Abstract:
A multi axis robot is mounted in a fuel transfer housing. A programmable controller is connected to the robot. A control console receives instructions, from a vehicle operator who remains in an operator&#39;s station, and transmits instructions to the controller. Cameras locate the vehicle fueling port. A tube is extended from the transfer housing toward the fueling port. The port is opened by robot arm and tools extending through the tube. The cap is stored. A fuel discharge is connected to the port. A fuel pump is activated and then deactivated. The fuel discharge is removed from the port. The robot retrieves the fuel cap, closes the port and closes other port covers. The tube is retracted into the transfer housing. During fueling air and fuel vapors are sucked into the housing. Filters separate air. Captured fuel is returned to storage. The operator and vehicle separate from the fuel housing.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of the filing date of U.S. Provisional Application No. 61/299,934 titled AUTOMATIC GROUND REFUELING USING A TELESCOPING PLENUM filed Jan. 30, 2010. 
    
    
     TECHNICAL FIELD 
     The invention is in an apparatus for fueling and defueling vehicles, capturing fuel vapors from the vehicle and fuel storage tank, and a method of operating the apparatus. 
     BACKGROUND OF THE INVENTION 
     Apparatus has been used for automated fueling of land vehicles. All of these land vehicles were modified to have a special fueling port in one specific location on the vehicle. One wheel of the vehicle was locked in a predetermined location during fueling. Fuel spilled during vehicle filling was received in a sump. Vapors from the vehicle tank were not captured. Vapors from the fuel in the sump were not captured. The apparatus was not able to defuel the vehicle tank. Errors in positioning of the vehicle and positioning of the fuel supply tube relative to the fuel receiving aperture on the vehicle were difficult to control. 
     SUMMARY OF THE INVENTION 
     Zero tolerance emissions capturing the underground or above ground vapors, vapors from the nozzle connection, also fugitive vapors, claiming up to 99% of all vapors are VOC (Volatile Organic Compounds). All vapors travel through a filtering and separation pumping station that the liquid travels to the storage tank and the vapors are separated and vented as clean air to the atmosphere. 
     Carbon credits possible on a carbon exchange with zero tolerance emissions. 
     Ultra high delivery speed is possible, greatly exceeding current 10 gpm for gasoline and 28-38 gpm for diesel fuel. 
     For the federal government, this is a shovel ready green project. 
     We can use virtually and practically any known nozzle on the market today, especially commercial high speed nozzles. 
     Telescoping plenum allows most vapors a time and place to be captured. A on the market filter system for all vapors will obsolete the clumsiness and time consuming efforts of both Stage 1 and Stage 2 vapor recovery. 
     The ORVR (On board Refueling for Vapor Recovery) is reported to capture up to 95% of refueling vapors on cars using gasoline. Our system captures up to 99% of the remaining vapors to give a zero tolerance vapor emissions system. 
     For diesel fuel, there is a reformer system that uses Urea on mostly Class 8 trucks to capture the Total Aromatic Hydrocarbons (TAH). This technology is called REF. We can capture up to 99% of TAH. 
     We can defuel a gasoline tank of a vehicle. When a wholesaler wants to sell a car on auction, only 3 gallons of fuel are needed. With a million cars, trading in at an 15 gallons in the tank equals $45 million dollars in wasted fuel. Turning a car in with 3 gallons of fuel at $3.00 per gallon is only $9 million dollars, giving a $36 million dollars in fuel or enough to buy 1800 new cars at $20 thousand dollars each. The same scenario is true for diesel fuel only larger numbers. Diesel fuel can be drained easily while gasoline cannot. 
     We are using an additive that treats the ultra low sulfur diesel fuel prevents foaming at high speeds of refueling. The fuel doesn&#39;t foam in the fuel chambers and burns better giving a cleaner engine and more miles per gallon in fuel economy. For our purposes without the additive the foam would shut off the venturi. 
     Physically challenged, mothers with small children, elderly people, and others would never have to leave their seat to refuel their vehicles. 
     Stronger formulas of gasoline can be blended without fear of damage to human eyes, ears, nose, throat, skin or lungs. 
