Delivery Unit Fill Level Sensor Calibration Reference Surface
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Solution Overview
Problem
Existing delivery units for liquid additives in tanks face challenges in measuring fill levels independently of tank shape and size, requiring measures that are durable, inexpensive, and simple to assemble and service, while ensuring accurate fill level monitoring.
Innovation Solution
A delivery unit with a fill level sensor that emits waves into the tank to measure propagation time, utilizing reference surfaces for accurate speed determination and quality assessment of the liquid additive, and a calibration component to account for manufacturing tolerances and temperature variations, allowing for precise fill level and quality monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a fill level sensor is installed in the tank to monitor liquid additive levels, then fill level monitoring capability is improved, but the device complexity and assembly difficulty increase
Solution Approach 1:
The delivery unit is installed inside the tank, with the fill level sensor integrated into the delivery unit structure. The sensor, housing, and reference surface form a nested arrangement where the reference surface is positioned on the housing exterior, eliminating the need for separate external monitoring devices and reducing overall system complexity.
Solution Approach 2:
The delivery unit serves multiple functions: it delivers liquid additive through the pump mechanism and simultaneously monitors fill level through the integrated sensor. This multi-functionality eliminates the need for separate monitoring systems, reducing device complexity while maintaining measurement capability.
2Measurement precision
If reference surfaces are added to the delivery unit for wave propagation time measurement, then measurement precision is improved, but manufacturing complexity increases
Solution Approach 1:
Reference surfaces are positioned at specific locations on the housing exterior at defined distances from the sensor. This localized placement creates specific measurement zones without requiring complex structures throughout the entire delivery unit, maintaining manufacturing simplicity while enabling precise measurement.
Solution Approach 2:
The reference surfaces are pre-positioned on the housing during manufacturing with defined distances from the sensor mounting location. This preliminary positioning allows for standardized assembly procedures and simplifies installation, as the reference geometry is already established before the delivery unit is installed in the tank.
3Adaptability or versatility
If the delivery unit is designed to be installed in different tanks, then adaptability is improved, but measurement precision may deteriorate due to varying tank shapes and sizes
Solution Approach 1:
The delivery unit with integrated sensor and reference surfaces is designed as a universal component that can be installed in various tank configurations. The reference surfaces provide consistent measurement geometry regardless of the external tank shape, enabling the same unit to maintain measurement precision across different applications.
Solution Approach 2:
The reference surfaces act as intermediary elements between the sensor and the liquid surface being measured. By providing known reference distances, they mediate the measurement process to compensate for variations in tank geometry, allowing accurate measurements across different tank types and sizes.
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
The solution provides accurate and reliable fill level monitoring and quality assessment of liquid additives, ensuring efficient operation and adaptability to different tank shapes and sizes, while minimizing errors due to manufacturing and temperature variations.
Implementation Method 1
the fill level sensor is constructed to emit waves into an emission region of the tank in such a way that the fill level can be measured by using a propagation time measurement of waves which are reflected by a liquid surface and which strike the fill level sensor again
Implementation Method 2
the fill level can be measured by using a propagation time measurement of waves which are reflected by a liquid surface and which strike the fill level sensor again
Data Source
AI summary
A delivery unit for extracting liquid additive from a tank can be mounted on the tank and includes a fill level sensor for measuring the fill level of liquid additive in the tank. The fill level sensor is set up to emit waves into an emission region of the tank, and the fill level can be measured by using a propagation time measurement of the waves reflected by a liquid surface and striking the fill level sensor again. At least one first reference surface extends at least partially into the emission region and is at a first distance from the fill level sensor. The at least one first reference surface is disposed on a separate calibration component mounted on an outer side of a housing of the delivery unit. A tank for storing liquid additive, a motor vehicle and a method for monitoring a fill level are also provided.