Fuel optimization system with improved fuel level sensor

• US 20030069684A1
• Filed: 05/24/2002
• Published: 04/10/2003
• Est. Priority Date: 05/04/1999
• Status: Active Grant

• Current Assignee: SSI Technologies, LLC (Amphenol Corporation)
• Original Assignee: SSI Technologies, Inc. (Amphenol Corporation)
• Inventors: Reimer, Lawrence B.
• Granted Patent: US 6,691,025 B2
• Time in Patent Office: Days
• US Class Current: 701/123
• CPC Class Codes: B60K 15/061 with level control
• CPC Class Codes: B60K 15/077 with means modifying or controlling distribution or motion of fuel, e.g. to prevent noise, surge, splash or fuel starvation
• CPC Class Codes: B60K 2015/03217 Fuel level sensors
• CPC Class Codes: G01F 23/296 Acoustic waves

Abstract

A system for monitoring fuel consumption and optimizing refueling of a vehicle. The system includes a fuel level sensor designed to be mounted on a fuel tank. The fuel sensor has a transducer, such as an ultrasonic transducer, for generating a distance signal that represents the distance between the sensor and the surface of the fuel in the fuel tank. A processor coupled to the transducer is programmed to convert the distance signal to a percentage of capacity signal, calculate the volume of fuel within the fuel tank, and create a message that includes information regarding the volume of fuel in the fuel tank.

The processor of the fuel level sensor is coupled to a network that may include a dispatch terminal, a fuel optimization server, and a fuel-price-by-location service. The network calculates an optimal location for refilling the fuel tank and a route to travel to the location. It broadcasts a message containing the refueling and route information to the vehicle information system, and devices coupled to the vehicle information system then display the message to inform the driver of the vehicle when and where to refuel.

Claims

1. A fuel level sensor for use with a fuel tank, the fuel level sensor comprising:

a transducer for generating a distance signal that represents the distance between the sensor and the surface of the fuel in the fuel tank; and

a processor coupled to the transducer, the processor programmed to convert the distance signal to a percentage of capacity signal, calculate the volume of fuel within the fuel tank, and create a message that includes information regarding the volume of fuel in the fuel tank.

2. A fuel sensor as set forth in claim 1 wherein the processor is further programmed to generate a gauge drive signal.

3. A fuel sensor as set forth in claim 1 wherein the processor is operable to receive data from a vehicle information system including data concerning the rate of fuel usage and the processor is further programmed to calculate the size of the fuel tank.

5. A fuel sensor as set forth in claim 1 further comprising an ultrasonic transmitter operable to bounce an ultrasonic signal off of the surface of the fuel in the fuel tank to the transducer.

4. A fuel sensor as set forth in claim I wherein the sensor further comprises a vehicle speed dependent filter to reduce measurement affects of standing waves in the fuel tank.

6. A fuel optimization system for a vehicle, the system comprising:

a fuel level sensor for being mounted on a fuel tank, the fuel level sensor having a transducer for generating a distance signal that represents the distance between the sensor and the surface of the fuel in the fuel tank and a processor coupled to the transducer, the processor programmed to convert the distance signal to a percentage of capacity signal, calculate the volume of fuel within the fuel tank, calculate the rate of fuel consumption per unit distance of the vehicle, and create a message that includes information regarding the volume of fuel in the fuel tank and the rate of fuel consumption per unit distance;

a vehicle information system to provide data concerning the distance traveled by the vehicle, and the identity of the vehicle; and

a network coupled to the processor to calculate an optimal location for refilling the fuel tank and an optimal route for reaching the location using the message provided by the fuel level sensor and data provided by the vehicle information system.

7. A fuel optimization system as set forth in claim 6 wherein the network transmits a message to the vehicle information system that includes information regarding the optimal location for refilling the fuel tank and the optimal route for reaching the location.

8. A fuel optimization system as set forth in claim 7 wherein the system further includes a display coupled to the processor for displaying the message transmitted by the network.

9. A fuel optimization system as set forth in claim 8 wherein the processor is programmed to calculate an average fuel economy value and a fuel remaining value.

10. A fuel optimization system as set forth in claim 9 wherein the average fuel economy and fuel remaining values are provided to the network.

11. A fuel optimization system as set forth in claim 6 wherein the network includes a fuel optimization server.

12. A fuel optimization system as set forth in claim 11 wherein the network includes a dispatch terminal.

13. A fuel optimization system as set forth in claim 11 or claim 12 wherein the network further comprises a fuel-price-by-location service.

14. A fuel optimization system as set forth in claim 12 wherein the network comprises a communication link and the processor is coupled through the communication link to the fuel optimization server and the dispatch terminal is coupled to the fuel optimization server.

15. A fuel optimization system as set forth in claim 6 wherein the network comprises a communication link and the processor is coupled through the communication link to the dispatch terminal and the dispatch terminal is coupled to a fuel-price-by-location service.

16. A fuel optimization system as set for in claim 15, further comprising a fuel optimization server coupled to the dispatch terminal and wherein the vehicle information system provides data concerning the location of the vehicle and the direction of travel of the vehicle to the dispatch terminal.

