Method and system for determining and monitoring dispensing point flow rates and pump flow capacities using dispensing events and tank level data Number:7,152,004 from the United States Patent and Trademark Office (PTO) owispatent A system and method for calculating the flow rate of a dispensing point or flow capacity of a pump and fuel delivery system and determining if the dispensing point or fuel delivery system has a blockage and/or a performance problem if the calculated dispensing point flow rate is other than expected. The calculated dispensing flow rate is calculated by collecting fuel tank level data points for a dispensing point that fall within start and stop events of the dispensing event. The slope of a fitted line to the fuel tank level data points is used as the indication of the flow rate of the dispensing point. Different mathematical techniques may be used to improve the flow rate calculation to compensate for the minimum resolution of collecting fuel tank level data and the dead time included in the data of a dispensing transaction.<H determining, dispensing, Method, and, syst, 7152004.html, Patent, pto, 7152004

Title: Method and system for determining and monitoring dispensing point flow rates and pump flow capacities using dispensing events and tank level data

Abstract: A system and method for calculating the flow rate of a dispensing point or flow capacity of a pump and fuel delivery system and determining if the dispensing point or fuel delivery system has a blockage and/or a performance problem if the calculated dispensing point flow rate is other than expected. The calculated dispensing flow rate is calculated by collecting fuel tank level data points for a dispensing point that fall within start and stop events of the dispensing event. The slope of a fitted line to the fuel tank level data points is used as the indication of the flow rate of the dispensing point. Different mathematical techniques may be used to improve the flow rate calculation to compensate for the minimum resolution of collecting fuel tank level data and the dead time included in the data of a dispensing transaction.

Patent Number: 7,152,004 Issued on 12/19/2006 to Reichler, et al.

Inventors: Reichler; Donald S. (West Simsbury, CT), Baglioni; Adriano (South Windsor, CT), Zalenski; Thomas C. (Avon, CT), Hart; Robert P. (East Hampton, CT), Lucas; Richard K. (Enfield, CT)
Assignee: Veeder-Root Company (Simsbury, CT)

Appl. No.: 10/963,429

Filed: October 12, 2004

Current U.S. Class: 702/55 ; 702/45

Current International Class: G01F 17/00 (20060101)

Field of Search: 702/45,55

References Cited [Referenced By]

U.S. Patent Documents


5170657	December 1992	Maresca, Jr. et al.
5375455	December 1994	Maresca, Jr. et al.
5415033	May 1995	Maresca, Jr. et al.
6352176	March 2002	Hartsell, Jr. et al.
6463389	October 2002	Dickson
6622757	September 2003	Hart et al.
6934644	August 2005	Rogers et al.

Foreign Patent Documents


0134990	Mar., 1985	EP
0153035	Aug., 1985	EP

Other References

"Data Smoothing" techniques, Vanguard Software Corporation, www.vanguardsw.com/dphelp4/dph00109.htm, Feb. 9, 2005. cited by other .
Piping Handbook, 7.sup.th edition, Mohinder L. Nayyar, Chapter B13, "Double Containment Piping System Design," pp. B.569-B.649, 1995. cited by other.

Primary Examiner: Barlow; John
Assistant Examiner: Cherry; Stephen J.
Attorney, Agent or Firm: Withrow & Terranova, PLLC

Parent Case Text

RELATED APPLICATION

This patent application claims priority to U.S. Provisional Patent Application No. 60/510,796 entitled, "Method and system for determining and monitoring dispensing point and pump flow rates using tank level data," filed on Oct. 11, 2003 and incorporated herein by reference in its entirety.

Claims

We claim:

1. A method of determining the flow rate of a single dispensing point for a dispensing transaction in a service station using dispensing point dispensing start and end event data and tank probe fuel level data from a fuel tank which supplies fuel to the single dispensing point, comprising the steps of: (a) receiving tank level data that is a record of the tank level of the fuel tank that supplies fuel to the dispensing point to formulate a plurality of tank level data points; (b) determining the start of the dispensing transaction using a dispensing start event for the dispensing point; (c) determining the end of the dispensing transaction using a dispensing end event for the dispensing point; (d) defining a region of interest in the plurality of tank level data points between the start of the dispensing transaction and the end of the dispensing transaction; (e) determining the amount of fuel dispensed by the dispensing point in the region of interest; (f) calculating the flow rate of the dispensing point for the dispensing transaction based on the amount of fuel dispensed by the dispensing point in the region of interest and the duration in the region of interest; and (g) storing the calculated dispensing flow rate.

2. The method of claim 1, wherein step (b) of determining the start of the dispensing transaction comprises determining a first point in the plurality of tank level data points indicative of when fueling at the dispensing point began.

3. The method of claim 2, wherein step (c) of determining the end of the dispensing transaction comprises determining a last point in the plurality of tank level data points indicative of when fueling at the dispensing point ended.

4. The method of claim 3, wherein step (e) comprises: (i) fitting a line through the plurality of tank level data points in the region of interest; (ii) determining the slope of the line; (iii) using the slope of the line as the calculated dispensing flow rate of the dispensing point; and (iv) storing the calculated dispensing flow rate in memory of a control system.

5. The method of claim 4, further comprising filtering the tank level data points in the region of interest to eliminate outlying tank level data points in the region of interest before performing steps (i) (iii).

6. The method of claim 4, wherein the step (i) of fitting a line comprises calculating a best fit line through the plurality of tank level data points in the region of interest.

7. The method of claim 6, wherein the best fit line is calculated using a technique from the group consisting of a least squares linear regression technique, and a resistant line technique.

8. The method of claim 6, further comprising weighting the tank level data points in the region of interest before performing steps (i) (iii).

9. The method of claim 8, wherein the tank level data points in the region of interest farther from the center of gravity of the tank level data points in the region of interest are weighted lower than the tank level data points in the region of interest closer to the center of gravity of the tank level data points in the region of interest.

