Float Arm Reinforcement Brace for Accurate Fuel Level Sensing
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Solution Overview
Problem
Conventional float arms in fuel level sensors are prone to deformation due to loads during packaging, handling, assembly, and use, leading to measurement errors in fuel level detection.
Innovation Solution
A reinforcement support brace for float arms, comprising a base, beam, and diagonal member with U-shaped channels and clips, which engages with the float arm wire to provide rigidity and prevent deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional float arm is used, then the device complexity is low, but the float arm is prone to deformation under load
Solution Approach 1:
The float arm is divided into two functional parts: the original float arm wire and the separate support brace. The brace is segmented into a base portion engaging the wire at one location and an extension portion engaging at another location, allowing the structure to be reinforced without redesigning the entire float arm assembly.
Solution Approach 2:
The support brace acts as an intermediary element between the float arm wire and the external loads. It intercepts and redistributes the loads applied to the float arm, preventing direct stress on the wire and reducing deformation through the engagement of multiple clips and channels.
2Measurement precision
If the float arm is reinforced with a support brace, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The support function is segmented from the float arm wire itself and implemented through a separate brace structure. This allows the measurement function (float arm movement) to remain simple while the reinforcement function is added independently through the brace with its base and extension portions.
Solution Approach 2:
The support brace provides localized reinforcement at specific critical points along the float arm wire where deformation is most likely to occur. The base portion and extension portion are positioned to provide support exactly where needed, rather than uniformly strengthening the entire structure.
3Reliability
If a simple float arm wire is used, then ease of manufacture is high, but reliability under load is poor
Solution Approach 1:
The manufacturing process is segmented into producing the simple float arm wire separately and the support brace separately, then assembling them together. This maintains the ease of manufacturing the wire while adding the reliability of the brace structure through a separate production step.
Solution Approach 2:
The support brace serves as an intermediary component that can be manufactured independently and then integrated with the float arm wire. This allows each component to be optimized for its specific function and manufactured using appropriate processes, then assembled through the engagement of clips and channels.
Data Source
AI summary
A support brace for a float arm of a fluid level sensor is provided. The support brace includes a base having opposite first and second ends, and a beam having opposite first and second ends. The first end of the beam is connected to the first end of the base, and the beam extends from base wherein an angle is formed between the base and the beam. A channel is formed along a length of the base. At least one side clip is attached to a side of the beam. An end clip is attached to the second end of the beam. The channel, the at least one side clip, and the end clip are engageable with a wire that forms the float arm, and the support brace reinforces the float arm. A float arm assembly and a fuel level sensor including the support brace are also provided.