Highly wear-resistant oil quantity sensor

Abstract

The application relates to the technical field of oil quantity sensors, in particular to a high-wear-resistance oil quantity sensor, a liquid level sensing swing assembly of the sensor is rotationally installed on a base; a copper contact piece is installed on the liquid level sensing swing assembly, the liquid level sensing swing assembly rotates relative to the base to drive the copper contact piece to rotate; a PCB is arranged on the base, a copper contact is arranged on the PCB, different positions of the copper contact are respectively electrically connected with different resistance branches; the copper contact abuts against the copper contact piece, and the copper contact piece is connected with different resistance branches on the PCB when contacting different positions of the copper contact during rotation. The copper-copper pair composed of the copper contact and the copper contact piece is adopted, the wear is smaller when the same kind of metal slides and rubs, and the service life of the whole mechanical structure is further prolonged. The resistance branches are plastic potting, so that the oil is isolated, the influence of oil impurities on the resistance branches is avoided, and the indication precision of the residual oil quantity in the use process is improved.

Description

Technical Field

[0001] This application relates to the field of oil level sensor technology, and more specifically, to a high wear-resistant oil level sensor. Background Technology

[0002] With the development of the automotive industry and the improvement of intelligence levels, fuel level sensors, as an important component of vehicle fuel monitoring systems, directly affect the user experience and safety of vehicles due to their performance and reliability. Existing fuel level sensor technology mainly uses printed carbon film resistors on ceramic circuit boards to detect fuel level; this technology reflects changes in fuel quantity through changes in resistance.

[0003] In existing technologies, ceramic circuit boards are widely used as sensor substrates due to their excellent insulation properties and mechanical strength. Carbon film resistors are fabricated on the ceramic substrate using a precision printing process to form the detection circuit. When the fuel level changes, a float causes the contacts to slide, altering the resistance value of the circuit and thus detecting the fuel level. While this technology can meet basic fuel level detection needs, it has significant shortcomings in practical applications: firstly, the printed circuit requires precious metal materials, leading to high production costs; secondly, long-term use causes mechanical friction between the contacts and the resistive film, resulting in film wear and affecting measurement accuracy and lifespan. Utility Model Content

[0004] The purpose of this application is to provide a high wear-resistant oil level sensor, which is more wear-resistant.

[0005] To achieve the above objectives, this application provides a high-wear-resistant oil quantity sensor, comprising: Base; A liquid level sensing swing assembly is rotatably mounted on the base; A copper contact piece is mounted on the liquid level sensing oscillating assembly, and the liquid level sensing oscillating assembly rotates relative to the base, causing the copper contact piece to rotate. A PCB board is disposed on the base. The PCB board is provided with copper-plated contacts immersed in oil. Different positions of the copper-plated contacts are electrically connected to different resistance branches. The copper-clad contact abuts against the copper contact piece. When the copper contact piece rotates and contacts different positions of the copper-clad contact, it connects to different resistor branches on the PCB board. The resistor branches are encapsulated in plastic to isolate them from oil.

[0006] In an optional embodiment, the liquid level sensing oscillation assembly includes: A pendulum block, which is rotatably mounted on the base; A pendulum rod is connected to the pendulum block, and the rotation of the pendulum rod causes the pendulum block to rotate; A float is connected to the pendulum rod, and the movement of the float causes the pendulum rod and the pendulum block to rotate.

[0007] In an optional embodiment, the pendulum rod includes a first rod segment, a second rod segment, and a third rod segment. The first rod segment and the third rod segment are configured as an L-shaped rod structure. One end of the second rod segment is fixedly connected to the first rod segment, and the other end of the second rod segment is fixedly connected to the third rod segment. The float is fixedly connected to the first rod segment, and the third rod segment is fixedly connected to the pendulum block.

[0008] In an optional embodiment, the first segment is inclined relative to the second segment in the plane direction in which the swing direction of the pendulum is located.

