Level Sensor Cable Sealing Structure for High-Pressure Reliability
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Solution Overview
Problem
Existing level sensors face issues with seal tightness due to high liquid pressures, leading to potential damage and failure, especially in containers with high liquid levels, and are often costly to manufacture.
Innovation Solution
A level sensor design featuring a housing with a cable leadthrough positioned upward, multiple barriers including a sealing element, crimp sleeve, and casting to prevent medium penetration, and a connection cable with a crimp sleeve and pressing element to ensure effective sealing and secure components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional single-seal design is used in level sensors, then the device complexity is low and manufacturing is simple, but the seal tightness deteriorates under high liquid pressure leading to potential damage and failure
Solution Approach 1:
The sealing structure is divided into multiple independent barriers (first barrier at cable leadthrough, second barrier at crimp sleeve, third barrier at pressing element) that work together to prevent medium penetration. Each barrier provides a separate sealing function, so that if one barrier is compromised, the other barriers continue to protect the evaluation electronics from high liquid pressure
Solution Approach 2:
The sealing approach transitions from a single-point seal to a multi-layered sealing system distributed along the cable entry path. The barriers are positioned at different locations and orientations (cable leadthrough orientation, crimp sleeve circumference, pressing element axial direction), creating a three-dimensional sealing network that resists pressure from multiple directions
2Reliability
If multiple barriers and sealing components are added to prevent medium penetration, then the seal tightness improves, but the manufacturing cost and device complexity increase
Solution Approach 1:
Multiple sealing functions are combined into an integrated sealing section where the first barrier (cable leadthrough seal), second barrier (crimp sleeve), and third barrier (pressing element) are assembled together as a unified sealing assembly. This modular approach allows for efficient manufacturing and assembly while maintaining high seal tightness through the coordinated action of multiple barriers
Solution Approach 2:
The sealing components (sealing element, crimp sleeve, pressing element) are designed as simple, inexpensive parts that can be easily manufactured and replaced if necessary. The use of common materials and standard manufacturing processes for these barriers keeps the overall manufacturing cost low while still achieving the required seal tightness
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
Enhances seal tightness, prevents damage to evaluation electronics, and reduces manufacturing costs by using a simple, reliable sealing mechanism with minimal components.
Implementation Method 1
a crimp sleeve (19) pressed around the connection cable (15)... a pressing element (20) by which the crimp sleeve (19) is pressed against a sealing surface (29)
Implementation Method 2
The housing (11) is at least partially filled with a first casting (21a), and the first casting (21a) encloses the connection cable (15), at least in sections
Data Source
AI summary
A level sensor includes a housing and at least one sensor that is designed to measure a pressure of a medium and that is electrically connected to evaluation electronics. The level sensor also includes a connection cable that is guided through the housing in a sealing section. At least one crimp sleeve is pressed around the connection cable in the sealing section inside the housing. A pressing element is fastened in the sealing section of the housing in such a way that the crimp sleeve is pressed against a sealing surface of the sealing section. The housing or at least the sealing section of the housing is at least partially filled with a first casting, and the casting encloses the connection cable, at least in sections.