US20200298991A1

US20200298991A1 - Electric power and data communications within a fuel tank and across a wall of the fuel tank using resistive non-metallic wire and a sealed active connector

Info

Publication number: US20200298991A1
Application number: US16/670,286
Authority: US
Inventors: Andrew M. Robb
Original assignee: Boeing Co
Current assignee: Boeing Co
Priority date: 2019-03-19
Filing date: 2019-10-31
Publication date: 2020-09-24
Also published as: US11305884B2; US20200298990A1

Abstract

A system for power and data communications within a fuel tank and across a wall of the fuel tank includes a plurality of fuel height sensors. The system also includes a sealed active connector extending through a wall of the fuel tank. The sealed active connector includes an internal electronic circuit configured to receive data from the plurality of fuel height sensors. The system also includes an electric power connection between each of the fuel height sensors and the sealed active connector. The system further includes an internal data communications connection between each of the fuel height sensor and the sealed active connector. At least the electric power connection between each fuel height sensor and the sealed active connector includes a resistive non-metallic wire.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority of U.S. Provisional Application No. 62/820,328, filed March 19, 2019 which is incorporated herein by reference in its entirety.
This application is related to U.S. Patent Application ______ (Attorney Docket No. 19-0421-US-NP), entitled “Electric Power and Data Communications within a Fuel Tank and across a Wall of the Fuel Tank Using Resistive Non-Metallic Wire,” filed the same date as the present application and incorporated herein by reference.
This application is also related to U.S. Patent Application ______ (Attorney Docket No. 19-0421-US-NP[2]), entitled “Electric Power and Data Communications within a Fuel Tank and across a Wall of the Fuel Tank Using Resistive Non-Metallic Wire and an Optical Hybrid Fuel Height Sensor,” filed the same date as the present application and incorporated herein by reference.

FIELD

The present disclosure relates generally to vehicles, such as aircraft, and more particularly to electric power and data communications within a fuel tank and across a wall of the fuel tank using resistive non-metallic wire and a sealed active connector.

BACKGROUND

Installation of electrically conductive materials in a fuel tank requires significant design detail and consideration to minimize a possibility of an electrical discharge within the fuel tank. Historically, non-metallic conductors such as carbon loaded plastics and foams have been widely used for shielding and anti-static applications. When exposed to transient electric fields these materials are resistant to the high current flows and sparks that would ignite fuels. Additionally, accurate and dependable measurements of the quantity of fuel in the tanks needs to be made.

SUMMARY

In accordance with an embodiment, a system includes a plurality of fuel height sensors within a fuel tank and a sealed active connector extending through a wall of the fuel tank. The sealed active connector includes an internal electronic circuit configured to receive data from the plurality of fuel height sensors. The system also includes an electric power connection between each of the fuel height sensors and the sealed active connector. The system additionally includes an internal data communications connection between each of the fuel height sensors and the sealed active connector. At least the electric power connection between each fuel height sensor and the sealed active connector includes a resistive non-metallic wire.
In accordance with another embodiment, a vehicle includes a fuel tank and a system for power and data communications within the fuel tank and across a wall of the fuel tank. The system includes a plurality of fuel height sensors and a sealed active connector extending through a wall of the fuel tank. The sealed active connector includes an internal electronic circuit configured to receive data from the plurality of fuel height sensors. The system also includes an electric power connection between each of the fuel height sensors and the sealed active connector. The system additionally includes an internal data communications connection between each of the fuel height sensors and the sealed active connector. At least the electric power connection between each fuel height sensor and the sealed active connector includes a resistive non-metallic wire.
In accordance with another embodiment, a method includes inserting one or more fuel height sensors in a fuel tank. The method also includes providing an electric power connection between each fuel height sensor and a sealed active connector extending through a wall of the fuel tank. The method additionally includes providing an internal data communications connection between each fuel height sensor and the sealed active connector. At least the electric power connection includes a resistive non-metallic wire.
In accordance with an embodiment and any of the preceding embodiments, wherein the internal electronic circuit is further configured to format the data from the fuel height sensors to Aeronautical Radio, Incorporated (ARINC) data.
In accordance with an embodiment and any of the preceding embodiments, wherein the sealed active connector is directly connected to devices of a core computer system (CCS) by an external data communications connection outside the fuel tank.
In accordance with an embodiment and any of the preceding embodiments, wherein the external data communications connection includes one of a digital data bus, Aeronautical Radio, Incorporated (ARINC) bus, or a Controller Area Network (CAN) bus.
In accordance with an embodiment and any of the preceding embodiments, wherein the sealed active connector includes a connector shell and the internal electronic circuit includes a microprocessor removably disposed within the connector shell.
In accordance with an embodiment and any of the preceding embodiments, wherein the sealed active connector includes an active adapter connected to a passive sealed connector that extends through the wall of the fuel tank. The internal electronic circuit is disposed within the active adapter and the active adapter is removable from the passive sealed connector without removing the passive sealed connector from the wall of the fuel tank.
In accordance with an embodiment and any of the preceding embodiments, wherein the fuel tank is mounted in a wing of an aircraft and the plurality of fuel height sensors are distributed at predetermined different locations within the fuel tank to accurately measure a quantity of fuel within the fuel tank.
In accordance with an embodiment and any of the preceding embodiments, wherein the resistive non-metallic wire includes a carbon loaded thermoplastic.
In accordance with an embodiment and any of the preceding embodiments, wherein the resistive non-metallic wire includes a carbon loaded polyether ether ketone (PEEK) thermoplastic.
In accordance with an embodiment and any of the preceding embodiments, wherein the resistive non-metallic wire includes a resistance between about 100 ohms/meter and about 1 Mohms/meter.
In accordance with an embodiment and any of the preceding embodiments, wherein the internal data communications connection includes a resistive non-metallic wire.
In accordance with an embodiment and any of the preceding embodiments, wherein the internal data communications connection includes an analog signal out connection.
In accordance with an embodiment and any of the preceding embodiments, wherein the internal data communications connection includes a digital signal out connection.
The features, functions, and advantages that have been discussed can be achieved independently in various embodiments or may be combined in yet other embodiments further details of which can be seen with reference to the following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a block schematic diagram of an example of a system for electric power and data communications within a fuel tank and across a wall of the fuel tank in accordance with an embodiment of the present disclosure.