[0009] In an optional embodiment, the pendulum block is provided with a mating through hole, and the third rod segment is rotatably installed on the base while being rotatably installed at the mating through hole of the pendulum block; The pendulum block is equipped with a pawl, which blocks the third rod segment, thereby fixing the pendulum block and the pendulum rod relatively in the swing direction.

[0010] In an optional embodiment, the base includes a fixing part, a housing part, and a mounting part, wherein the housing part is fixedly mounted on the fixing part; The mounting part is fixedly installed on the housing part at one end away from the fixed part, and the mounting part provides a mounting base for the liquid level sensing swing assembly and the PCB board; The housing portion has an injection cavity, and the resistor branch on the PCB board is located in the injection cavity of the housing portion.

[0011] In an optional embodiment, a sealing groove is provided on the end face of the fixing part near the housing part; A first sealing ring is provided at the sealing groove of the fixing part.

[0012] In an optional embodiment, the housing portion is provided with a mounting through hole, the PCB board passes through the mounting through hole of the housing portion, and a second sealing ring is provided on the housing portion near the mounting through hole. The second sealing ring is located in the injection cavity and is sleeved on the PCB board so that the PCB board is sealed to the inner wall of the mounting through hole.

[0013] In an optional embodiment, a first limiting structure for limiting the positive swing limit angle of the liquid level sensing swing assembly is fixedly provided on the mounting part.

[0014] In an optional embodiment, a second limiting structure for limiting the reverse swing limit angle of the liquid level sensing swing assembly is fixedly provided on the mounting part.

[0015] The "copper-copper pair" used in this application, consisting of copper-clad circuitry and copper contacts, exhibits less wear during sliding friction between similar metals. As the float drives the copper contacts to rotate and repeatedly contacts the copper-clad contacts, this low-wear characteristic ensures that a good contact state is maintained between the two, further extending the service life of the entire mechanical structure.

[0016] Other features and advantages of this application will be described in detail in the following detailed description section. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 A schematic diagram of the structure from one perspective of one embodiment of the high wear-resistant oil level sensor provided in this application; Figure 2 A two-view structural schematic diagram of one embodiment of the high wear-resistant oil volume sensor provided in this application; Figure 3 A schematic diagram of the structure of a pendulum block from two perspectives, representing one embodiment of the high wear-resistant oil volume sensor provided in this application; Figure 4 A schematic diagram of the PCB board structure of one embodiment of the high wear-resistant oil level sensor provided in this application; Figure 5 A three-view structural schematic diagram of one embodiment of the high wear-resistant oil volume sensor provided in this application; Figure 6 for Figure 5 Sectional view along the BB direction; Figure 7 A schematic diagram of the structure of a lever from one perspective of one embodiment of the high wear-resistant oil level sensor provided in this application; Figure 8 for Figure 1 A magnified view of a portion of the image.

[0019] icon: 100 - Base; 110 - Fixing part; 112 - Sealing groove; 120 - Mounting part; 122 - First limiting structure; 124 - Second limiting structure; 130 - Housing part; 132 - Injection cavity; 140 - First sealing ring; 150 - Second sealing ring; 200-Liquid level sensing swing assembly; 210-Swing block; 211-Claw; 220-Float; 230-Swing rod; 231-First rod segment; 231a-First rod body; 231b-Second rod body; 232-Second rod segment; 233-Third rod segment; 233a-Third rod body; 233b-Fourth rod body; 300-copper contact plate; 400 - PCB board; 410 - Copper-clad contacts; 420 - Resistor branch. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0021] In the description of this application, it should be noted that the terms "inner" and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product is in use. They are used only for the convenience of describing this application and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application. Furthermore, the terms "first," "second," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0022] In the description of this application, it should also be noted that, unless otherwise expressly specified and limited, the terms "setup" and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0023] like Figures 1 to 3 As shown, embodiments of this application provide a high wear-resistant oil level sensor, including a base 100, a liquid level sensing oscillating assembly 200, a copper contact 300, and a PCB board 400.

