AU2018100195A4 - System, method, and apparatus for monitoring a plurality of tanks - Google Patents

Abstract

A device for monitoring a multi-tank fluid supply arrangement including a manifold and/or regulator in fluid communication with an outlet and a plurality of tanks, the manifold and/or regulator comprising a switch for determining which of the plurality of tanks acts as a supply tank for the outlet., the device including a housing containing at least one processor in wired and/or wireless communication with at least two pressure sensors adapted to be placed in-line with the flow of fluid from each of the plurality of tanks into the regulator; wherein the at least one processor is configured to determine, based on data received from the at least two pressure sensors, information regarding whether the pressure in at least one of the plurality of tanks has fallen below a predetermined threshold and to generate an indication thereof.

Description

SYSTEM, METHOD, AND APPARATUS FOR MONITORING A FLUID SUPPLY ARRANGEMENT INCLUDING AT LEAST ONE TANK

BACKGROUND OF THE INVENTION

Field of the Invention [0001] The invention relates generally to the monitoring of fluid supply systems and, more specifically, to a system, method, and apparatus for monitoring one or more multi-tank fluid supply arrangements and/or one or more fluid supply arrangements comprising at least one tank. Description of Related Art [0002] Fluids, in a liquid phase, gaseous phase, or combination thereof are often stored in tanks or containers. The fluids may be pressurized or at atmospheric pressure.

[0003] In some cases, for example, in many commonly used propane tanks, fluids are stored in such a way that the fluids are in liquid form but evaporate into gaseous form. The evaporation creates a head pressure in the portion of the tank not occupied by liquid fluid. The fluid is then let out of the tank in gaseous form through a pressure regulator or valve. However, due to the multiphase nature of the fluid stored in these tanks, it can be difficult to determine the amount of fluid remaining in them even if the size of the tanks is known in advance.

[0004] In order to alleviate this issue, a multi-tank arrangement may be provided in which two or more tanks may be connected via a manifold or switching regulator. When a certain condition is met, such as when a certain pressure is reached within one of the tanks or when a user manually adjusts one or more valves, the manifold or switching regulator will switch from which tank the fluid is being drawn.

[0005] However, in such systems, particularly when large numbers of multi-tank arrangements are in use, it is often difficult for a supplier or user to accurately monitor the amount of fluid in such multi-tank arrangements.

[0006] Accordingly, there is a need in the art for improved systems which may allow for more accurate predictions of when one or more of the tanks in the system requires refilling or replacement or when the arrangement as a whole is soon to be empty. Further, there is a need in the art for improved systems for accomplishing this task inexpensively across multiple disparate locations while minimizing the required hardware changes to existing systems.

[0007] Additionally, in some applications, particularly where a constant supply of fluid is not critical, a single tank may be sufficient to fulfill the needs of a given fluid supply system, or, in some cases, only one tank may be connected to the fluid supply system at a time. Accordingly, there is also a need in the art for improved systems for more accurate predictions of when a single tank requires refilling or replacement or is soon to be empty. Further, there is a need in the art for improved systems for accomplishing this task inexpensively across multiple disparate locations while minimizing the required hardware changes to existing systems.

SUMMARY OF THE INVENTION

[0008] Accordingly, it is an object of the invention to provide a system, method, and apparatus for monitoring one or more multi-tank fluid supply arrangements and for providing an indication regarding an amount of the fluid remaining in the arrangement.

[0009] In various aspects, a device may be provided for monitoring an arrangement including two or more tanks that are filled with both liquid and gaseous phase fluid. The tanks may be connected to a manifold, or switching regulator. This manifold or switching regulator switches from which tank fluid is drawn. This switching may either be effected manually or be effected automatically when certain criteria are met, i.e., a pressure in one or more of the tanks falls below or rises above a threshold.

[0010] The manifold or switching regulator may be configured to switch from one tank that is empty or almost empty to another tank when the pressure in the empty or nearly empty tank crosses a certain threshold, for example, via a mechanical switch inside of the regulator that is triggered when the pressure in one of the tanks falls below a certain level. This threshold is crossed because, as fluid leaves the tank, eventually there will be no liquid phase fluid left in the tank, and only gaseous phase fluid will remain. Once this occurs and as fluid continues to be drawn from the tank, the pressure inside of the tank will drop.

