harder to accurately measure the volume of fuel remnant in the irregularly shaped tank. Additionally, irregular tank geometries can cause fuel to slosh around inside the tank, which can further negatively affect the accuracy of fuel level sensors and gauges. As described herein, “irregular tank geometries” refers to fuel tanks that have a non-standard shape or structure, which may include complex curves, varying widths, or irregular surfaces. These unconventional geometries make it difficult to accurately measure the volume of fuel in the tank regardless of whether the machine is stationary or moving, leading to errors in measuring fuel consumption and the fuel remaining in the tank. Therefore, accurate systems for measuring fuel consumption are necessary to provide precise fuel consumption and remaining fuel calculations. Others have attempted to develop systems for measuring fuel consumption of fuel stored in tanks with irregular geometries. For example, Korean Application KR 20160120021 (hereinafter referred to as “the ’021 reference”) discloses a fuel tank system for calculating fuel consumption having a tank body, a detection unit, and a calculation unit. However, the ’021 reference discloses that the fuel tank system measures fuel consumption in a tank body that is formed in a rectangular parallelepiped shape and does not measure fuel, or compensate for errors in measurement of fuel, when fuel is stored in tanks having irregular geometries. The ’021 reference fails to provide a system for measuring fuel consumption that provides precise fuel consumption and calculations for fuel that is remnant in tanks having irregular geometries. Hence, there exists a need for a system for measuring fuel consumption that accurately measures the dynamically changing rate of fuel consumption and calculates an exact volume of fuel remnant in fuel tanks, esp. when the tank has an irregular shape, for efficient fuel consumption monitoring and subsequent planning of a refueling routine for the tank present on the machine. Summary In accordance with one aspect of the disclosure, a system for measuring fuel consumption of a fuel consumed by a prime mover from a tank in a machine is disclosed. The system comprises: an electrical circuit; a level sensor in the tank electrically connected to the electrical circuit, the level sensor is configured to output a fuel level signal indicative of a fuel level in the tank; a gauge electrically connected to the electrical circuit and in communication with the level sensor, the gauge is configured to display the fuel level in the tank; a resistor electrically connected to the electrical circuit; a tilt sensor on the machine configured to output a tilt si