Fuel Sender Detector Retention Ribs and Crimped Connector Assembly
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Solution Overview
Problem
Existing fuel sender technologies face challenges in securely retaining detectors within the housing and efficiently assembling components, leading to potential interference and assembly complexities.
Innovation Solution
The fuel sender design incorporates a detector retaining structure, such as ribs or apexes, to securely position the detector, and an assembly method using a roller and crimping mechanism to secure the connector to the mounting member, ensuring proper alignment and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional detector retention methods are used, then the detector may become loose or misaligned, but adding complex retention structures increases assembly complexity
Solution Approach 1:
The detector retaining structure is segmented into multiple ribs (typically three ribs) that are distributed around the detector. Each rib independently contributes to holding the detector in place, providing stable retention without requiring a complex monolithic structure. The ribs can be formed as integral parts of the housing, further simplifying the overall design.
Solution Approach 2:
The retention function is localized to specific regions where ribs contact the detector body. Rather than using a complex structure throughout, the ribs provide targeted local contact points that securely hold the detector in the correct position while leaving other areas of the housing simple and easy to manufacture.
2Manufacturing precision
If manual assembly methods are used, then assembly precision may be insufficient, but automated assembly equipment increases device complexity and cost
Solution Approach 1:
The housing and mounting member are designed with pre-formed ribs and circular walls that guide the detector and connector into proper alignment during assembly. The ribs are positioned to automatically locate the detector, and the circular wall with crimpable edge provides built-in alignment features that eliminate the need for complex alignment equipment.
Solution Approach 2:
The assembly structure is designed to be self-aligning and self-securing. The crimpable edge of the circular wall automatically secures the connector when deformed, and the ribs automatically position the detector without requiring external alignment tools or complex assembly machinery. The structure performs its own alignment and securing functions.
3Ease of manufacture
If simple connector attachment is used, then assembly is easy but sealing and secure retention are compromised, while complex attachment methods improve security but reduce ease of assembly
Solution Approach 1:
The circular wall is designed with a crimpable edge that can be deformed to secure the connector. This flexible edge portion allows the rigid circular wall to perform a securing function through simple deformation, combining the strength of rigid structure with the adaptability of flexible material. The crimping action creates a secure mechanical interlock without requiring complex fastening mechanisms.
Data Source
AI summary
Fuel senders and methods of assembling fuel senders are disclosed. Fuel senders according to the present disclosure include a housing with detector retaining structure, a detector that is wedged against an inside surface of the housing by the detector retaining structure, and a connector for electrically coupling the detector to a display device. In some embodiments, the detector retaining structure consists of two ribs extending longitudinally along the inside surface of the housing.