10. The method of claim 9 wherein step (ii) of determining the slope of the line is comprised of: weighting the tank level data points in the region of interest using their associated weighting factors; and fitting a line through the weighted tank level data points in the region of interest.

11. The method of claim 8, wherein the step of weighting comprises: fitting a preliminary line through the tank level data points; and for all tank level data points in the region of interest: applying a weighting factor to a current tank level data point from the plurality of tank level data points in the region of interest based on the residual of the current tank level data point to the preliminary line; and storing the weighting factor result in memory associated with the current tank level data point.

12. The method of claim 11, wherein the step of applying a weighting factor to a current tank level data point comprises: applying a first weighting factor to a current tank level data point from the plurality of tank level data points in the region of interest based on the residual of the current tank level data point to the preliminary line according to the formula: .times..sigma. ##EQU00003## applying a second weighting factor to the current tank level data point according to the formula: .SIGMA..times..times. ##EQU00004## multiplying the first weighting factor times the second weighting factor to calculate a weighting factor result.

13. The method of claim 3, wherein the step of determining the last point comprises determining from the plurality of tank level data points after the first point where the slope begins to decrease to less than a slope threshold value.

14. The method of claim 13 wherein the last point is a point in the plurality of tank level data points that is one point before the last point.

15. The method of claim 14, wherein step (f) comprises dividing the amount of fuel dispensed by the dispensing point in the region of interest by the duration in the region of interest.

16. The method of claim 13, wherein step (f) comprises dividing the amount of fuel dispensed by the dispensing point in the region of interest by the duration in the region of interest.

17. The method of claim 3, further comprising smoothing the tank level data points in determining the first point and the last point.

18. The method of claim 2, wherein the step of determining the first point comprises determining from the plurality of tank level data points where the slope begins to increase to greater than a slope threshold value.

19. The method of claim 18, wherein step (f) comprises dividing the amount of fuel dispensed by the dispensing point in the region of interest by the duration in the region of interest.

20. The method of claim 1, further comprising determining if the calculated dispensing flow rate is different than an expected value.

21. The method of claim 20, wherein the step of determining if the calculated dispensing flow rate is different than an expected value comprises determining if the calculated dispensing flow rate is significantly lower than a threshold value.

22. The method of claim 20, wherein the step of determining if the calculated dispensing flow rate is different than an expected value comprises determining if the calculated dispensing flow rate is significantly higher than the threshold value.

23. The method of claim 20, further comprising reporting a problem if the calculated dispensing flow rate is different than the expected value.

24. The method of claim 20, further comprising generating an alarm if the calculated dispensing flow rate is different than the expected value.

25. The method of claim 1, further comprising: comparing the calculated dispensing flow rate to other previously calculated dispensing flow rates for other dispensing points; and determining if the calculated dispensing flow rate is less than the other previously calculated dispensing flow rates for other dispensing points.

26. The method of claim 25, further comprising reporting a problem if the calculated dispensing flow rate is less than the other previously calculated dispensing flow rates for other dispensing points.

27. The method of claim 25, further comprising generating an alarm if the calculated dispensing flow rate is less than the other previously calculated dispensing flow rates for other dispensing points.

28. The method of claim 1, further comprising: comparing the calculated dispensing flow rate to other previously calculated dispensing flow rates for the dispensing point; and determining if the calculated dispensing flow rate is different than the other previously calculated dispensing flow rates for the dispensing point.

29. The method of claim 28, further comprising reporting a problem if the calculated dispensing flow rate is different than the other previously calculated dispensing flow rates for the dispensing point.

30. The method of claim 28, further comprising generating an alarm if the calculated dispensing flow rate is different than the other previously calculated dispensing flow rates for the dispensing point.

31. The method of claim 1, wherein step (f) comprises dividing the amount of fuel dispensed by the dispensing point in the region of interest by the duration in the region of interest.

32. A system for determining the flow rate of a single dispensing point for a dispensing transaction in a service station using dispensing point dispensing start and end event data and tank probe fuel level data from a fuel tank which supplies fuel to the single dispensing point, comprising: a tank that contains fuel; a probe electronically coupled to a control system having memory wherein the probe determines the tank level of the tank and communicates the tank level to a control system; a fuel dispenser, comprising: a dispensing point; a controller coupled to the dispensing point wherein the controller: controls fueling through said dispensing point; generates a dispensing start event when fueling is allowed to be dispensed through the dispensing point; and generates a dispensing end event when fueling is no longer allowed to be dispensed through said dispensing point; said control system adapted to: (a) receive tank level data that is a record of the tank level of the fuel tank that supplies fuel to the dispensing point to formulate a plurality of tank level data points; (b) determine the start of the dispensing transaction using a dispensing start event for the dispensing point; (c) determine the end of the dispensing transaction using a dispensing end event for the dispensing point; (d) define a region of interest in the plurality of tank level data points between the start of the dispensing transaction and the end of the dispensing transaction; (e) determine the amount of fuel dispensed by the dispensing point in the region of interest; and (f) calculate the flow rate of the dispensing point for the dispensing transaction based on the amount of fuel dispensed by the dispensing point in the region of interest and the duration in the region of interest.

33. The system of claim 32, wherein the control system is further adapted to determine the start of the dispensing transaction by determining a first point in the plurality of tank level data indicative of when fueling at the dispensing point began.

34. The system of claim 33, wherein the control system is further adapted to determine the end of the dispensing transaction by determining a last point in the plurality of tank level data points indicative of when fueling at the dispensing point ended.

35. The system of claim 34, wherein the control system is adapted to calculate the flow rate of the dispensing point for the dispensing transaction by: (i) fitting a line through the plurality of tank level data points in the region of interest; (ii) determining the slope of the line; (iii) using the slope of the line as the calculated dispensing flow rate of the dispensing point; and (iv) storing the calculated dispensing flow rate in memory of a control system.

36. The system of claim 35, wherein the control system is further adapted to filter the tank level data points in the region of interest to eliminate outlying tank level data points in the region of interest.

