GB2489528A

GB2489528A - An automated liquid reagent dispensing system

Info

Publication number: GB2489528A
Application number: GB1105589.4A
Authority: GB
Inventors: Kathryn Jane Locke; Lindsay Phoenix Locke
Original assignee: WOODLAND GUARDIANS UK Ltd
Current assignee: WOODLAND GUARDIANS UK Ltd
Priority date: 2011-04-01
Filing date: 2011-04-01
Publication date: 2012-10-03
Also published as: GB201105589D0

Abstract

An automated liquid reagent dispensing system designed to accurately dose a fluid storage vessel 10 used by an internal combustion engine. Computer12A with installed software programs is activated by a trigger event caused by an independent filler cap sensor 2 and uses fluid level sensor 9 to measure an increase in level in the fluid storage vessel 10 to accurately calculate the required dose and deliver it by pump 11B from reagent reservoir11C. The reagent reservoir contains a level switch 11D that will trigger a low level alarm that is communicated to an operator via wireless technology 12D. The reagent dispensing system may be powered by an AC or DC electric power source 8 through the power controller 12B. Moisture sensitive components may be contained in a single (AA to CC) or in multiple (AA to BB & BB to CC) water and dust proof housings.

Description

Automated Dispenser/Dosing System for Any Fluid Additive/Catalyst: The use of additives/catalysts (referred to as the reagent' here in after) within the daily operations of most industries is common practice in one form or another.

Even though this invention can be used across all industries, for the purpose of this tender, we will focus on the internal combustion engine' system (referred to as the ICE here in after) industry.

In the past there have been several problematic dosing methods used, leading to inaccurate reagent delivery methods ranging from; * Manual dosing with a fluid container * Predefined decanting doser's made of plastic with a feeder tube * Gravity fed units integrated with a basic venturi feeder * "Automated" systems were by the reagent is dispensed in accordance to the volume of combustible fluid fuel added to the tank, using the same source as the combustion engine's on board systems * "Automated" systems where by the reagent is added to the tank through the application of a venturi system integrated into the return flow of fuel from the combustion chamber injectors to the tank.

Due to these inaccurate and inconsistent delivery methods of the past, the full potential of the reagent are never achieved and the reagent design specifications are thus not fulfilled. Through the invention of the Automated Dispenser/Dosing System for Any Fluid Additive/Catalyst' (referred to herein after as the "system"), this problem can be eliminated. This has been achieved through the designing of a system by integrating various electronic components, controlled by a central on board computer or microprocessor' (referred to as the OBC from this point onward) and software program.

The system is WO% self-sufficient and is not reliant on any one electric power source, which can alternate between any DC or AC electric power sourced either from an on-board source or an external source. The system does not require any other input from any other external source relating to the ICE industry systems or peripherals, in order to fulfil its dispensing capabilities or parameters.

The system whether contained as a single unit or multiple unites are all placed inside a watertight, dust proof housing with water proof, dust proof automatic atmospheric pressure compensating relief valve, preventing any pressure or vacuum occurrences within the containers housing the components, electronics or reagent reservoir.

The system has computer with software program which controls an independent cap sensor, Fluid Level Sensor (referred to as FLS from here on), pump and a reagent reservoircontaining a level switch that will trigger a low level alarm' in the event the reagent is running below a predefined capacity.

Through the application of the system, the incorrect and inconsistent dosing of fluid reagents is totally eliminated, thus achieving 100% of the reagent design potential. The system can be pre-calibrated to a variety of reagent ratio to applied liquids, depending on the specification issued by the manufacturer of the reagent.

The system can be post-calibrated or calibration adjustments can be effected through a hard line connection or wirelessly from anywhere in the world through the use of any form of wireless technology communication devise, ranging from 3G. GPS GPRS, RF, etc., making the system more versatile and adaptable to different industrial applications.

The system can be applied to any industry that sources a form of energy from the ICE or by the combustion of Liquid Fossil Fuel, with the added benefits associated from the introduction of the reagent such as; reduction of emissions, increase in power output, reduction of fuel consumption, etc., but not limited to; * Internal Combustion Engine (ICE) Industry * Medical, Agricultural and Science Industry * Food Industry The system features extremely accurate dosing capability, with consistent and uninterrupted dosing as and when required, through the sensing of the presence of an increase in fluid levels within any storage vessel' through the use of a FLS devise fitted either to the base of the storage vessel or placed inside the vessel or at the lowest point, submerged in the fluid. The system can also operate from manually inputting the added fluid amounts through a human interface devise' with a built in microprocessor with control unit and software with a basic feedback screen into its most core function of fluid input versus dosage output. This input value is translated to a dosing amount through pre calibration of the pump controller but retaining its level of dosing accuracy.