FIG. 1B is a block schematic diagram of an example of a system for electric power and data communications within a fuel tank and across a wall of the fuel tank in accordance with another embodiment of the present invention.

FIGS. 2A and 2B are an illustration of an example of a fuel height to capacitance probe in accordance with an embodiment of the present disclosure.

FIG. 3A is a block schematic diagram of an example of a sealed active connector including an internal electronic circuit in accordance with an embodiment of the present disclosure.

FIG. 3B is an illustration of an example of a sealed active connector including an internal electronic circuit in accordance with another embodiment of the present disclosure.

FIG. 3C is a block schematic diagram of example of a sealed active connector in accordance with a further embodiment of the present disclosure.

FIG. 3D is an illustration of a portion of an aircraft including a plurality of fuel tanks in accordance with an embodiment of the present disclosure.

FIGS. 4-13 are examples of different electric power and data communications configurations for a fuel tank in accordance with different embodiments of the present disclosure.

FIG. 14 is an example of a vehicle including a system for power and data communications within a fuel tank and across a wall of the fuel tank in accordance with an embodiment of the present disclosure.

FIG. 15 is a flow chart of an example of a method for monitoring a quantity of fuel in a fuel tank in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION

The following detailed description of embodiments refers to the accompanying drawings, which illustrate specific embodiments of the disclosure. Other embodiments having different structures and operations do not depart from the scope of the present disclosure. Like reference numerals may refer to the same element or component in the different drawings.
FIG. 1A is a block schematic diagram of an example of a system 100 for electric power and data communications within a fuel tank 102 and across a wall 115 of the fuel tank 102 in accordance with an embodiment of the present disclosure. The system 100 includes one or more fuel height sensors 103 disposed within the fuel tank 102 and at different locations within the fuel tank to accurately measure a quantity of fuel in the fuel tank 102. Each fuel height sensor 103 includes a probe electronics package 104 and a fuel height probe 106. In accordance with an embodiment, the fuel height probe 106 is a fuel height to capacitance probe 200 similar to that illustrated in FIG. 2. Referring also to FIG. 2, FIG. 2 is an illustration of an example of a fuel height to capacitance probe 200 in accordance with an embodiment of the present disclosure. The fuel height to capacitance probe 200 includes two concentric tubes 202 and 204. The fuel height 208 is measured by measuring the capacitance 206 between the concentric tubes 202 and 204 placed in the fuel tank 102. The spacing 210 between the tubes 202 and 204 is carefully controlled, and because the dielectric constant of fuel is approximately twice that of air, changes in the fuel height 208 can be read by changes in the capacitance 206 measured between the tubes 202 and 204. From the fuel height 208 reading given by the fuel height to capacitance probe 200, the volume of fuel in the fuel tank 102 can be determined, and ultimately, the weight of the fuel 212 is calculated based on the density of the fuel 212 by a device 406 (FIG. 4). In accordance with an embodiment, for example the embodiment in FIG. 4, examples of the device 406 include, but are not necessarily limited to, a probe reader, a computer or other device. In the exemplary embodiment in FIG. 1A, the fuel weight is calculated by a core computer system (CCS) 130. The CCS 130 receives data from multiple fuel height sensors 103 and data from a fuel density measurement to calculate total fuel weight on a vehicle 129. The fuel weight is reported to a flight crew and/or a ground servicing crew in the example of the system 100 being onboard an aircraft.
The probe electronics package 104 includes probe power electronics 108. The probe power electronics 108 receive electric power 110 from an electric power source 112 located outside the fuel tank 102. The probe power electronics 108 include filters and provide stable electric power to oscillators and other components of the probe electronics package 104. In accordance with an embodiment, the probe power electronics 108 also include a power storage device 109, such as a capacitor to provide any additional power for increased power requirements during fuel height measurement and/or communications. In another embodiment, the power storage device 109 is a separate component from the probe power electronics 108.
A sealed connector 114 extends through a wall 115 of the fuel tank 102. An electric power connection 117 between the sealed connector 114 to the fuel height sensor 103 provides electric power 110 from the electric power source 112 outside the fuel tank 102 to the fuel height sensor 103. The electric power connection 117 includes a resistive non-metallic wire 116. The sealed connector 114 is configured for connecting components of the probe electronics package 104 within the fuel tank 102 to elements outside the fuel tank 102, such as the electric power source 112 and other devices for determining the quantity of fuel in the fuel tank 102. The sealed connector 114 is electrically connected to the probe power electronics 108 within the fuel tank 102 by the resistive non-metallic wire 116. In accordance with an embodiment, at the sealed connector 114, the electric power and communications signals transition to metallic wiring outside of the fuel tank 102. In accordance with an embodiment, the resistive non-metallic wire 116 is a carbon loaded thermoplastic. In an example, the resistive non-metallic wire 116 is a carbon loaded polyether ether ketone (PEEK) thermoplastic. The resistive non-metallic wire 116 includes a resistance between about 100 ohms/meter and about 1 Mega-ohms/meter. Components of the fuel height sensor 103 and probe electronics package 104 are interconnected as illustrated in the example in FIG. 1A by resistive non-metallic wire 116.
The probe electronics package 104 also includes a capacitance-to-digital converter 118. The fuel height probe 106 is directly connected to the probe electronics package 104 that includes the capacitance-to-digital converter 118. The resistive non-metallic wire 116 runs from the probe electronics package 104 to the sealed connector 114. An example of the capacitance-to-digital converter 118 is an FDC1004 provided by Texas Instruments, Incorporated. The capacitance-to-digital converter 118 receives capacitance data from the fuel height probe 106 and converts the capacitance data to a digital signal 120. In the example in FIG. 1A, the probe electronics package 104 also includes a microcontroller 122 and a temperature sensor 124. The microcontroller 122 receives temperature measurements from the temperature sensor 124 and receives digital signals 120 corresponding to the fuel height 208 (FIG. 2) from the capacitance-to-digital converter 118. The temperature sensor 124 is a digital or analog temperature sensor. The temperature sensor 124 and the capacitance to digital converter 118 are connected to the microcontroller 122. The capacitance-to-digital converter 118, temperature sensor 124 and the microcontroller 122 receive electric power from the probe power electronics 108. In accordance with the example illustrated in FIG. 1A, the microcontroller 122 of the probe electronics package 104 is electrically connected to the sealed connector 114 by resistive non-metallic wire 116.
In accordance with an embodiment, the system 100 also includes an external data communications connection 125 outside the fuel tank 102. In accordance with the example in FIG. 1A, the external data communications connection 125 includes a signal repeater/converter 126 outside the fuel tank 102. The external data communications connection 125 also includes copper wires 128 that electrically connect the signal repeater/converter 126 to the sealed connector 114. The signal repeater/converter 126 receives data signals from the microcontroller 122 containing data indicative of a quantity of fuel 212 within the fuel tank 102.
In accordance with another embodiment, a data concentrator replaces the signal repeater/converter 126 to receive data signals from the microcontroller 122 via the sealed connector 114.