37. The system of claim 35, wherein the control system is further adapted to fit a line through the plurality of tank level data points in the region of interest by calculating a best fit line through the plurality of tank level data points in the region of interest.

38. The system of claim 37, wherein the control system is further adapted to calculate the best fit line using a technique from the group consisting of a least squares linear regression technique, and a resistant line technique.

39. The system of claim 37, wherein the control system is further adapted to weight the tank level data points in the region of interest.

40. The system of claim 39, wherein the control system is further adapted to weight lower the tank level data points in the region of interest farther from the center of gravity of the tank level data points in the region of interest than the tank level data points in the region of interest closer to the center of gravity of the tank level data points in the region of interest.

41. The system of claim 40, wherein the control system is further adapted to: fit a preliminary line through the tank level data points; and for all tank level data points in the region of interest: apply a weighting factor to a current tank level data point from the plurality of tank level data points in the region of interest based on the residual of the current tank level data point to the preliminary line; and store the weighting factor result in memory associated with the current tank level data point.

42. The system of claim 41, wherein the control system is further adapted to: apply a first weighting factor to a current tank level data point from the plurality of tank level data points in the region of interest based on the residual of the current tank level data point to the preliminary line according to the formula: .times..sigma. ##EQU00005## apply a second weighting factor to the current tank level data point according to the formula: .SIGMA..times..times. ##EQU00006## multiply the first weighting factor times the second weighting factor to calculate a weighting factor result.

43. The system of claim 40, wherein the control system is further adapted to: weight the tank level data points in the region of interest using their associated weighting factors; and fit a line through the weighted tank level data points in the region of interest.

44. The system of claim 33, wherein the control system determines the first point by determining from the plurality of tank level data points where the slope begins to increase to greater than a slope threshold value.

45. The system of claim 44 wherein the control system determines the last point by determining from the plurality of tank level data points after the first point where the slope begins to decrease to less than a slope threshold value.

46. The system of claim 45 wherein the last point is a point in the plurality of tank level data points that is one point before the last point.

47. The system of claim 46, wherein the control system is adapted to calculate the flow rate of the dispensing point for the dispensing transaction based on the amount of fuel dispensed by the dispensing point in the region of interest and the duration in the region of interest by dividing the amount of fuel dispensed by the dispensing point in the region of interest by the duration in the region of interest.

48. The system of claim 45, wherein the control system is further adapted to smooth the tank level data points in determining the first point and the last point.

49. The system of claim 45, wherein the control system is adapted to calculate the flow rate of the dispensing point for the dispensing transaction based on the amount of fuel dispensed by the dispensing point in the region of interest and the duration in the region of interest by dividing the amount of fuel dispensed by the dispensing point in the region of interest by the duration in the region of interest.

50. The system of claim 44, wherein the control system is adapted to calculate the flow rate of the dispensing point for the dispensing transaction based on the amount of fuel dispensed by the dispensing point in the region of interest and the duration in the region of interest by dividing the amount of fuel dispensed by the dispensing point in the region of interest by the duration in the region of interest.

51. The system of claim 32, wherein the control system is further adapted to determine if the calculated dispensing flow rate is different than an expected value.

52. The system of claim 51, wherein the control system is further adapted to determine if the calculated dispensing flow rate is significantly lower than a threshold value.

53. The system of claim 51, wherein the control system is further adapted to determine if the calculated dispensing flow rate is significantly higher than the threshold value.

54. The system of claim 51, wherein the control system is further adapted to report a problem if the calculated dispensing flow rate is different than the expected value.

55. The system of claim 51, wherein the control system is further adapted to generate an alarm if the calculated dispensing flow rate is different than the expected value.

56. The system of claim 32, wherein the control system is further adapted to: compare the calculated dispensing flow rate to other previously calculated dispensing flow rates for other dispensing points; and determine if the calculated dispensing flow rate is less than the other previously calculated dispensing flow rates for other dispensing points.

57. The system of claim 56, wherein the control system is further adapted to report a problem if the calculated dispensing flow rate is less than other previously calculated dispensing flow rates for other dispensing points.

58. The system of claim 56, wherein the control system is further adapted to generate an alarm if the calculated dispensing flow rate is less than other previously calculated dispensing flow rates for other dispensing points.

59. The system of claim 32, wherein the control system is further adapted to: compare the calculated dispensing flow rate to other previously calculated dispensing flow rates for the dispensing point; and determine if the calculated dispensing flow rate is different than the other previously calculated dispensing flow rates for the dispensing point.

60. The system of claim 59, wherein the control system is further adapted to report a problem if the calculated dispensing flow rate is different than the previously calculated dispensing flow rates for the dispensing point.

61. The system of claim 59 wherein the control system is further adapted to generate an alarm if the calculated dispensing flow rate is different than the other previously calculated dispensing flow rates for the dispensing point.

62. The system of claim 32, wherein the control system is adapted to calculate the flow rate of the dispensing point for the dispensing transaction based on the amount of fuel dispensed by the dispensing point in the region of interest and the duration in the region of interest by dividing the amount of fuel dispensed by the dispensing point in the region of interest by the duration in the region of interest.

63. A method of determining the capacity of a pump and/or the flow rate of a dispensing point for a dispensing transaction in a service station using dispensing point dispensing start and end event data and tank probe data from a tank for multiple concurrent dispensing transactions, comprising the steps of: (I) receiving tank level data that is a record of the tank level of the fuel tank that supplies fuel to a plurality of dispensing points using the pump to formulate a plurality of tank level data points; (II) receiving the start of dispensing transactions using dispensing start events for the plurality of dispensing points; (III) receiving the end of dispensing transactions using dispensing end events for the plurality of dispensing points; and (IV) determining periods in the plurality of tank level data points where more than one dispensing point is active; and for each of the periods: (a) determining the number of dispensing points that are active in the plurality of tank level data points; (b) determining the start of the dispensing transactions using dispensing start events for the dispensing points; (c) determining the end of the dispensing transactions using dispensing end events for the dispensing points; (d) defining a region of interest in the plurality of tank level data points between the start of the dispensing transactions and the end of the dispensing transactions; (e) determining the amount of fuel dispensed by the plurality of dispensing points in the region of interest; (f) calculating an aggregate dispensing flow rate of the dispensing points based on the amount of fuel dispensed by the plurality of dispensing points in the region of interest and the duration in the region of interest; and (g) storing the calculated dispensing flow rate.

