Fuel Delivery Unit Ultrasonic Sensor Guide
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Solution Overview
Problem
Existing fuel delivery units in motor vehicles face challenges in accurately measuring fuel levels due to manufacturing tolerances and fill-level-dependent changes in the distance between the fuel tank's bottom and upper boundary, leading to unguided ultrasound wave propagation and incorrect measurements.
Innovation Solution
The fuel delivery unit incorporates a receptacle for the support element that extends to the bottom, with a transmitting and receiving unit for ultrasonic waves arranged to guide waves through the support element, eliminating the need for a separate measuring tube and ensuring guided propagation regardless of manufacturing tolerances or fill-level changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a rigid measuring tube is used for ultrasound propagation, then wave guidance is improved, but manufacturing tolerances and fill-level-dependent distance changes prevent optimal positioning and require additional components
Solution Approach 1:
The support element is designed to serve dual functions: mechanically supporting the surge chamber while simultaneously acting as the measuring tube for ultrasound propagation. This merging of functions eliminates the need for a separate rigid measuring tube, reducing device complexity while maintaining measurement precision through the support element's stable connection to the fuel tank bottom
Solution Approach 2:
The support element is designed as a multi-functional component that provides both mechanical support for the surge chamber and serves as the ultrasound propagation path. This universal component replaces what would traditionally require separate elements (support structure plus measuring tube), simplifying the overall device while ensuring both structural stability and accurate fuel level measurement
2Stability of the object's composition
If the support element is fixed rigidly, then structural stability is improved, but manufacturing tolerances prevent optimal ultrasonic wave guidance
Solution Approach 1:
The support element is designed with sliding capability in the surge chamber bore, allowing dynamic adjustment to compensate for manufacturing tolerances and fill-level-dependent distance changes. This dynamic feature enables the ultrasonic measurement system to maintain optimal positioning without requiring extremely precise manufacturing, while the connection to the fuel tank bottom provides sufficient structural stability
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 design allows for precise fuel level determination, reduces production costs, and ensures reliable operation by maintaining guided ultrasonic wave propagation and equal fill levels within the fuel tank, while protecting electronic components from aggressive fuel components.
Implementation Method 1
a level sensor arranged on the surge pot... the level sensor has a transmitting and receiving unit for ultrasonic waves... the ultrasonic waves run in the receptacle and the support element
Implementation Method 2
The swirl pot is prestressed against the bottom of the fuel tank via at least one spring element, which is arranged around a support element. This preload is necessary for ground referencing of the fuel level sensor
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a fuel delivery unit (1), which can be inserted into the fuel tank (3) of a motor vehicle, comprising a swirl pot (6), a flange (11) for closing an opening (2) in the fuel tank (3), at least one support element (12) configured as a hollow profile, which is arranged between the flange (11) and the swirl pot (6) and prestresses the swirl pot (6) relative to the bottom (4) of the fuel tank (3), and a filling level sensor arranged on the swirl pot (6). The swirl pot (6) comprises at least one receptacle (16) for the at least one support element (12), the support element (12) gliding in said receptacle when the distance between the flange (11) and swirl pot (6) changes. The receptacle (16) extends to the bottom (17) of the swirl pot (6) and completely surrounds the periphery of the support element (12) and comprises an opening (22) in the bottom region through which fuel from the fuel tank (3) can enter the receptacle (16). The filling level sensor comprises a transmission and receiving unit (20) for ultrasonic waves, wherein the transmission and receiving unit (20) is arranged in the fuel delivery unit (1) such that the ultrasonic waves run in the receptacle (16) and the support element (12).