17. A fuel optimization system as set forth in claim 14 or claim 15 wherein the communication link is a cellular-based communication system.

18. A fuel optimization system as set forth in claim 14 or claim 15 wherein the communication link is a satellite network.

19. A fuel optimization system as set forth in claim 14 or claim 15 wherein the communication link includes an RF receiver-transmitter pair.

20. A method of calculating a miles-to-empty value for a fuel tank of a vehicle, the vehicle having a vehicle information system, the method comprising the acts of:

acquiring a percentage of capacity value from a fuel level sensor mounted on the fuel tank;

acquiring a total fuel capacity value for the fuel tank from data storage;

calculating a fuel economy value based on a vehicle distance traveled value obtained from the vehicle information system;

calculating a fuel remaining value by multiplying the percentage of capacity value by the total fuel capacity value; and

calculating a miles-to-empty value by multiplying the fuel remaining value by the fuel economy value.

21. A method as set forth in claim 20, further comprising the act of filtering the percentage of capacity value to reduce measurement effects of standing waves in the fuel tank.

22. A method as set forth in claim 20 further comprising the acts of determining whether the miles-to-empty value is less than a predetermined level, determining whether the percentage of capacity value is less than a predetermined value and, upon determining that the miles-to-empty value is less than the predetermined level or the percentage of capacity value is less than the predetermined value, broadcasting a low fuel message to a display device in the vehicle.

23. A method as set forth in claim 20 wherein a distance signal is acquired from the fuel level sensor and converted using a look-up table to generate the percentage of capacity value.

24. A method of calculating a miles-to-empty value for a fuel tank of a vehicle having a vehicle management system, the method comprising the acts of:

acquiring a first percentage of capacity value from a fuel level sensor mounted on the fuel tank at a first moment in time;

acquiring a second percentage of capacity value from a fuel level sensor mounted on the fuel tank at a second moment in time after the first moment in time;

acquiring a vehicle distance traveled value from the vehicle management system;

calculating a change in percentage of capacity value based on the first percentage of capacity value and the second percentage of capacity value; and

calculating a miles-to-empty value by dividing the vehicle distance traveled value by the change in percentage of capacity value and multiplying the result by the second percentage of capacity value.

25. A method as set forth in claim 24 further comprising the act of filtering the second percentage of capacity value through a filter to reduce measurement effects of standing waves in the fuel tank.

26. A method as set forth in claim 24 further comprising the acts of determining whether the miles-to-empty value is less than a predetermined level and upon determining that the miles-to-empty value is less than the predetermined level, broadcasting a low fuel message to a display device in the vehicle.

27. A method as set forth in claim 24 wherein the act of acquiring the second percentage of capacity value further includes the acts of acquiring a distance signal from the fuel level sensor and converting the distance signal to a present percentage of capacity value.

28. A method of calculating a tank size for a fuel tank of a vehicle, the vehicle having a vehicle management system, the method comprising the acts of:

acquiring a first percentage of capacity value from a fuel level sensor mounted on the fuel tank at a first moment in time;

acquiring a second percentage of capacity value from the fuel level sensor mounted on the fuel tank at a second moment in time after the first moment in time;

calculating a fuel economy value by acquiring a vehicle distance traveled value from the vehicle management system;

calculating a change in percentage of capacity value based on the first percentage of capacity value and the second percentage of capacity value;

calculating a tank size value by dividing the vehicle distance traveled value by the change in percentage of capacity value, multiplying the quotient by 100, and dividing the multiplied quotient by the fuel economy value.

29. A method as set forth in claim 28, further comprising the act of filtering the second percentage of capacity value through a filter to reduce measurement effects of standing waves in the fuel tank.

30. A method of calculating an amount of fuel remaining in a fuel tank of a vehicle, the vehicle having a vehicle management system, the method comprising the acts of:

acquiring a first percentage of capacity value from a fuel level sensor mounted on the fuel tank at a first moment in time;

acquiring a second percentage of capacity value from the fuel level sensor mounted on the fuel tank at a second moment in time after the first moment in time;

calculating a fuel economy value based on information from the vehicle management system;

calculating a change in percentage of capacity value based on the first percentage of capacity value and the second percentage of capacity value; and

calculating a fuel remaining value by multiplying the second percentage of capacity value by the change in percentage of capacity value, multiplying the result by 100, and then dividing the multiplied result by the fuel economy value.

31. A method as set forth in claim 30 further comprising the act of filtering the second percentage of capacity value through a filter to reduce measurement effects of standing waves in the fuel tank.

32. A method of determining the number of hours until a fuel tank of a vehicle is empty, the vehicle having a vehicle management system, the method comprising the acts of:

acquiring a first percentage of capacity value from the fuel level sensor mounted on the fuel tank at a first moment in time;

acquiring a second percentage of capacity value from the fuel level sensor mounted on the fuel tank at a second moment in time after the first moment in time;

acquiring a tank capacity value from a storage device;

calculating a fuel remaining value by multiplying the second percentage of capacity value by the tank capacity value;

acquiring a fuel flow rate value from the vehicle management system; and

calculating an hours to empty value by multiplying the fuel remaining value by the fuel flow rate value.