64. The method of claim 63, further comprising calculating average aggregate flow rates for each number of dispensing points that are active using the calculated aggregate flow rates associated with the number of dispensing points that are active to detect a deteriorating or failing pump.

65. The method of claim 64, further comprising comparing the difference of the average aggregate flow rates to corresponding aggregate average flow rates for the same number of dispensing points that are active to detect a deteriorating or failing pump.

66. The method of claim 64, further comprising comparing the difference of the average aggregate flow rates to expected aggregate average flow rates for the same number of dispensing points that are active to detect a deteriorating or failing pump.

67. The method of claim 64, further comprising reporting the deteriorating or failing pump.

68. The method of claim 64, further comprising generating an alarm of the deteriorating or failing pump.

69. The method of claim 63, further comprising calculating individual flow rates for each of the plurality of dispensing points using the aggregate flow rates by: forming a generalized equation for the relationship of the aggregate flow rates, to the active dispensing points contained in the aggregate flow rates and the flow rates of individual dispensing points from the plurality of dispensing points; and solving the generalized equation for each of the individual dispensing points in each of the plurality of fuel dispensing points.

70. The method of claim 63, wherein step (b) of determining the start of the dispensing transactions comprises determining a first point in the plurality of tank level data points indicative of when fueling at the plurality of dispensing points began.

71. The method of claim 70, wherein step (c) of determining the end of the dispensing transactions comprises determining a last point in the plurality of tank level data points indicative of when fueling at the plurality of dispensing points ended.

72. The method of claim 71, wherein step (e) comprises: (i) fitting a line through the plurality of tank level data points in the region of interest; (ii) determining the slope of the line; (iii) using the slope of the line as the calculated aggregate dispensing flow rate of the plurality of dispensing points; and (iv) storing the calculated aggregate dispensing flow rate in memory of a control system.

73. A system for determining the capacity of a pump and/or the flow rate of a dispensing point for a dispensing transaction in a service station using dispensing point dispensing start and end event data and tank probe data from a tank from multiple concurrent dispensing transactions, comprising: a probe electronically coupled to a control system having memory wherein the probe determines the tank level of the tank and communicates the tank level to the control system; said control system adapted to: (I) receive tank level data that is a record of the tank level of the fuel tank that supplies fuel to a plurality of dispensing points using the pump to formulate a plurality of tank level data points; (II) receive the start of dispensing transactions using dispensing start events for the plurality of dispensing points; (III) receive the end of dispensing transactions using dispensing end events for the plurality of dispensing points; and (IV) determine periods in the plurality of tank level data points where more than one dispensing point is active; and for each of the periods: (a) determine the number of dispensing points that are active in the plurality of tank level data points; (b) determine the start of the dispensing transactions using dispensing start events for the dispensing points; (c) determine the end of the dispensing transactions using dispensing end events for the dispensing points; (d) define a region of interest in the plurality of tank level data points between the start of the dispensing transactions and the end of the dispensing transactions; (e) determine the amount of fuel dispensed by the plurality of dispensing points in the region of interest; and (f) calculate an aggregate dispensing flow rate of the dispensing points based on the amount of fuel dispensed by the plurality of dispensing points in the region of interest and the duration in the region of interest.

74. The system of claim 73, wherein the control system is further adapted to calculate average aggregate flow rates for each number of dispensing points that are active using the calculated aggregate flow rates associated with the number of dispensing points that are active to detect a deteriorating or failing pump.

75. The system of claim 74, wherein the control system is further adapted to compare the difference of the average aggregate flow rates to corresponding aggregate average flow rates for the same number of dispensing points that are active to detect a deteriorating or failing pump.

76. The system of claim 74, wherein the control system is further adapted to compare the difference of the average aggregate flow rates to expected aggregate average flow rates for the same number of dispensing points that are active to detect a deteriorating or failing pump.

77. The system of claim 74, wherein the control system is further adapted to report the deteriorating or failing pump.

78. The system of claim 74, wherein the control system is further adapted to generate an alarm of the deteriorating or failing pump.

79. The system of claim 73, wherein the control system is further adapted to calculate individual flow rates for each of the plurality of dispensing points using the aggregate flow rates wherein the control system is further adapted to: form a generalized equation for the relationship of the aggregate flow rates, to the active dispensing points contained in the aggregate flow rates and the flow rates of individual dispensing points from the plurality of dispensing points; and solve the generalized equation for each of the individual dispensing points in each of the plurality of fuel dispensing points.

80. The system of claim 73, wherein the control system is further adapted to determine the start of the dispensing transactions by determining a first point in the plurality of tank level data points indicative of when fueling at the plurality of dispensing points began.

81. The system of claim 80, wherein the control system is further adapted to determine the end of the dispensing transactions by determining a last point in the plurality of tank level data points indicative of when fueling at the plurality of dispensing points ended.

82. The system of claim 81, wherein the control system is further adapted to: (i) fit a line through the plurality of tank level data points in the region of interest; (ii) determine the slope of the line; (iii) use the slope of the line as the calculated aggregate dispensing flow rate of the plurality of dispensing points; and (iv) store the calculated aggregate dispensing flow rate in memory of a control system.

Description

FIELD OF THE INVENTION

The present invention relates to a system and method for determining the flow rate of a dispensing point for a fuel dispenser and pump capacities using tank level data in a service station environment to determine if a dispensing point contains a blockage and/or performance problem.

BACKGROUND OF THE INVENTION

Service stations are comprised of a plurality of fuel dispensers that dispense fuel to motor vehicles. A conventional exemplary fueling environment 10 is illustrated in FIGS. 1 and 2. Such a fueling environment 10 may comprise a central building 12, a car wash 14, and a plurality of fueling islands 16.

