An integrated urea liquid level sensor assembly and method of use thereof

Abstract

The application discloses an integrated urea liquid level sensor assembly and a use method thereof, which comprises a urea liquid level sensor, a water cut electromagnetic valve and a filter element installed on a urea tank; the urea liquid level sensor is connected with a urea liquid inlet pipe, a urea liquid return pipe and a cooling water pipe; the urea liquid inlet pipe is used to be connected with an inlet of a urea pump, and an outlet of the urea pump is connected with a urea nozzle; the filter element is arranged at the bottom of the urea liquid level sensor; the urea liquid return pipe is semi-closed with the filter element as a whole; when the urea liquid is returned, the filter element is flushed by the returned urea liquid, so that impurities attached to the filter element are flushed away, and the filter element realizes self-cleaning. The heating module on the device is connected with an external power supply through an electrified liquid level plug, and is fixed in position through a positioning buckle, so that the tightness of the electrified liquid level plug and the external power supply connection can be effectively improved, the normal use of the heating function is guaranteed, and the service life of the device is prolonged.

Description

Technical Field

[0001] This invention relates to the technical field of diesel engines, and in particular to an integrated urea level sensor assembly and its usage method. Background Technology

[0002] During the exhaust gas emission process of light truck after-treatment, the urea injection system will gradually clog the filter screen due to the precipitation of urea and the accumulation of impurities during the actual urea absorption process, resulting in insufficient absorption and deviation of injection volume. It is necessary to clean the impurities attached to the filter screen in time. In addition, in existing technologies, the urea tank and the water shut-off solenoid valve are assembled separately, the urea level sensor is installed on the urea tank, and there are connecting pipes between the engine and the water shut-off solenoid valve, as well as between the water shut-off solenoid valve and the urea level sensor. This installation structure not only increases the workload of the main unit installation, but also has numerous pipes, affecting the appearance of the main unit. Moreover, the urea level sensors that come with vehicles currently use traditional water circulation heating devices to heat the urea solution. However, most heating devices are connected to the power supply via connectors. During long-term use, the bumps and vibrations of the vehicle can easily cause the power level plug or pipe joint to loosen, resulting in the urea heating function failing to work properly. Improvements are needed. To address these issues, we propose an integrated urea level sensor assembly and its usage method. Summary of the Invention

[0003] The purpose of this section is to outline some aspects of embodiments of the present invention and to briefly describe some preferred embodiments. Simplifications or omissions may be made in this section, as well as in the abstract and title of this application, to avoid obscuring the purpose of these documents; however, such simplifications or omissions should not be construed as limiting the scope of the invention.

[0004] Therefore, in order to solve the above-mentioned technical problems, the present invention provides the following technical solution: an integrated urea level sensor assembly, including a urea level sensor, a water shut-off solenoid valve, and a filter element installed on a urea tank; The urea level sensor is connected to a urea return pipe, an engine hot water inlet pipe, and a cooling water pipe. The urea return pipe and the cooling water pipe are connected by a pipe clamp. The urea return pipe and the engine hot water inlet pipe are used to connect the urea pump and the urea tank. The outlet of the urea pump is connected to the urea nozzle. A spiral heating tube is connected to the outlet of the water shut-off solenoid valve, and the spiral heating tube is connected to the engine hot water return pipe; the cooling water pipe is connected to the urea inlet pipe, and the urea inlet pipe is connected to the inlet of the water shut-off solenoid valve; the control terminal of the water shut-off solenoid valve is connected to the engine control module. The filter element is located at the bottom of the urea level sensor, and the urea return pipe is connected to the top of the filter element. Urea enters the urea tank through the urea return pipe, and engine hot water enters the urea inlet pipe and then enters the spiral heating tube to exchange heat with the urea in the urea tank or to thaw the frozen urea solution in the urea tank. The engine hot water after heat exchange is discharged through the engine hot water return pipe and circulated back to the engine. When the urea liquid is drawn back, the drawn-back urea liquid is used to flush the filter element, so that the impurities attached to the filter element are washed away, and the filter element achieves self-cleaning.

