Adaptive Fuel Level Calibration via End-Stop Detection
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Solution Overview
Problem
Existing fuel level indicators in vehicles face challenges in accurately determining the filling level, especially when the tank is almost full or empty, due to manufacturing tolerances and changes over time, leading to incorrect readings and reduced traveling range.
Innovation Solution
An adaptive calibration method that detects end stops in the sensor signal during vehicle movement, statistically evaluates these stops to determine calibration values, and adjusts the fuel level display to provide accurate readings, accounting for different end regions and tank forms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If preset tolerances are applied to the fuel level indicator, then the indicator reliably indicates empty/full status, but the indicated filling level does not match the real filling level, reducing traveling range
Solution Approach 1:
The patent implements adaptive calibration that dynamically adjusts the tolerance ranges for empty and full indications based on actual tank characteristics. The system continuously learns the specific end-stop points through sensor signal analysis during vehicle operation, transforming static preset tolerances into dynamic, customized ranges that match the individual tank's behavior, thereby resolving the contradiction between reliable indication and measurement accuracy
Solution Approach 2:
The system changes the calibration parameters (tolerance thresholds) based on detected end-stop positions. By analyzing the sensor signal's periodic course during vehicle movement and identifying constant value regions, the system adjusts the calibration values to optimize both the reliability of empty/full indications and the accuracy of intermediate filling levels, eliminating the fixed tolerance limitations
2Manufacturing precision
If the tank and sensor arrangement are subject to manufacturing tolerances and changes over lifespan, then initial calibration may be accurate, but accuracy degrades over time
Solution Approach 1:
The system performs preliminary adaptive calibration during the first operation phases by detecting end-stop positions through sensor signal analysis. This preliminary action establishes baseline calibration values that account for manufacturing tolerances before normal operation begins, ensuring accurate initial performance despite production variations
Solution Approach 2:
The patent implements continuous feedback mechanisms where the sensor signal's periodic course during vehicle movement is constantly monitored. By detecting end-stop occurrences and recalibrating based on detected constant values, the system continuously corrects for drift and changes over the system's lifespan, maintaining long-term reliability despite manufacturing tolerances and aging effects
3Measurement precision
If discrete pins with filling level sensors are used, then filling level can be detected at different heights, but sloshing zones interfere with signal accuracy during tank movement
Solution Approach 1:
The patent utilizes the vibration and movement characteristics of the sensor during vehicle operation to detect end-stop positions. By analyzing the periodic course of the sensor signal and identifying constant value regions that occur when the sensor contacts tank walls, the system transforms the harmful sloshing effect into a useful detection mechanism for calibration, allowing accurate filling level measurement despite tank movement
Solution Approach 2:
The system converts the harmful sloshing effect into a beneficial calibration mechanism. The sensor signal's periodic variations during vehicle movement, caused by liquid sloshing and sensor contact with tank walls, are analyzed to identify end-stop positions. This transforms the interference into a means for automatic calibration, improving measurement precision while accounting for dynamic tank conditions
Data Source
AI summary
A method for adaptive calibration of a fuel level indicator of a filling level of a liquid in a tank accompanying operations. A filling level of the liquid is detected with a sensor arrangement. A sensor signal of the arrangement is provided during a movement of the vehicle. In case that the course of the sensor signal is obtained in a respective defined time interval in which the sensor signal is provided several times, a constant value is assumed, an end stop is detected. The respective time intervals at which the end stops were detected and the respective associated constant values are stored. A minimum number of end stop is defined for the tank, and in the case that the minimum number of end stops is reached, a calibration phase is carried out.