In the systems standard form/s (Ref to Figure 2 & 3); the system is triggered out of Standby Mode' to ON Mode' by the removal of the vessel inlet filler cap. The fluid level is immediately recorded by the FLS and the OBC calculates the difference in original starting fluid level versus the current fluid level in either predefined intervals or continuous measure. This information is interpreted by the software which records, calculates and sends instructions to the I/O interface board that instructs the pump via the controller to dose according to the calibrated settings, which in turn doses the storage vessel with the required amount of reagent. The dosing cycle is concluded with the vessel filler cap being replaced and the OBC software finalising the calculations.

The dosing is precise in that the pump is controlled independently to the point of per stroke' and not to a set time frame, thus eliminating the lag between instruction and power on/off triggers.

A number of drawings/sketches are attached for reference and further visual representation, they are as follows: Figure 1: Page 1 of 5 -Total Process Flow Chart This representation is a visual explanation of the core process and functionality of the entire system at full automation.

Figure 2: Page 2 of 5 -System Configuration Option A used for mobile and static environments This sketch is an example of the different possible arrangements depending on the application.

Figure 3: Page 3 of 5 -System Configuration Option B used for mobile and static environments This sketch is another example of the different possible arrangements depending on the application.

Figure 4: Page 4 of 5 -System Configuration Option C as it could be constructed in a hand held devise form -Semi Automatic System This sketch is another example of the different possible arrangements in the form of a hand held devise, were the OBC and software is minima lized to the point where the amount of fluid entering the storage vessel is manually entered via a hand held devise such as a keypad, PDA, panel PC or touch screen and the dosing requirements calculated by the OBC in the form of a microprocessor and use of the software.

Figure 5: Page 5 of 5 -Core function of Reference Numbers 11, 12 and 22 including software functionality This sketch is another example of the different possible arrangements depending on the application but through the scaling of the system to a Semi Automated unit, eliminating the use vessel filler cap sensor, fluid sensor and the reagent reservoir low level switch. This system is the most basic form of the invention and relies totally on the input figures from the operator.

Legend for easy interoretation of Ficiures 1 and 5: This symbol depicts the Reagent Reservoir out let to the pump This symbol pertains to the storage vessel This symbol signifies a function of the software that has been loaded to the OBC AA or These lines represent the most practical division of the electronics. It is not limited BB or to these points, but rather makes the system more practical. No division of any CC components is required to achieve the systems functionality.

This symbol represents any type of fluid sensor ranging from a weight based sensor, an ultrasonic level sensor, a sonic sensor or even a laser type level sensor, all mounted either to the external of the storage vessel or internally to the storage ______ vessel.

Figure 1 explains the process and flow of information and instruction from a trigger event'5, through to the dosing of the fluid storage vessel'0.

Dose cycle: * The system is activated with the removal of the storage vessel'0 filler cap.

This will be referred to as Trigger 1A. The cap sensor2 (capacitive sensor or trigger switch) registers that there is no longer a filler caplA in position, which in turn sends a signal through the controlleriM to the TO boardl2C.The JO board'2' translates the pulse (amps or volts) into computer code which the softwarel2E that has been installed on the OBCl2A, recognises as the trigger event 1A and starts all peripheral softwarel2E applications and calculations.

* All signals and instructions are received via the control board, through the JO board2C which translates the signal (volt or amps) into data for the softwarel2E installed on the OBC12A. In the same way the OBC2A softwarel2E sends the instruction through the JO boardl2C which changes the data to a signal (volt or amp) to the controller boardhiA which directs the corresponding signal to the relevant component. This process shall not be mentioned again, it shall simply be assumed to occur.

* The first action is an instruction sent to the FLS9 to take a reading of the fluid level in the storage vessel10. The sensor transmits the information to the OBC12A. The softwarel2E records the information as the starting fluid level in the storage vessel'0.

* There is a five litre delay before dosing commences. This allows for a top off cycle to be performed after the End Trigger Event lB is signalled by replacing the filler cap'5 onto the vessel filler neck. The pump118 is instructed to start pumping the reagent from the reagent reservoirhiC. The pump"5 is controlled in stroke signals thus gaining maximum dosing accuracy. This is achieved through calibrating the softwarel2E to the exact frequency of the pump"5 and gaining or lessening the frequency to match the pump"5 stoke' frequency.