[0005] In a preferred embodiment of the integrated urea level sensor assembly of the present invention, the urea level sensor and the water shut-off solenoid valve are both arranged on a sealing seat, which is connected to the urea tank; a wiring box is arranged on the sealing seat.

[0006] In a preferred embodiment of the integrated urea level sensor assembly of the present invention, the wiring box is electrically connected to a connecting cable, which is led out from the wiring box and connected to a power-on level plug. The power-on level plug is provided with a positioning buckle, and the position is fixed by the positioning buckle.

[0007] In a preferred embodiment of the integrated urea level sensor assembly of the present invention, a flame-retardant connector is provided at the joint between the connecting cable and the energized level plug, and an anti-deformation sheath is sleeved on the outside of the flame-retardant connector, with multiple silicone rings arranged on the outside of the anti-deformation sheath; a sealing connector is provided at the joint between the flame-retardant connector and the connecting cable and the energized level plug, and the connection is sealed with the connecting cable and the energized level plug through the sealing connector.

[0008] In a preferred embodiment of the integrated urea level sensor assembly of the present invention, a urea concentration sensor and a spiral heating tube are provided on one side of the filter element, a rubber tube is connected to the urea concentration sensor, and the spiral heating tube is wound around the outside of the urea return pipe.

[0009] As a preferred embodiment of the integrated urea level sensor assembly of the present invention, wherein: the top of the energized level plug is connected to an integrated positioning buckle, the positioning buckle includes a locking umbrella buckle and a limiting bracket, the locking umbrella buckle has an umbrella-shaped structure with elastic bending structure on both sides, after the locking umbrella buckle is pressed inward and inserted into the vehicle body socket that it is used with, the locking umbrella buckle expands on both sides and is fixed in the socket, and the limiting bracket is located on the outside of the vehicle body socket.

[0010] In a preferred embodiment of the integrated urea level sensor assembly of the present invention, a guide rod is arranged on one side of the spiral heating tube, and a magnetic float that can move up and down is arranged on the guide rod.

[0011] As a preferred embodiment of the integrated urea level sensor assembly of the present invention, the pipe clamp has a U-shaped cross-section and a pipe clamping groove adapted to the corresponding pipe structure is provided in the inner cavity of the pipe clamp.

[0012] As a preferred embodiment of the integrated urea level sensor assembly of the present invention, a fastening hole is provided at the opening of the pipe clamp, a fastening bolt is connected to the fastening hole, the fastening bolt passes through the fastening hole and is threadedly connected to the fastening nut, and the opening of the pipe clamp is clamped by the fastening nut.

[0013] The present invention also provides a method for using the above-mentioned integrated urea level sensor assembly, which specifically includes the following steps: S1: Before use, pinch both sides of the locking umbrella buckle tightly with your hands, then insert it into the vehicle body socket that it is used with. Release your hands so that the locking umbrella buckle resets under its own elasticity. The vehicle body socket limits and fixes the position of the energized liquid level plug on both sides of the locking umbrella buckle. When there is a risk of the connecting cable shaking, the limiting bracket limits the swing amplitude of the connecting cable and improves the tightness of the connection between the energized liquid level plug and the external power source. S2: By connecting the power-on liquid level plug to an external power source, the urea liquid level sensor enables the liquid level detection function of the urea liquid in the urea tank. S3: When the power supply to the water shut-off solenoid valve is turned on, the engine control module collects ambient temperature and engine load status information through the sensor device connected to it, and automatically adjusts the opening and closing degree and time of the water shut-off solenoid valve to control the temperature and flow of the urea heating system, so that the water shut-off solenoid valve can realize the function of controlling the temperature and flow of the urea heating system. S4: Urea enters the urea tank through the urea inlet pipe, and engine hot water enters the heater inlet pipe and then enters the spiral heating tube to exchange heat with the urea in the urea tank or to thaw the frozen urea solution in the urea tank. The engine hot water after heat exchange is discharged through the heater outlet pipe and circulated back to the engine.