[0024] The base 100 is used to provide an installation base and is mounted on the oil tank. The level sensing swing assembly 200 is located in the oil tank to detect the level of the oil.

[0025] The liquid level sensing oscillating assembly 200 is rotatably mounted on the base 100. The liquid level sensing oscillating assembly 200 is in contact with the oil in the oil tank and floats on the surface of the oil. One end of the liquid level sensing oscillating assembly 200 moves up and down with the liquid level of the oil, and drives the other end of the liquid level sensing oscillating assembly 200 to rotate on the base 100.

[0026] like Figure 3 As shown, the copper contact 300 is fixedly installed on the liquid level sensing swing assembly 200 (hereinafter referred to as swing block 210). The liquid level sensing swing assembly 200 rotates relative to the base 100, causing the copper contact 300 to rotate. The fixing method is, for example, welding, gluing, snap-fitting, bolting or riveting.

[0027] like Figure 4 As shown, the PCB board 400 is fixedly mounted on the base 100. The PCB board 400 is provided with copper-plated contacts 410, and different positions of the copper-plated contacts 410 are electrically connected to different resistor branches 420.

[0028] The copper-clad contact 410 is immersed in oil. The resistor branch 420 is potted with plastic to isolate it from the oil, thus preventing oil impurities from affecting the resistor branch 420 and improving the accuracy of oil level indication during use.

[0029] like Figure 5 and Figure 6 As shown, the copper-plated contact 410 abuts against the copper contact piece 300. When the copper contact piece 300 rotates and contacts different positions of the copper-plated contact 410, it is connected to different resistor branches 420 on the PCB board 400.

[0030] For example, the pin is connected to the resistor branch 420 wire.

[0031] Compared to existing technologies, this application eliminates the use of ceramic substrate + carbon film resistors, instead employing standard PCB + metal film chip resistors. This change significantly reduces costs. In product manufacturing, cost control is crucial for enhancing market competitiveness. Lower costs can generate greater profit margins for companies and allow for more price advantages, thereby attracting more customers.

[0032] Carbon film resistors are prone to wear and detachment, which can affect the performance and stability of the entire fuel level sensor. However, using a standard PCB with metal film chip resistors avoids these defects, improves the reliability and durability of the resistor component, reduces sensor failures caused by resistor issues, and extends the sensor's lifespan.

[0033] Both the copper-clad contact 410 and the copper contact piece 300 are made of copper, forming a "copper-copper pair". This type of sliding friction between similar metals reduces wear compared to friction between dissimilar metals. As the liquid level sensing oscillating assembly 200 rotates the copper contact piece 300 and continuously contacts the copper-clad contact 410, this low-wear characteristic ensures good contact between the copper contact piece 300 and the copper-clad contact 410, enabling the sensor to operate stably for extended periods and further extending the lifespan of the entire mechanical structure.

[0034] In this application, a float 220 is located in the oil tank to detect the oil level. One end of the float floats up and down with the oil level, causing the other end to rotate on the base 100, which in turn causes the copper contact 300 fixed on the level sensing swing assembly 200 to rotate. During the rotation of the copper contact 300, it contacts different positions of the copper-plated contact 410, connecting to different resistor branches 420 on the PCB board. This design accurately converts changes in oil level into changes in resistance, thereby achieving precise detection of the oil level. This mechanical structure ensures the accuracy and reliability of the detection, providing accurate data support for subsequent oil level monitoring and control.

[0035] like Figure 1 As shown, in one embodiment, the liquid level sensing oscillating assembly 200 includes an oscillating block 210, an oscillating rod 230, and a float 220.

[0036] The pendulum block 210 is rotatably mounted on the base 100, and the pendulum block 210 is rotatable relative to the base 100.

[0037] The swing arm 230 is connected to the swing block 210, and the rotation of the swing arm 230 drives the swing block 210 to rotate.

