Heat Exchanger Sensor Positioning Using Elastic Prestressing Element
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Solution Overview
Problem
Existing heat exchanger arrangements for fuel-operated vehicle heaters face challenges in correctly and reliably positioning sensors within the heat transfer medium flow space for accurate thermal state monitoring.
Innovation Solution
A heat exchanger arrangement featuring a biasing element, such as a U-shaped leaf spring, is integrated into the outer housing to securely support the sensor within the heat transfer medium flow space, eliminating the need for additional assembly measures and minimizing stress on the fixing area, while preventing tilting moments and rotation through orthogonal abutment surfaces and anti-rotation projections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is positioned in the heat transfer medium flow space to engage with the heat transfer medium or inner wall, then accurate thermal state monitoring is achieved, but the sensor positioning becomes complex and unreliable
Solution Approach 1:
The prestressing element acts as an intermediary component between the sensor and the inner wall, providing a reliable positioning mechanism. The prestressing element includes a support area that engages with the sensor and an abutment area that rests against the inner wall, thereby mediating the positioning force and ensuring accurate thermal contact without complex assembly procedures
Solution Approach 2:
The prestressing element is designed to automatically apply positioning force through its elastic deformation. When the sensor is inserted, the prestressing element self-adjusts to provide the necessary support force, eliminating the need for additional assembly measures or complex positioning mechanisms
2Reliability
If additional assembly measures are implemented to secure the sensor, then sensor positioning reliability improves, but the assembly process becomes more complex
Solution Approach 1:
The prestressing element is designed to automatically apply positioning force through its elastic deformation. When the sensor is inserted, the prestressing element self-adjusts to provide the necessary support force, eliminating the need for additional assembly measures or complex positioning mechanisms
Solution Approach 2:
The prestressing element utilizes elastic deformation as its working principle, changing its physical state from a relaxed condition to a deformed condition that generates positioning force. This parameter change enables the element to provide reliable sensor support through simple elastic recovery rather than complex mechanical constraints
3Ease of manufacture
If the prestressing element is supported directly on the outer housing, then assembly is simplified, but significant reaction forces stress the fixing area
Solution Approach 1:
The support function is extracted from the outer housing and transferred to the prestressing element. The prestressing element assumes the role of providing positioning force, while the outer housing is relieved of direct support responsibilities, reducing stress concentration at the fixing area
Solution Approach 2:
The prestressing element acts as an intermediary that distributes the support forces. Instead of the outer housing directly supporting the sensor and承受ing all reaction forces, the prestressing element mediates the force transmission, spreading the load more evenly and reducing peak stresses at the fixing area
4Stability of the object's composition
If the sensor is firmly fixed to prevent movement, then positioning stability improves, but thermal expansion accommodation is reduced
Solution Approach 1:
The prestressing element is designed with elastic properties that allow it to dynamically adjust to thermal expansion. As the inner wall expands or contracts with temperature changes, the prestressing element flexes accordingly, maintaining continuous contact with the sensor while accommodating the dimensional changes without compromising positioning stability
Solution Approach 2:
The prestressing element utilizes elastic deformation as its working principle, changing its physical state from a relaxed condition to a deformed condition that generates positioning force. This parameter change enables the element to provide reliable sensor support through simple elastic recovery rather than complex mechanical constraints
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 design ensures simple, reliable, and stable sensor positioning, allowing for accurate thermal monitoring without additional assembly steps and accommodating thermal expansion, ensuring effective heat transfer and safety by preventing overheating risks.
Implementation Method 1
a prestressing element which acts on it for support on the inner wall
Implementation Method 2
the sensor can be positioned with the flow space engagement region supported on the inner wall in order to thereby enter into direct thermal interaction with the inner wall
Data Source
Figure 1~2
Figure 3~4
AI summary
A heat exchanger arrangement, in particular for a fuel-operated vehicle heater, comprises a heat exchanger housing (16) with an outer wall (24) and an inner wall (30), wherein the outer wall (24) and the inner wall (30) define a heat transfer medium flow space (36) through which heat transfer medium (M) flows, wherein at least one sensor receiving opening (42) is formed in the outer wall (24) and a sensor (40) is received in the at least one sensor receiving opening (42) in a fluid-tight and displaceable manner and with a flow space engagement area (50) in the heat transfer medium flow space (36) and supported against the inner wall (30), wherein a preloading element (52) is associated with the sensor (40) for supporting it against the inner wall (30).wherein the preloading element (52) is fixed in a fixing area (54) with respect to an outer housing (58) which at least partially surrounds the heat exchanger arrangement (22) and acts upon the sensor (40) in an actuation area (56) for support against the inner wall (30).