33. A method as set forth in claim 32 further comprising the act of filtering the second percentage of capacity value through a filter to reduce measurement effects of standing waves in the fuel tank.

34. A method of determining the number of hours until a fuel tank of a vehicle is empty, the vehicle having a vehicle management system, the method comprising the acts of:

acquiring a first percentage of capacity value from a fuel level sensor mounted on the fuel tank at a first moment in time;

acquiring a second percentage of capacity value from the fuel level sensor mounted on the fuel tank at a second moment in time after the first moment in time;

acquiring a relative hours value from the fuel level sensor;

calculating a change in percentage of capacity value based on the first percentage of capacity value and the second percentage of capacity value; and

calculating an hours to empty value by dividing the relative hours value by the change in percentage capacity value and multiplying the result by the second percentage of capacity value.

35. A method as set forth in claim 34 further comprising the act of filtering the second percentage of capacity value through a filter to reduce measurement effects of standing waves in the fuel tank.

36. A method of calculating a tank size for a fuel tank of a vehicle, the vehicle having a vehicle management system, the method comprising the acts of:

acquiring a first percentage of capacity value from a fuel level sensor mounted on the fuel tank at a first moment in time;

acquiring a second percentage of capacity value from the fuel level sensor mounted on the fuel tank at a second moment in time after the first moment in time;

acquiring a relative hours value from the fuel level sensor;

acquiring a fuel flow rate value from the vehicle management system;

calculating a change in percentage of capacity value based on the second percentage of capacity value and the first percentage of capacity value; and

calculating a ratio value of the relative hours value to the change in percentage of capacity value; and

calculating a tank size value by multiplying the ratio value by the fuel flow rate value.

37. A method of identifying a tank leak in a fuel tank of a vehicle, the vehicle having a vehicle management system comprising the acts of:

acquiring a first tank size value at a first time;

acquiring a second tank size value at a second, later time;

dividing the second tank size value by the first tank size value to obtain a quotient; and

determining whether the quotient is less than a predetermined value and, upon determining that the quotient is less than the predetermined value, broadcasting a leak message.

38. A method as set forth in claim 37 wherein each of the first and second tank size values is calculated by

acquiring a first percentage of capacity value from a fuel level sensor mounted on the fuel tank at a first moment in time;

acquiring a second percentage of capacity value form the fuel level sensor mounted on the fuel tank at a second moment in time;

acquiring a relative hours value from the fuel level sensor;

acquiring a fuel flow rate value from the vehicle management system;

calculating a change in percentage of capacity value based on the second percentage of capacity value and the first percentage of capacity value;

calculating a ratio value of the relative hours value to the change in percentage of capacity value for a relative fuel flow value; and

multiplying the ratio value by the fuel flow rate value.

39. A method of identifying fraud in refueling a fuel tank of a vehicle, the vehicle having a vehicle information system, the method comprising the acts of:

measuring a first fuel value at a first time;

filling the fuel tank with fuel;

measuring a second fuel value at a second time following filling the fuel tank with fuel;

broadcasting the first and second fuel values to a terminal computer, the terminal computer calculating and recording the difference between the second and first fuel values;

acquiring a third fuel value through a man-machine interface and delivering the third fuel value to the terminal computer;

comparing the third fuel value to the difference between the second and first fuel values and generating a comparison value; and

generating a fraud message if the comparison value is greater than a predetermined fraud value.

40. A method as set forth in claim 39 wherein each of the first and second fuel values is determined by

acquiring a present percentage of capacity value from a fuel level sensor mounted on the fuel tank at a first moment in time;

acquiring a second percentage of capacity value from the fuel level sensor mounted on the fuel tank at a second moment in time;

acquiring a relative hours value from the fuel level sensor;

acquiring a fuel flow rate value from the vehicle information system;

calculating a change in percentage of capacity value based on the second percentage of capacity value and the first percentage of capacity value;

calculating a ratio value of the relative hours value to the change in percentage of capacity value for a relative fuel flow value; and

multiplying the ratio value by the fuel flow rate value.

41. A vehicle monitoring system comprising:

a vehicle information system to provide data concerning the operation of the vehicle and the identity of the vehicle;

a network coupled to the vehicle information system to record and process the data concerning the operation of the vehicle.

42. A vehicle monitoring system as set forth in claim 41 wherein the network includes a fuel optimization server.

43. A vehicle monitoring system as forth in claim 42 wherein the network includes a dispatch terminal.

44. A vehicle monitoring system as set forth in claim 42 or claim 43 wherein the network further comprises a fuel-price-by-location service.

45. A vehicle monitoring system as set for in claim 42, wherein the fuel optimization server is coupled to the dispatch terminal and wherein the vehicle information system provides data concerning the location of the vehicle and the direction of travel of the vehicle to the dispatch terminal.