[0038] The float 220 is connected to the rocker arm 230. The float 220 contacts the oil in the oil tank and floats on the surface of the oil. The float 220 moves up and down with the oil level and drives the rocker arm 230 and the rocker block 210 to rotate.

[0039] like Figure 7 As shown, in one embodiment, the rocker arm 230 includes a first rod segment 231, a second rod segment 232, and a third rod segment 233. The first rod segment 231 and the third rod segment 233 are configured as an L-shaped rod structure. One end of the second rod segment 232 is fixedly connected to the first rod segment 231, and the other end of the second rod segment 232 is fixedly connected to the third rod segment 233. The fixing method is, for example, welding, threaded connection, or integral molding.

[0040] For example, the first rod segment 231 includes a first rod body 231a and a second rod body 231b. One end of the first rod body 231a is vertically fixedly connected to one end of the second rod body 231b, and the other end of the second rod body 231b is fixedly connected to one end of the second rod segment 232. The third rod segment 233 includes a third rod body 233a and a fourth rod body 233b. One end of the third rod body 233a is fixedly connected to the other end of the second rod segment 232, and the fourth rod body 233b is vertically fixed to the other end of the third rod body 233a.

[0041] like Figure 5 As shown, the float 220 is fixedly connected to the first rod body 231a of the first rod segment 231, and the fixing method is, for example, adhesive or snap-fit.

[0042] The fourth rod 233b of the third rod segment 233 is fixedly connected to the pendulum block 210, and the fixing method is, for example, welding, gluing, bolting or riveting.

[0043] like Figure 7 As shown, in one embodiment, the first segment 231 is inclined relative to the second segment 232 in the plane where the swing direction of the swing rod 230 is located.

[0044] For example, the first rod body 231a of the first rod segment 231 is inclined relative to the second rod segment 232, so that the float disposed on the first rod body 231a is inclined relative to the second rod segment 232.

[0045] When the oil level is low, the bottom plane of the float, which is inclined relative to the second rod section 232, can remain as parallel as possible to the oil surface. This design results in a larger projected area of ​​the float's bottom plane on the oil surface, thus allowing for greater contact with the oil. Compared to traditional structures, this design enables more precise sensing of changes in the oil level, effectively reducing detection errors caused by a small contact area. This leads to more accurate and reliable surface detection results, providing more precise information for subsequent operations and control based on the oil level data.

[0046] like Figure 1 As shown, when the oil level is high, although the bottom plane of the float is tilted relative to the oil surface (while the oil surface remains horizontal), it can still perform its detection function normally. Conversely, when the oil level is low, the bottom plane of the float ensures accurate detection by maintaining maximum parallelism and contact with the oil surface. This structure adapts well to changes in oil level, providing stable and accurate level detection regardless of the oil level, thus enhancing the adaptability and versatility of the mechanical structure under different operating conditions.

[0047] Unlike the fixing method of the pendulum block 210 and the third rod segment 233 in the above embodiments, such as Figure 8As shown, in another embodiment, the swing block 210 is provided with a mating through hole (not shown in the figure), and the fourth rod 233b of the third rod segment 233 is simultaneously rotatably mounted at the mating through hole of the swing block 210 and on the base 100.

[0048] like Figure 8 As shown, the pendulum block 210 is provided with a pawl 211, which blocks the third rod body 233a of the third rod segment 233, so that the pendulum block 210 and the pendulum rod 230 are relatively fixed in the swing direction. The third rod segment 233 rotates and drives the pendulum block 210 to rotate through the pawl 211.

[0049] like Figure 6 As shown, in one embodiment, the base 100 includes a fixing part 110, a housing part 130 and a mounting part 120, with the housing part 130 fixedly mounted on the fixing part 110.

[0050] The mounting part 120 is fixedly mounted on the housing part 130 at the end away from the fixing part 110. The fixing part 110, the housing part 130 and the mounting part 120 are integrally formed.

