Flex Fuel Sensor Calibration Structure Eliminating Liquid Hazards
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Solution Overview
Problem
The calibration of flex fuel sensors in manufacturing environments poses a safety risk due to the use of hazardous fuels and presents challenges in managing volatile test liquids, which are used to simulate fuel properties for calibration.
Innovation Solution
A calibration structure comprising a first and second electrode, electrically insulated and connected with a capacitor or resistor of specific values, is used to provide a known input to the flex fuel sensor, eliminating the need for test liquids by directly contacting the sensor electrodes, thereby simulating fuel properties without the risks associated with hazardous materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If fuels or test liquids are used for calibration, then the sensor can be calibrated to offset manufacturing errors, but safety hazards and fire risks arise in the manufacturing environment
Solution Approach 1:
The patent replaces the chemical/liquid-based calibration system with an electrical calibration system. Instead of using fuels or test liquids that contact the sensor electrodes, the invention uses an electrical calibration circuit with known capacitance and conductance values that electrically connects to the sensor electrodes through a connector. This substitution eliminates fire hazards while maintaining calibration accuracy by providing controlled electrical parameters that simulate fuel properties without requiring actual liquid contact.
2Object-affected harmful factors
If test liquids are used to replace fuels, then fire hazards are reduced, but challenges arise in managing liquid concentrations and removing liquid from the sensor
Solution Approach 1:
The patent replaces the liquid-based calibration approach with an electrical calibration circuit. The calibration circuit comprises electrical components (capacitors and resistors) with known values that are electrically connected to the sensor electrodes through a connector. This eliminates all liquid management complexities including concentration control, liquid removal, and spill management, while providing stable and repeatable calibration parameters through purely electrical means.
3Adaptability or versatility
If combinations of fuels are used for calibration, then various fuel concentrations can be simulated, but safety risks and handling difficulties increase
Solution Approach 1:
The patent replaces multiple fuel combinations with a single electrical calibration circuit that can simulate various fuel concentrations through electrical parameter adjustments. The calibration circuit uses capacitors and resistors with specific values to emulate the capacitance and conductance characteristics of different fuel types and concentrations. This provides the same versatility in simulating various fuel conditions while completely eliminating safety risks associated with handling multiple hazardous liquid fuels.
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
This solution allows for safe and accurate calibration of flex fuel sensors without the use of fuels or liquids, ensuring reliable engine performance by providing consistent capacitance or conductance values, and enabling the use of various calibration values to emulate different fuel concentrations.
Implementation Method 1
at least one capacitor, or at least one resistor, or at least one combination of a capacitor with a resistor, of a certain value electrically connected with the first and second electrodes
Implementation Method 2
The sensor outputs the value of the fuel to an electronic engine controller which, along with other inputs, adjusts the fuel air ratio accordingly
Data Source
AI summary
A calibration structure (10) for calibrating a flex fuel sensor (12) for a vehicle is provided. The flex fuel sensor has a first sensor electrode (14) and a second sensor electrode (16). The calibration structure includes a first electrode (30), a second electrode (36) spaced from and electrically insulated from the first electrode, and at least one capacitor (40), or at least one resistor (42), or at least one combination of a capacitor with a resistor, of a certain value electrically connected with the first and second electrodes. The first electrode (30) is constructed and arranged to contact the first sensor electrode (16) and the second electrode (36) is constructed and arranged to contact the second sensor electrode (14) to provide a known input value to the flex fuel sensor for calibration of the flex fuel sensor without the use of test liquids.