[0011] In various aspects of the present disclosure, provided is a device that can detect when a pressure threshold has been crossed and, therefore, approximate when the manifold or switching regulator has been switched from one tank to another. The tank that was switched from can now be considered empty and in need of replacement. The presently disclosed device then may provide an indication based on the detection of a pressure threshold having been crossed. The indication can be used to plan refills and deliveries for the empty tank.

[0012] In accordance with various aspects of the present disclosure, the device may detect a pressure threshold being crossed in any of the tanks by adding pressure sensors in-line with the flow of fluid from the tanks into the manifold or switching regulator. When a pressure within one of the tanks crosses the pressure threshold, the pressure sensor for that tank is triggered and the device provides an indication. The pressure sensors could be a variety of sensor types including, but not limited to, pressure transducers, pressure switches, and devices that provide a pressure reading over a discrete or continuous pressure range. In one non-limiting embodiment, in order to reduce costs, the pressure sensor may be a switch that is activated or deactivated when the pressure of the associated tank falls below a threshold, and which does not otherwise measure the pressure in the tank.

[0013] In various aspects, this allows for existing multi-tank arrangements to be monitored without the need for modifying or replacing the regulator or manifold, which may be expensive, labor intensive, or otherwise undesirable.

[0014] Additionally, it is an object of the invention to provide a system, method, and apparatus for monitoring one or more fluid supply arrangements containing at least one tank and for providing an indication regarding an amount of the fluid remaining in the arrangement.

[0015] Additionally, provided is a device that can detect when a pressure threshold has been crossed in a single tank of a fluid supply arrangement and which may provide an indication based on the detection of a pressure threshold having been crossed that the tank is or will soon be in need of replacement. The indication can be used to plan refills and deliveries for the empty tank.

[0016] In some non-limiting aspects of the invention, the device may be adapted to conform with various safety requirements such as, but not limited to, being sealed or being explosion proof. This can be achieved a number of ways depending on the specific safety requirements including, but not limited to, gaskets, sealing gels, glues, and appropriate components and connectors. In various aspects, the device may be powered by batteries, rechargeable batteries, solar power, wind power, or any combination thereof.

[0017] The present invention further includes the subject matter of the following numbered clauses: [0018] Clause 1: A device for monitoring a multi-tank fluid supply arrangement comprising a manifold and/or regulator in fluid communication with an outlet and a plurality of tanks, the manifold and/or regulator comprising a switch for determining which of the plurality of tanks acts as a supply tank for the outlet by allowing fluid to flow from one or more of the plurality of tanks to the outlet and preventing fluid from flowing from the remaining plurality of tanks from flowing to the outlet, the device comprising: (i) a housing containing at least one processor in wired and/or wireless communication with at least two pressure sensors adapted to be placed inline with the flow of fluid from each of the plurality of tanks into the regulator; (ii) wherein the at least one processor is configured to determine, based on data received from the at least two pressure sensors, information regarding whether the pressure in at least one of the plurality of tanks has fallen below a predetermined threshold and to generate an indication thereof.

[0019] Clause 2: The device according to clause 1, wherein the at least one processor is further configured or programmed to determine a head pressure of at least one of the plurality of tanks, based on data received from at least one of the at least two pressure sensors.

[0020] Clause 3: The device according to any of the preceding clauses, wherein the at least one processor is further configured or programmed to determine whether a tank is attached to the manifold and/or regulator based on data received from the pressure sensor.

[0021] Clause 4: The device according to any of the preceding clauses, further comprising at least one tank sensor in communication with the at least one processor, the at least one processor being further configured or programmed to generate an indication regarding how many or which of the plurality of tanks are connected to the manifold and/or regulator based on data received from the at least one tank sensor.

[0022] Clause 5: The device according to clause 4, wherein the at least one tank sensor comprises a tactile sensor, a visual sensor, a magnetic sensor, or any combination thereof.

