Patent Publication Number: US-2021164215-A1

Title: Non-contact sensor for determining a f.o.g. level in a separator, including ultrasonics

Description:
BACKGROUND OF THE INVENTION 
     Historically, grease traps have been used in restaurants and other commercial facilities to limit the amount of fats, oils and grease (F.O.G.) and solid waste that is carried into sewer systems via waste water. Typical grease traps are either passive grease traps or automatic grease traps (also called a grease separator or interceptor). Examples of passive traps are the Trapzilla® line of traps sold by Thermaco, Inc. of Asheboro, N.C. disclosed in U.S. Pat. No. 7,367,459 to Batten et al. entitled Passive Grease Trap Using Separator Technology and U.S. Pat. No. 7,641,805 to Batten et al. entitled Passive Grease Trap With Pre-Stage For Solids Separation. Thermaco also offers a Big Dipper® line of Automatic grease separators. Passive grease traps are usually only emptied of the F.O.G. periodically and therefore F.O.G. tends to build up inside the tank. Passive grease traps typically include a tank with an inlet that brings in waste water and an outlet that carries water out of the tank from a low point of the tank. Lightweight F.O.G. rises to the top of the water in the tank and heavier solids settle in the bottom of the tank, a process of stratification. As the amount of F.O.G. that accumulates in the tank becomes excessive, water flushing through the tank can disrupt the F.O.G. that has already separated, causing the F.O.G. to be entrained with the water and become expelled with grey water. This is especially true as the tank fills up with F.O.G., so that the F.O.G./water interface is closer to the grease trap bottom. Grease interceptors also use stratification, and when the thickness of a grease mat in an interceptor reaches a certain level, skimming is needed. 
     Determining when to pump out the passive grease traps or to actuate a skimmer in a grease interceptor to remove accumulated F.O.G. has been a problem for the art. Typically, to be on the safe side, grease traps and other passive separation devices have been pumped based upon a schedule (for example once a month or once every two weeks). If not much F.O.G. has accumulated when pumping occurs, the pumping may be a waste since more time could have elapsed before pumping. If too much F.O.G. accumulates before the trap is pumped, then there is a risk of F.O.G. becoming re-entrained in grey water and discharged to the sewer pipe, defeating the purpose of F.O.G. separation. Similar issues of when to skim also arise in an active grease separator or interceptor. 
     It is known to locate thermocouples or other temperature sensors in the separator to determine the amount of F.O.G. stored in the separator container, as taught in U.S. Pat. No. 7,828,960 to Batten et al, entitled F.O.G. Separator Control, the entire disclosure of which is incorporated herein by reference. 
     Other ways to address the issues of determining when to remove a stratified F.O.G. mat without using sensors are disclosed in U.S. Patent Publication US-2015-0308094-A1, the entire disclosure of which is incorporated herein by reference. 
     Kingspan Environmental Service, 180 Gilford Road, Portadown, Co. Armagh., Northern Ireland BT63 5LF offers Kingspan Sensor&#39;s Smart Sery Grease solution, which uses a sensor of unknown technology. 
     Sensors like capacitance sensors that are immersed in the effluent and/or F.O.G. encounter issues with fouling, including by biofilm buildup, so avoiding immersion is a benefit. 
     There remains a need in the art to be able to reliably sense when the F.O.G. mat reaches a threshold at which F.O.G. removal by pumping or skimming is warranted. 
     SUMMARY OF THE INVENTION 
     The present invention fulfills one or more of these needs in the art by providing an apparatus for containing an F.O.G. layer on water, including a tank having an inlet and an outlet. The inlet is configured to connect to a source of F.O.G.-laden effluent and the outlet is configured to connect to a sewer pipe so that the outlet defines a normal static water level for F.O.G. and effluent in the tank. A sensor mounted above the static water level is configured to determine a distance from the sensor to a top of F.O.G. within the tank, so that a thickness of the F.O.G. in the tank can be determined. 
     The sensor can be a LIDAR sensor, such as a LIDAR sensor operating at about 940 nm. The sensor may be held in place by magnets. 
