Flexible Fuel Sensor for Trailer Tank Installation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The installation of rigid fuel sensors in refrigerated truck trailers is hindered by insufficient clearance between the tank and the trailer, requiring tanks to be removed, emptied, and rotated for sensor replacement, which is time-consuming and inconvenient, especially when the tank contains a large amount of fuel.
Innovation Solution
A flexible fuel sensor with a down tube that can bend under applied force for installation through a small opening and return to its straight configuration for accurate fuel level measurement, allowing for installation without draining or rotating the tank.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a rigid down tube is used for fuel level detection, then the sensor can detect fuel level at essentially any level, but the clearance between the tank and trailer is insufficient for the down tube to be inserted into the tank when the tank is attached to the trailer
Solution Approach 1:
The down tube is changed from a rigid structure to a flexible structure that can dynamically change its configuration. The flexible down tube can bend into a curved path to navigate around the clearance obstruction between the trailer and tank, allowing insertion and fuel level detection without removing or rotating the tank.
Solution Approach 2:
The down tube transitions from a straight linear path to a curved three-dimensional path. By bending the down tube in a curved configuration, it can pass through the limited clearance space between the trailer and tank opening, effectively utilizing the available spatial dimension to achieve insertion where a straight tube would fail.
2Ease of manufacture
If the tank is removed, emptied, and rotated to install a fuel sensor, then the sensor can be installed, but the operation becomes time-consuming and inconvenient, particularly if the tank contains a large amount of fuel
Solution Approach 1:
The flexible down tube allows the sensor to be installed on the attached tank without requiring the tank to be removed, emptied, or rotated. The tube's flexibility enables it to navigate the clearance constraints in the installed position, dramatically reducing installation time and operational complexity.
Solution Approach 2:
The flexible down tube structure serves itself by automatically adapting to the clearance constraints through its ability to bend and curve. This self-adjusting capability eliminates the need for external intervention such as tank removal or rotation, allowing straightforward installation in the original tank position.
3Ease of operation
If the tank is rotated to provide clearance for sensor installation, then the down tube can be inserted, but the tank must be emptied, detached, and refilled, which is inconvenient when the tank contains a large amount of fuel
Solution Approach 1:
The flexible down tube enables sensor installation and replacement on the attached tank without requiring tank rotation or emptying. The tube bends to accommodate clearance constraints, allowing the tank to remain in its original position with fuel intact, thus preventing fuel loss and operational inconvenience.
Solution Approach 2:
The limited clearance space, which previously prevented sensor installation, becomes beneficial by guiding the flexible down tube into a curved configuration that successfully navigates the obstruction. The constraint itself helps demonstrate and enable the flexible tube's adaptive capability.
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
Enables quick and easy installation and replacement of fuel sensors on attached trailers, even when the tank is full, reducing operational time and complexity.
Implementation Method 1
a flexible down tube that is sufficiently flexible to bend under an applied force while being inserted into the fuel tank through a hole in the top of the tank, yet sufficiently rigid to return to its default straight configuration when the force is removed
Data Source
AI summary
A flexible fuel sensor for measuring the fuel level in a tank in which the sensor is installed. The flexible fuel sensor comprises a fitting arranged to be mounted to a mated fitting on a fuel tank associated with a hole in the fuel tank, a flexible down member extending from the fitting in a first direction and including a fuel level sensing mechanism, the down member configured to be mounted to extend through the hole into the fuel tank, and a sensor head extending from the fitting in a second direction and including sensor electronics coupled to the fuel level sensing mechanism. The flexible down member may comprise a coil made of steel wire.