[0014] The beneficial effects of this invention are: 1. This invention proposes an integrated urea level sensor assembly and its usage method. This device semi-encloses the urea return pipe and filter element into a single unit. When urea liquid is drawn back, the drawn-back urea liquid flushes the filter element, removing impurities adhering to it and achieving a self-cleaning function, preventing filter clogging. 2. This invention's integrated urea level sensor assembly and its usage method eliminates the need for external heating, using engine circulating hot water to defrost the urea, extending the device's lifespan. 3. This invention's integrated urea level sensor assembly and its usage method integrate the level sensor assembly with a heating solenoid valve, mounted on the urea tank. This prevents urea solution crystallization in the urea nozzle, preventing blockage of the urea injection system and improving control accuracy. Furthermore, the installation method is simple in structure, reduces piping, and is convenient for installation and maintenance. Attached Figure Description

[0015] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Wherein: Figure 1 This is a partial three-dimensional structural diagram of the present invention.

[0016] Figure 2 This is a schematic diagram of the overall front structure of the present invention.

[0017] Figure 3 This is a schematic diagram of the overall side structure of the present invention.

[0018] Figure 4 For the present invention Figure 3 A magnified schematic diagram of the structure at point A in the diagram.

[0019] Figure 5 This is a top view of the structure of the present invention.

[0020] Figure 6 This is a schematic diagram of the specific structure of the flame-retardant connector of the present invention.

[0021] Figure 7 This is a side view of the pipe clamp structure of the present invention. Figure 8 This is a schematic diagram of the installation structure of the pipe clamp of the present invention. Figure 9 This is a schematic diagram of the specific structure of the pipe clamp of the present invention.

[0022] In the diagram: 100, urea level sensor; 101, urea return pipe; 102, engine hot water inlet pipe; 103, coolant pipe; 104, pipe clamp; 105, fastening bolt; 106, fastening nut; 107, pipe groove. 200. Water shut-off solenoid valve; 201. Urea inlet pipe; 202. Spiral heating element; 203. Engine hot water return pipe; 204. Sealing seat; 2041. Wiring box; 2042. Connecting cable; 2043. Power-on liquid level plug; 2044. Flame-retardant connector; 2045. Deformation-resistant sheath; 2046. Silicone ring; 2047. Sealing connector; 205. Magnetic float; 206. Urea concentration sensor; 207. Guide rod; Filter cartridge; 400. Positioning buckle; 401. Locking umbrella buckle; 402. Limiting support. Detailed Implementation

[0023] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0024] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0025] Secondly, the term "one embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The phrase "in one embodiment" appearing in different places in this specification does not necessarily refer to the same embodiment, nor is it a single or selective embodiment that is mutually exclusive with other embodiments.

[0026] Secondly, the present invention is described in detail with reference to the schematic diagrams. When detailing the embodiments of the present invention, for ease of explanation, the cross-sectional views illustrating the device structure may be partially enlarged, not according to the usual scale. Furthermore, the schematic diagrams are merely examples and should not limit the scope of protection of the present invention. In addition, actual fabrication should include three-dimensional spatial dimensions of length, width, and depth.