The central building 12 need not be centrally located within the fueling environment 10, but rather is the focus of the fueling environment 10, and may house a convenience store 18 and/or a quick serve restaurant (QSR) 20 therein. Both the convenience store 18 and the quick serve restaurant 20 may include a point-of-sale 22, 24, respectively. The central building 12 may further house a site controller (SC) 26, which in an exemplary embodiment may be the G-SITE.RTM. sold by Gilbarco Inc. of Greensboro, N.C. The site controller 26 may control the authorization of dispensing events and other conventional activities as is well understood. The site controller 26 may be incorporated into a point-of-sale, such as point of sale 22, if needed or desired. Further, the site controller 26 may have an off-site communication link 38 allowing communication with a remote location for credit/debit card authorization, content provision, reporting purposes or the like, as needed or desired. The off-site communication link 38 may be routed through the Public Switched Telephone Network (PSTN), the Internet, both, or the like, as needed or desired.

The car wash 14 may have a point-of-sale 30 associated therewith that communicates with the site controller 26 for inventory and/or sales purposes. The car wash 14 alternatively may be a stand-alone unit. Note that the car wash 14, the convenience store 18, and the quick serve restaurant 20 are all optional and need not be present in a given fueling environment.

The fueling islands 16 may have one or more fuel dispensers 32 positioned thereon. Each fuel dispenser 32 may have one or more fuel dispensing points. The term "dispensing point" can be used interchangeably with fuel dispenser 32 for the purposes of this application. A dispensing point 32 is delivery point for fuel. The fuel dispensers 32 may be, for example, the ECLIPSE.RTM. or ENCORE.RTM. sold by Gilbarco Inc. of Greensboro, N.C. The fuel dispensers 32 are in electronic communication with the site controller 26 through a wired or wireless connection, such as a LAN or the like.

The fueling environment 10 also has one or more underground storage tanks 34 adapted to hold fuel therein. As such, the underground storage tank 34 may be a double-walled tank. Further, each underground storage tank 34 may include a liquid level sensor or other sensor 35 positioned therein. The sensors 35 may report to a tank monitor (TM) 36 associated therewith. The tank monitor 36 may communicate with the fuel dispensers 32 (either through the site controller 26 or directly, as needed or desired) to determine amounts of fuel dispensed, and compare fuel dispensed to current levels of fuel within the underground storage tanks 34 to determine if the underground storage tanks 34 are leaking. In a typical installation, the tank monitor 36 is also positioned in the central building 12, and may be proximate the site controller 26.

The tank monitor 36 may communicate with the site controller 26 via a wired or wireless connection, and further may have an off-site communication link 38 for leak detection reporting, inventory reporting, or the like, which may take the form of a PSTN, the Internet, both, or the like. As used herein, the tank monitor 36 and the site controller 26 are site communicators to the extent that they allow off-site communication and report site data to a remote location. The site controller 26 and the tank monitor 36 are typically two separate devices in a service station environment.

In addition to the various conventional communication links between the elements of the fueling environment 10, there are conventional fluid connections to distribute fuel about the fueling environment as illustrated in FIG. 2. The underground storage tanks 34 may each be associated with a vent 40 that allows over-pressurized tanks to relieve pressure thereby. A pressure valve (not shown) is placed on the outlet side of each vent 40 to open to atmosphere when the underground storage tank 34 reaches a predetermined pressure threshold. Additionally, under-pressurized tanks may draw air in through the vents 40. In an exemplary embodiment, two underground storage tanks 34 exist--one a low octane tank (87 grade for example) and one a high octane tank (93 grade for example). Blending may be performed within the fuel dispensers 32, as is well understood, to achieve an intermediate grade of fuel. Alternatively, additional underground storage tanks 34 may be provided for diesel and/or an intermediate grade of fuel (not shown).

Pipes 42 connect the underground storage tanks 34 to the fuel dispensers 32. Pipes 42 may be arranged in a main conduit 44 and branch conduit 46 configuration, where the main conduit 44 carries the fuel that is pumped by a fuel pump, such as a submersible turbine pump (not shown) for example, from the underground storage tanks 34 to the branch conduits 46, and the branch conduits 46 connect to the fuel dispensers 32. Typically, the pipes 42 are double-walled pipes comprising an inner conduit and an outer conduit. Fuel flows in the inner conduit to the fuel dispensers, and the outer conduit insulates the environment from leaks in the inner conduit. For a better explanation of such pipes and concerns about how they are connected, reference is made to Chapter B13 of PIPING HANDBOOK, 7.sup.th edition, copyright 2000, published by McGraw-Hill, which is hereby incorporated by reference.

As better illustrated in FIG. 3, each fuel dispenser 32 is coupled to a branch conduit 46 to receive fuel from the underground storage tank 34 via the main conduit 44. The fuel dispenser 32 is coupled to a branch conduit 46 that is coupled to the main conduit 44 to receive fuel. As fuel enters into the fuel dispenser 32 via the branch conduit 46, the fuel typically first encounters a shear valve 48. The shear valve 48 is designed to cut off the fuel supply piping 47 internal to the fuel dispenser 32 from the branch conduit 46 in the event that an impact is made on the fuel dispenser 32 for safety reasons. The fuel delivery piping 47 carries the fuel inside the fuel dispenser 32 to its various components before being delivered to a vehicle. As is well known in the fuel dispensing industry, the shear valve 48 is designed to shut off the supply of fuel from the underground storage tank 34 and the branch conduit 46 if the fuel dispenser 32 is impacted to ensure that any damaged internal fuel supply piping 47 due to an impact cannot continue to receive fuel from the branch conduit 46 that may then be leaked to the ground, the customer, and/or the environment.