     The tank may have an extension collar above a main body of the tank, with the sensor mounted in the extension collar. The extension collar may be generally cylindrical and formed of four arc segments molded of thermoplastic plastic, such as polyethylene. 
     The sensor preferably includes a sensor unit mounted in a low part of the extension collar and a battery and electronics unit mounted at a higher part of the extension collar. The electronics unit desirably includes a transmitter to transmit a signal indicative of F.O.G. level in the tank. The sensor and battery and electronics unit may be linked by a coiled electrical cord and a separate tether having tensile strength sufficient to pull the sensor upwardly through the extension collar for service. 
     In one embodiment the tank has a tank top, an extension collar extending upward and supported by the tank top, and an extension top resting on the extension collar. The extension top, extension collar and tank top have aligned openings enabling a suction pipe to pass through the aligned openings for suctioning of F.O.G. A cover fits on the opening in the extension top to close the aligned openings when suctioning is not needed. 
     The invention may also be considered as a method of sensing an F.O.G. level in a tank having an inlet and an outlet, in which the inlet is configured to connect to a source of F.O.G.-laden effluent and the outlet is configured to connect to a sewer pipe so that the outlet defines a normal static water level for F.O.G. and effluent in the tank. The method includes sensing a distance from a fixed sensor and a top of F.O.G. above the static water level within the tank and using the sensed distance to determine if the amount of F.O.G in the tank exceeds a threshold warranting F.O.G. removal from the tank. 
     F.O.G. removal may include actuating a skimmer. F.O.G. removal may include pumping F.O.G. from the tank. The sensing may be LIDAR sensing, particularly LIDAR sensing at about 940 nm. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will be better understood by a reading of the Detailed Description of the Examples of the Invention along with a review of the drawings, in which: 
         FIG. 1  is a perspective view of a passive grease trap equipped with a sensor in accordance with an embodiment of the invention; 
         FIG. 2  is a top perspective view of a sensor housing for the embodiment of  FIG. 1 ; 
         FIG. 3  is a bottom perspective view of a sensor housing for the embodiment of  FIG. 1 ; 
         FIG. 4  is a partial, sectional view of a second embodiment; 
         FIG. 5  is a partial, exploded sectional view of the second embodiment; 
         FIG. 6  is a partial view of the sensor and electronics assembly for the second embodiment; 
         FIG. 7  is a bottom view of a cover for the passive grease trap in accordance with the second embodiment; 
         FIG. 8  is a lower partial perspective view of components of a third embodiment; 
         FIG. 9  is an upper partial perspective view of components of a third embodiment; 
         FIG. 10  is an upper partial perspective view of fewer ones of the components of a third embodiment; and 
         FIG. 11  is an upper partial perspective view of even fewer of the components of a third embodiment. 
     
    
    
     DETAILED DESCRIPTION OF EXAMPLES OF THE INVENTION 
     F.O.G. has a specific gravity of about 0.88 and water has a specific gravity of 1.00, so for every ten inches of F.O.G. build up in a trap, the F.O.G. displaces 8.8 inches of water while simultaneously projecting upward above the original, normal static water level 1.2 inches. Applicant has found that using this known differential property and the known distance from a sensor positioned above the liquid level to the top of the F.O.G. stratum, a determination can be made of how much F.O.G. is in the trap. 
     Various sensor technologies can be used, such as laser sensors (popular for golf range finders and a host of industrial uses) and ultrasonic sensors (popular with robotics both industrial and hobbyist applications). A suitable ultrasonic sensor is non-contact and non-immersed, looking at sound bounce back to discern the distance to the surface only. The ultrasonic sensor can be an electronic module located at the top of the extension collar containing the sensor and cellular electronics. Putting the sensor and cellular electronics in a single module reduces cost and keeps the sensor electronics out of the high temperature and humidity area near the contained F.O.G. and effluent. Using a modular cellular approach allows changing among different wireless service providers and standards. The ultrasonic transducer and temperature probe (such as a thermocouple) may be at the bottom of the extension collar. The ultrasonic transducer may be temperature rated to 90 C (194 F) and can use a 3 or 4 wire shielded cable, any length. The transducer mounting could be normal (downward facing) or rotated 90 degrees (horizontal facing with deflector) depending on the performance needs of the high temperature and humidity environment. An ultrasonic signal can be generated horizontally from a transducer that is remote from the source of potentially deleterious heat and humidity and then directed downward to the F.O.G. layer by a deflector. The ultrasonic transmitter and receiver can be separate. Since the speed of sound in air varies with temperature, a temperature sensor allows compensation for changes in the time of travel of the ultrasonic signal caused by a temperature variation. The ultrasonic signal can be subject to a dynamic gain analysis to discern the F.O.G. from other floating objects. 
