DEF Tank Quality Sensor With Replaceable Control Circuitry
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Solution Overview
Problem
Existing DEF quality sensors integrated into tanks require the entire tank replacement upon failure, leading to increased storage needs and reduced serviceability due to exposure of control electronics to diesel exhaust fluid.
Innovation Solution
A DEF quality sensor with removable control circuitry, where the control electronics are housed in a detachable cover outside the tank, allowing for replacement without exposing the electronics to diesel exhaust fluid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the DEF quality sensor is integrated into the DEF tank with the control electronics exposed to the diesel exhaust fluid, then the sensor can be replaced by replacing only the sensor head, but the control electronics are exposed to harmful chemical constituents
Solution Approach 1:
The sensor is divided into two distinct segments: a sensor head that can be replaced and control electronics that remain integrated into the tank. This segmentation allows the sensor head to be replaced without exposing the control electronics to the diesel exhaust fluid, resolving the contradiction between replaceability and protection from harmful factors.
Solution Approach 2:
The control electronics are extracted from the sensor head and integrated directly into the tank structure. This extraction eliminates the need for the control electronics to be exposed to the diesel exhaust fluid while maintaining the ability to replace the sensor head independently.
2Reliability
If the entire DEF tank must be replaced when the sensor fails, then the sensor is protected from chemical exposure, but parts supplier storage space requirements increase
Solution Approach 1:
By segmenting the sensor into a replaceable head and integrated control electronics, the system allows replacement of only the small sensor head rather than the entire tank. This significantly reduces the storage space required by parts suppliers while maintaining protection of the control electronics from chemical exposure.
3Device complexity
If the control electronics are integrated into the tank bottom, then the sensor structure is simplified, but the control electronics are exposed to thermal and chemical conditions
Solution Approach 1:
The control electronics are extracted from the sensor head and integrated into the tank structure at a location protected from chemical and thermal exposure. This extraction maintains structural simplicity while protecting the control electronics from harmful conditions.
Solution Approach 2:
The tank bottom structure serves as an intermediary that protects the control electronics from direct exposure to the diesel exhaust fluid and thermal conditions. The control electronics are integrated into this protective structure, allowing them to function without direct contact with harmful factors.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Reduces replacement part storage needs and enhances serviceability by enabling easy replacement of control electronics externally, maintaining sensor robustness.
Implementation Method 1
A half portion of an ultrasound speed detector will be located inside the DEF tank
Data Source
AI summary
A DEF quality sensor integrated into a DEF tank with removable control circuitry preferably includes a housing and control circuitry. The housing preferably includes a base housing portion and a detachable cover. A sensor opening is formed through a bottom of the DEF tank to receive an outside perimeter of the base housing portion. The base housing portion is sealed to the DEF tank with any suitable sealant. Most of the base housing portion is located inside the DEF tank. The detachable cover is located outside the DEF tank. The detachable cover includes the control circuitry. The detachable cover may be secured to a bottom of the base housing portion with any suitable attachment device or method. The improved removable DEF quality sensor includes the benefits of decreased replacement part storage capacity for parts supplies as well as improved ease of serviceability for repair.