* Once the filler cap15 is replaced onto the storage vessel'0 filler neck, the end' Trigger Event lB is signalled to the softwarel2E, which recognises the change in signal (change in volt or amp signal sent) and records the final level of the fluid in the storage vessel'0. A calculation based on ratio of reagent to fluid volume is finalized and the pump stroke cycle completed after Trigger Event lB.

Reagent Reservoir low stock warning: * The reagent reservoirlC fluid level can be monitored in several ways. For the purpose of this explanation we shall use the term: Low Level Trigger (LLT11D) which shall mean any of the following, but not limited to, reed switch, weight switch, pressure gauge, float level switch/meter, resistance float level meter, etc. * The LLT is positioned in accordance to the device manufacturer's instructions and the selected low level warning required by the operator.

* The LLT11D signals the OBC12A on reaching the predetermined stock low warning level, at which point the softwar&2E activates the communications port and transmits a predefined message in accordance with the system and operator preference using it. This message can be a text message, email, audible alarm or other form of warning as defined by the operator.

* The operator simply refills the reagent reservoir, which automatically resets the LLT1W devise.

OBC and Software explained: * There are five core processes within the software, namely o Pump Control * This portion of the softwarel2E interprets the fluid input and converts the information into number of pump strokes required to meet the reagent manufacturers design ratios.

o Storage Vessel'0 Fluid Level Interpretation * The FLS9 can either weigh the total volume of fluid or interpret the pressure via a probe mounted externally, internally or submerged in the fluid.

* The FLS9 is calibrated in two ways: Auto Calibration is achieved by systematically filling the storage vessel'0 with the desired fluid in pre-defined increments. The "Zero" or empty level is recorded by the softwarel2E as part of the system initiation in calibration mode and the initiation of the Trigger Event 1A. As the storage vessel'0 is filled, the softwarel2E records each pause as a level record. Once the storage vessel'0 is full, Trigger Event lB is used to close the calibration range. The softwarel2E now interprets the different calibration levels and interpolates the "void" levels between the incremental calibration fills. The FLS9 system is now ready for full activation.

The storage vessel'0 is measured accurately and entered into the softwareE program which lineate's the formula as volume proportional to height. The density of the fluid is defined and inserted into the software. The empty' and fuji' log is recorded as per the FLS9 parameters of minimum and maximum output signals. The system is now calibrated and ready for use.

o On/Off Trigger Event Interpretation * The trigger event is signalled by the filler cap" sensor2. The sensor2 sends a signal when the filler cap is removed or replaced. The software12E interprets the signal and activates or ends the systems functions with regards to dosing * The Trigger Event 1A is primarily an activation signal.

* Trigger Event lB is primarily an end of cycle signal.

* The Trigger Event lB in turn is a signal for other post cycle software functions to be activated.

o Communications and Interface Control * The portion of the softwar&2E controls the wireless technology communication between the hardware and the operator. For example, when the LLT is initiated for the reagent reservoir, the softwaret2E interprets the signal and prepares the wireless technology communications devisel2D to send a communiqué in text, SMS or another operator defined manner.

* The softwar&2E also interprets incoming coded information through the communications devisel2D for the purposes of system checks, wireless calibrations or dosage ratio alterations, without the need for the operator to be anywhere near the unit.

o Calibration and Calculation Parameters * This portion of the softwarel2E is where the calibration of components and the softwarel2E itself is done.

* As we have already covered the two FLS9 methods of calibration methods we shall not repeat it here.

* The calibration of the dosing ratio is as follows: The reagent manufacturer dosing ratio is defined in the softwa rel2E.

o For example:

* One litre of reagent treats 600 litres of fluid.

* Thus one litre of reagent dosing is equal to 40 000 pump strokes where each pump stroke is equal to 0.025mL per stroke * This equates to one' pumpB stroke per lSml of fluid entering the fluid storage vessel'6.

The reagent reservoirC storage capacity is confirmed.

PeriDherals explained: * The storage vessel'0 is the vessel that the operator fills on requirement. This storage vessel'0 is not part of the system but rather the storage vessel'0 being dosed with the reagent.

* The check valve3 prevents the siphoning of the reagent out though the delivery tube4 from the reagent reservoir, in the event the storage vessel'6 encounters/creates a vacuum. This is a preventative measure.

* The communications cable6 is used when the OBC12A, TO Board2C and electric power controller'26 are separated from the component controller'TM, pump9, reagent reservoirC and FLS9. It supplies both communications between the modules as well as electric power to the peripheral components.

