Fuel Water Separator Sensor Probe Design
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Solution Overview
Problem
Conventional fuel-water separators require the sensor to be disconnected and reconnected each time a new filter is installed, leading to installation challenges and potential reattachment issues, and the sensor wire length can complicate this process.
Innovation Solution
A fuel water separator design where a sensor is coupled to the top end cap and a probe with a pair of prongs is positioned outside the filter, allowing the sensor to remain attached and eliminating the need for reconnection, with the probe's ends contacting or separating based on filter presence to indicate proper installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sensor is attached by a wire to the bottom of the filter, then the sensor can detect water levels, but the sensor must be disconnected and reconnected when the filter is replaced, causing installation challenges and potential reattachment issues
Solution Approach 1:
The sensor system is segmented into two parts: a stationary sensor housing attached to the filter base and a movable probe attached to the filter. This allows the filter (with probe) to be removed and replaced independently while the sensor housing remains in place, eliminating the need to disconnect and reconnect the sensor during filter changes.
Solution Approach 2:
The probe acts as an intermediary element that bridges the stationary sensor and the filter. The probe contains contacts that engage with corresponding contacts in the sensor housing when the filter is properly installed, enabling electrical connection without requiring direct attachment of the sensor to the filter.
2Ease of operation
If the sensor wire length is increased to allow easier connection, then the sensor can be reconnected more easily, but the wire length makes it challenging to install and remove the sensor
Solution Approach 1:
The wire management complexity is extracted and eliminated by removing the need for a flexible wire connection. Instead, rigid electrical contacts are used through the probe, which provides a stable and simple connection path without requiring long wires or complex wire routing.
3Ease of operation
If the sensor is integrated with the filter, then the sensor moves with the filter for easy installation, but the sensor would need to be recalibrated or repositioned frequently
Solution Approach 1:
The sensor system is divided into a stationary sensing portion (housing with contacts) and a movable triggering portion (probe with contacts). The stationary housing maintains precise alignment for accurate water level detection, while the movable probe on the filter provides ease of installation and removal without affecting sensor positioning precision.
Solution Approach 2:
The electrical connection between the probe contacts and sensor housing contacts provides feedback on proper filter installation. When the filter is correctly positioned, the contacts engage and complete the circuit, confirming accurate sensor positioning without requiring manual calibration.
Data Source
AI summary
A fuel water separator is provided. The fuel water separator includes a filter having a top end cap and a bottom end cap. A sensor is coupled to the top end cap of the filter. A probe is configured to be coupled to the sensor and to the bottom end cap. The probe is configured to be positioned outside the filter between the top end cap and the bottom end cap.