[0023] Clause 6: The device according to any of the preceding clauses, further comprising at least one power source comprising at least one of the following: a battery, a rechargeable battery, a solar panel, a wind turbine, or any combination thereof, wherein the at least one power source is arranged to power the device.

[0024] Clause 7: The device according to any of the preceding clauses, wherein the at least one processor is further configured or programmed to periodically or continuously generate the indication that the pressure in one of the plurality of tanks has fallen below a predetermined threshold until the one of the plurality of tanks is refilled or replaced.

[0025] Clause 8: The device according to any of the preceding clauses, wherein the indication comprises at least one of the following: a visual representation on a display device or graphical user interface, a change in an appearance of a warning light, an audible alarm, an electronically generated voice, a release of a scented gas, an electronic alert, an electronic signal, or any combination thereof.

[0026] Clause 9: The device according to any of the preceding clauses, wherein the at least one processor is further configured to communicate the indication to a remote system or device comprising a software application configured to plan or predict supply chain events, capital expenses, and/or delivery routes to customers based at least partially on the generated indication.

[0027] Clause 10: The device according to any of the preceding clauses, wherein the indication further comprises information regarding at least one of the following: whether one or more of the plurality of tanks is empty or close to empty, which of the plurality of tanks is empty or close to empty, which of the plurality of tanks is acting as a supply tank, an amount of time that has passed since one or more of the plurality of tanks has been replaced, a consumption rate, a consumption rate history, an estimated time remaining before one or more of the plurality of tanks will need to be replaced, or any combination thereof.

[0028] Clause 11: A method for monitoring a previously existing multi-tank fluid supply arrangement comprising a manifold and/or regulator in fluid communication with an outlet and a plurality of tanks, the manifold and/or regulator comprising a switch for determining which of the plurality of tanks acts as a supply tank for the outlet by allowing fluid to flow from one of the plurality of tanks to the outlet and preventing fluid from the remaining plurality of tanks from flowing to the outlet, the method comprising: (i) placing at least two pressure sensors in communication with the at least one processor in-line with the flow of fluid from each of the plurality of tanks into the manifold and/or regulator; (ii) determining, using the at least one processor and based on data received from the at least two pressure sensors, a head pressure of each of the plurality of tanks; and (iii) generating, based on the determined head pressures, an indication comprising information regarding whether the pressure in at least one of the plurality of tanks has fallen below a predetermined threshold.

[0029] Clause 12: The method according to clause 11, further comprising: communicating, using the at least one processor, the indication to a remote system or device comprising a software application configured to plan or predict supply chain events, capital expenses, and/or delivery routes to customers based at least partially on the generated indication.

[0030] Clause 13: A system for monitoring a plurality of multi-tank fluid supply arrangements, each of the multi-tank fluid supply arrangements comprising a manifold and/or regulator in fluid communication with an outlet and a plurality of tanks, the manifold and/or regulator comprising a switch for determining which of the plurality of tanks acts as a supply tank for the outlet by allowing fluid to flow from one of the plurality of tanks to the outlet and preventing fluid from flowing from the remaining plurality of tanks to the outlet, the system comprising: (i) a plurality of monitoring devices, each monitoring device being arranged to monitor one of the plurality of multi-tank fluid supply arrangements, each monitoring device comprising: (i) a housing containing at least one processor in communication with the at least two pressure sensors adapted to be placed in-line with the flow of fluid from each of the plurality of tanks of the respective multi-tank fluid supply arrangement into the manifold and/or regulator thereof; (ii) wherein the at least one processor is configured to determine, based on data received from the at least two pressure sensors, information regarding whether the pressure in at least one of the plurality of tanks of the respective multi-tank fluid supply arrangement has fallen below a predetermined threshold; and (iii) generate based on the determined head pressures, an indication comprising the information regarding whether the pressure in at least one of the plurality of tanks of the respective multi-tank fluid supply arrangement has fallen below a predetermined threshold and information regarding which of the plurality of multi-tank fluid supply arrangements to which the indication pertains.

[0031] Clause 14: The system according to clause 13, wherein the at least one processor is further configured or programmed to determine a head pressure of at least one of the plurality of tanks of the respective multi-tank fluid supply arrangement, based on data received from at least one of the at least two pressure sensors.