     Diesel fuel spills and TAH are slippery and dangerous for humans walking around refueling trucks. A robot saves humans and attendants from accidents and keeps them out of other human&#39;s way. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  is a perspective view of a six axis robot; 
         FIG. 2  is a front elevational view, with parts broken away showing simultaneous filling of two truck tanks with diesel fuel; 
         FIG. 3  is a front elevational view of an automobile being fueled; 
         FIG. 4  is a perspective view of a truck in a fueling bay adjacent to a control console; 
         FIG. 5  is a perspective view of a mobile robot fueling an aircraft; 
         FIG. 6  is a top plan schematic view of the truck of  FIG. 2  being fueled with parts broken away; 
         FIG. 7  is a modified side elevational view of a fuel transfer housing; 
         FIG. 8  is a schematic view of the fuel storage tank, the fuel supply system, the defueling system and the fuel vapor capture system; 
         FIG. 9  is a sectional view of the fuel transfer housing showing the robot fueling a vehicle with parts broken away. 
         FIG. 10  shows a Highway spur plan view with nine fueling lanes; and 
         FIG. 11  is a perspective view of a cap less fueling assembly. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The robot  10 , as shown in  FIG. 1 , includes a fixed robot base  12 . The base  12  is clamped to a concrete slab  14  by bolts embedded in the slab and passing through bores  16  through the base. A pivotable base  18  is journaled on the fixed robot base  12  for pivotal movement about a base axis  20 . A first arm  22  is pivotally attached to the pivotable base  18 . The first arm  22  pivots about a first arm axis  24  which is perpendicular to the base axis  20 . A second arm assembly  26  is pivotably attached to the first arm  22  for pivotal movement about a second arm axis  28 . The second arm axis  28  is parallel to the first arm axis  24 . 
     The second arm assembly  26  includes a second arm elbow housing  30  that is journaled on the first arm  22 . An elongated second arm portion  32  is pivotally attached to the elbow housing  30 . The elongated second arm portion  32  pivots about an elongated second arm portion axis  34 . The elongated second arm axis  34  is transverse to and offset from the second arm axis  28 . A wrist portion  36  on the free end of the elongated second arm portion  32  is pivotable about a wrist axis  38 . The wrist axis  38  is perpendicular to the elongated second arm axis  34 . 
     A tool end assembly  40  is journaled on the wrist portion  32  for pivotal movement about a tool end axis  42 . The tool end assembly plate member  44  is rotatable relative to the wrist plate  46 . The tool end assembly  40 , as shown in  FIG. 1  is a grasping tool with two fingers  48  and  50  that pivot relative to single finger  52  about pivot pin  54 . 
     The tool end assembly  40  is one of many tools each of which is designed to perform a specific function or functions. Tool end assembly  40  is removable and replaceable with another tool end assembly. These tool end assemblies are changeable automatically during operation to perform different tasks, if the robot is programmed to make a change. 
     The robot  10  described above is a FANUC ROBOTICS M710 model unit with six axes. The robot  10  is designed to operate in hostile environments, in which a human cannot work, during use of the robot. Movement of the robot  10  is controlled by a programmable controller  60  shown in  FIG. 7 . The controller  60  controls reversible electric motors that pivot members about at least six axes. An electric motor in housing  62  pivots the pivotal base  18  about the base axis  20 . A motor  63  pivots the first arm  22  relative to the pivotable base  18 . A motor inside elbow housing  30  pivots the second arm assembly  26  about the second arm axis  28 . Three motors are under a cover  64 . Each of the three motors is mounted on the elbow housing  30 . One of the three motors pivots the elongated second arm portion  32  about axis  28 . The second motor of the three motors under cover  64  pivots the wrist portion  36  about the wrist axis  38 . The third motor under cover  64  pivots the tool end assembly  40  about the tool end axis  42 . The tool end assembly  40  can be rotated about the tool end axis  42 , in either direction, more than three hundred and sixty degrees. Pivotal movement about base axis  20 , second arm axis  28 , second arm portion axis  34  and wrist axis  38  in one direction is limited to no more than three hundred and sixty degrees in one direction. Pivotal movement about all six axes is coordinated by the programmable controller  60  to move the tool end assembly  40  from one position to the next scheduled position along the shortest allowable path in one smooth coordinated movement and ready to perform the next scheduled task. 
