Abstract:
A tank monitor control device is disclosed which comprises a monitoring device for insertion into a day tank to monitor a level of fluid stored in the day tank, a shutoff valve connected between a main storage tank and a diaphragm pump, a solenoid valve connected between an air supply and the diaphragm pump, and a control device connected to the monitoring device for receiving a signal indicative of the level of fluid in the day tank, the control device connected to the shutoff valve and the solenoid valve.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This non-provisional patent application claims priority to the provisional patent application having Ser. No. 61/967,260, filed on Mar. 13, 2014. 
    
    
     FIELD OF THE DISCLOSURE 
     This disclosure generally relates to monitoring and control systems, and more particularly to a tank monitor control device for controlling operation of various devices associated with a storage tank. 
     BACKGROUND 
     Day tanks are used to store a supply of fuel that is separate from a main fuel storage tank. The day tank has enough fuel stored therein to be able to supply fuel to, for example, a generator or a heater for at least a day. In some areas it may take a day to obtain a delivery of fuel to replenish the main fuel storage tank. In this situation, the day tank will be able to store enough fuel to power a generator or heater until a deliver is made to replenish the main fuel storage tank. 
     It is also known that some establishments generate waste oil and the waste oil is used to fuel generators or heaters. Use of waste oil helps in reducing energy costs. For example, waste oil is stored in a main storage tank and is pumped to a day tank to supply a generator or a heater. Instead of having to purchase fuel or electricity, the waste oil is used to fuel a generator or a heater. In this manner, energy costs are saved or reduced. 
     The day tank may have one or more threaded openings in the top of the tank. One of the openings may be a 2 inch diameter bung hole opening that is used to fill or empty the container. Another one of the openings may be a ¾ inch diameter bung hole opening used for ventilation of the contents of the tank. Over time, the contents of the day tank are emptied and it is important to know when the day tank has reached a low level condition to pump or transfer waste oil from the main storage tank to the day tank to refill the day tank. It is also desirable to know when the day tank has been filled to an upper level condition to shutoff a pump device that is pumping waste oil from the mail storage tank to the day tank. It is extremely important to avoid an overflow condition where waste oil could exit out of the day tank and contaminant any surrounding area. Cleaning up spilled waste oil can be expensive and should be avoided. 
     In order to determine the level of the contents within the day tank, various gauges have been used. For example, a float device may be inserted into the tank to determine the level of liquid contents. A stick gauge may also be inserted into the tank to determine the level of the contents within the tank. However, such gauges do not provide any warning or indication as to when the contents of the tank reaches a critical level. Also, none of these devices is capable of controlling the pumping of waste oil from the main storage tank to the day tank. Further, these devices do not assist in avoiding an overflow condition. 
     The present disclosure is designed to obviate and overcome many of the disadvantages and shortcomings experienced with prior devices for determining a level of liquid in a day tank and for controlling operation of a pump that transfers waste oil from a main storage tank to a day tank. Moreover, the present disclosure is related to a tank monitor control device that can determine when the tank will be empty, full, or at an overflow condition. 
     SUMMARY OF THE DISCLOSURE 
     The present disclosure is a tank monitor control device which comprises a monitoring device for insertion into a day tank to monitor a level of fluid stored in the day tank, a shutoff valve connected between a main storage tank and a diaphragm pump, a solenoid valve connected between an air supply and the diaphragm pump, and a control device connected to the monitoring device for receiving a signal indicative of the level of fluid in the day tank, the control device connected to the shutoff valve and the solenoid valve. 
     In another form of the present disclosure, a tank monitor control device comprises a monitoring device for insertion into a day tank to monitor a level of fluid stored in the day tank, a shutoff valve connected between a main storage tank and a diaphragm pump, a solenoid valve connected between an air supply and the diaphragm pump, and a control device positioned at a location remote from the monitoring device, the control device electrically connected to the monitoring device for receiving a signal indicative of the level of fluid in the day tank, the control device connected to the shutoff valve and the solenoid valve. 
     In yet another form of the present disclosure, a tank monitor control device is disclosed which comprises a monitoring device for insertion into a day tank to monitor a low level of waste oil stored in the day tank to produce a low level signal, a high level of fluid stored in the day tank to produce a high level signal, and an overflow level of fluid stored in the day tank to produce an overflow level signal, a shutoff valve connected between a main storage tank and a diaphragm pump, a solenoid valve connected between an air supply and the diaphragm pump, and a control device connected to the monitoring device for receiving the low level signal, the high level signal, and the overflow level signal, the control device connected to the shutoff valve and the solenoid valve. 
     The present disclosure provides a tank monitor control device that can be easily employed with highly reliable results to control a waste oil storage and supply system. 
     The present disclosure further provides a tank monitor control device that provides an audible alarm when an overflow condition has been detected. 