[0051] Mounting section 120 provides a mounting base for level sensing swing assembly 200 and PCB board 400.

[0052] An injection cavity 132 is provided inside the housing 130, and the resistor branch 420 on the PCB board 400 is located in the injection cavity 132 of the housing 130.

[0053] The injection molding cavity 132 within the housing 130 houses the resistor branch 420 on the PCB board 400, and the plastic potting prevents the resistor from directly contacting the oil. This design effectively avoids impurities in the oil directly contacting the resistive element, preventing resistance value drift caused by impurity adhesion, moisture erosion, sulfide corrosion, etc. Stable resistance is crucial for accurate measurement; the protection provided by the injection molding cavity 132 significantly improves the electrical performance stability of the resistor branch 420, thereby enhancing the measurement accuracy of the entire liquid level detection system.

[0054] For example, in one embodiment, the resistors in resistor branch 420 are configured as surface mount resistors, which reduces manufacturing costs.

[0055] To improve the sealing between the fixing part 110 and the oil tank, such as Figure 6 As shown, in one embodiment, a sealing groove 112 is provided on the end face of the fixing part 110 near the housing part 130.

[0056] A first sealing ring 140 is provided at the sealing groove 112 of the fixing part 110. The first sealing ring 140 abuts against the outer wall of the oil tank, thereby improving the sealing performance.

[0057] For example, the fixing part 110 is also provided with bolt holes, and the fixing part 110 is also fixedly connected to the oil tank by bolts provided in the bolt holes.

[0058] like Figure 6 As shown, in one embodiment, a mounting through hole (not shown) is provided on the housing portion 130. The PCB board 400 passes through the mounting through hole of the housing portion 130. A second sealing ring 150 is provided on the housing portion 130 near the mounting through hole. The second sealing ring 150 is located in the injection cavity 132 and is sleeved on the PCB board 400, so that the PCB board 400 is sealed with the inner wall of the mounting through hole. The second sealing ring 150 prevents oil from seeping into the injection cavity 132.

[0059] like Figure 1 As shown, in one embodiment, a first limiting structure 122 for limiting the positive swing limit angle of the liquid level sensing swing assembly 200 is fixedly provided on the mounting part 120.

[0060] For example, the first limiting structure 122 is configured as a block structure with an inclined surface and is fixedly installed on the mounting part 120 by means of adhesive, bolt connection or integral molding. When the oil level is too high, the first limiting structure 122 restricts the swing rod 230 from rotating excessively upward.

[0061] like Figure 1 As shown, in one embodiment, a second limiting structure 124 for limiting the reverse swing limit angle of the liquid level sensing swing assembly 200 is fixedly provided on the mounting part 120.

[0062] For example, the second limiting structure 124 is configured as a block structure with an inclined surface and is fixedly installed on the mounting part 120 by means of adhesive, bolt connection or integral molding. When the oil level is too low, the second limiting structure 124 restricts the swing rod 230 from rotating excessively downward.

[0063] The working process of the high wear-resistant oil volume sensor provided in this application is as follows: 1. The float 220 rises and falls with the oil level, causing the rocker arm 230 and the rocker block 210 to rotate clockwise (relative to the oil level). Figure 1 ).

[0064] 2. The copper contact 300 then slides on the copper-plated contact 410 on the surface of the PCB board 400.

[0065] 3. When the contact piece contacts different copper-plated contacts 410, different resistor branches 420 are connected.

[0066] 4. Output the corresponding resistance signal to the vehicle's instrument system to display the real-time fuel level.

[0067] It should be noted that, where there is no conflict, the features in the embodiments of this application can be combined with each other.

