Fuel Level Sensor Sealing and Lubrication
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Solution Overview
Problem
Existing fuel level sensing apparatuses in fuel tanks face issues with corrosion and abrasion of resistance substrates and wipers due to contact with fuel, leading to inaccurate fuel level sensing, especially with biofuels, and difficulties in sealing the filling solution space, resulting in defective products and poor performance at low temperatures.
Innovation Solution
A sealable filling solution filling space is created with a filling solution inlet on the case to easily confirm sealing, using a filling solution with anti-rusting and lubricating properties that does not mix with fuel, and a metal arm that rotates within a set range to prevent excessive rotation and ensure accurate fuel level sensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a filling solution is injected into the space containing the resistance substrate and wiper to prevent corrosion and abrasion, then the durability of the resistance substrate and wiper is improved, but the sealing state is difficult to confirm and the filling solution may leak
Solution Approach 1:
The patent applies color change indicators to visually confirm the sealing state of the filling solution injection space. The case includes a sealing member that can be observed through a transparent or translucent portion, allowing detection of whether the filling solution has been properly sealed without disassembly or complex testing procedures.
Solution Approach 2:
The patent implements a self-checking mechanism where the sealing state automatically indicates itself through visual observation. The transparent case portion and sealing member configuration allow the system to self-verify its sealed state without requiring external testing equipment or disassembly.
2Measurement precision
If the arm rotates within a set range to prevent excessive rotation, then the accuracy of fuel level sensing is improved, but the device complexity increases due to rotation prevention mechanisms
Solution Approach 1:
The patent inverts the traditional approach by making the case rotatable rather than the arm. The case includes a rotatable member that rotates together with the arm, allowing the arm to maintain a fixed position while the case rotates to accommodate different fuel levels. This eliminates the need for complex rotation prevention mechanisms for the arm itself.
Solution Approach 2:
The patent introduces a rotatable case as an intermediary between the arm and the fuel level measurement. The case acts as a mediator that absorbs the rotation needed for different fuel levels, allowing the arm to remain stationary and simple while still achieving accurate measurement across the full range of fuel levels.
3Ease of manufacture
If a mechanical apparatus with floater and wiper is used for fuel level sensing, then the cost is reduced, but corrosion and abrasion occur due to contact with fuel
Solution Approach 1:
The patent introduces a filling solution as an intermediary substance that fills the space between the fuel and the resistance substrate/wiper assembly. This mediator prevents direct contact between the fuel and the sensitive components, protecting them from corrosion and abrasion while maintaining the simple mechanical structure and low cost of the original design.
Solution Approach 2:
The patent extracts the harmful fuel from direct contact with the resistance substrate and wiper by creating a separate filling space. The fuel remains in the fuel tank while the filling solution occupies the space where the mechanical components are located, effectively separating the fuel from the sensitive parts.
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
The solution prevents abrasion and corrosion, reduces defective rates by confirming the sealing state, and enables smooth fuel level sensing even at low temperatures by using a filling solution that does not form an oil film and a metal arm that maintains rotation within a set range.
Implementation Method 1
using a filling solution with anti-rusting and lubricating properties
Implementation Method 2
using a filling solution with anti-rusting and lubricating properties
Implementation Method 3
a metal arm that rotates within a set range to prevent excessive rotation
Implementation Method 4
using a filling solution that does not mix with fuel
Data Source
AI summary
Provided is an apparatus for sensing a fuel level in a fuel tank for sensing an amount of fuel remaining in the fuel tank mounted in a vehicle. The apparatus for sensing a fuel level according to the present invention senses a residual amount of fuel in a fuel tank by contacting a resistance substrate with a wiper, the apparatus including: a case that forms a sealable filling solution filling space and has a filling solution inlet formed on a top thereof; a stopper that blocks the filling solution inlet formed in the case to seal the filling solution filling space; and a filling solution that is filled in the filling solution filling space to perform an anti-rusting and lubricating function, wherein the resistance substrate and the wiper are disposed in the filling solution filling space.