Internal combustion engines fueled by liquid diesel or gasoline are used in a variety of mobile and stationary applications. In many of these, it is desirable to monitor the fuel level at any given time to ensure that an ample supply is always present. Current state of the art sensors include those operating on sensing the positions of floats, sensors using ultrasonic techniques to gage the fuel level, and sensors using capacitive techniques to infer the fuel level. It is to this last type that the herein disclosed systems and methods are related to.
Capacitive fuel sensors work on the principle that the dielectric constant of fuel is markedly different from that of air (approximately twice as big). Such sensors are constructed such that two conductors (the plates of a capacitor) are inserted in the fuel from the top of the tank. For the part of the conductors that is submerged in the fuel, the dielectric will be the fuel; for the part remaining, the dielectric will be air. The total capacitance will be the algebraic sum of the capacitances for each section:
C
total
=C
fuel
+C
air (1)
For a parallel plate capacitor, the capacitance is proportional to the dielectric constant of the insulating medium between the plates and the height of that medium:
where:
ε0 is the dielectric constant of a vacuum (8.854×10−12 F/m)
εr is the relative dielectric constant of the insulating substance (unitless)
W is the width of the parallel plates
h is the height of the parallel plates
d is the distance between the parallel plates
If the geometry (w, d) is constant, Equation 2 reduces to:
Cparallel∝εrh (3)
For a cylindrical capacitor, the capacitance is also proportional to the dielectric constant of the insulating medium and the height of that medium:
where:
ε0 is the dielectric constant of a vacuum (8.854×10−12 F/m)
εr is the relative dielectric constant of the insulating substance (unitless)
h is the height of the coaxial capacitor
b is the diameter of the outer cylinder
α is the diameter of the inner cylinder
If the geometry (b,a) is constant, Equation 4 reduces to:
Ccyl ∝ εrh (5)
Folding Equations (2) and (3) into (1) we see that:
Ctotal ∝ εr
Since the total height h of the sensor is known, (6) may be reduced to:
Ctotal ∝ εr
or
Ctotal ∝ εr
Since h and εr
Ctotal ∝ constant+hfuel(εr
Thus, if εr
However, the dielectric constant of the fuel is not always the same. Different additives, for example, can cause this value to change significantly. Other patents explain how to measure the dielectric constant of a sample of fuel and use this to infer its composition. For example, U.S. Pat. No. 7,800,379 by Hernandez et al. (“the '379 Patent”) describes a system by which the concentration of ethanol in a fuel sample is inferred by measuring the dielectric constant of a sample of the fuel. This patent shows a variability of nearly 4:1 in the dielectric constant of fuel to which ethanol has been added.
In an implementation, the case is about 3″ in diameter by about ½″ inch thick. The cylinders may be made from rigid tubing, from stiff springs such as compression springs, or other materials, without adversely affecting the operation of the disclosed sensors. The fuel level is reported to the outside world via an external connector 6. The reporting signal may be in the form of an analog voltage proportional to the fuel height, an analog current proportional to the fuel height, a digital signal conveying the height information, or the like, for example. It also may be a wireless signal conveyed by a wireless transmitter.
In operation, electronics 8 computes the capacitance between the inner and outer cylinders, and uses this in combination with an assumed fuel dielectric value to infer the fuel level as described above. One prior art implementation having the tube dimensions cited above shows a sensitivity of about 1.27 pf/in for diesel fuel.
The prior art capacitive sensors are subject to errors due to the variability of the dielectric constant of the fuel. The herein described systems and methods can compensate for these errors.
Accordingly, a self-calibrating liquid fuel level sensor is provided, comprising: a calibrator that determines a dielectric constant of a liquid fuel; a fuel depth capacitance sensor that determines a capacitance of an unknown depth of the fuel; and a processor that calculates a determined depth based on the unknown depth using the dielectric constant and the capacitance. The sensor may further comprise: a first conductive member that acts as a charge plate of a first capacitor; a second conductive member that is electrically isolated from the first conductor member that acts as a charge plate of a second capacitor ; and a third conductive member that acts as an opposite charge plate of the first capacitor and the second capacitor; wherein the calibrator comprises the first conductive member, the third conductive member, and elements for determining capacitance including a processor comprising algorithms.
Further, a method is provided for determining a level of fuel in a tank, comprising: determining a dielectric constant of fuel in a tank; measuring a capacitance of an unknown depth of the fuel in the tank; and calculating the depth using the dielectric constant and the capacitance.
The determining of the dielectric constant may comprise: providing a first conducting member that acts as a charge plate of a first capacitor; providing a second conductive member that is electrically isolated from the first conductor member that acts as a charge plate of a second capacitor; providing a third conductive member that acts as an opposite charge plate of the first capacitor and the second capacitor; completely submerging the first conducting member in the fuel; measuring a capacitance of the first capacitor; and calculating the dielectric constant based on the measured capacitance of the first capacitor.
As discussed above, the prior art utilizes the variability in the dielectric constant of fuel to infer the composition of the fuel. In contrast, the herein disclosed systems and methods use the variability of the dielectric constant of fuel in a fuel tank to accurately determine the fuel level in the tank.
As the analysis presented previously shows, a 4:1 change in the dielectric constant of a fuel sample would introduce a significant error in the reported height of the fuel. The present disclosure teaches systems and methods of compensating for the effect of dielectric constant change on the reported height of the fuel. It presents a novel capacitive fuel sensor design and an illustrative implementation with exemplary electronics and firmware. The novel design may be used to determine a more accurate reporting of the level of fuel in a tank than can be achieved using prior art capacitive fuel sensors.