After the fuel leaves the shear valve 48, the fuel typically passes through a flow control valve 49 located inline to the fuel supply piping 47. The flow control valve 49 may be used to control the flow of fuel into the fuel dispenser 32. The flow control valve 49 may be a two-stage valve so that the fuel dispenser 32 controls the flow of fuel in a slow mode at the beginning of a dispensing event and at the end of the dispensing event (in the case of a prepaid dispensing event), and a fast mode for fueling during steady state after slow flow mode is completed.

After the fuel leaves the flow control valve 49 in the fuel supply piping 47, the fuel may encounter a filter 50 to filter out any contaminants in the fuel before the fuel reaches the flow meter 52 that is typically located on the outlet side of the filter 50. The filter 50 helps to prevent contaminates from passing to the fuel flow meter 52 and the customer's fuel tank. Contaminates can cause a fuel flow meter 52 to malfunction and/or become un-calibrated if the meter 52 is a positive displacement meter, since the contaminate can scrub the internal housing of the meter 52 and increase the volume of the meter 52. If a filter 50 becomes clogged or blocked in any way, either wholly or partially, this will impede the flow of fuel from the fuel dispenser 32 and thereby reduce the maximum throughput/flow rate of the fuel dispenser 32. The maximum throughput of the fuel dispenser 32 is the maximum flow rate at which the fuel dispenser 32 can deliver fuel to a vehicle if no blockages or performance problems exist.

The filter 50 is changed periodically by service personnel during service visits, and is typically replaced at periodic intervals or when a fuel dispenser 32 is noticeably not delivering fuel at a fast enough flow rate. Because the filter 50 is changed in this manner, a fuel dispenser 32 may encounter unusual and unintended low flow rates for a period of time before they are noticed by the station operators and/or before service personnel replace such filters 50 during periodic service visits. There are also other components of a fuel dispenser 32 in addition to the filter 50 that may cause a fuel dispenser 32 to not deliver fuel at the intended flow rate, such as a defective or blocked valve 48, meter 52, hose 58, nozzle 60, or any other component in the fuel supply piping 47 of the fuel dispenser 32.

After the fuel leaves the filter 50, the fuel enters into the fuel flow meter 52 to measure the amount of volumetric flow of fuel. The amount of volumetric flow of fuel is communicated to a controller 54 in the fuel dispenser 32 via a pulse signal line 56 from the fuel flow meter 52. The controller 54 typically transforms the pulses from the pulse signal line 56 into the total number of gallons dispensed and the total dollar amount charged to the customer, which is then typically displayed on LCD displays (not shown) on the fuel dispenser 32 visible to the customer. Note that the flow control valve 49 discussed above may be located on either the inlet or outlet side of the fuel flow meter 52.

After the fuel leaves the fuel flow meter 52, the fuel is delivered to the fuel supply piping 47 on the outlet side of the fuel flow meter 52 where it then reaches a hose 58. The hose 58 is coupled to a nozzle 60. The customer controls the flow of fuel from the hose 58 and nozzle 60 by engaging a nozzle handle (not shown) on the nozzle 60 as is well known.

If there is any blockage, either partially or wholly, in the fuel supply piping 47 within the fuel dispenser 32 or any components located inline to the fuel supply piping 47, the fuel cannot be delivered by the fuel dispenser 32 to a vehicle at the maximum throughput or flow rate that the fuel dispenser 32 would be capable of performing if no blockage existed. A blockage in the fuel supply piping 47 can occur within the piping 47 itself or as a result of a blockage in any of the components that are located inline to the fuel supply piping 47, including but not limited to the shear valve 48, the flow control valve 49, the filter 50, the fuel flow meter 52, the hose 58, and the nozzle 60. Also, if the submersible turbine pump (not shown) that pumps fuel from the underground storage tank 34 to the fuel dispensers 32 is suffering from reduced performance and/or pumping rate, this may result in fuel dispensers 32 not delivering the maximum throughput or flow rate of fuel.

Any decline in the submersible turbine pump performance, a blockage in the fuel supply piping 47, or a blockage in components located inline to the fuel supply piping 47 may cause the fuel dispenser 32 to either not deliver fuel at all or at a reduced rate, thereby reducing the throughput efficiency of the fuel dispenser 32 and possibly requiring a customer to spend more time refueling a vehicle. The customer may be frustrated and therefore not visit the same service station for his or her fueling needs. The reduced throughput of the fuel dispenser 32 may also cause other customers to wait longer for a fueling position thereby resulting in lost revenue in terms of lost opportunity revenues. If the fuel dispenser 32 throughput efficiency can be measured and then compared against a normal throughput in an automated manner, fuel dispenser 32 throughput problems can be detected shortly after their occurrence to allow a station operator and/or service personnel to remedy the problem more quickly.

If a number of motorists dispense fuel simultaneously, the performance of the pump (not pictured) or fuel supply piping 47 may not be sufficient to deliver fuel to the fuel dispenser 32 at all or may cause fuel to be delivered at a reduced rate and possibly require a customer to spend more time refueling a vehicle. The customer may be frustrated and therefore not visit the same service station for his or her fueling needs. The reduced throughput of the fuel dispenser 32 may also cause other customers to wait longer for a fueling position thereby resulting in lost revenue in terms of lost opportunity revenues. If the fuel dispenser 32 flow rate for isolated dispenses (where no other dispensing is taking place at the same time) can be measured and then compared against flow rates for simultaneous dispenses, insufficient pump capacity can be determined or fuel supply piping 47 problems can be detected shortly after their occurrence to allow a station operator and/or service personnel to repair or upgrade their pump or remedy the problem more quickly.

When the flow rate is calculated at a fuel dispenser 32, a reduced flow rate may be caused by a blockage in the fuel supply piping 47, a problem in performance with a fuel pump, or simply human behavior of a motorist dispensing fuel slowly. Only if the tank monitor 36, site controller 26, and/or other control system determines whether there are other dispenses which occurred at the same time can it determine whether the flow rate was affected by the other dispenses.