In the example in FIG. 1A, a core computer system (CCS) 130 receives digital signals 132 including fuel height data from the signal repeater/converter 126. The CCS 130 includes a fuel management system 134 configured to determine at least a quantity of fuel 212 in the fuel tank 102. In accordance with example, the signal repeater/converter 126 is a data concentrator. The data concentrator includes an output configured to transmit data based on the fuel height data received from the fuel height sensor 103 or sensors to the fuel management system 134 embodied on the core computer system 130. The core computer system 130 is configured to convey a fuel quantity indication based on the fuel height data received from the fuel height sensor 103 or sensors.
FIG. 1B is a block schematic diagram of an example of a system 150 for electric power and data communications within a fuel tank 102 and across a wall 115 of the fuel tank 102 in accordance with another embodiment of the present invention. The system 150 is similar to the system 100 in FIG. 1A except the sealed connector 114 is replaced by a sealed active connector 152. The sealed active connector 152 includes an internal electronic circuit 154 configured to receive data 156 corresponding to the fuel height 208 (FIG. 2) measured by the fuel height sensor 103. Referring also to FIG. 3A, in accordance with another example, the internal electronic circuit 154 is configured to receive data 156 corresponding to the fuel height 208 in the fuel tank 102 from a plurality of fuel height sensors 103 a-103 n. In accordance with an example, the internal electronic circuit 154 is further configured to format the data 156 from the fuel height probes to Aeronautical Radio, Incorporated (ARINC) data 158.
In accordance with an example, the sealed active connector 152 includes a connector shell 153 (FIG. 3A) and the internal electronic circuit 154 includes a microprocessor 160 that is removably disposed within the connector shell 153.
The system 150 also includes an electric power connection 117 between the sealed active connector 152 and each of the fuel height sensors 103 a-103 n. The system 150 additionally includes an internal data communications connection 123 between each of the fuel height sensor 103 a-103 n and the sealed active connector 152. At least the electric power connection 117 between each fuel height sensor 103 a-103 n and the sealed active connector 152 includes a resistive non-metallic wire 116. In accordance with the example in FIG. 3A, the internal data communications connection 123 between each of the fuel height sensors 103 a-103 n and the sealed active connector 152 includes a resistive non-metallic wire 116.
The sealed active connector 152 is directly connected to a core computer system (CCS) 130 by an external data communications connection 125 outside the fuel tank 102. The external data communications connection 125 includes one of a digital data bus, Aeronautical Radio, Incorporated (ARINC) bus, or a Controller Area Network (CAN) bus or canbus. As previously described, a fuel management system 134 is embodied on the CCS 130.
Referring also to FIG. 3B, FIG. 3B is an illustration of an example of a sealed connector 300 including an internal electronic circuit 302 in accordance with an embodiment of the present disclosure. In accordance with an example, the sealed connector 300 is used for the sealed active connector 152 in FIGS. 1B and 3A. The sealed connector 300 is an active connector that communicates over resistive non-metallic wire 116 to one or more digital probes 304 within the fuel tank 102. Signals propagating over high resistance wire have a high source impedance and require a high impedance active receiver to translate those signals typically used on copper wiring. In accordance with an embodiment, each digital probe 304 includes the fuel height sensor 103 in FIGS. 1B and 3A. In the example in FIG. 3B, the sealed active connector 300 is connected to a vehicle core computer system (CSS) 306 by an external data communications connection 125. In accordance with an example, the external data communications connection 125 uses standard copper wire data buses 308. The internal electronic circuit 302 of the sealed active connector 300 reads digital data from the digital probe 304 via the resistive non-metallic wire 116. The sealed active connector 300 transmits the digital data onto the data bus 308, for example, an aircraft data bus, such as a standard copper wire Aeronautical Radio, Incorporated (ARINC) bus, canbus or mil-std-1553 data bus. At the digital probe 304 the changing fuel level changes the capacitance which is then read by a capacitance-to-digital converter, for example, capacitance-to-digital converter 118 in FIG. 1B and sent to the microcontroller 122. The microcontroller 122 adds the probe ID number and formats the data packet then transmits the data packet over an internal data communications connection 123 between the fuel height sensor 103 and the sealed active connector 300 or sealed active connector 152 in FIGS. 1B and 3A. The internal data communications connection 123 includes a resistive non-metallic wire 116.
In accordance with an embodiment, the sealed active connector 300 reads probe data packets from multiple digital probes 304. For example, about eight to about twelve digital probes 304 are connect to a single sealed active connector 300 via resistive non-metallic wire 116. The sealed active connector 300 collects the probe data from the multiple digital probes 304, formats the probe data into standard aircraft data bus packets and communicates the probe data directly to the vehicle CCS 306. At the vehicle CCS 306, the data bus packets are read so that the vehicle CCS 306 now knows the fuel height at each digital probe 304. A software program within the vehicle CCS 306 then looks at height/volume relationship tables, for example, curves of fuel probe levels vs volume, and calculates the total volume of fuel. Combining that data with a measure or estimate of fuel density provides total weight of fuel in each instrumented fuel tank 102. This information is transferred to, accessed by, and/or used by various components of the vehicle, for example, the cockpit of an aircraft, refuel panel, diagnostics, etc. Once the CCS 306 software module has calculated total fuel weight, the total fuel weight can be transmitted to whatever application on the aircraft needs this information.
FIG. 3C is a block schematic diagram of example of a sealed active connector 350 in accordance with a further embodiment of the present disclosure. In accordance with an example, the sealed active connector 350 is used for the sealed active connector 152 in FIGS. 1B and 3A. The sealed active connector 350 includes an active adapter 352 connected to a passive sealed connector 354 that extends through the wall 115 of the fuel tank 102. As used herein a passive sealed connector 354 or dumb connector is a connector that simply interconnects two elements and does not include any active components configured to perform a certain function, such an internal electronic circuit or microprocessor. The internal electronic circuit 154 is disposed within the active adapter 352 and the active adapter 352 is removable from the passive sealed connector 354 without removing the passive sealed connector 354 from the wall 115 of the fuel tank 102.
Referring to FIG. 3D, FIG. 3D is an illustration of a portion of an aircraft 360 including a plurality of fuel tanks 102 a-102 g in accordance with an embodiment of the present disclosure. The aircraft 360 includes one of the system 100 in FIG. 1A or the system 150 of FIG. 1B. In the example in FIG. 3D more than one fuel tank 102 a-102 g is mounted in a wing 362 of the aircraft 360. A plurality of fuel height sensors 103 are distributed at predetermined different locations within each fuel tank 102 a-102 g to accurately measure a quantity of fuel 212 within each fuel tank 102 a-102 g.