In an exemplary embodiment shown in
For fuel levels 5 that do not completely submerge the entire bottom section 4.2 of the center cylinder 4, the system may use a default or previously calculated value for the dielectric constant of the fuel, and treats the two sections 4.1, 4.2 of the center cylinder 4 as if they were one, i.e., as if the system were built as in
A calibrator is used to determine the dielectric constant of the liquid fuel in the tank. In an embodiment, the calibrator uses the bottom section 4.2 and calculation algorithms associated with measured values related to the bottom section 4.2. For fuel levels 5 that do completely submerge the bottom section 4.2 of the center cylinder 4, the capacitance of the bottom section 4.2 is first determined. Since its length is known (1″ in this example), the dielectric constant of the fuel may be calculated. That dielectric constant may then be used to compute the length of the fuel column in which the top section 4.1 is immersed. In one embodiment, the two sections 4.1, 4.2 of the inner cylinder 4 are then electrically coupled together, and the newly calculated dielectric constant is then used to compute the fuel level 5.
The capacitances which are measured are shown schematically in
The capacitance values may be determined by any of several methods which will be known to one of ordinary skill in the pertinent art. In one method, a inductor of known inductance is placed in parallel with the capacitor of unknown capacitance, and the resonant frequency of the parallel inductor-capacitor network is measured. From this, the value of the unknown capacitor may be determined. Another method measures the charging (and/or discharging) time constant formed by charging (or discharging) the capacitor through a resistor of known resistance. This resistor-capacitor network may be incorporated in a free running multivibrator, in which case the oscillation period may be used to determine the unknown capacitor. Another implementation may involve timing the charging of the capacitor to a known threshold and using this to determine the capacitor's value. The systems and methods disclosed herein are not affected by the method used. For purposes of illustration, a resistor-capacitor network is presented below, and a generic control block is used for timing and thresholds.
Operation of this System
If it is desired to read the whole length of the sensor 1 (i.e., the capacitance of inner conductive cylinder 4) including both the top 4.1 and bottom 4.2 sections, switch 36 is put in its upper position. This puts the two sections 4.1, 4.2 of the sensor (and their respective capacitances C1 and C2) in parallel. The controller 34 in concert with switch 39 and comparator 38 may then compute the unknown value of (C1+C2).
Ascertaining the value of C1 cannot be done by just connecting the resistor 37 to it because the capacitance of the wire connecting C1 to the electronics through the upper section 4.2 of the inner cylinder 4 has a significant stray capacitance, C12, coupling C1 to the top of C2. In order to nullify this effect, switch 36 is moved to its lower position, causing buffer amplifier 35 to force the top of C2 to the same voltage as the top of C1. Consequently, the voltage across C12 is substantially zero, resulting in no significant current flowing through it regardless of its value, thereby removing its effect on the measurement of C1.
Thus, the value of either of C1 (the capacitance of the bottom section 4.2) or C1+C2 (the capacitance of the entire sensor 4) may be accurately read, depending on the position of switch 36.
Since the geometry of C1 is known, the dielectric constant of the fuel may be calculated from the capacitance of C1 alone, 44. This calculated fuel dielectric value is used in subsequent readings until a new one is calculated. The combined capacitance of C1+C2 is then measured 45, and the height of the fuel column in the sensor is then calculated using the most recently calculated fuel dielectric constant 46.
Capacitive sensors are especially susceptible to the presence of water in fuel because the electrical conductivity of water shorts out the small capacitance that is being read at C1. Because the density of water exceeds that of diesel fuel, if there is water in the fuel tank, it will accumulate at the bottom of the tank, where C1 is located. With a single section sensor such as in the prior art and shown in
The foregoing discussions relating to measuring C1 in the unmodified switch of
A flowchart using this modification is shown in
All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated as incorporated by reference and were set forth in its entirety herein.
For the purposes of promoting an understanding of the principles of the invention, reference has been made to the preferred embodiments illustrated in the drawings, and specific language has been used to describe these embodiments. However, no limitation of the scope of the invention is intended by this specific language, and the invention should be construed to encompass all embodiments that would normally occur to one of ordinary skill in the art.
The embodiments may be described in terms of functional block components and various processing steps. Such functional blocks may be realized by any number of components that perform the specified functions.
The particular implementations shown and described herein are illustrative examples of the invention and are not intended to otherwise limit the scope of the invention in any way. For the sake of brevity, conventional aspects of the systems (and components of the individual operating components of the systems) may not be described in detail. Furthermore, the connecting lines, or connectors shown in the various figures presented are intended to represent exemplary functional relationships and/or physical or logical couplings between the various elements. It should be noted that many alternative or additional functional relationships, physical connections or logical connections may be present in a practical device. Moreover, no item or component is essential to the practice of the invention unless the element is specifically described as “essential” or “critical”.
The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings. Expressions such as “at least one of,” when preceding a list of elements, modify the entire list of elements and do not modify the individual elements of the list.
The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) should be construed to cover both the singular and the plural. Furthermore, recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. Finally, the steps of all methods described herein are performable in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed.
The words “mechanism” and “element” are used herein generally and are not limited solely to mechanical embodiments. Numerous modifications and adaptations will be readily apparent to those skilled in this art without departing from the spirit and scope of the invention.
The present application claims the benefit of U.S. Provisional Application No. 61/616,148, filed Mar. 27, 2012, entitled, “Self Calibrating Capacitive Fuel Sensor”, herein incorporated by reference.
Number | Date | Country | |
---|---|---|---|
61616148 | Mar 2012 | US |