* The electric power cable7 is used to transfer the electric power8 from the source to the electric power controller'26.

* The electric power8 source can be any variety of AC or DC supply.

* The electric power controller'28 is what converts all electric power8 sources from various ranges to a stable, uniform l2voltDC supply used throughout the system. The electric power controller'28 also regulates and prevents any electric power8 surges or drop in electric power8 from the supply.

o Example: if using a vehicles battery as an electric power8 source.

* During the vehicle start up, the electric power8 source is strained for electric power8 during the cranking of the engine, which in turn leaches the electric power8 supply from the system, and there after a sudden spike occurs due to the engine turning over.

* The electric power controller'28 stabilises these dips and spikes and only allows a steady flow of electric power8 through to the system.

* Communications port can be any derivative of a communications devisei2C raging from a GSM network card through to Radio Frequency depending on the country and application.

Figure 2 shows a fully automated system but showing the splitting' the system into two defined units. Unit one can be defined as item 12 and unit two can be defined as item 11. With reference to Figure 1, you will note that this division has been made along line AA to BB and line BB to CC. This signifies that each unit is in actual fact two separately contained units, communicating with each other along the communications cable6. The electric power8 source is still external to the units and supplied either only to unit 12 or to both unit 12 and 11, depending on the system requirements. In the event the power is supplied to both unit 11 and 12, then unit 11 shall receive a power controller Ficjurel:128 as well. This configuration is ideally suited to mobile or semi mobile applications, were unit 12 can be kept is one place while moving the satellite unit 11 around were required.

The dosing procedure and system function remains the same as explained under Figure 1: Dosing cycle.

It must be noted that the FLS9 can be mounted to the bottom of the storage vessel'0 or be submerged inside the storage vessel'0. For externally mounted FLS's9 the fluid can be measured through pressure devise9. For internal/submerged applications a pressure devise9, Ultrasonic9 or Laser' type devise9 can be used, depending on the fluid priorities and storage vessel'0 size.

Item 5 represents the refill port5 for refilling the reagent reservoir Figure 1:11C Item 1 represents the storage vessel'0 filler necks, filler cap'. The filler cap' and sensor2 is what causes the Trigger Event 1A and lB to occur with the removal of the f9ller cap' or replacement thereof.

Figure 3 shows a fully automated system but showing a representation of the system as one unit. All the peripherals and functions remain the same. The only difference is that everything except the filler cap1 sensor2 and FLS9 is not housed inside the unit. This configuration is ideally suited for large static storage vessel'0 applications.

Figure 4 shows a semi-automatic system through the implementation of the most basic functions of the system. Unit 12 is replaced by Unit 13. Unit 13 still comprises of the 0BCicJures:l2A power and 10 board Figures:12C but are scaled down to a hand held devise13.

The hand held devise'3 or human interface devise"3 makes the system a semi-automated system. The system is now reliant on the external (human) input of the fluid volumes filled into the storage vessel'0 by entering the information through a keypad'4 mounted to the face of the hand held devise'3. In order to scale the system down in this proportion, the following components are omitted from Unit 11: * FLS9 * Filler Cap Sensor2 * LLT11D is removed from the reagent reservoir and the function is replaced with a calculation based warning system through the software Figures:12E The system is split in two, so that Unit 13 can be freely placed either at the refill point or as a location specified by the operator. Unit 11 still containing the fluid pump9 and are located in a secure location/position close to the dosing point.

The LLT Figure 1: 1113 is replaced by software Figure 5:12E calculation and low level alert. The warning is calculated on the bases that the reagent reservoirC is no longer an integral part of the unit but rather a disposable reservoir Figure 5:15 The operator, on receiving the low level alert through the display "Reagent Reservoir Almost Depleted" and an empty alert "Reagent Reservoir Depleted" simply opens Unit 11, removes the old reagent reservoir Figure 5:15 and replaces it with a new full (predefined volume) reagent 5:15 Once the task is completed, the operator notifies the system by depressing two prescribed keys'4 on the interface devise'3, or picking the refill/reset button. This in turn will remove the reagent low level alert from the screen and restarts the low level alert countdown calculations based on pumpB stroke volume dispensed versus the predefined volume of the reagent replacement reservoir Figure 5:15 fluids available.

Figure 5 represents the process and control based on Figure 4 arrangements as a hand held devise. The Event Trigger is the activation of the hand held interface devise'3. By tapping or pressing any key'4 the hand held devise'3 is brought out of Standby Mode' to ON Mode'. The operator then enters the volume of fluid that has be placed or replaced into the storage vessel'0. The OBC2A and software2E interpret the input data and calculate the required dose, translating it into pumphiB strokes.