     Suitable ultrasonic sensors may be available from Senix Corporation, 10516 Route 116, Suite 300, Hinesburg, Vt. 05461 USA. 
     Sonar sensors may be used but are not presently preferred because sonar sensors that are waterproof, have a high enough range, and high enough accuracy while taking account the humidity are expensive. Computer vision could be another choice: a video sensor aimed at the top surface of the F.O.G. stratum could capture an image, and a computer associated with the electronics unit could compare the image with an image taken of the same scene when the water is at the normal static water level with minimal F.O.G. Computer vision (and/or artificial intelligence) could then detect the height difference by comparing pictures when F.O.G. has accumulated. The less of the inside wall of the trap that the device “sees” means the higher the liquid level inside the tank caused by accumulated F.O.G. 
     One sensor option uses LIDAR, particularly LIDAR operating at about the 940 nm wavelength. 
     The sensor technology includes the sensor, control board(s), software controls and housing(s). Moisture-resistant properties can be applied to the sensor technology, by way of an enclosing housing or a conformal coating. 
     The sensor may be located 300 mm to 1000 mm above the static water level, with the distance between the sensor and the liquid surface being filled with air. The sensor may be hung/attached onto an expansion collar or on the underside of a top cover (like a manhole cover) of a tank or trap in which the stratification of F.O.G. above the water takes place. 
       FIG. 1  shows an embodiment  10  of a separator equipped with the sensor technology. A tank  12  has an inlet  14  and outlet (not shown). The height of the outlet usually defines the normal static water level. The inlet  14  receives effluent containing F.O.G. (and likely solid kitchen waste). The tank  12  has sufficient volume to slow the effluent flow so the less dense F.O.G. has time to rise above the water in the effluent and collects to form a mat within the tank  12 . The outlet is usually provided with an invert, so that the water exiting the tank  12  comes from the water that is at a low part of the tank, below the accumulated F.O.G. mat. The tank  12  may be installed below ground, such as in a parking lot of a restaurant. A widened tank top  16  supports a ring-shaped lid  18  and an extension collar  20 . The collar  20  supports a top ring  22  and a ground-access cover  30 . Extension collars for underground mounts are further disclosed in U.S. Pat. No. 7,540,967 to Batten et al. and U.S. Pat. No. 9,528,258 to McBride et al., and the disclosures of both of those patents are hereby incorporated herein by reference. 
     A tube  26  extends between an electronics unit  28  just below grade and an opening  24  in lid  18 . The electronics unit  28  contains electronics to analyze data from a sensor in a sensor housing  32  (shown in  FIG. 2 ) positioned at the bottom of the tube  26  and directed downward into the tank  12 . The electronics unit  28  may include batteries (or other power supply) and a communication link such as a cell phone connection, WiFi, NFC, Bluetooth or the like, so that information about the the grease mat can be sent to a pumping service to come to pump out the tank. Information gleaned from the sensor may be transmitted to a pumper or to a monitoring station using technology as disclosed in International Patent Publication WO 2017/035220, the entire disclosure of which is incorporated herein by reference. 
     Pumping involves removing the lid  30 , extending a suction hose into the tank and pumping the F.O.G. from the tank  12  to a truck that transports the F.O.G. to a rendering plant or other disposal facility. Pumping may also include pumping solids that have accumulated at the bottom of the tank. 