[0032] Clause 15: The system according to clause 13 or 14, wherein the information regarding which of the plurality of multi-tank fluid supply arrangements to which the indication comprises at least one of the following: a tank volume, a tank fill level, a fluid type, a location identifier, geographic coordinates, a nearest supply location, or any combination thereof.

[0033] Clause 16: The system according to any of clauses 13-15, wherein the indication is communicated to a remote system or device comprising a software application configured to plan or predict supply chain events, capital expenses, and/or delivery routes to customers based at least partially on the generated indication.

[0034] Clause 17: The system according to any of clauses 13-16, wherein the indication comprises a visual representation of a location of the pertinent multi-fluid supply arrangement displayed on a graphical user interface.

[0035] Clause 18: A device for monitoring a fluid supply arrangement comprising a manifold and/or regulator in fluid communication with at least one tank, the device comprising: (i) a housing containing at least one processor in wired and/or wireless communication with at least one pressure sensor adapted to be placed in-line with the flow of fluid from the at least one tank into the manifold and/or regulator; (ii) wherein the at least one processor is configured to determine, based on data received from the at least one pressure sensor, information regarding whether the pressure in the tank is above or below a predetermined threshold and to generate an indication thereof.

[0036] Clause 19: A device for monitoring a fluid supply arrangement comprising at least one tank, and a manifold and/or regulator in fluid communication with an outlet of the at least one tank, the device comprising: (i) a housing containing at least one processor in communication with at least one pressure sensor adapted to be placed in-line with the flow of fluid from one of the at least one tank into the manifold and/or regulator thereof; (ii) wherein the at least one processor is configured to determine, based on data received from the at least one pressure sensor, information regarding whether the pressure at least one tank of the fluid supply arrangement has fallen below a predetermined threshold; and (iii) generate, based on data received from the at least one pressure sensor, an indication comprising the information regarding whether the pressure in at least one tank of the monitored fluid supply arrangement has fallen below a predetermined threshold; wherein the at least one processor is further configured to communicate the indication to a remote system or device comprising a software application configured to plan or predict supply chain events, capital expenses, and/or delivery routes to customers based at least partially on the generated indication; and wherein the indication further comprises information regarding at least one of the following: whether one of the at least one tank is empty or close to empty, which of the at least one tank is empty or close to empty, which of the at least one tank is acting as a supply tank in the monitored fluid supply arrangement, an amount of time that has passed since one or more of the at least one tank has been replaced, a consumption rate, a consumption rate history, an estimated time remaining before one or more of the at least one tank will need to be replaced, or any combination thereof.

[0037] These and other features and characteristics of the present invention, as well as the methods of operation and functions of the related elements of structures and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention. As used in the specification and the claims, the singular form of “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise.

BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 is an exploded view of a monitoring device in accordance with a non-limiting embodiment of the invention, and also contains a collapsed view of this non-limiting embodiment in the top right corner.

[0039] Figure 2 is an assembly view of a monitoring device attached to two tanks in accordance with a non-limiting embodiment of the invention.

DESCRIPTION OF THE INVENTION

[0040] For purposes of the description herein, the terms “end”, “upper”, “lower”, “right”, “left”, “vertical”, “horizontal”, “top”, “bottom”, “lateral”, “longitudinal”, and derivatives thereof shall relate to the invention as it is oriented in the drawing figures. However, it is to be understood that the invention may assume various alternative variations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary configurations of the invention. Hence, specific dimensions and other physical characteristics related to the configurations disclosed herein are not to be considered as limiting.

[0041] As used herein, the terms “communication” and “communicate” refer to the receipt or transfer of one or more signals, messages, commands, or other type of data. For one unit or component to be in communication with another unit or component means that the one unit or component is able to directly or indirectly receive data from and/or transmit data to the other unit or component. This can refer to a direct or indirect connection that may be wired and/or wireless in nature. Additionally, two units or components may be in communication with each other even though the data transmitted may be modified, processed, and/or routed between the first and second unit or component. For example, a first unit may be in communication with a second unit even though the first unit passively receives data, and does not actively transmit data to the second unit. As another example, a first unit may be in communication with a second unit if one or more intermediary units processes data from one unit and transmits processed data to the second unit. It will be appreciated that numerous other arrangements are possible.