FIGS. 4-13 are examples of different electric power and data communications configurations for a fuel tank 102 in accordance with different embodiments of the present disclosure. In accordance with different embodiments, the sealed connector 114 in FIG. 1 or the sealed active connectors 152, 300 or 350 in FIGS. 1B or 3A-3C are usable in combination with any of the different electric power and data communications configurations in FIGS. 4-13. FIG. 4 is an electric power and data communications configuration 400 including an electric power connection 117 and an internal data communications connection 123, each coupled between the sealed connector 114 and the probe electronics package 104. The electric power connection 117 and the internal data communications connection 123 both include resistive non-metallic wires 116 similar to that previously described. A device 406, for example, a probe reader, computer, etc. outside the fuel tank 102 is electrically connected to the sealed connector 114 by an external data communications connection 125. In accordance with the example illustrated in FIG. 4, the external data communications connection 125 includes cooper wires 408.
FIG. 5 illustrates an example of an electric power and data communications connection 500 including a plurality of probes 502 a-502 n within a fuel tank 102. In accordance with an embodiment, each of the plurality of probes 502 a-502 n is a fuel height sensor 103 similar to that described with reference to FIG. 1A. Each of the probes 502 a and 502 n are connected to a sealed connector 114 by a resistive non-metallic wire 116 for both electric power and data communications within the fuel tank 102. In accordance with an embodiment, a probe reader 504 receives data signals from the probes 502 a-502 n via the sealed connector 114. In another embodiment, the probe reader 504 is replaced by a data concentrator suitable for receiving high source impedance signals. The probe reader 504 or data concentrator is electrically connected to the sealed connector 114 by an external data communications connection 125. In accordance with an example, the external data communications connection 125 includes copper wires 506.
FIG. 6 illustrates an example of a four wire architecture 600 including a fuel height probe 106 with a local electric ground connection 131. An electric power connection 117 within the fuel tank 102 includes a power resistive non-metallic wire 602 a and a return power resistive non-metallic wire 602 b connecting the probe electronics package 104 to the sealed connector 114. An internal data communications connection 123 within the fuel tank 102 includes a signal Hi resistive non-metallic wire 604 a and a signal Lo resistive non-metallic wire 604 b connecting the probe electronics package 104 to the sealed connector 114. The resistive non-metallic wires 602 a, 602 b, 604 a and 604 b are the same as resistive non-metallic wires 116 in FIG. 1A. The sealed connector 114 is electrically connected to a probe reader 504 by an external data communications connection 125. In accordance with an example, the external data communications connection 125 includes a copper bundle 608. In another embodiment, the probe reader 504 is replaced by a data concentrator.
FIG. 7 illustrates an example of a four wire architecture 700 including a fuel height probe 106 with a local electric ground connection 131 and local power return. The local electric ground connection 131 provides an electric current return path via a structural ground rather than a wire return path as illustrated in the example in FIG. 6. An electric power connection 117 within the fuel tank 102 includes a single power resistive non-metallic wire 702 a connecting the probe electronics package 104 to the sealed connector 114. An internal data communications connection 123 within the fuel tank 102 includes a signal Hi resistive non-metallic wire 604 a and a signal Lo resistive non-metallic wire 604 b connecting the probe electronics package 104 to the sealed connector 114. The resistive non-metallic wires 702 a, 604 a and 604 b are the same as resistive non-metallic wires 116 in FIG. 1A. The sealed connector 114 is electrically connected to a probe reader 504 outside the fuel tank 102 by an external data communications connection 125. In accordance with an example, the external data communications connection 125 includes a copper bundle 608. In another embodiment, the probe reader 504 is replaced by a data concentrator.
FIG. 8 illustrates an example of a four wire architecture 800 including a fuel height probe 106 with a local electric ground connection 131, a local power return and a local data signal return. An electric power connection 117 within the fuel tank 102 includes a single power resistive non-metallic wire 702 a connecting the probe electronics package 104 to the sealed connector 114. An internal data communications connection 123 within the fuel tank 102 includes a single signal Hi resistive non-metallic wire 804 a connecting the probe electronics package 104 to the sealed connector 114. The resistive non-metallic wires 702 a and 804 a are the same as resistive non-metallic wires 116 in FIG. 1A. The sealed connector 114 is electrically connected to a probe reader 504 outside the fuel tank 102 by an external data communications connection 125. In accordance with an example, the external data communications connection 125 includes a copper bundle 608. In another embodiment, the probe reader 504 is replaced by a data concentrator.
FIG. 9 illustrates an example of a four wire architecture 900 including a floating fuel height probe 106, i.e., the fuel height probe 106 is not grounded. An electric power connection 117 within the fuel tank 102 includes a power resistive non-metallic wire 602 a and a return power resistive non-metallic wire 602 b connecting the probe electronics package 104 to the sealed connector 114. An internal data communications connection 123 within the fuel tank 102 includes a signal Hi resistive non-metallic wire 604 a and a signal Lo resistive non-metallic wire 604 b connecting the probe electronics package 104 to the sealed connector 114. The resistive non-metallic wires 602 a, 602 b, 604 a and 604 b are the same as resistive non-metallic wires 116 in FIG. 1A. The sealed connector 114 is electrically connected to a probe reader 504 by an external data communications connection 125. In accordance with an example, the external data communications connection 125 includes a copper bundle 608. In another embodiment, the probe reader 504 is replaced by a data concentrator.
FIG. 10 illustrates an example of a four wire architecture 1000 including an analog signal out connection 1001 and a floating fuel height probe 106, i.e., the probe 106 is not grounded. An electric power connection 117 within the fuel tank 102 includes an excitation voltage resistive non-metallic wire 1002 a and a return resistive non-metallic wire 1002 b connecting the probe electronics package 104 to the sealed connector 114. An internal data communications connection 123 within the fuel tank 102 includes a pair of analog signal out resistive non-metallic wires 1004 a and 1004 b connecting the probe electronics package 104 to the sealed connector 114. The resistive non-metallic wires 1002 a, 1002 b, 1004 a and 1004 b are the same as resistive non-metallic wires 116 in FIG. 1A. The internal data communications connection 123 includes the analog signal out connection 1001. The sealed connector 114 is electrically connected to a probe reader 504 by an external data communications connection 125. In accordance with an example, the external data communications connection 125 includes a copper bundle 608. In another embodiment, the probe reader 504 is replaced by a data concentrator.
FIG. 11 illustrates an example of a four wire architecture 1100 including a digital signal out connection 1102 from the probe electronics package 104 and a floating fuel height probe 106 (no ground). In accordance with the example illustrated in FIG. 11, an electric power connection 117 within the fuel tank 102 includes an excitation voltage resistive non-metallic wire 1104 a and a return resistive non-metallic wire 1104 b connecting the probe electronics package 104 to the sealed connector 114. An electric power source 112 outside the fuel tank 102 is connected to the sealed connector 114 by a copper wire 1105. An internal data communications connection 123 within the fuel tank 102 includes a pair of digital signal out resistive non-metallic wires 1106 a and 1106 b. The resistive non-metallic wires 1104 a, 1104 b, 1106 a and 1106 b are the same as resistive non-metallic wires 116 in FIG. 1A. The internal data communications connection 123 includes the digital signal out connection 1102. An external data communications connection 125 electrically connects the sealed connector 114 to a CCS 130. In the example illustrated in FIG. 11, the external data communications connection 125 includes a canbus 1112. The sealed connector 114 transmits the digital signal out 1102 to an amplifier 1108 outside the fuel tank 102 via a copper wire 1110. In accordance with another embodiment, the amplifier 1108 is replaced by a canbus buffer. The digital signal out 1102 is transmitted from the canbus buffer or amplifier 1108 by a canbus 1112 to the CCS 130.
