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Automatic Batch Control of Fuel Mix

01/19/2009 10:01 AM

I've been pulled onto a project that has become the victim of creeping elegance. The original idea was to blend fuel manually from jerry cans. Then it was decided that the amounts had to grow and so a system of two batch controllers was purchased with a system of two pumps and flow meters to pump the two fuels into a tank. Now the system is supposed to run over night and mix new batches of fuel automatically - the tank is too small to run the engine over night on one fill.

Turns out the batch controllers that were purchased can't be controlled by a computer. I am now trying to find a replacement batch controller but it seems that very few of these units are set up so that they can run in manual mode or be controlled by a PC using RS232 communications. The control on the RS232 is very limited. My searches so far have found nothing in a batch controller that will accept external programming to set and start the batch run.

Does anybody have any experience with this? I am getting the impression that using a "batcher" is the wrong way to go about this. It would seem that using a PC application (e.g. LabVIEW) with a manual or auto decision and GUI is the better way to go and then just scrap the batch control units completely. I would just monitor the flow meters in LabVIEW and drive the pumps with a couple of I/O.

But I don't want to re-invent the wheel. Is there a batcher that will accept exteral control?

Thoughts? Thanks!

Yeah, in case you haven't noticed I've never worked with batchers before....

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#1

Re: Automatic batch control of fuel mix

01/19/2009 10:07 AM

Eric

I think the simplist solution would be to attach a larger fuel tank, one with enough capacity to run the particular device over night.

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#4
In reply to #1

Re: Automatic batch control of fuel mix

01/19/2009 11:18 AM

Unfortunately the fire code and the cost of retrofit won't allow a larger tank to be used. That's gotcha number one....

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#6
In reply to #4

Re: Automatic batch control of fuel mix

01/20/2009 6:00 AM

Fire Code won't allow a larger tank but its ok to have 2 separate tanks pumping a fuel mixture into the existing tank????????

That does not make sense to me. I can understand that there may not be enough room for a larger tank to be attached directly but I can't see them allowing 2 other tanks to be sitting someplace near by pumping a fuel mixture into the existing tank either.

Why aren't you premixing the fuel manually in one separate tank then pumping it to the existing tank.

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#8
In reply to #6

Re: Automatic batch control of fuel mix

01/20/2009 8:10 AM

Sorry, not enough detail. The main supply tanks are outside the building. The "day tank" is the only tankage in the dyno room.

The idea of having a large mix tank outside the building and then supplying the day tank is an interesting idea. Too bad nobody thought of is a few months ago.

It always fun to be brought in at the last minute!

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#2

Re: Automatic Batch Control of Fuel Mix

01/19/2009 10:36 AM

we use pulse meters for delivery of lubricating solutions these can be programed from a master controller and set to gallons or quarts mabey these could work for you. also if you need a bigger tank we sell those also

http://www.liftandlube.com/default.asp

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#3
In reply to #2

Re: Automatic Batch Control of Fuel Mix

01/19/2009 10:44 AM

That is just not fair, I checked the web site, you have access to all the toys I want.

Tell you what, sned me a lift and some tool boxes and I will write a veview for the magazine I wrtie for.

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#5

Re: Automatic Batch Control of Fuel Mix

01/19/2009 4:07 PM

Use servo motors on your pumps to mix the batches. Controllers can then allow you to adjusted mixture by increasing or decreasing motor speed. Sensors for level control from the tank can provide information to controller maintaining fuel level. With the right match of pumps the system could maintain level with out shutting the pumps off.

I question your information are we mixing fuel into a tank to run a engine or is it the engine that is pumping the fuels and the tank holding the mixture too small for the engine to run over night?

If you are mixing fuels to fill a tank to run the engine overnight i would recommend auxiliary tank would eliminate the chance of over filling tank and causing a hazard. The auxiliary tank can be mounted off the engine.

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#7

Re: Automatic Batch Control of Fuel Mix

01/20/2009 8:05 AM

I have a few problems about this discussion.

First you mention "fuel". This usually makes engineers and designers run for cover because it means volatile or flammable and it involves mechanical action (mixing). This is never a good situation.

Second you mention monitoring with a PC meaning the action will take place unsupervised. Once again not a good situation.

I also notice you didn't mention how fine a tolerance your mixture must be. If for example you are mixing ethenol with gasoline at a gas station they use a splash mix, meaning they just throw it in there together and hope it achieves a percentage mix that won't burn your none ethenol engine up.

It might be a better idea to use some short of stirring motion other than batch mixing.

I recommend you talk to someone in the petrochemical refining industry both about how to achieve a mixture and the cautions you need to take when mixing two hazardous materials.

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