     The sensor housing  32  is seen in  FIGS. 2 and 3 . The housing  32  fits within the tube  26 , lowered from the top of the tube to rest on a ledge at about the height of the lid  18 . Ferromagnetic metal fixed in place at the lid  18  and magnets  42 A,  42 B and  42 C on the sensor housing  32  hold the housing in a fixed position at the lid. The fixed position sets a reference point for the sensor, so that the distance traversed by the beam of the sensor, such as a Lidar sensor or ultrasonic sensor, can be determined by measuring the round-trip time of flight from the known position of the sensor to the variable height of the top of the F.O.G. mat. A Lidar sensor  40  is located in the housing  32 , with an attached, coiled data and power cable  34 . A similar mounting can be used for an ultrasonic sensor. The housing  32  has an attachment  36  and a connected tether  38 . The tether is strong enough to be pulled upward, enabling the housing  32  to break free of the hold of the magnets and be pulled upward through the tube  26  if servicing is needed. 
     The sensor  40  directs a pulse downward into the tank  12 , and the pulse is reflected by F.O.G. within the tank. The time interval between the sensor&#39;s sending of the pulse and the sensor&#39;s receipt of the reflected pulse is proportional to the distance from the sensor to the top of the F.O.G. mat. Data indicative of that time interval is sent to the electronics unit  28  for analysis. 
     The analysis of Lidar data can include subtracting the time of flight when the tank has zero F.O.G. mat (which can be a stored value) from the measured time of flight. If the result exceeds a threshold that is characteristic of the tank, the data indicates that the F.O.G. mat is thick enough that pumping is warranted, so a signal can be sent to the pumping service to come pump the tank. If the data indicates that the mat thickness is too large, an urgency alarm can be added to the signal to the pumping service. Also within the scope of the invention is for the electronics unit to send a signal that pumping is not needed if the F.O.G. mat is determined not to be thick enough to warrant pumping. Similar analysis can be used with an ultrasonic sensor. 
     The sensing of the F.O.G. thickness can be repeated continually, to provide continual monitoring of when pumping or other removal is needed. A schedule of sensing the thickness may be once a day, once a week or some other schedule, depending on the needs of the installation. The sensing can be triggered by a signal from a remote communication source, or by a timer or other mechanism internal to the electronics unit  28 . 
       FIGS. 4-7  show an alternate embodiment, differing in the construction of the extension collar and the tube configuration for the sensor housing. In  FIG. 4  the lower part of the tank  112  is omitted. The tank  112  has an inlet  114  and outlet (not shown). The inlet receives effluent containing F.O.G. (and likely solid kitchen waste) The tank  112  has sufficient volume to slow the effluent flow so the lower-density F.O.G. rises above the water in the effluent and collects to form a mat within the tank  112 . The outlet is usually provided with an invert, so that the water exiting the tank  112  is from the water at a low part of the tank, below the accumulated mat. The tank  112  may be installed below ground, such as in a parking lot of a restaurant. A widened tank top  116  supports a ring-shaped lid  118  and an extension collar made of arc segments  120  and  121 . The collar supports a top ring  122  and a ground-access cover  130 . 
     The extension collar is made up of four extruded sections (arcs) that interlock together to form a generally cylindrical shape with vertical flutings or corrugations. The extruded sections are knocked down for shipping and field assembled to create a cylinder. The collar includes three identical arcs  120  and a fourth arc  121 . The arc  121  differs from the three arcs  120  in that it has the tube  126  for the sensor assembly. The edges of adjacent arcs join one another with an interlock like a tongue and groove construction. 
     The tube  126  can also tie the pieces above and below it together for alignment of the tube. After assembly of the arcs, the collar is cut to length. The desired length will be specific for an installation, but will be sufficient to extend from the top surface of the lid  118  to a height to receive a top ring  122  that supports a cover  130 , typically ground level. The cover  130  can be bolted into place on the top ring so it is removable for F.O.G. pumping or servicing of the sensor unit. 