     The present disclosure provides a tank monitor control device that requires only a few tools for installation in a day tank or removal from a day tank. 
     The present disclosure provides a tank monitor control device that is easy to program to detect various operating conditions. 
     The present disclosure is further directed to a tank monitor control device that can replace existing gauges and does not require a day tank to be retrofitted for use of the tank monitor control device of the present disclosure. 
     The present disclosure also provides a tank monitor control device that can be constructed of readily available components for easy installation into a day tank. 
     The present disclosure is directed to a tank monitor control device that provides for manual filling of a waste fuel day tank during off hours. 
     The present disclosure provides a tank monitor control device that automatically ensures that a waste fuel day tank is full for optimum heating or operation. 
     These and other advantages of the present disclosure will become apparent to those skilled in the art after considering the following detailed specification in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a block diagram of a tank monitor control device constructed according to the present disclosure; 
         FIG. 2  is a block diagram of another embodiment of a tank monitor control device constructed according to the present disclosure; 
         FIG. 3  is a perspective view of the tank monitor control device connected to a monitoring device, and adapted to be connected to a shutoff valve and a solenoid valve constructed according to the present disclosure; and 
         FIG. 4  is a perspective view of a circuit board installed in the tank monitor control device with the control board being connected to a monitoring device, a shutoff valve, and a solenoid valve. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     Referring now to the drawings, wherein like numbers refer to like items, number  10  identifies a preferred embodiment of a tank monitor control device constructed according to the present disclosure. With reference now to  FIG. 1 , the tank monitor control device  10  is shown being positioned above and connected to a day tank  12  that contains a quantity of waste oil (not shown). Although not shown, a monitoring device is inserted into the day tank  12  through a bung hole (not shown) positioned on top of the day tank  12 , as will be described in detail further herein. The monitoring device is connected to the control device  10 , as will be described in detail further herein. The device  10  is capable of monitoring various levels of waste oil stored in the day tank  12 . For example, a low level condition, a high level condition, and an overflow condition may be monitored by the device  10 . The day tank  12  provides waste oil to a generator  14  by a pipe or conduit  16 . The generator  14  may also be a heating unit that is used to heat an enclosed structure, such as a garage. In this manner, waste oil is used to generate power or heat that would otherwise have to be provided by paying a utility company for electricity or gas. The day tank  12  receives waste oil from a main storage tank  18  through an emergency or overflow shutoff valve  20  and a diaphragm pump  22 . The main storage tank  18  is connected to the shutoff valve  20  by a pipe or conduit  24 , the shutoff valve  20  is connected to the pump  22  by a pipe or conduit  26 , and the pump  22  is connected to the day tank  12  via a pipe or conduit  28 . In this manner, the day tank  12  is filled with waste oil from the storage tank  18  through the pipe  24 , the shutoff valve  20 , the pipe  26 , the pump  22 , and the pipe  28 . As can be appreciated, if either the shutoff valve  20  is activated or the pump  22  is deactivated then no waste oil will flow to the day tank  12 . 
     The pump  22  is connected to an air supply  30  through a solenoid valve  32 . The air supply  30  provides a supply of air through a pipe or conduit  34  to the solenoid valve  32  and through the solenoid valve  32  to the pump  22  via a pipe or conduit  36 . In this manner, air flows from the air supply  30  through the solenoid valve  32  to operate the pump  22 . When the pump  22  is operating or moving, waste oil from the storage tank  18  is pumped into the day tank  12 . Although the control device  10  has been described as being used with waste oil being stored in the main storage tank  18  and the day tank  12 , it is also possible that the tanks  12  and  18  may be used to store oil, diesel fuel, antifreeze, and other fluids having a low flash point. 
     The control device  10  is connected to the shutoff valve  20  by an electrical connection, wire, or cable  38 . The control device  10  can control operation of the shutoff valve  20  by sending a signal over the electrical connection  38 . In particular, when an overflow condition is detected by the control device  10 , a signal is sent over the electrical connection  38  to operate the shutoff valve  20  to stop the flow of waste oil from the main storage tank  18  to the day tank  12 . The control device  10  is also connected to the solenoid valve  32  via an electrical connection, wire, or cable  40 . The control device  10  can control operation of the solenoid valve  32  by sending a signal over the electrical connection  40 . For example, manual filling of the day tank  12  may be desirable. In order to accomplish this, the control device  10  sends a signal over the electrical connection  40  to operate the solenoid valve  32  to allow air to flow from the air supply  30  to the pump  22 . Although electrical connections  38  and  40  have been described, it should be understood that such connections  38  and  40  may include one or more wires, leads, cables, or conductors, as will be described more fully herein. 