     Fuel transfer housing  70 , shown in  FIG. 7 , has a front wall  72 , a rear wall  74 , an entry end wall  76  an exit end wall  78 , and a top panel  80 . These walls  72 ,  74 ,  76 , and  78  and the top panel  80  are preferably carbon fiber reinforced polyester material. The surfaces of the walls and top panel are smooth and slick for ease of cleaning and to minimize collection of contaminants. The entry end wall  76  may have an entry opening for maintenance and service activities. The exit end wall  78  may also have an entry opening for maintenance and service activities. These maintenance entry openings (not shown) are air tight when closed. A control console  82  is mounted in the front wall  72  adjacent to the exit end wall  78 . The control console  82  should be at about the height of a vehicle driver&#39;s window on vehicles that are to receive fuel. A fuel transfer opening  84  is provided in the front wall  72 . The fuel transfer opening  84  has a bottom edge  86  that is below the lowest vehicle fuel port  88  that is to be fueled. An entry end  89  of the fuel transfer opening  84  is positioned near the rear most vehicle fuel port  88  that is to be fueled when the vehicle driver&#39;s window is adjacent to the control console  82 . An exit end  90  of the fuel transfer opening  84  is positioned near the forward most vehicle fuel port  88  that is to be fueled when the vehicle driver&#39;s window is adjacent to the control console  82 . The upper edge  92  of the fuel transfer opening  84  is above the maximum height of the first arm  22  and the second arm assembly  26  of a robot  10  when fueling a vehicle with the highest vehicle fuel port  88 . 
     The fuel transfer housing  70  for most personal passenger vehicles will have different dimensions than a fuel transfer housing for large commercial vehicles. 
     The fuel transfer housing  70  is mounted on the concrete slab  14 . A seal is provided between the fuel transfer housing  70  and the concrete slab  14 . A rectangular plenum tube  94  made from carbon fiber reinforced polyester material is slidably mounted in the fuel transfer opening  84  through the front wall  72  of the fuel transfer housing  70 . The rectangular tube  94  is slightly smaller than the fuel transfer opening  84 . Two beams  96  have ends that are received inside the rectangular tube  94  as shown in  FIG. 7 . The beams  96 , inside the housing  70  are offset at  98  away from the robot  10 , to provide additional space for the robot. Upper rollers  100  and lower rollers  102  are attached to beams  104  and  106  respectively. These beams  104  and  106  are attached to supports  108  and  110 . Both supports  108  and  110  are anchored to the concrete slab  14 . The rollers  100  and  102  support the beam  96  and permit the beam to move toward and away from the rear wall  74 . The beam  96  on the opposite side of the robot  10  from the beam  96  shown in  FIG. 9  with the exception of being rotated 180° so that the offset at  98  is away from the robot  10 . The rollers  100  and  102  supporting the beams  96 , on both sides of the robot  10  are substantially identical on both sides of the robot  10 . The two sets of rollers  100  and  102  support both beams  96  as well as the rectangular plenum tube  94 . Acme threaded screw threads  112  on rods  114  engage nuts  116  fixed to the beams  96 . Motors  118  rotate the rods to advance and retract the beams  96  and the rectangular tube  94 . 
     The open rectangular plenum tube  94  provides substantial space and room for the passage of the second beam assembly  26  of the robot  10  and possibly a portion of the first beam  22 . The inside width of the rectangular plenum tube  94  permits a substantial pivotal movement of the pivotable base  18  to accommodate a large range of positions of a vehicle fuel port  88 . However the area of the opening through the rectangular plenum tube  94  is relatively large and collection of fuel vapors requires increased air movement. 