     The tube  126  has a stainless steel or other ferromagnetic metal ring  143  (see  FIG. 5 ) below its bottom and secured to the tank top  118  for magnetic attraction to magnets  142  in the sensor housing  132 . The housing  132  has a coiled data and power cable  134  extending to a cylindrical electronics unit  128 . A ring  129  on the housing  132  causes it to rest at a desired height in the tube  126 , typically on the top ring  122  with the portion of the electronics unit above the ring  129  being short enough that it can be covered and protected by the cover  130 . An antenna for cell phone connection, WiFi, NFC, Bluetooth or the like is positioned at the top of electronics unit  128 , the top of which itself nests within a space  131  formed in the top ring  122 . 
     The Lidar unit (sensor and electronics unit) can be shipped with the unit when it is new or retrofitted at a later date. Once the top cover  130  is removed, the top of the Lidar unit can be pulled out of its tube  126  for servicing, such as to replace batteries. A cable or other line, like the tether  38  of the embodiment of  FIG. 1 , can be used to pull the sensor up the tube  126 . To install Lidar in a unit that is not equipped with it, the top cover is removed and the tube is exposed. The sensor housing  132  is lowered into the tube  126  and is held in place onto the stainless washer  143  by the magnets  142  at the bottom of the tube  126 . 
     Lidar sensors with wavelengths in the mid to far IR range have been found not to be suitable because oil absorbs radiation at those wavelengths. 
     A preferred LIDAR sensor operates at 940 nm for the VL53L0X Lidar chip. The VL53L0X is a new generation Time-of-Flight (ToF) laser-ranging module. It can measure absolute distances up to 2 m. Another usable chip is the VL53L1, which is a Time-of-Flight (ToF) laser-ranging miniature sensor. This chip integrates a SPAD (Single Photon Avalanche Diodes) array, physical infrared filters and optics. Both sensors are available from STMicroelectronics NV of Geneva, Switzerland (st.com). The VL53L0x does not accurately read a water level, but that is immaterial because the only time there will not be at least a film of oil on the surface of the liquid in the trap is when the unit is first installed. 
     The use of a converter circuit may be needed to convert the I2C signal to another digital signal with a longer communications range. 
     Since the VL53L0x chip has a very short range when dealing with oils, it is preferably mounted at about 10 inches from the static water level. Mounting the sensor and its electronics in a tube separate from the main central opening of the trap reduces the risk that a pumper&#39;s suction equipment could collide with it. 
     Similar mountings and analysis can be used with an ultrasonic sensor. An ultrasonic transducer and temperature probe (such as a thermocouple) may be at the bottom of the extension collar. The ultrasonic transducer may be temperature rated to 90 C (194 F) and can use a 3 or 4 wire shielded cable, any length. The transducer mounting could be normal (downward facing) or rotated 90 degrees (horizontal facing with deflector) depending on the performance needs of the high temperature and humidity environment. An ultrasonic signal can be generated horizontally from a transducer that is remote from the source of potentially deleterious heat and humidity and then directed downward to the F.O.G. layer by a deflector. The ultrasonic transmitter and receiver can be separate. Since the speed of sound in air varies with temperature, a temperature sensor can be used to allow compensation for changes in the time of travel of the ultrasonic signal caused by temperature variations. The ultrasonic signal can be subject to a dynamic gain analysis to discern the F.O.G. from other floating objects. Suitable ultrasonic sensors may be available from Senix Corporation, 10516 Route 116, Suite 300, Hinesburg, Vt. 05461 USA. 
