Fuel Level Sensor Error Correction via Calibration Data
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing fuel remaining amount detectors suffer from detection errors due to manufacturing errors that cause discrepancies between the data output by the angle sensor and the actual angle of the arm, leading to low detection accuracy and variation between individual detectors.
Innovation Solution
A manufacturing method that creates conversion data by measuring and storing values at predetermined angles, allowing the data conversion circuit to correct detection errors by converting first data from the angle sensor into accurate second data, thereby improving the detection accuracy of the remaining fuel amount.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an angle sensor is used to detect the relative angle between the body and the arm, then the remaining fuel amount can be detected, but detection errors occur due to manufacturing errors causing offset between the rotation center axis of the arm and the axis of the angle sensor
Solution Approach 1:
The patent applies preliminary action by measuring and storing correction values for detection errors at predetermined angles (0°, 45°, 90°, 135°, 180°, 225°, 270°, 315°) during the manufacturing process. These correction values are stored in a correction value storage unit and used to compensate for axis offset errors before the detector is deployed, thereby improving measurement precision without requiring higher manufacturing precision.
2Measurement precision
If conventional angle sensors are used without correction, then the device structure remains simple, but detection accuracy varies between individual detectors due to manufacturing errors
Solution Approach 1:
The patent introduces an intermediary correction mechanism consisting of a correction value storage unit and a correction value application unit. The correction value storage unit stores pre-measured correction values for detection errors at various angles, and the correction value application unit applies these corrections to the angle sensor readings. This intermediary system compensates for manufacturing variations without fundamentally changing the angle sensor structure, thereby improving detection accuracy consistency while maintaining relatively simple device architecture.
3Measurement precision
If detection errors are not corrected, then the manufacturing process remains simple and fast, but the detection accuracy of remaining fuel amount is not very high
Solution Approach 1:
The patent implements preliminary action by performing detection error measurements and correction value storages during the manufacturing process at predetermined angles. This preliminary correction data collection enables automated error compensation during operation, significantly improving detection accuracy. The process adds measurement steps but streamlines the overall manufacturing by eliminating the need for complex manual calibration procedures, thereby maintaining productivity while enhancing precision.
Data Source
AI summary
A fuel remaining amount detector may include an arm supported rotatably to a body; an angle sensor configured to output first data in accordance with a relative angle between the body and the arm; a storage circuit configured to store conversion data; and a data conversion circuit configured to convert the first data to second data based on the conversion data. A manufacturing method of the fuel remaining amount detector may include creating the conversion data by performing processing for each of at least three predetermined angles, in which the processing includes: measuring the first data outputted by the angle sensor with the relative angle set to one of the predetermined angles; and storing a value corresponding to the one of the predetermined angles in the storage circuit as a value of the second data in association with the value of the measured first data.