[0042] As used herein, the term indication refers to any conveyance of information which can be perceived by the human senses and/or by a processor or other electronic device in communication with the system whether or not such conveyance of information may also be perceived by a human being. In non-limiting, illustrative examples, an indication may be a signal that can be perceived by sight, hearing, touch, smell, and/or taste. In further non-limiting examples, an indication may be an electronic signal sent to a processor or other electronic device in communication with the system. An indication may also be, for example, data displayed on an interface such as a graphical user interface. In non-limiting embodiments, an electronic device may be configured to perform an action in response to or otherwise based on the receipt of the indication (or lack thereof), or based on information conveyed as part of the indication.

[0043] Figure 1: Figure 1 is an exploded view of a device in accordance with non-limiting embodiment of the invention, and also contains a collapsed view of this exemplary device in the top right comer. The device has a housing 103 with lid 108 and sealing gasket 107. The housing 103, lid 108, and sealing gasket 107 are held together by attachment hardware 109. Inside of the housing are circuit board 104 with components 106, battery holder 105, and communication equipment 111. The battery holder 105 is attached to the circuit board 104 via attachment hardware 110. Entering the housing is an antenna 101 which connects to the communication equipment 111. Also entering the housing are connectors 112 which electrically connect to pressure sensors that are not shown in this drawing. There are also connectors 102 which connect to connectors 112 through the wall of housing 103. Connectors 102 are then electrically connected to circuit board 104.

[0044] Figure 2: Figure 2 is an assembly view of the device of Figure 1 attached to two tanks in accordance with a non-limiting embodiment of the invention. The assembly has device 207, which is the same as the device shown in Figure 1. There are two tanks 201 and 216 which each have valves 202 and 215, respectively. Coming from valves 202 and 215 are pigtail connectors 203 and 214. Pigtail connectors 203 and 214 each connect into T-fittings 204 and 213. Connected to T fittings 204 and 213 are pressure sensors 205 and 211. Pressure sensors 205 and 211 are connected to device 207 by connectors 206 and 209. Device 207 has an antenna 208. Also connected to T-fittings 204 and 213 are additional pigtail connectors which connect to switching regulator or manifold 210. Switching regulator or manifold 210 has an outlet 212.

[0045] In a non-limiting example, the pressure threshold, which triggers a response from the monitoring device, may be set somewhere between the normal operating pressure of a cylinder when it has liquid and the highest pressure at which a regulator would initiate a switch over. For example, if the normal operating pressure of a cylinder is l,300kPa, and the highest pressure at which any regulator would switch is 800kPa, the system can be set to trigger at 750kPa or in a similar range, such that, a reading is obtained only when the regulator has actually switched. In another non-limiting example, the device may trigger whenever the pressure in the cylinder drops below 103kPa and turn off when the pressure rises above 206kPa. Of course, depending on the application, various pressure thresholds can be used in accordance with the principles of the present invention.

[0046] In single tank arrangements, the non-limiting embodiments of the present invention may operate similarly to the above, although, in such embodiments, only one pressure sensor is needed and there is no need to account for switching between tanks. In such cases, the monitoring device may communicate an indication upon determining that the head pressure in a single tank has fallen below a threshold.

[0047] Although the invention has been described in detail for the purpose of illustration based on what is currently considered to be the most practical and preferred embodiments, it is to be understood that such detail is solely for that purpose and that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims. For example, it is to be understood that the present invention contemplates that, to the extent possible, one or more features of any embodiment can be combined with one or more features of any other embodiment.

Claims (5)

1. A device for monitoring a multi-tank fluid supply arrangement comprising a manifold and/or regulator in fluid communication with an outlet and a plurality of tanks, the manifold and/or regulator comprising a switch for determining which of the plurality of tanks acts as a supply tank for the outlet by allowing fluid to flow from one or more of the plurality of tanks to the outlet and preventing fluid from flowing from the remaining plurality of tanks from flowing to the outlet, the device comprising: a housing containing at least one processor in wired and/or wireless communication with at least two pressure sensors adapted to be placed in-line with the flow of fluid from each of the plurality of tanks into the regulator; wherein the at least one processor is configured to determine, based on data received from the at least two pressure sensors, information regarding whether the pressure in at least one of the plurality of tanks has fallen below a predetermined threshold and to generate an indication thereof.