The pumplB is instructed through the 10 boardlZC which translates the data into a signal (volt or amp) which is routed by the controller to the pump, which in turn doses the fluid storage vessel'0 accordingly. The reagent is delivered to the pump via the feeder tube4, and then pumped into the storage vessel'0 by additional feeder tubing4. Before the reagent enters the fluid storage vessel'0, it passes through a check valve3 which ensures that the reagent is not siphoned out the system by any vacuum caused in the storage vessel'0.

The electric power8 is transferred to the hand held devise'3 by an electric power cable7. The electric power cable7 enters the electric power controller'28, where the electric power8 source is converted to a l2Volt DC supply, which is what the system operates on.

All alerts and entered data can be viewed on the keypad'4 screen located on the hand held devise'3

Claims

Claims 1. A fully automated liquid reagent dispenser specifically designed to accurately dose a fluid supply based on the amount of fluid being refilled into the fluid storage vessel during any random refill event used by an internal combustion engine, which is independent to the fluid storage vessel and system being dosed, which is a self-contained unit means with capability of accepting a variable electric power source through a controller able to accept AC or DC input, which has a communication means of sending information and receiving instructions, which is activated by a trigger event caused by a filler cap sensor means positioned on the filler neck to the fluid storage vessel being dosed with reagent liquid, which uses an on-board computer means and software program means to accurately calculate and dose the fluid storage vessel, which uses a fluid level sensor means to measure the increase in fluid levels in the fluid storage vessel, which is dosed from a reagent reservoir means with a low level warning system means used to alert the operator of a low level event, which is then transferred from the reagent reservoir by a pump means via a feeder means, which draws the fluid into the pumps dosing chamber and pushes the fluid on through a feeder, which is connected to an anti-syphon devise and delivered into the fluid storage vessel used by an internal combustion engine.
2. A fully automated liquid reagent dispenser according to claim 1, in which the self-contained unit means is provided by a waterproof and dust proof container with an automatic waterproof and dust proof atmospheric pressure differential relief valve.
3. A fully automated liquid reagent dispenser according to claim 1, in which the communication means is a hardware component used to communicate wirelessly through any local network.
4. A fully automated liquid reagent dispenser according to claim 1, in which the filler cap sensor means is the use of a sensing devise positioned within the proximity of the closed filler cap.
5. A fully automated liquid reagent dispenser according to claim 1, in which the use of an on-board computer means is a solid state computer designed for industrial use.
6. A fully automated liquid reagent dispenser according to claim 1, in which the software means is a preloaded operating system with customised program developed specifically for this system.
7. A fully automated liquid reagent dispenser according to claim 1, in which the fluid level sensor is a fluid pressure metering devise used for measuring the fluid level through interpretive calculation.
8. A fully automated liquid reagent dispenser according to claim 1, in which the reagent reservoir is a watertight container with a refill inlet and delivery outlet.
9. A fully automated liquid reagent dispenser according to claim 1, in which the low level warning system means is a devise use for the triggering of a switch when a present fluid level is reached.
10. A fully automated liquid reagent dispenser according to claim 1, in which a pump means an electrical power fluid delivery devise of which the exact per cycle pumping volume is known and remains unchanged.
11. A fully automated liquid reagent dispenser according to claim 1, in which the feeder means is a fluid delivery method from one point to another without incurring any loss of the fluid being transferred.
12. A fully automated liquid reagent dispenser according to claim 2, in which the self-contained unit means is provided by a waterproof and dust proof container with an open airflow or drainage vent.
13. A fully automated liquid reagent dispenser according to claim 2, in which the self-contained unit means is provided by a hand held waterproof and dust proof container.
14. A fully automated liquid reagent dispenser according to claim 4, in which the filler cap sensor means is the use of a sensor devise positioned within the filler neck detecting the presents of a lights source when the filler cap is removed.
15. A fully automated liquid reagent dispenser according to claim 5, in which the use of an on-board computer means is a microprocessor designed for use in a hand held devise.
16. A fully automated liquid reagent dispenser according to claim 6, in which the software means is an embedded operating system with customised program developed specifically for this system.
17. A fully automated liquid reagent dispenser according to claim 6, in which the software means is a customised logic program developed specifically for use in an industrial application.
18. A fully automated liquid reagent dispenser according to claim 8, in which the reagent reservoir is a disposable container with a delivery outlet.