Until the present invention, one method known for monitoring the throughput efficiency of a fuel dispenser 32 is to measure the flow rate of the fuel dispenser 32. The flow rate is the amount of fuel delivered by the fuel dispenser 32, as measured by the fuel flow meter 52, over the period of time that the dispending event was active. For example, if a fuel dispenser 32 delivers ten gallons of fuel to a vehicle in a two minute dispensing event, the flow rate of the fuel dispenser 32 is five gallons per minute. The fuel dispenser 32 may determine the flow rate by dividing the volume of fuel dispensed, as measured by the fuel flow meter 52, by time, or the flow rate may be determined manually by dividing the volume of fuel delivered as indicated by the fuel dispenser 32 volume display by time. However, with these techniques, several issues can occur which will inaccurately reduce the measured flow rate from the true maximum flow rate capability of the fuel dispenser 32. For example, the nozzle may not be fully engaged during the entire dispensing event thereby reducing the volume throughput and also the calculated flow rate. If the fuel dispenser 32 were to start a timer when performing a flow rate calculation based on the activation and deactivation of the fuel dispenser 32, the timer may start before fuel flow begins thereby causing the time factor in the flow rate calculation to include what is known as "dead time."

FIG. 4 illustrates an example of a typical dispensing event at a fuel dispenser 32 showing volume of fuel dispensed versus time to illustrate the concept of "dead time." At the beginning of the dispensing event, labeled as "Dispense Start," the customer has initiated a dispensing event at a fuel dispenser 32, but has not yet engaged the nozzle 60 handle. The "Dispense Start" event may be obtained from a status of the dispenser 32 being turned on via a switch or relay present in the dispenser 32 that may be associated with the nozzle 60 handle, or may be a digital event that is generated and/or stored in memory of the dispenser 32 and may be accessed. For the purposes of this description, the dispensing start event may also be known to those in the art as a dispensing transaction start event, and the dispense start event data encompasses any of the aforementioned methods.

The customer may begin a dispensing event by lifting a nozzle 60 holder lift (not shown) on the fuel dispenser 32 or by pressing a button. After the customer begins the dispensing event, the tank monitor 36 and/or site controller 26 receives the "Dispense Start" message that indicates the dispensing event start time and fueling point number or name. After "Dispense Start" and before the nozzle 60 handle is engaged to begin fuel flow, time passes for the dispensing event even though fueling is not yet occurring. Once the customer engages the nozzle 60, fuel flow begins which is labeled as "Flow Start" in FIG. 4. "Flow Start" information is typically not made available to the tank monitor 36 and/or site controller 26. The time between the "Dispense Start" message and "Flow Start" is known as "dead time," where fuel is not flowing even though the dispensing event is active at the fuel dispenser 32. After "Flow Start," fueling occurs and the customer may even discontinue fueling during this period of time on purpose or because of a nozzle 60 snap also causing "dead time" in the middle of a dispensing event, which is not illustrated in FIG. 4. The customer may reduce the rate of fueling by not fully engaging the nozzle 60 handle or a pre-pay dispensing event may cause automatic slow down of the rate at the end of fueling, which are not "dead time" since some fuel is flowing, but these also cause the flow rate of the fuel dispenser 32 to be reduced from its maximum flow rate.

When the customer desires to end the dispensing event, the customer will disengage the nozzle 60 handle, labeled as "Flow End", and then deactivate the fuel dispenser 32. This deactivation causes a "Dispense End" message to be generated. Again, the "Dispense End" event may simply be a status of the dispenser 32 being turned off via a switch or relay present in the dispenser 32 that may be associated with the nozzle 60 handle, or may be a digital event that is generated and/or stored in memory of the dispenser 32 and may be accessed. For the purposes of this description, the dispensing end event may also be known to those in the art as a dispensing transaction end event, and the dispense end event data encompasses any of the aforementioned methods. This message is received by the tank monitor 36, site controller 26, and/or other control system and indicates the ending time of the dispensing event, the fueling point number or name, and the total amount and/or running totalizer amount of fuel dispensed. The time between disengaging the nozzle 60 handle and deactivating the fuel dispenser 32 is also "dead time."

As you can see in FIG. 4, the flow rate of the fuel dispenser 32 as measured using the "Dispense Start" and "Dispense End" messages will be lower than the actual flow rates that occur between "Flow Start" and "Flow End" times due to the dead time and due to any discontinuing or reduced engaging of the nozzle 60 handle by the customer or automatically reduced flow during the dispensing event. Therefore, it is not possible to ensure that a reduced flow rate measured by using the "Dispense Start" and "Dispense End" messages is caused by a blockage in the fuel supply piping 47 or a problem in performance with a fuel pump, rather than such reduced flow rate, as measured, occurring as a result of dead time during a dispensing event by any or all of the aforementioned causes.

Therefore, there exists a need to calculate flow rates of actual dispensing, excluding any dead time and/or time of purposefully reduced dispensing flow rates. There further exists a need to correlate the actual dispensing of multiple fuel dispensers 32 at the same time. These needs are fulfilled by using tank level data and a tank monitor 36, site controller 26, and/or other control system and methods for analyzing the data.

SUMMARY OF THE INVENTION

The present invention relates to a system and method for determining the flow rate of dispensing points and flow capacities of pumps in a service station environment wherein the dead time and periods of reduced flow of the dispensing events used are reduced and/or eliminated. The system and method further correlates the actual dispensing of fuel from multiple dispensing points at the same time.

A control system, which may be a site controller, tank monitor, or other controller, receives the start and stopping events generated when a dispensing event is activated and deactivated, respectfully. The control system monitors the tank level information in the underground storage tanks, via tank probes or tank gauges, and records tank levels at different times immediately before, during and after a dispensing event, called "tank level data points."

The control system next uses various mathematical techniques to analyze the tank level data points and determine a region of interest in the tank level data points that has been determined to minimize and/or eliminate tank level data points that will include dead time or other time when dispensing is not occurring or not occurring at maximum flow rates, such as a top off for example. After the tank level data points are analyzed to determine the region of interest, a fitted line is formed through the remaining tank level data points that most likely represent periods of maximum flow rate. The slope of this line is the calculated dispensing flow rate of the dispensing event on the dispensing point.