     With reference now to  FIG. 2 , a tank monitor control device  100  is shown being positioned at a location remote from a day tank  102 . For example, the tank monitor control device  100  may be mounted on a wall in a room that is remote from the day tank  102 . The control device  100  is capable of monitoring various levels of waste oil stored in the day tank  102  by use of various level sensors  104  inserted into the day tank  102 . The control device  100  is connected to the level sensors  104  by various wires  106 . For example, the level sensors  104  are used to determine, monitor, or sense a low level condition, a high level condition, and an overflow condition. The day tank  102  provides waste oil to a generator  108  by a pipe or conduit  110 . The generator  108  may also be a heating unit that is used to heat an enclosed structure, such as a garage. In this manner, waste oil is used to generate power or heat that would otherwise have to be provided by paying a utility company for electricity or gas. The day tank  102  receives waste oil from a main storage tank  112  through an emergency or overflow shutoff valve  114  and a diaphragm pump  116 . The main storage tank  112  is connected to the shutoff valve  114  by a pipe or conduit  118 , the shutoff valve  114  is connected to the pump  116  by a pipe or conduit  120 , and the pump  116  is connected to the day tank  102  via a pipe or conduit  122 . In this manner, the day tank  102  is filled with waste oil from the storage tank  112  through the pipe  118 , the shutoff valve  114 , the pipe  120 , the pump  116 , and the pipe  122 . As can be appreciated, if either the shutoff valve  114  is activated or the pump  116  is deactivated then no waste oil will flow to the day tank  102 . 
     The pump  116  is connected to an air supply  124  through a solenoid valve  126 . The air supply  124  provides a supply of air through a pipe or conduit  128  to the solenoid valve  126  and through the solenoid valve  126  to the pump  116  via a pipe or conduit  130 . In this manner, air flows from the air supply  124  through the solenoid valve  126  to operate the pump  116 . When the pump  116  is operating or moving, waste oil from the storage tank  112  is pumped into the day tank  102 . 
     The control device  100  is connected to the shutoff valve  114  by an electrical connection  132 . The control device  100  can control operation of the shutoff valve  114  by sending a signal over the electrical connection  132 . In particular, when an overflow condition is detected by the control device  100 , a signal is sent over the electrical connection  132  to operate the shutoff valve  114  to stop the flow of waste oil from the main storage tank  112  to the day tank  102 . The control device  100  is also connected to the solenoid valve  126  via an electrical connection  134 . The control device  100  can control operation of the solenoid valve  126  by sending a signal over the electrical connection  134 . For example, if manual filling of the day tank  102  is desired, then the control device  100  sends a signal over the electrical connection  134  to operate the solenoid valve  126  to allow air to flow from the air supply  124  to the pump  116 . 
       FIG. 3  is a perspective view of the control device  10  connected to a monitoring device  150  and adapted to be connected the shutoff valve  20  and the solenoid valve  32 . The control device  10  has a housing  152  having a front face plate  154 . Provided on the face plate  154  is an on off toggle switch  156 , a manual fill push button  158 , a test push button  160 , an overflow indicator  162 , a pump indicator  164 , a level within range indicator  166 , a power indicator  168 , and an audible alarm or siren  170 . The indicators  162 ,  164 ,  166 , and  168  may be LEDs (light emitting diodes). The siren  170  may be operated to indicate an overflow condition has been detected. A right side cord grip  172  is provided on the housing  152  and the electrical connection  38  ( FIG. 1 ) may be threaded through the cord grip  172  to connect the control device  10  to the shutoff valve  20 . A left side cord grip  174  is also provided on the housing  152  and the electrical connection  40  ( FIG. 1 ) may be threaded through the cord grip  174  to connect the control device  10  to the solenoid valve  32 . It is also possible that only one of the cord grips  172  and  174  may be provided on the housing  152 . 
     The monitoring device  150 , which is inserted into the day tank  12  to monitor the level of waste oil in the day tank  12 , has a low level reed switch  176 , a high level reed switch  178 , and an overflow level reed switch  180 . As can be appreciated, the level of waste oil within the day tank  12  can be monitored or detected by the reed switches  176 ,  178 , and  180 . A tube  182  has a low spacer  184  positioned thereon with the lower spacer  184  have the low level reed switch  176  connected thereto. A high spacer  186  is also connected to the tube  182  and the high level reed switch  178  is connected to the high spacer  186 . Further, the overflow level reed switch  180  is connected to an overflow spacer  188 . An adapter  190  is used to connect the control device  10  to the monitoring device  150 . The adapter  190  has a threaded end  192  that is used to secure the adapter  190  to a threaded opening (not shown) associated with the day tank  12 . Once threaded into position, the control device  10  and the monitoring device  150  are held in place with respect to the day tank  12 . The tube  182  also allows for any electrical connections between the reed switches  176 ,  178 , and  180  and the control device  10  to pass through the tube  182 . The tube  182  can also have any length with the length being dependent upon the height or depth of the day tank  12 . 
