Fuel Tank Cap With Integrated Electronic Level Sensor
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Solution Overview
Problem
Existing fuel tank caps with integrated level sensors face design and manufacturing challenges due to the encumbrance of control logic seats and the need for a rectilinear detection rod in irregularly shaped fuel tank volumes, limiting sensor placement and adaptability.
Innovation Solution
A fuel tank cap design with an integrated electronic level sensor that includes a modular, potentially curved or flexible detection device and separate electronic control units housed in distinct seats within the cap's base and flap, allowing for adaptable placement and operation without contact, enabling precise liquid level detection and hands-free or keyless locking functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a rectilinear detection rod is used in the level sensor, then the sensor can be integrated into the fuel tank cap, but the sensor placement is restricted due to the irregular geometry of the fuel tank internal volume
Solution Approach 1:
The cap is divided into a base portion and a flap portion, with separate control logic seats in each. The detection device is also segmented into multiple sections that can be independently positioned. This segmentation allows the detection device to adapt to irregular tank geometries while distributing control logic across separate locations.
Solution Approach 2:
The detection device is made flexible or articulated rather than rigid and rectilinear, allowing it to bend or articulate to match the irregular internal geometry of the fuel tank. This dynamic configuration enables the detection rod to reach optimal sensing positions without being constrained by straight-line geometry.
2Ease of operation
If control logic is integrated into the fuel tank for level sensing, then level detection function is achieved, but the tank design becomes complicated and encumbered
Solution Approach 1:
The control logic for both the hands-free locking mechanism and the level sensing function are merged into a single electronic control unit located in the cap. This consolidation integrates multiple functions (locking control and level detection) into one unit, reducing overall system complexity while maintaining hands-free operation capability.
Solution Approach 2:
The electronic control unit is designed to perform multiple functions: controlling the hands-free lock mechanism and processing level sensor data. This multi-functional approach eliminates the need for separate control logic for each function, simplifying the overall system architecture while preserving both hands-free operation and accurate level detection.
Data Source
Figure 1
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AI summary
The tank cap (1) comprises a containment body (20, 30) and an electronic level sensor (4, 6), which, in turn, comprises a detection device (4, 4') for detecting the level of liquids and a first electronic control unit (61) configured to transmit a level signal as a function of the detection carried out by the device (4, 4'), wherein said first control unit (61) is housed in a first seat (5) comprised in the containment body (20, 30).