Fuel Filter Water Separator With Vibration-Stable Sensor Contact
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Solution Overview
Problem
Existing water separator elements in fuel filters are difficult to replace reliably, prone to disconnection under vibrations, and require complex positioning with water level sensors, increasing production costs and maintenance complexity.
Innovation Solution
A fuel filter design with a water level sensor extending into a collection chamber, featuring a conductive element with a water level electrode and an intermediate contact electrode, allowing for a stable electrical connection and simplified installation, while using a filtering element support with a through opening for the sensor and a self-aligning coupling mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional water separator elements are used with separate conductive elements, then electrical contact can be established, but the connection is unstable under vibrations and impulse forces
Solution Approach 1:
The conductive element is integrated directly into the water separator element body, merging the separation function and electrical conduction function into a single component. This eliminates separate conductive elements that could disconnect under vibration, ensuring stable electrical contact between the water separator element and the water level sensor throughout the fuel filter's service life.
2Manufacturing precision
If complex positioning mechanisms are used between water level sensor and conductive element, then accurate positioning is achieved, but production costs increase
Solution Approach 1:
The conductive element is positioned asymmetrically within the water separator element at a predetermined location that naturally aligns with the water level sensor's electrical contact. This asymmetric positioning eliminates the need for complex adjustment mechanisms during assembly, reducing production costs while ensuring accurate electrical contact and functional alignment.
3Adaptability or versatility
If multiple separate components are used for water separation and electrical contact, then functionality is achieved, but device complexity increases
Solution Approach 1:
The water separator element is designed as a multi-functional component that simultaneously performs water-fuel separation and provides electrical conduction for water level detection. This universal design consolidates multiple functions into a single component, reducing the number of parts, simplifying assembly, and lowering production costs while maintaining all necessary functionalities.
4Ease of manufacture
If conventional water separator elements are designed, then basic separation function is provided, but they are prone to tampering and counterfeiting
Solution Approach 1:
The conductive element is permanently integrated into the water separator element body through co-molding or integral formation, making the component difficult to tamper with or counterfeit. This merging of functions creates a more reliable, tamper-resistant design while maintaining the basic water separation functionality and keeping production costs reasonable.
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
Ensures reliable separation of water from fuel, reduces production costs, and simplifies the installation and replacement process of water separator elements, maintaining effective electrical contact even under vibrations.
Implementation Method 1
a water level electrode extending into the collection chamber
Implementation Method 2
a filtering element adapted to be crossed by the fuel
Implementation Method 3
the contact electrode is in contact with the intermediate electrical contact of the water level sensor
Data Source
Figure 1~6
Figure 2
Figure 3~5
AI summary
A fuel filter (10) that comprises: - a casing (20) that has a chamber (26) for collecting the water separated from the fuel; - a water level sensor (30) that extends into the casing (20) and is provided with an electrical water level contact (33) extending into the collection chamber (26) and an intermediate electrical contact (34) arranged inside the casing (20) and outside the collection chamber (26); and - a water separator element (40) comprising: ■ a filtering element (41, 42); ■ a filtering element support (43, 44) provided with a through opening (444) crossed by the water level sensor (30) so that the electrical water level contact (33) extends into the collection chamber (26); and ■ a conductive element (50) provided on the filtering element support (43, 44) and provided with: • a water level electrode (51) extending into the collection chamber (26); and • a contact electrode (52) electrically connected with the water level electrode (51 ), away from it and in contact with the intermediate electrical contact (34) of the water level sensor (30).