[0068] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A high-wear-resistant oil level sensor, characterized in that, include: Base (100); A liquid level sensing swing assembly (200) is rotatably mounted on the base (100); A copper contact piece (300) is mounted on the liquid level sensing swing assembly (200). The liquid level sensing swing assembly (200) rotates relative to the base (100), causing the copper contact piece (300) to rotate. PCB board (400), the PCB board (400) is disposed on the base (100), the PCB board (400) is provided with copper-plated contacts (410) immersed in oil, different positions of the copper-plated contacts (410) are electrically connected to different resistor branches (420), the resistor branches (420) are encapsulated in plastic to isolate the oil; The copper-clad contact (410) abuts against the copper contact piece (300), and when the copper contact piece (300) contacts different positions of the copper-clad contact (410) during rotation, it is connected to different resistor branches (420) on the PCB board (400).

2. The high wear-resistant oil level sensor according to claim 1, characterized in that, The liquid level sensing swing assembly (200) includes: A swing block (210) is rotatably mounted on the base (100); A swing arm (230) is connected to the swing block (210), and the rotation of the swing arm (230) drives the swing block (210) to rotate; A float (220) is connected to the pendulum rod (230). The movement of the float (220) causes the pendulum rod (230) and the pendulum block (210) to rotate.

3. The high wear-resistant oil level sensor according to claim 2, characterized in that, The pendulum (230) includes a first rod segment (231), a second rod segment (232), and a third rod segment (233). The first rod segment (231) and the third rod segment (233) are configured as an L-shaped rod structure. One end of the second rod segment (232) is fixedly connected to the first rod segment (231), and the other end of the second rod segment (232) is fixedly connected to the third rod segment (233). The float (220) is fixedly connected to the first rod segment (231), and the third rod segment (233) is fixedly connected to the pendulum block (210).

4. The high wear-resistant oil level sensor according to claim 3, characterized in that, In the plane direction in which the swing direction of the swing rod (230) is located, the first rod segment (231) is inclined relative to the second rod segment (232).

5. The high wear-resistant oil level sensor according to claim 3, characterized in that, The swing block (210) is provided with a mating through hole. The third rod segment (233) is rotatably installed at the mating through hole of the swing block (210) and at the same time, the third rod segment (233) is rotatably installed on the base (100). The pendulum block (210) is provided with a claw (211), which blocks the third rod segment (233), so that the pendulum block (210) and the pendulum rod (230) are relatively fixed in the swing direction.

6. The high wear-resistant oil level sensor according to any one of claims 1 to 5, characterized in that, The base (100) includes a fixing part (110), a housing part (130) and a mounting part (120), wherein the housing part (130) is fixedly mounted on the fixing part (110); The mounting part (120) is fixedly mounted on the housing part (130) at one end away from the fixing part (110), and the mounting part (120) provides a mounting base for the liquid level sensing swing assembly (200) and the PCB board (400); The housing portion (130) is provided with an injection cavity (132), and the resistor branch (420) on the PCB board (400) is located in the injection cavity (132) of the housing portion (130).

7. The high wear-resistant oil level sensor according to claim 6, characterized in that, A sealing groove (112) is provided on the end face of the fixing part (110) near the housing part (130). A first sealing ring (140) is provided at the sealing groove (112) of the fixing part (110).

8. The high wear-resistant oil level sensor according to claim 6, characterized in that, The housing part (130) is provided with a mounting through hole, and the PCB board (400) passes through the mounting through hole of the housing part (130). A second sealing ring (150) is provided on the housing part (130) near the mounting through hole. The second sealing ring (150) is located in the injection cavity (132). The second sealing ring (150) is sleeved on the PCB board (400) so that the PCB board (400) seals against the inner wall of the mounting through hole.

9. The high wear-resistant oil level sensor according to claim 6, characterized in that, A first limiting structure (122) for limiting the positive swing limit angle of the liquid level sensing swing assembly (200) is fixedly provided on the mounting part (120).

10. The high wear-resistant oil level sensor according to claim 9, characterized in that, A second limiting structure (124) is fixedly provided on the mounting part (120) for limiting the reverse swing limit angle of the liquid level sensing swing assembly (200).

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