     An auxiliary plenum tube  130  may be telescopically received in the rectangular plenum tube  94  that contacts the side of the vehicle creating at least a partial seal. Seal members  132  on the open end of the auxiliary plenum tube  130  may contact the vehicle side as shown in  FIGS. 2 ,  3 ,  6  and  9  thereby making recovery of fuel vapors easier. The motors  118  can sense the increase force required to extend the rectangular tube  94  upon contact between the seals  132  and a vehicle and stop the motors  112 . 
     A seal  132 , shown in  FIG. 7 , seals the space between the rectangular plenum tube  94  and the wall  72  of the fuel transfer housing  70 . An alternate seal can be created by a flange  136  on the rectangular plenum tube  94  as shown in  FIG. 9 . 
     The fuel transfer system  140  as shown in  FIG. 8 , includes a fuel storage tank  142 . Fuel storage tanks  142  are generally underground. A fuel discharge pipe  144  extends from the tank  142  to a fuel pump  146 . The pump  146  sucks fuel from the tank  142  and supplies the fuel to a flexible discharge hose  148 . A discharge valve  150  with a discharge tube  152  is connected to the flexible hose  148 . The discharge valve  150  includes a venturi shutoff that is activated when the fuel receiving tank  154  is full. The discharge valve  150  is a drip less valve with a venturi shutoff and machined parts manufactured by Husky Corporation of Pacific, Mo. and others. A quick disconnect  155  is provided in the flexible hose  148  to minimize damage and fuel loss if excess force is exerted on the hose. 
     A defueler valve  156  is connected to a suction pump  158  by a flexible hose  160 . A quick disconnect  162  is provided in the flexible hose  160  to release the defueler valve  156  and a portion of the flexible hose if a tension load that is too large is exerted on the flexible hose. A defueler wand  164  made by Bennett Pump Company of Spring Lake, Mich. is connected to the defueler valve  156  and the suction pump  158  is delivered to the storage tank  142  by a pipe  166 . 
     A fuel vapor separator  168  separates fuel from air and delivers the fuel from a collector tank  170  to a holding tank  172  through a fuel line  174 . A second fuel vapor separator  176  separates fuel from air and fuel mixture received from a storage tank vent line  178 . The separated fuel is collected in a collector tank  180 . The separated fuel is transferred from the collector tank  180  to the holding tank  172  through a fuel line  182 . Air separated from a mixture of air and fuel from the storage tank vent line  178  is discharged to atmosphere through a clean air discharge pipe  184 . 
     Fuel received in the holding tank  172  is measured and delivered to the storage tank  142  by an inlet line  185 . 
     The fuel vapor separator  168  includes a substantial airflow fan that reduces pressure inside the fuel transfer housing  70 . The reduced pressure draws air and fuel vapors through rectangular plenum tube  94 . If the auxiliary plenum tube  130  is attached to the rectangular plenum tube  94 , the reduced pressure inside the fuel transfer housing  70  draws air and fuel particles through the auxiliary plenum tube  130 . The quantity of air that is drawn into the fuel transfer housing  70  must be increased to insure that all the fuel vapors from the vehicle fuel tank  154  are captured when the auxiliary plenum tube  130  is not employed. The quantity of air drawn into the fuel transfer housing  70  may be reduced somewhat when the auxiliary plenum tube  130  is employed. However, it may require more power to draw in air when the auxiliary plenum tube  130  is in use. Cleaned air from the fuel particle separator  168  is discharged from the fuel transfer housing  70  through a pipe  186 . 
     All of the structure shown in  FIG. 8 , but the fuel storage tank  142  is preferably mounted in the fuel transfer housing  70 . 
