Vehicle Fuel Tank Lever Sensor Stop Integration
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Solution Overview
Problem
Existing tank devices for motor vehicles, such as fuel tanks, require separate end stop components for lever sensors, which are costly and complex to attach, and can lead to sticking issues with the tank wall, affecting the reliability of the lever transmitter's operation.
Innovation Solution
The tank wall is designed to serve as a stop zone with a textured surface structure, featuring grooves or ribs, eliminating the need for a separate end stop component and preventing sticking by using the tank wall's shape and curvature to act as an end stop for the lever transmitter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate end stop component is used for the lever sensor, then the lever sensor can be reliably stopped at the end position, but the device complexity and manufacturing cost increase due to additional components and attachment requirements
Solution Approach 1:
The patent merges the end stop function with the tank wall structure itself. The stop area is formed by shaping a portion of the tank wall (through curvature, protrusions, or grooves) to create the stopping surface, eliminating the need for separate end stop components. This integration reduces device complexity while maintaining the reliability of lever sensor operation.
Solution Approach 2:
The tank wall is designed to serve multiple functions: containing the liquid, providing structural support, and acting as the end stop for the lever sensor. The stop area on the tank wall performs the stopping function without requiring additional dedicated components, demonstrating multi-functionality that reduces overall device complexity.
2Reliability
If a separate end stop component is attached to the tank wall, then the lever sensor can be reliably stopped, but the manufacturing cost and assembly complexity increase
Solution Approach 1:
The end stop function is combined with the tank wall structure, eliminating separate components that would require attachment processes. The stop area is formed directly during tank wall manufacturing through shaping techniques such as creating curvatures, protrusions, or grooves, significantly simplifying both manufacturing and assembly.
Solution Approach 2:
The tank wall structure provides its own end stop function through its geometric design. The shaped stop area on the tank wall automatically serves as the stopping surface for the lever sensor without requiring additional components or assembly steps, making the system self-sufficient and easier to manufacture.
3Ease of manufacture
If the tank wall has a smooth surface, then manufacturing is simpler, but the lever transmitter may stick to the tank wall affecting reliability
Solution Approach 1:
The tank wall surface is designed with different local properties: the stop area features geometric shapes (curvatures, protrusions, or grooves) that prevent sticking, while other areas of the tank wall can maintain smooth surfaces for ease of manufacture. This localized differentiation ensures reliability at the stop area without compromising overall manufacturing simplicity.
Solution Approach 2:
The stop area incorporates curved surfaces such as convex curvatures or grooves that prevent the lever transmitter from sticking. These geometric features create a surface topology that reduces adhesion while maintaining manufacturability through standard forming processes, resolving the contradiction between smooth surfaces and anti-sticking properties.
Data Source
Figure 1~2
Figure 3~4
AI summary
A refueling device for a motor vehicle comprising a tank container formed by a tank wall (1) and at least one lever actuator (2) inside the tank container, wherein at least one stop area (3) of the tank wall is designed to act as an end stop of the lever actuator (2) and to prevent the lever actuator (2) from sticking to the stop area (3) of the tank wall (1).