2. The device according to claim 1, wherein the at least one processor is further configured or programmed to periodically or continuously generate the indication that the pressure in one of the plurality of tanks has fallen below a predetermined threshold until the one of the plurality of tanks is refilled or replaced; wherein the indication comprises at least one of the following: a visual representation on a display device or graphical user interface, a change in an appearance of a warning light, an audible alarm, an electronically generated voice, a release of a scented gas, an electronic alert, an electronic signal, or any combination thereof.

3. The device according to any of the preceding claims, wherein the at least one processor is further configured to communicate the indication to a remote system or device comprising a software application configured to plan or predict supply chain events, capital expenses, and/or delivery routes to customers based at least partially on the generated indication; wherein the indication further comprises information regarding at least one of the following: whether one or more of the plurality of tanks is empty or close to empty, which of the plurality of tanks is empty or close to empty, which of the plurality of tanks is acting as a supply tank, an amount of time that has passed since one or more of the plurality of tanks has been replaced, a consumption rate, a consumption rate history, an estimated time remaining before one or more of the plurality of tanks will need to be replaced, or any combination thereof.

4. A system for monitoring a plurality of multi-tank fluid supply arrangements, each of the multi-tank fluid supply arrangements comprising a manifold and/or regulator in fluid communication with an outlet and a plurality of tanks, the manifold and/or regulator comprising a switch for determining which of the plurality of tanks acts as a supply tank for the outlet by allowing fluid to flow from one of the plurality of tanks to the outlet and preventing fluid from flowing from the remaining plurality of tanks to the outlet, the system comprising: a plurality of monitoring devices, each monitoring device being arranged to monitor one of the plurality of multi-tank fluid supply arrangements, each monitoring device comprising: a housing containing at least one processor in communication with the at least two pressure sensors adapted to be placed in-line with the flow of fluid from each of the plurality of tanks of the respective multi-tank fluid supply arrangement into the manifold and/or regulator thereof; wherein the at least one processor is configured to determine, based on data received from the at least two pressure sensors, information regarding whether the pressure in at least one of the plurality of tanks of the respective multi-tank fluid supply arrangement has fallen below a predetermined threshold; and generate, based on data received from the at least two pressure sensors, an indication comprising the information regarding whether the pressure in at least one of the plurality of tanks of the respective multi-tank fluid supply arrangement has fallen below a predetermined threshold and information regarding which of the plurality of multi-tank fluid supply arrangements to which the indication pertains.

5. A device for monitoring a fluid supply arrangement comprising at least one tank, and a manifold and/or regulator in fluid communication with an outlet of the at least one tank, the device comprising: a housing containing at least one processor in communication with at least one pressure sensor adapted to be placed in-line with the flow of fluid from one of the at least one tank into the manifold and/or regulator thereof; wherein the at least one processor is configured to determine, based on data received from the at least one pressure sensor, information regarding whether the pressure at least one tank of the fluid supply arrangement has fallen below a predetermined threshold; and generate, based on data received from the at least one pressure sensor, an indication comprising the information regarding whether the pressure in at least one tank of the monitored fluid supply arrangement has fallen below a predetermined threshold; wherein the at least one processor is further configured to communicate the indication to a remote system or device comprising a software application configured to plan or predict supply chain events, capital expenses, and/or delivery routes to customers based at least partially on the generated indication; and wherein the indication further comprises information regarding at least one of the following: whether one of the at least one tank is empty or close to empty, which of the at least one tank is empty or close to empty, which of the at least one tank is acting as a supply tank in the monitored fluid supply arrangement, an amount of time that has passed since one or more of the at least one tank has been replaced, a consumption rate, a consumption rate history, an estimated time remaining before one or more of the at least one tank will need to be replaced, or any combination thereof.