Fuel Tank Level Sensor Electronic Correction for Assembly Automation
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Solution Overview
Problem
Existing fuel tank level sensors require manual adjustment, which is time-consuming and limits automatic assembly, due to deviations in electrical signals caused by component tolerances and complex fuel tank shapes, leading to increased production and logistics costs.
Innovation Solution
Integration of electronics that provide corresponding electrical target signals to correct the electrical signals generated by the fill level sensor, allowing for automatic electronic adjustment and reducing the need for mechanical adjustments, enabling the use of existing resistance networks across various fuel tank shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual adjustment of the level sensor is performed to correct electrical signal deviations, then measurement precision is improved, but loss of time and productivity deteriorate due to time-consuming adjustment processes
Solution Approach 1:
The patent replaces manual mechanical adjustment with an electronic correction system. The electronics unit receives the electrical signal from the level sensor, compares it with a characteristic curve stored in memory, and automatically generates a corrected signal that accounts for deviations caused by component tolerances and tank geometry. This eliminates the need for time-consuming manual adjustment while maintaining measurement precision.
2Measurement precision
If manual adjustment of individual key points is performed, then measurement precision is improved at specific points, but productivity deteriorates due to limited adjustment scope and inability to automate assembly
Solution Approach 1:
The patent replaces point-by-point mechanical adjustment with continuous electronic correction across the entire measurement range. The electronics unit processes the electrical signal continuously and generates corrected signals for all fuel levels, not just key points. This enables full automation of the assembly process while maintaining high measurement precision across the complete measurement spectrum.
Solution Approach 2:
The patent transitions from static adjustment at discrete key points to dynamic continuous correction across the entire measurement range. The electronics unit continuously processes electrical signals and generates corrected outputs for all possible fuel levels, allowing the system to adapt dynamically to any position of the lever arm rather than being limited to predetermined adjustment points.
3Adaptability or versatility
If separate resistor networks are produced for each fuel tank shape, then adaptability to different tank geometries is improved, but manufacturing complexity and logistics costs worsen
Solution Approach 1:
The patent creates a universal level sensor system where a single resistor network can be used with fuel tanks of various shapes. The electronics unit contains a characteristic curve memory that stores correction data for different tank geometries. By selecting the appropriate characteristic curve from memory, the same physical sensor can accurately measure fuel levels in different tank shapes, eliminating the need to manufacture separate resistor networks for each tank design.
Solution Approach 2:
The patent uses characteristic curves stored in memory as digital copies of the relationship between lever arm position and fuel level for different tank shapes. Instead of creating physical variations of the resistor network for each tank geometry, the system replicates the necessary correction data in the form of stored characteristic curves, allowing software-based adaptation to different tank geometries.
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
This solution reduces personnel effort and production costs by enabling precise electronic adjustment of the fill level sensor over the entire pivoting angle, allowing for faster assembly and maintenance, and eliminating the need for separate resistance networks for each fuel tank shape, while using lighter materials like fuel-resistant plastic for the lever arm.
Implementation Method 1
a float (15) which is attached to the lever arm (13) in such a way that the lever arm (13) can be moved by the float (15) depending on the fuel level
Implementation Method 2
one or more electrical contacts (14) which, depending on the pivoting of a lever arm (13), are in contact with the resistor network (11) to generate an electrical signal
Data Source
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AI summary
The invention relates to a filling level sensor (8) in a fuel tank (1) of a motor vehicle, comprising a substrate (10) having a resistance network (11) arranged thereon, one or more electrical contacts (14), which are in contact with the resistance network (11) in order to produce an electrical signal depending on the pivoting of a lever arm (13), and a float (15), which is fastened to the lever arm (13) in such a way that the lever arm (13) can be moved by the float (15) in accordance with the filling level. The filling level sensor (8) is connected to electronics (17), and the electronics (17) are designed in such a way that the electronics provide a respective corresponding electrical target signal for each of the electrical signals generated by the filling level sensor (8).