[0027] Reference Figures 1-9 As an embodiment of the present invention, an integrated urea level sensor assembly and its usage method are provided, including a urea level sensor 100, a water shut-off solenoid valve 200 and a filter element 300 installed on a urea tank. The urea level sensor 100 is connected to a urea return pipe 101, an engine hot water inlet pipe 102, and a cooling water pipe 103. The urea return pipe 101 and the cooling water pipe 103 are connected by a pipe clamp 104. The pipe clamp 104 has a U-shaped cross-section, and a pipe groove 107 adapted to the corresponding pipe structure is opened in the inner cavity of the pipe clamp 104. A fastening hole is opened at the opening of the pipe clamp 104, and a fastening bolt 105 is connected to the fastening hole. The fastening bolt 105 passes through the fastening hole and is threaded to a fastening nut 106, and the fastening nut 106 clamps the opening of the pipe clamp 104. The urea return pipe 101 and the engine hot water inlet pipe 102 are used to connect the urea pump and the urea tank. The outlet of the urea pump is connected to the urea nozzle. A spiral heating tube 202 is connected to the outlet of the water shut-off solenoid valve 200, and is connected to the engine hot water return pipe 203 through the spiral heating tube 202; the cooling water pipe 103 is connected to the urea inlet pipe 201, and the urea inlet pipe 201 is connected to the inlet of the water shut-off solenoid valve 200; the control terminal of the water shut-off solenoid valve 200 is connected to the engine control module. A urea concentration sensor 206 and a spiral heating tube 202 are installed on one side of the filter element 300. A rubber tube is connected to the urea concentration sensor 206. The spiral heating tube 202 is wound around the outside of the urea return pipe 101, providing a large heat dissipation area and transferring more heat to the urea solution within a certain unit of time. A guide rod 207 is arranged on one side of the spiral heating tube 202, and a magnetic float 205 that can move up and down is arranged on the guide rod 207. When a jamming fault occurs or the engine running time exceeds the set time, the vibration component of the diesel engine can apply a vibration excitation of a set frequency to the guide rod 207, thereby loosening the impurities between the guide rod 207 and the magnetic float 205, allowing the jammed magnetic float 205 to maintain a free movement state. This ensures the accuracy of urea level measurement and effectively avoids insufficient urea due to measurement errors, which could lead to excessive vehicle emissions. The urea level sensor 100 and the water shut-off solenoid valve 200 are both mounted on the sealing seat 204, which is connected to the urea tank. The water shut-off solenoid valve 200 opens the circulating hot water channel when the urea needs to thaw in cold weather and closes the channel when the temperature is suitable. A wiring box 2041 is mounted on the sealing seat 204, and a connecting cable 2042 is electrically connected to the wiring box 2041. The connecting cable 2042 extends from the wiring box 2041 and connects to a power-on level plug 2043. The power-on level plug 2043 is the power and communication connector for monitoring the urea level and concentration. A positioning buckle 400 is arranged on the head 2043, and the position is fixed by the positioning buckle 400; a flame-retardant connector 2044 is arranged at the joint between the connecting cable 2042 and the energized liquid level plug 2043, and an anti-deformation sheath 2045 is sleeved on the outside of the flame-retardant connector 2044, and multiple silicone rings 2046 are arranged on the outside of the anti-deformation sheath 2045; a sealing connector 2047 is arranged at the connection between the flame-retardant connector 2044 and the connecting cable 2042 and the energized liquid level plug 2043, and a sealed connection is made between the sealing connector 2047 and the connecting cable 2042 and the energized liquid level plug 2043. The top of the power-on liquid level plug 2043 is connected to an integrated positioning buckle 400. The positioning buckle 400 includes a locking umbrella buckle 401 and a limiting bracket 402. The locking umbrella buckle 401 has an umbrella-shaped structure with elastic bending structures on both sides. After the locking umbrella buckle 401 is pressed inward and inserted into the vehicle body socket that it is used with, the locking umbrella buckle 401 expands on both sides and is fixed in the socket. The limiting bracket 402 is located on the outside of the vehicle body socket. The filter element 300 is located at the bottom of the urea level sensor 100, and the urea return pipe 101 is connected to the top of the filter element 300. When the urea liquid is drawn back, the drawn-back urea liquid is used to flush the filter element 300, so that the impurities attached to the filter element 300 are washed away, and the filter element 300 achieves self-cleaning. Specifically, the temperature is monitored by the T6 sensor on the smoke vent during the post-treatment process. When the temperature of the T6 sensor reaches 150°C, the urea pump builds up pressure; when the temperature of the T6 sensor reaches 180°C, urea is injected; under certain road conditions, when the urea pump depressurizes, the urea will return through the return pipe to flush the filter screen; when the machine stops, the urea pump draws back to flush the filter screen.