Various mathematical techniques may be used to analyze the tank level data points. The tank level data points may be smoothed to define a more narrow region of interest where only tank level data points meeting certain criteria in the region of interest are used to fit a line for determining the slope and flow rate. The tank level data points may also be filtered to reduce issues relating to outlying tank level data points. Various techniques may be used to reduce the effect of outlying points and achieve a more accurate flow rate calculation, including but not limited to the well known techniques of least square fit, weighted least square fit, and resistant fit.

Multiple dispensing event calculated dispensing flow rate results for each dispensing point may be further analyzed using weighted averaging or other statistical means to find a more accurate estimation of true maximum flow rate on each dispensing point.

These techniques may be extended to find maximum aggregate flow rates of multiple concurrent dispensing events on multiple dispensing points. Maximum aggregate flow rates are further analyzed to determine the flow capacity characteristics of each fueling pump in the fueling system under increasing pumping load. These flow capacities can be monitored and analyzed to determine if there is a blockage or performance problem with a particular pump or if the pump is not sufficiently powerful for the motorist throughput at the service station.

If the control system determines that the calculated dispensing flow rate for a dispensing point is less than it should be, this is a result of a blockage and/or performance problem at the fuel dispenser or piping system, since the calculated dispensing flow rate has essentially removed the inclusion of "dead time" from the calculation. In this instance, the control system can generate an alarm, send a message to a site controller and/or tank monitor, notify an operator and/or service personnel, and/or send a message to an off-site system.

The control system may use a number of techniques for determining if the calculated dispensing flow rate of a dispensing point indicates a blockage or performance problem. The control system may compare the calculated dispensing flow rate of a dispensing point to a threshold value stored in memory or calculated in real time according to a formula. The control system may compare the calculated dispensing flow rate of a dispensing point to all other calculated dispensing flow rates for all other dispensing points. The control system may compare the currently calculated dispensing flow rate of a dispensing point to past calculated dispensing flow rate for the dispensing point to determine if an anomaly exists.

Similarly, the control system may compare the calculated flow capacity characteristics of each fueling pump in the fueling system under increasing pumping load to expected load characteristics, to all other pumps in the systems, and to past calculated characteristics on the same pump to determine if an anomaly exists.

Analysis of aggregate flow rates of multiple concurrent dispensing events on multiple dispensing points may also be used to determine if the performance of a fuel tank pump is deteriorating or is failing. Dispensing event periods consisting of multiple concurrent dispensing events on multiple dispensing points are first identified in the stored data by examining the chronological sequence of dispense start and end times for all dispensing points at a dispensing facility. Periods where more than one dispensing point 32 are active are isolated and tank fuel level data points are found between the start and end of each isolated period.

Each period of tank level data points is analyzed to calculate a best fit line to the highest slope portion of the period data points. The slope of the best fit line is an aggregate flow rate for the combined dispensing activity on the multiple active dispensing points. A set of calculated aggregate flow rates may be accumulated and analyzed in two different manners.

First, a set of aggregate flow rates are accumulated and grouped for each active pump by number of active dispensing points supplied by a pump. An average aggregate flow rate is calculated from the individual rates for each dispensing point on a pump using volume weighted averaging method or other statistical means to improve resulting accuracy. An aggregate flow rate sequence that falls off from linear with number of dispensing points' earlier than expected or more so than compared to historical aggregate flow rate performance is an indication of a deteriorating or failing pump.

A set of aggregate flow rates of multiple concurrent dispensing event periods on multiple dispensing points may be combined with singly active dispensing point dispensing event periods and further analyzed to improve the accuracy of the estimated flow rate on a dispensing point or to reduce the time required to accumulate adequate data for an analysis on a dispensing point.

Each single or multiple concurrent active dispensing point dispensing period is categorized by the dispensing number or numbers that are active during the period. The aggregate flow rate and associated dispensing point numbers for a period form one data point. A set of such data points is analyzed using multiple linear regression or other statistical method to calculate a flow rate for each individual dispensing point found in the data set.

Those skilled in the art will appreciate the scope of the present invention and realize additional aspects thereof after reading the following detailed description of the invention in association with the accompanying drawing figures.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawing figures incorporated in and forming a part of this specification illustrate several aspects of the invention, and together with the description serve to explain the principles of the invention.

FIG. 1 illustrates a conventional communication system within a fueling environment in the prior art;

FIG. 2 illustrates a conventional fueling path layout in a fueling environment in the prior art;

FIG. 3 illustrates, according to an exemplary embodiment of the present invention, a fuel dispenser;

FIG. 4 illustrates a typical dispensing event of volume versus time;

FIG. 5 illustrates one embodiment of determining the calculated dispensing flow rate for a dispensing point using fuel tank level data having a 30 second resolution;

FIG. 6 illustrates the embodiment illustrated in FIG. 5 for determining the calculated dispensing flow rate for a dispensing point using fuel tank level data, except that the fuel tank level data has a 5 second resolution;

FIGS. 7A and 7B illustrate flow chart diagrams of how the calculated dispensing flow rate is determined for a dispensing point in accordance with the embodiments illustrated in FIGS. 5 and 6;

FIGS. 8A and 8B illustrate a flow chart diagram of an alternative embodiment of determining a calculated dispensing flow rate for a dispensing point using a weighted least square regression line technique;

FIG. 9 is a flow chart diagram illustrating one embodiment of analyzing a calculated dispensing flow rate for a dispensing point;

FIG. 10 is a flow chart diagram illustrating an alternative embodiment of analyzing a calculated dispensing flow rate for a dispensing point;

FIG. 11 is a flow chart diagram illustrating another alternative embodiment of analyzing a calculated dispensing flow rate for a dispensing point; and

FIG. 12 is a flow chart diagram illustrating an analysis of aggregate flow rates of multiple concurrent dispensing events on multiple dispensing points to determine if the fuel tank pump has a performance problem or