     A low frequency transmitter  190  is mounted on the windshield of a vehicle  192  that is to be serviced. The transmitter  190  emits a signal that is received by a receiver  194 . The signal is transmitted to the controller  60 . The signal provides information concerning the fuel needed, the location of the vehicle fuel port  88 , the number of fuel tanks  154  and the type of fuel cap  240 . With this information, the controller turns off a red light  196  and illuminates a green light  198 . The green light indicates the proper fueling bay that is available. The vehicle  192  then proceeds to the proper bay for fueling. A pair of cameras  200  and  202  that are mounted in the upper corners of the rectangular plenum tube  94 , as shown in  FIG. 7 . At least one camera  200  needs to have a clear view of a fuel cap  240  or a cap less fuel entry port  228 . If the auxiliary plenum tube  130  is used, a camera may be mounted inside the auxiliary plenum tube. The cameras  200  and  202  must remain out of the path of movement of the robot  10  at all times. At least one of the cameras needs to be able to record the location and orientation of the vehicle fuel port  88  or  228  that is to be fueled. Apertures in the auxiliary plenum tube  130  may be helpful. A camera  204  can also be mounted any place on the front wall that provides a view of the fuel port  88 . A camera may also be mounted on the robot  10 . 
     A driver stops his vehicle when the control console  82  is adjacent to the driver&#39;s side window. The driver opens his window. The method of payment is entered by answering an inquiry on a display screen  206 . A card identifying the name and address of the owner is inserted into a card reader slot  208 . A customer vehicle number can be entered with the card. A credit card can be entered in the card reader slot  208 . Paper money can be inserted into a money slot  210 . Change can be issued through a money dispersing slot  212 . Coins can be dispersed in a coin cup if needed. The fuel type and grade can be selected by activating one of a row of selection indicators  216 . The control console  82  also has a receipt issuing slot  218 . After all of the required selections have been made, the controller  60  turns on the fuel vapor separator  168  to lower air pressure in the fuel transfer housing  70 . 
     The motors  118  are activated to advance the rectangular plenum tube  94  toward the vehicle fuel port  88 . When the plenum tube  94  or the auxiliary plenum tube  130  is in the correct position relative to the fuel entry port  88 , the motors  118  are turned off. 
     The pictures of the fuel entry port  88  or door  230  disclose what needs to be done and confirms information received. The robot  10  is activated to open a door  230  covering a cap less fuel tank. The robot  10  is activated to open the door  230  if there is such a door. The robot removes a fuel cap  240  if there is one and moves the cap to a location inside the fuel transfer housing  70 . The robot  10  grasps the correct discharge valve  150  for the fuel to be dispensed, moves the fuel discharge tube  152  into the fuel entry port  88  and opens the discharge valve  150 . When the valve  150  is closed, because the fuel tank is full or the requested quantity of fuel has been dispensed, the robot returns the discharge valve  150  to the correct position in the fuel transfer housing  70 . The fuel cap  240  is retrieved by the robot  10 , from the place it was stored and replaced back in a closed position. An open door  230  is closed, if there was such a door, and the robot  10  returns to a rest position. The motors  118  are energized to retract the rectangular plenum tube  94  and the auxiliary plenum tube  130  if employed. 
     The fuel vapor separator  168  continues to run for a fixed period of time until the fuel transfers housing  70  is clear of vapors. 
     The control console  82  prints a receipt. The green light  198  is then illuminated indicating that the robot  10  is ready to fuel another vehicle. 
       FIG. 5  shows the robot  10  on a fueling vehicle  250  and in position to fuel an aircraft  256 . A cover on the bottom of the wing is opened by the robot  10  using cameras to locate and open the cover. A screw or cap for the fuel inlet is removed and stored by the robot  10 . A fueling connector  252  together with the air and vapor return pipe  258  is lifted into engagement with the fuel inlet and rotated to a locked position. The robot  10  has a controller that is recognize when the fitting is properly seated. The robot  10  then pivots the air return fitting to lock the fitting in place. After the specified quantity of fuel has been pumped into the fuel tank, the fittings are both unlocked and lowered to a storage place. The inside caps are retrieved and screwed onto the two pipes by the robot. The cover on the bottom of the wing is returned to a closed position and retainers are moved to locked positions. The robot is then ready to move to another aircraft for fueling. 
       FIG. 6  shows two fueling robots  10 . The pivot axis  28 , about which the second arm assembly  26  pivots relative to the first arm  22 , is vertical as shown. With the programmable controller controlling the movements of the robot  10 , the orientation of the robot.