     When the sensing system is installed in an automatic grease trap or interceptor that uses active skimming for F.O.G. removal, the sensing that the thickness of the F.O.G. layer exceeds a threshold can be used to activate skimming. As used in this application, “skimming” includes other ways of taking the F.O.G. off the top, including opening spouts that drain the F.O.G. (see U.S. Pat. No. 7,186,346 for examples), pumping the F.O.G. (see U.S. Pat. No. 6,517,715 for an example), or other active methods. More examples and details of a F.O.G. removal assembly may be found in U.S. Pat. No. 6,800,195 to Batten et al. and U.S. Pat. No. 7,208,080 to Batten et al. which are both herein incorporated by reference in their entireties. Other types of skimmers can be used in the invention, too, including but not limited to: belt skimmers, examples of which can be seen in U.S. Pat. No. 7,427,356 to Chapin and U.S. Pat. No. 7,296,694 to Weymouth; skimmers that include one or more rotating cylinders that partially or completely submerge, one example as is shown in U.S. Pat. No. 4,051,024 to Lowe et al; skimmers with an absorptive affinity for F.O.G and/or skimmers that include non-cylindrical grease collectors pivoting to come into contact with F.O.G. for removal, one example as seen in U.S. Pat. No. 4,235,726 to Shimko. 
     The tank and its attachments preferably have an International Protection Rating of IP  65 . 
     The sensor can also be installed in conventional concrete grease traps. 
     An added feature can include a data analysis module associated with the electronics unit to deal with deviations from normal static water levels. The data analysis can include distinguishing levels of normal flow events from levels created from downstream full or partial plumbing obstructions. These two events, like accumulations of F.O.G., result in sensor readings that are higher than the normal static water level (which is usually determined by the height of the outlet from the trap). Rising levels that are due to normal flow events are transitory and can be distinguished by taking several readings over a period of time and disregarding those that show a high level that soon returns to the normal level. 
     Changes that are due to downstream obstructions are more permanent and will continue over several readings. A level that rises faster than is possible for a F.O.G. accumulation to cause would indicate a downstream obstruction, permitting the signaling of an alarm of that potential condition. Alternatively, if data about a downstream partial obstruction is available from another source, that data can be added to the analysis of what the F.O.G. level is in the tank, enabling a rise in level to be disregarded as not a thickening of the F.O.G. level. 
       FIGS. 8-11  show an alternate embodiment, differing in the construction of the extension collar and the tube configuration for the sensor housing. In these figures the tank  112  is omitted, showing the ring-shaped lid  218 , top ring  222  and extension collar. The tank, inlet and outlet are configured as described above. 
     As in the embodiment of  FIGS. 4-7  the extension collar is made up of four extruded sections (arcs) that interlock together to form a generally cylindrical shape with vertical flutings or corrugations, although only arc section  221  is shown in  FIGS. 8 to 10 . The extruded sections are knocked down for shipping and field assembled to create a cylinder. The collar includes three identical arcs and a fourth arc  221 . The arc  221  differs from the three arcs in that it has the tube  226  for the sensor assembly. The edges of adjacent arcs join one another with an interlock like a tongue and groove construction. 
     The tube  226  can also tie the pieces above and below it together for alignment of the tube. After assembly of the arcs, the collar is cut to length. The desired length will be specific for an installation, but will be sufficient to extend from the top surface of the lid  218  to a height to receive a top ring  222  that supports a cover  230 , typically ground level. The cover  230  can be bolted into place on the top ring  22  so it is removable for F.O.G. pumping or servicing of the sensor unit. 
     The tube  226  has a stainless steel or other ferromagnetic metal ring below its bottom and secured to the tank top  218  for magnetic attraction to magnets in the sensor housing  232 . A preferred metal is 400 series grade stainless metal plate, which provides reasonably good magnetic attraction properties balanced with reasonably good corrosion resistance properties. The housing  232  has a coiled data and power cable  234  extending to antenna  229  (see  FIG. 11 ). The housing  232  may contain the sensor, the electronics unit, and the battery. Antenna  229  provides cell phone connection, WiFi, NFC, Bluetooth or the like is positioned at the top of the tube  226  connected by a wire that extends to the electronics unit in the housing  232 . The antenna is built into a handle-shape, so the housing and the components it contains can be easily pulled up the tube  226  when service is needed. A separate tether can be used to add tensile strength. In some embodiments the electrical wire connecting the antenna to the items below can also serve as the tether. 
     Certain modifications and improvements will occur to those skilled in the art upon reading the foregoing description. It should be understood that such modifications and improvements have been omitted for the sake of conciseness and readability, but are properly within the scope of the following claims