FIG. 12 illustrates an example of a four wire architecture 1200 including a combination optical and resistive communications connection configuration 1202 and floating fuel height probe 106. In accordance with the example illustrated in FIG. 12, an electric power connection 117 in the fuel tank 102 includes a probe power in resistive non-metallic wire 1204 a and a return power resistive non-metallic wire 1204 b connecting the probe electronics package 104 to the sealed connector 114. An electric power source 112 outside the fuel tank 102 is connected to the sealed connector 114 by a copper wire 1205. An internal data communications connection 123 within the fuel tank 102 includes an optical signal out connection 1206 (fiber optic cable connection) that transmits an electrical light emitting diode (LED) signal 1212 to the sealed connector 114. The sealed connector 114 is connected to an optical data converter 1208 outside the fuel tank 102 by an external data communications connection 125. In accordance with an example, the external data communications connection 125 includes a fiber optic cable 1210. In accordance with another example, the optical data converter 1208 is replaced by a data concentrator.
FIG. 13 illustrates an example of a four wire architecture 1300 including a combination optical and resistive communications connection configuration 1202 and a fuel height probe 106 with a local electric ground connection 131. In accordance with the example illustrated in FIG. 13, an electric power connection 117 within the fuel tank 102 includes a probe power in resistive non-metallic wire 1204 a and a return power resistive non-metallic wire 1204 b connecting the probe electronics package 104 to the sealed connector 114. An electric power source 112 outside the fuel tank 102 is connected to the sealed connector 114 by a copper wire 1205. An internal data communications connection 123 within the fuel tank 102 includes an optical signal out connection 1206 (fiber optic cable connection) that transmits an electrical light emitting diode (LED) signal 1212 to the sealed connector 114. The sealed connector 114 is connected to an optical data converter 1208 outside the fuel tank 102 by an external data communications connection 125. The external data communications connection 125 includes a fiber optic cable 1210 in accordance with an example. In another example, the optical data converter 1208 is replaced a data concentrator.
FIG. 14 is an example of a vehicle 1400 including a system 1402 for power and data communications within a fuel tank 102 and across a wall 115 of the fuel tank 102 in accordance with an embodiment of the present disclosure. In accordance with one or more embodiments, the system 1402 for power and data communications is the same or similar to the exemplary system 100 in FIG. 1A or the system 150 in FIG. 1B and includes any of the different embodiments described with reference to FIGS. 1A-13. In accordance with an example, the vehicle 1400 is an aircraft. The vehicle 1400 includes a fuel tank 102. The fuel tank 102 includes a power and data communications systems 1404. The power and data communications system 1404 includes a fuel height probe 106 and a sealed connector 114 extending through a wall 115 of the fuel tank 102. The sealed connector 114 includes an internal electronic circuit 302 (FIG. 3B). The power and data communications system 1404 also includes an electric power connection 117 between the fuel height probe 106 and the sealed connector 114. The power and data communications system 1404 additionally includes an internal data communications connection 123 between the probe electronics package 104 of the fuel height sensor 103 and the sealed connector 114. At least the electric power connection 117 between the probe electronics package 104 and the sealed connector 114 includes a resistive non-metallic wire 116.
The vehicle 1400 also includes a device 1410 outside the fuel tank 102. The devices 1410 is at least one of a data concentrator, a core computer system, an optical reader, a probe reader, an amplifier, or a canbus. The device 1410 is connected to the sealed connector 114 by an external data communications connection 125. In accordance with another embodiment, the device 1410 includes a data connection 1412 between the sealed connector 114 and the device 1410.
The device 1410 or data concentrator is communicatively coupled to the fuel height sensor 103 through a resistive non-metallic wire 116 on at least one portion 1415 of a communications link 1416 between the fuel height sensor 103 and the sealed connector 114. An input 1417 of the sealed connector 114 is configured to receive data from the fuel height sensor 103 over the resistive non-metallic wire 116 on the at least one portion 1415 of the of the communications link 1416. The resistive non-metallic wire 116 is internal to the fuel tank 102.
In accordance with an embodiment, the device 1410 or data concentrator is communicatively coupled to the fuel height probe 106 through a first wire 1418 and a second wire 1420, wherein the first wire 1418 and the second wire 1420 have different electrical properties. The first wire 1418 and the second wire 1420 are each in a different environment. One environment is a wet environment 1422 and the other environment is a dry environment 1424.
In accordance with an embodiment, the device 1410 or data concentrator is communicatively coupled to the fuel height probe 106 over a communications link 1416 that includes two or more segments 1419, wherein a first segment 1419 a is over a resistive non-metallic wire and a second segment 1419 b is over a metallic wire.
In accordance with an embodiment, the device 1410 or data concentrator further includes an output configured to transmit data based on the data received from the fuel height sensor 103 to a fuel management system 134 embodied on a core computer system, such as core computer system (CCS) 130 in FIG. 1A, configured to convey a fuel quantity indication based on the data received from the fuel height sensor 103.
FIG. 15 is a flow chart of an example of a method 1500 for monitoring a quantity of fuel in a fuel tank 102 in accordance with an embodiment of the present disclosure. In block 1502, one or more fuel height sensors are inserted into a fuel tank 102. In accordance with an example, the fuel height sensors are similar to the fuel height sensors 103 described with reference to FIGS. 1A and 1B.
In block 1504, an electric power connection 117 is provided between each fuel height sensor 103 and a sealed connector 114 extending through a wall 115 of the fuel tank 102. The electric power connection 117 includes any of the electric power connections previously described and the sealed connector 114 is similar to sealed connector 114.
In block 1506, an internal data communications connection 123 is provided between each fuel height sensor 103 and the sealed connector 114. The internal data communications connection 123 includes any of the internal data communications connection 123 embodiments previously described.
In block 1508, fuel height data is transmitted from each fuel height sensor 103 to a device configured to determine the fuel height in the fuel tank based on the fuel height data from each fuel height sensor. In accordance with an example, the device incudes a fuel management system 134 embodied on a CCS 130.
In block 1510, a fuel quantity indication is generated by the fuel management system 134 based on the fuel height in the fuel tank 102. In block 1512, the fuel quantity indication is presented to an operator of the vehicle 129 or system, for example, via most any human-machine interface (HMI).
Although the above embodiments have been described with respect to an aircraft, the embodiments and features described herein are not limited to an aircraft and can be implemented in other vehicles, such as land vehicles and watercraft.
Further, the disclosure comprises embodiments according to the following clauses:
Clause 1. A system, comprising:

- a plurality of fuel height sensors within a fuel tank;
- a sealed active connector extending through a wall of the fuel tank, wherein the sealed active connector comprises an internal electronic circuit configured to receive data from the plurality of fuel height sensors;
- an electric power connection between each of the fuel height sensors and the sealed active connector; and
- an internal data communications connection between each of the fuel height sensors and the sealed active connector, wherein at least the electric power connection between each fuel height sensor and the sealed active connector comprises a resistive non-metallic wire.

Clause 2. The system of clause 1, wherein the internal electronic circuit is further configured to format the data from the fuel height sensors to Aeronautical Radio, Incorporated (ARINC) data.
Clause 3. The system of any of clauses 1 or 2, wherein the sealed active connector is directly connected to devices of a core computer system (CCS) by an external data communications connection outside the fuel tank.
Clause 4. The system of any of clauses 1-2, or 3, wherein the external data communications connection comprises one of a digital data bus, Aeronautical Radio, Incorporated (ARINC) bus, or a Controller Area Network (CAN) bus.
Clause 5. The system of any of clauses 1-3, or 4, wherein the sealed active connector comprises a connector shell and the internal electronic circuit comprises a microprocessor removably disposed within the connector shell.
Clause 6. The system of any of clauses 1-4, or 5, wherein the sealed active connector comprises an active adapter connected to a passive sealed connector that extends through the wall of the fuel tank, wherein the internal electronic circuit is disposed within the active adapter and the active adapter is removable from the passive sealed connector without removing the passive sealed connector from the wall of the fuel tank.
Clause 7. The system of any of clauses 1-5, or 6, wherein the fuel tank is mounted in a wing of an aircraft and the plurality of fuel height sensors are distributed at predetermined different locations within the fuel tank to accurately measure a quantity of fuel within the fuel tank.
Clause 8. The system of any of clauses 1-6, or 7, wherein the resistive non-metallic wire comprises a carbon loaded thermoplastic.
Clause 9. The system of any of clauses 1-7, or 8, wherein the resistive non-metallic wire comprises a carbon loaded polyether ether ketone (PEEK) thermoplastic.
Clause 10. The system of any of clauses 1-8, or 9, wherein the resistive non-metallic wire comprises a resistance between about 100 ohms/meter and about 1 Mohms/meter.
Clause 11. The system of any of clauses 1-9, or 10, wherein the internal data communications connection comprises a resistive non-metallic wire.
Clause 12. The system of any of clauses 1-10, or 11, wherein the internal data communications connection comprises an analog signal out connection.
Clause 13. The system of any of clauses 1-11, or 12, wherein the internal data communications connection comprises a digital signal out connection.
Clause 14. A vehicle comprising:

- a fuel tank;
- a system for power and data communications within the fuel tank and across a wall of the fuel tank, the system comprising:
- a plurality of fuel height sensors;
- a sealed active connector extending through a wall of the fuel tank, wherein the sealed active connector comprises an internal electronic circuit configured to receive data from the plurality of fuel height sensors;
- an electric power connection between each of the fuel height sensors and the sealed active connector; and
- an internal data communications connection between each of the fuel height sensors and the sealed active connector, wherein at least the electric power connection between each fuel height sensor and the sealed active connector comprises a resistive non-metallic wire.

Clause 15. The vehicle of clause 14, wherein the internal electronic circuit is further configured to format the data from the fuel height sensors to ARINC data.
Clause 16. The vehicle of any of clauses 14 or 15, wherein the sealed active connector is directly connected to devices of a core computer system (CCS) by an external data communications connection outside the fuel tank.
Clause 17. The vehicle of any of clauses 14-15, or 16, wherein the external data communications connection comprises one of a digital data bus, Aeronautical Radio, Incorporated (ARINC) bus, or a Controller Area Network (CAN) bus.
Clause 18. The vehicle of any of clauses 14-16, or 17, wherein the sealed active connector comprises a connector shell and the internal electronic circuit comprises a microprocessor removably disposed within the connector shell.
Clause 19. The vehicle of any of clauses 14-17, or 18, wherein the sealed active connector comprises an active adapter connected to a passive sealed connector that extends through the wall of the fuel tank, wherein the internal electronic circuit is disposed within the active adapter and the active adapter is removable from the passive sealed connector without removing the passive sealed connector from the wall of the fuel tank.
Clause 20. The vehicle of any of clauses 14-18, or 19, wherein the fuel tank is mounted in a wing of an aircraft and the plurality of fuel height sensors are distributed at predetermined different locations within the fuel tank to accurately measure a quantity of fuel within the fuel tank.
Clause 21. The vehicle of any of clauses 14-19, or 20, wherein the resistive non-metallic wire comprises a carbon loaded thermoplastic.
Clause 22. The vehicle of any of clauses 14-20, or 21, wherein the resistive non-metallic wire comprises a carbon loaded polyether ether ketone (PEEK) thermoplastic.
Clause 23. The vehicle of any of clauses 14-21, or 22, wherein the resistive non-metallic wire comprises a resistance between about 100 ohms/meter and about 1 Mohms/meter.
Clause 24. The vehicle of any of clauses 14-22, or 23, wherein the internal data communications connection comprises a resistive non-metallic wire.
Clause 25. The vehicle of any of clauses 14-23, or 24, wherein the internal data communications connection comprises an analog signal out connection.
Clause 26. The vehicle of any of clauses 14-24, or 25, wherein the internal data communications connection comprises a digital signal out connection.
Clause 27. A method, comprising:

- inserting one or more fuel height sensors in a fuel tank;
- providing an electric power connection between each fuel height sensor and a sealed active connector extending through a wall of the fuel tank; and
- providing an internal data communications connection between each fuel height sensor and the sealed active connector, wherein at least the electric power connection comprises a resistive non-metallic wire.