[0028] The present invention also provides a method for using the above-mentioned integrated urea level sensor assembly, which specifically includes the following steps: S1: Before use, pinch both sides of the locking umbrella buckle 401 tightly with your hand, then insert it into the vehicle body socket that it is used with. Release your hand so that the locking umbrella buckle 401 returns to its original position under its own elasticity. The vehicle body socket limits and fixes the position of the energized liquid level plug 2043 on both sides of the locking umbrella buckle 401. When there is a risk of the connecting cable 2042 shaking, the limiting bracket 402 limits the swing amplitude of the connecting cable 2042 and improves the tightness of the connection between the energized liquid level plug 2043 and the external power source. S2: By connecting the energized liquid level plug 2043 to an external power source, the urea liquid level sensor 100 enables the liquid level detection function of the urea liquid in the urea tank. S3: When the power supply to the water shut-off solenoid valve 200 is turned on, the engine control module collects ambient temperature and engine load status information through the sensor device connected to it, and automatically adjusts the opening and closing degree and time of the water shut-off solenoid valve 200 to control the temperature and flow of the urea heating system, so that the water shut-off solenoid valve 200 can realize the function of controlling the temperature and flow of the urea heating system. S4: Urea enters the urea tank through the urea return pipe 101, and engine hot water enters the urea inlet pipe 201 and then enters the spiral heating pipe 202 to exchange heat with the urea in the urea tank or to thaw the frozen urea solution in the urea tank. The engine hot water after heat exchange is discharged through the engine hot water return pipe 203 and circulated back to the engine.

[0029] It is worth noting that the entire device is controlled by a controller. Since the controller is a common device and belongs to existing mature technology, its electrical connection relationship and specific circuit structure will not be described in detail here.

[0030] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. An integrated urea level sensor assembly, characterized in that: Includes a urea level sensor (100), a water shut-off solenoid valve (200), and a filter element (300) installed on the urea tank. The urea level sensor (100) is connected to a urea return pipe (101), an engine hot water inlet pipe (102), and a cooling water pipe (103). The urea return pipe (101) and the cooling water pipe (103) are connected by a pipe clamp (104). The urea return pipe (101) and the engine hot water inlet pipe (102) are used to connect the urea pump and the urea tank. The outlet of the urea pump is connected to the urea nozzle. A spiral heating tube (202) is connected to the outlet of the water shut-off solenoid valve (200), and is connected to the engine hot water return pipe (203) through the spiral heating tube (202); the cooling water pipe (103) is connected to the urea inlet pipe (201), and the urea inlet pipe (201) is connected to the inlet of the water shut-off solenoid valve (200); the control terminal of the water shut-off solenoid valve (200) is connected to the engine control module; the urea level sensor (100) and the water shut-off solenoid valve (200) are both arranged on the sealing seat (204), and the sealing seat (204) is connected to the urea tank. Connection; a wiring box (2041) is arranged on the sealing seat (204); a connecting cable (2042) is electrically connected to the wiring box (2041), and the connecting cable (2042) is led out from the wiring box (2041) and connected to the power-on liquid level plug (2043). A positioning buckle (400) is arranged on the power-on liquid level plug (2043), and the position is fixed by the positioning buckle (400); a urea concentration sensor (206) is connected to the spiral heating tube (202), and the spiral heating tube (202) is wrapped around the outside of the engine hot water inlet pipe (102); The filter element (300) is arranged at the bottom of the urea level sensor (100). The engine hot water inlet pipe (102) is connected to the top of the filter element (300). Urea enters the urea tank through the urea return pipe (101). Engine hot water enters the urea inlet pipe (201) and enters the spiral heating pipe (202) to exchange heat with the urea in the urea tank or to thaw the frozen urea solution in the urea tank. The engine hot water after heat exchange is discharged through the engine hot water return pipe (203) and circulated back to the engine. When the urea liquid is drawn back, the urea liquid is used to flush the filter element (300) so that the impurities attached to the filter element (300) are flushed out, and the filter element (300) achieves self-cleaning.

