Fuel Level Sensor Contact Spring U-Shape Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing fuel level sensors with resistance networks and contact spring structures are complex and susceptible to contamination and magnetic interference, which can affect their accuracy and reliability.
Innovation Solution
A fuel level sensor design featuring contact springs with a u-shaped or v-shaped distal end and a stiffening portion to ensure multiple contact points and reduce lateral movement, allowing for reliable contact even with contamination and minimizing magnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the contact spring structure uses multiple contact springs positioned opposite each contact to ensure reliable connection, then the reliability improves, but the device complexity increases
Solution Approach 1:
The contact spring is divided into multiple contact spring elements (at least two) positioned opposite each electrical contact. This segmentation allows the system to maintain reliability through redundancy while managing complexity by organizing the elements in a structured, opposing arrangement that systematically addresses contamination issues.
Solution Approach 2:
The distal end of each contact spring is given a specific U-shaped or V-shaped configuration. This local structural modification concentrates the reliability improvement at the critical contact point without requiring complex changes throughout the entire contact spring structure, thus improving reliability while controlling overall complexity.
2Stability of the object's composition
If the contact spring elements are mechanically interconnected to restrict lateral movement, then the stability improves, but the ease of manufacture decreases
Solution Approach 1:
Multiple contact spring elements are mechanically interconnected through a common connection element. This merging approach provides stability by restricting lateral movement of individual elements while simplifying manufacture by using a single connection component that can be integrated into the existing sensor assembly process.
3Reliability
If the distal end of contact spring has u-shaped or v-shaped form to create multiple contact points, then the reliability improves, but the magnetic influence increases
Solution Approach 1:
The U-shaped or V-shaped configuration is applied only to the distal end of the contact spring where contact occurs, rather than throughout the entire spring structure. This localized approach creates multiple contact points for improved reliability while minimizing the amount of magnetic material present, thereby reducing magnetic interference.
Solution Approach 2:
The magnetic properties of the contact spring material, which could potentially cause interference, are utilized to enhance the contact force and ensure reliable electrical connection. The magnetic attraction between the contact spring and the magnet helps maintain stable contact pressure, converting what could be a harmful factor into a beneficial force for connection reliability.
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 design simplifies the construction of fuel level sensors, ensures reliable contact and reduced magnetic influence, and maintains accuracy even in the presence of contaminants, enhancing the overall performance and robustness of the sensor.
Implementation Method 1
a contact spring structure which can be deflected under the action of a permanent magnet
Implementation Method 2
contact springs being deflectable under the force of the magnet
Data Source
Figure 1~2
AI summary
The invention relates to a fuel level sensor (10), with a magnet (12) being moveable along a circle segment shaped path responsive to the fuel level in a tank, a resistance network (14) comprising a plurality of individual electrical contacts (14a, 14b, 14c,...), a plurality of contact springs (16a, 16b, 16c,...) being deflectable under the force of the magnet (12) in a direction towards the resistance network (14) so as to establish an electrical connection with one individual electrical contact (14a, 14b, 14c,...) of the resistance network (14) depending on the position of the magnet (12) along the circle segment shaped path, the fuel level being determined depending on which individual electrical contact (14a, 14b, 14c,...) of the resistance network (14) is in contact with a contact spring (16a, 16b, 16c,...), characterized in that the distal end of each contact spring (16a, 16b, 16c,...) has a u-shaped or v-shaped form.