Clause 28. The method of clause 27, wherein the internal electronic circuit is further configured to format the data from the fuel height sensors to ARINC data.
Clause 29. The method of any of clauses 27 or 28, wherein the sealed active connector is directly connected to devices of a core computer system (CCS) by an external data communications connection outside the fuel tank.
Clause 30. The method of any of clauses 27-28, or 29, wherein the external data communications connection comprises one of a digital data bus, Aeronautical Radio, Incorporated (ARINC) bus, or a Controller Area Network (CAN) bus.
Clause 31. The method of any of clauses 27-29, or 30, wherein the sealed active connector comprises a connector shell and the internal electronic circuit comprises a microprocessor removably disposed within the connector shell.
Clause 32. The method of any of clauses 27-30, or 31, wherein the sealed active connector comprises an active adapter connected to a passive sealed connector that extends through the wall of the fuel tank, wherein the internal electronic circuit is disposed within the active adapter and the active adapter is removable from the passive sealed connector without removing the passive sealed connector from the wall of the fuel tank.
Clause 33. The method of any of clauses 27-31, or 32, wherein the fuel tank is mounted in a wing of an aircraft and the plurality of fuel height sensors are distributed at predetermined different locations within the fuel tank to accurately measure a quantity of fuel within the fuel tank.
Clause 34. The method of any of clauses 27-32, or 33, wherein the resistive non-metallic wire comprises a carbon loaded thermoplastic.
Clause 35. The method of any of clauses 27-33, or 34, wherein the resistive non-metallic wire comprises a carbon loaded polyether ether ketone (PEEK) thermoplastic.
Clause 36. The method of any of clauses 27-34, or 35, wherein the resistive non-metallic wire comprises a resistance between about 100 ohms/meter and about 1 Mohms/meter.
Clause 37. The method of any of clauses 27-35, or 36, wherein the internal data communications connection comprises a resistive non-metallic wire.
Clause 38. The method of any of clauses 27-36, or 37, wherein the internal data communications connection comprises an analog signal out connection.
Clause 39. The method of any of clauses 27-37, or 38, wherein the internal data communications connection comprises a digital signal out connection.
The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present disclosure. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of instructions, which comprises one or more executable instructions for implementing the specified logical function(s). In some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts or carry out combinations of special purpose hardware and computer instructions.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of embodiments of the disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “include,” “includes,” “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present embodiments has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to embodiments in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of embodiments.
Although specific embodiments have been illustrated and described herein, those of ordinary skill in the art appreciate that any arrangement which is calculated to achieve the same purpose may be substituted for the specific embodiments shown and that the embodiments have other applications in other environments. This application is intended to cover any adaptations or variations. The following claims are in no way intended to limit the scope of embodiments of the disclosure to the specific embodiments described herein.

Claims

What is claimed is:

1. A system, comprising:

a plurality of fuel height sensors within a fuel tank;

a sealed active connector extending through a wall of the fuel tank, wherein the sealed active connector comprises an internal electronic circuit configured to receive data from the plurality of fuel height sensors;

an electric power connection between each of the fuel height sensors and the sealed active connector; and

an internal data communications connection between each of the fuel height sensors and the sealed active connector, wherein at least the electric power connection between each fuel height sensor and the sealed active connector comprises a resistive non-metallic wire.

2. The system of claim 1, wherein the internal electronic circuit is further configured to format the data from the fuel height sensors to Aeronautical Radio, Incorporated (ARINC) data.

3. The system of claim 1, wherein the sealed active connector is directly connected to devices of a core computer system (CCS) by an external data communications connection outside the fuel tank.

4. The system of claim 3, wherein the external data communications connection comprises one of a digital data bus, Aeronautical Radio, Incorporated (ARINC) bus, or a Controller Area Network (CAN) bus.

5. The system of claim 1, wherein the sealed active connector comprises a connector shell and the internal electronic circuit comprises a microprocessor removably disposed within the connector shell.

6. The system of claim 1, wherein the sealed active connector comprises an active adapter connected to a passive sealed connector that extends through the wall of the fuel tank, wherein the internal electronic circuit is disposed within the active adapter and the active adapter is removable from the passive sealed connector without removing the passive sealed connector from the wall of the fuel tank.

7. The system of claim 1, wherein the fuel tank is mounted in a wing of an aircraft and the plurality of fuel height sensors are distributed at predetermined different locations within the fuel tank to accurately measure a quantity of fuel within the fuel tank.

8. The system of claim 1, wherein the resistive non-metallic wire comprises a carbon loaded thermoplastic.

9. The system of claim 1, wherein the resistive non-metallic wire comprises a carbon loaded polyether ether ketone (PEEK) thermoplastic.

10. The system of claim 9, wherein the resistive non-metallic wire comprises a resistance between about 100 ohms/meter and about 1 Mohms/meter.

11. The system of claim 1, wherein the internal data communications connection comprises a resistive non-metallic wire.

12. The system of claim 1, wherein the internal data communications connection comprises an analog signal out connection.

13. The system of claim 1, wherein the internal data communications connection comprises a digital signal out connection.

14. A vehicle comprising:

a fuel tank;

a system for power and data communications within the fuel tank and across a wall of the fuel tank, the system comprising:

a plurality of fuel height sensors;

15. The vehicle of claim 14, wherein the internal electronic circuit is further configured to format the data from the fuel height sensors to ARINC data.

16. The vehicle of claim 14, wherein the sealed active connector is directly connected to a core computer system (CCS) by an external data communications connection outside the fuel tank.

17. The vehicle of claim 16, wherein the external data communications connection comprises one of a digital data bus, Aeronautical Radio, Incorporated (ARINC) bus, or a Controller Area Network (CAN) bus.

18. The vehicle of claim 14, wherein the sealed active connector comprises an active adapter connected to a passive sealed connector that extends through the wall of the fuel tank, wherein the internal electronic circuit is disposed within the active adapter and the active adapter is removable from the passive sealed connector without removing the passive sealed connector from the wall of the fuel tank.

19. The vehicle of claim 14, wherein the vehicle is an aircraft and the fuel tank is mounted in a wing of the aircraft, and wherein the plurality of fuel height sensors are distributed at predetermined different locations within the fuel tank to accurately measure a quantity of fuel within the fuel tank.

20. A method, comprising:

inserting one or more fuel height sensors in a fuel tank;

providing an electric power connection between each fuel height sensor and a sealed active connector extending through a wall of the fuel tank; and

providing an internal data communications connection between each fuel height sensor and the sealed active connector, wherein at least the electric power connection comprises a resistive non-metallic wire.