2. The integrated urea level sensor assembly as described in claim 1, characterized in that: The top of the energized liquid level plug (2043) is connected to an integrated positioning buckle (400). The positioning buckle (400) includes a locking umbrella buckle (401) and a limiting bracket (402). The locking umbrella buckle (401) has an umbrella-shaped structure with elastic bending structures on both sides. The locking umbrella buckle (401) is inserted into the body hole reserved in the vehicle body, and the limiting bracket (402) is located outside the body hole.

3. The integrated urea level sensor assembly as described in claim 2, characterized in that: A flame-retardant connector (2044) is provided at the joint between the connecting cable (2042) and the energized liquid level plug (2043). An anti-deformation sleeve (2045) is sleeved on the outside of the flame-retardant connector (2044). Multiple silicone rings (2046) are arranged on the outside of the anti-deformation sleeve (2045). A sealing connector (2047) is provided at the joint between the flame-retardant connector (2044) and the connecting cable (2042) and the energized liquid level plug (2043), and the sealing connector (2047) is used to seal the connection with the connecting cable (2042) and the energized liquid level plug (2043).

4. The integrated urea level sensor assembly as described in claim 3, characterized in that: A guide rod (207) is arranged on one side of the spiral heating tube (202), and a magnetic float (205) that moves up and down is arranged on the guide rod (207).

5. The integrated urea level sensor assembly as described in claim 4, characterized in that: The cross-section of the pipe clamp (104) is U-shaped, and the inner cavity of the pipe clamp (104) is provided with a pipe clamping groove (107) that is adapted to the corresponding pipe structure.

6. The integrated urea level sensor assembly as described in claim 5, characterized in that: The pipe clamp (104) has a fastening hole at the opening, and a fastening bolt (105) is connected to the fastening hole. The fastening bolt (105) passes through the fastening hole and is threaded to the fastening nut (106), and the fastening nut (106) clamps the opening of the pipe clamp (104).

7. The method of using the integrated urea level sensor assembly as described in claim 6, characterized in that: It includes the following specific steps: S1: Before use, pinch the two sides of the locking umbrella buckle (401) tightly with your hand, then insert it into the vehicle body socket that it is used with, and release your hand so that the locking umbrella buckle (401) resets under its own elasticity. The vehicle body socket limits and fixes the position of the energized liquid level plug (2043) on both sides of the locking umbrella buckle (401). When there is a risk of shaking of the connecting cable (2042), the swing amplitude of the connecting cable (2042) is limited by the limiting bracket (402) to improve the tightness of the connection between the energized liquid level plug (2043) and the external power source. S2: By connecting the energized liquid level plug (2043) to an external power source, the urea liquid level sensor (100) enables the urea liquid level detection function in the urea tank; S3: Connect the power supply to the water shut-off solenoid valve (200). The engine control module collects ambient temperature and engine load status information through the sensor device connected to it, and automatically adjusts the opening and closing degree and time of the water shut-off solenoid valve (200) to control the temperature and flow of the urea heating system, so that the water shut-off solenoid valve (200) can realize the function of controlling the temperature and flow of the urea heating system. S4: Urea enters the urea tank through the urea return pipe (101), and engine hot water enters the urea inlet pipe (201) and enters the spiral heating pipe (202) to exchange heat with the urea in the urea tank or to thaw the frozen urea solution in the urea tank. The engine hot water after heat exchange is discharged through the engine hot water return pipe (203) and circulated back to the engine.

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