     With reference now to  FIG. 4 , a circuit board  200 , which may be installed in the control device  10 , is shown being connected to the shutoff valve  20 , the solenoid valve  32 , and the monitoring device  150 . The circuit board  200  has a terminal block  202  that provides for connection of the various electrical connections, such as electrical connections  38  and  40  ( FIG. 1 ) or  106 ,  132 , and  134  ( FIG. 2 ). The overflow valve  20  may be connected to the terminal block  202  by a pair of wires  204  and  206 . A signal sent over the wires  204  and  206  from the control device  10  will control the operation of the overflow valve  20 . As can be appreciated, if the monitoring system  150  detects an overflow condition by the overflow level reed switch  180  being activated, then the control device  10  will send a signal to activate the overflow valve  20  to stop any waste oil from being pumped. The solenoid valve  32  is connected to the terminal block  202  by a first pair of power wires  208  and  210  and a pair of control wires  212  and  214 . Power from the circuit board  200  is provided to the solenoid valve  32  over the wires  208  and  210 . A signal to control operation of the solenoid valve  32  is provided over the wires  212  and  214 . For example, if the monitoring system  150  detects a low level condition by the low level reed switch  176  being activated, then the control device  10  will send a signal over the wires  212  and  214  to activate the solenoid valve  32 . The control device  10  may also send a signal over the wires  212  and  214  when the manual fill push button  158  ( FIG. 3 ) is manually activated. The button  158  may be operated after working hours to manually fill the day tank  12 . 
     The monitoring system  150  is connected to the terminal block  202  in the following manner. A pair of wires  216  and  218  connect the low level reed switch  176  to the block  202 , a pair of wires  220  and  222  connect the high level reed switch  178  to the block  202 , and a pair of wires  224  and  226  connect the overflow level reed switch  180  to the block  202 . In this manner, when the low level reed switch  176  is activated, which corresponds to waste oil dropping below the switch  176 , a signal is sent over the wires  216  and  218  to the control device  10 . When the high level reed switch  178  is activated, which indicates that the level of waste oil is above the switch  178 , then a signal is provided over the wires  220  and  222  to indicate a high level has been obtained. Also, when the overflow level reed switch  180  is activated, this corresponds to an overflow condition and a signal is sent to the control device  10  over the wires  224  and  226 . Although the wires  216 ,  218 ,  220 ,  222 ,  224 , and  226  are illustrated being connected to their respective reed switches  176 ,  178 , and  180 , as has been discussed, the wires  216 ,  218 ,  220 ,  222 ,  224 , and  226  are routed through the tube  182  ( FIG. 3 ). The wires  216 ,  218 ,  220 ,  222 ,  224 , and  226  are only shown in this manner for purposes of clarity. 
     The circuit board  200  also includes other components such as a control circuit  228  and power leads  230  and  232 . The control circuit  228  may be a microcontroller, a microprocessor, an ASIC (applications specific integrated circuit), or other integrated circuit device or chip. The control circuit  228  may include software code or a software program for controlling operation of the control device  10 . Other components, such as an RAM (random access memory) chip, an EPROM (electrically programmable read only memory) chip, an electronically erasable programmable read only memory chip, an PLA (programmable logic array) chip may also be part of the circuit board  200 . 
     With the control device  10  installed, the control device  10  operates in the following manner. Typically, waste oil will be stored in the day tank  12  and the level of waste oil will be between the high level reed switch  178  and the overflow reed switch  180 . The level within range indicator  166  will be activated to indicate that the day tank  12  is full. Over time, waste oil will be sent to the generator  14 . As the day tank  12  empties, the low level reed switch  176  will be energized. Once this occurs, a signal will be sent by the control device  10  over the electrical connection  40  to operate the solenoid valve  32  to allow waste oil from the main storage tank  18  to be pumped into the day tank  12 . At some point during the pumping process, the high level reed switch  178  will become activated. The control device  10  will wait until the overflow reed switch  180  becomes active and then send a signal over the electrical connection  38  to activate the shutoff valve  20  to stop the pumping of waste oil from the main storage tank  18  to the day tank  12 . The control device  100  functions in the same manner. One of the differences between the control device  10  and the control device  100  is that the control device  100  is located remotely from the day tank  102 . As can be appreciated, the control device  10  is capable of performing various other functions or procedures, such as being able to manually fill the day tank  12  and to test the control device  10 . 
     From all that has been said, it will be clear that there has thus been shown and described herein a tank monitor control device. It will become apparent to those skilled in the art, however, that many changes, modifications, variations, and other uses and applications of the subject tank monitor control device are possible and contemplated. All changes, modifications, variations, and other uses and applications which do not depart from the spirit and scope of the disclosure are deemed to be covered by the disclosure, which is limited only by the claims which follow.