Motor Vehicle Level Sensor Sealing via Segmented Housing
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Solution Overview
Problem
Existing level sensors in motor vehicles face complexity and high costs in protecting printed circuit boards and electronic components from environmental influences due to intricate sealing requirements, which complicates production and reliability.
Innovation Solution
A level sensor design featuring a chamber within the housing that securely encloses the printed circuit board and electronic components, using a plug as a cover with a simple O-ring seal, and guide ramps for precise positioning, along with deformable structures for alignment, ensures protection against humidity, moisture, and dust, while simplifying installation and production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large cover and complex sealing structure are used to protect the printed circuit board, then protection against environmental influences is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The housing is divided into a sealed chamber for the printed circuit board and an open region for the rotor. The plug seals only the opening to the chamber, not the entire housing. This segmentation allows simple sealing of only the necessary area while maintaining overall protection.
Solution Approach 2:
The printed circuit board is extracted from the open housing and placed inside a sealed chamber. This separates the sensitive electronic components from the external environment, requiring sealing only at the chamber opening rather than the entire housing.
2Reliability
If a casting compound is used to seal the printed circuit board, then protection against environmental influences is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The housing is segmented into a sealed chamber and open region. Only the opening to the chamber requires sealing, which can be done with a simple plug and O-ring rather than requiring complex casting compounds to seal the entire housing.
Solution Approach 2:
A simple plug with an O-ring seal is used instead of expensive casting compounds. The O-ring provides reliable sealing at low cost and can be easily replaced if needed, making the manufacturing process simpler and more economical.
3Ease of operation
If the opening for the rotor is made large, then rotor installation is facilitated, but sealing complexity increases
Solution Approach 1:
The housing is segmented into a sealed chamber and an open region. The rotor is installed in the open region, which does not require sealing. Only the smaller opening to the chamber needs sealing, reducing sealing complexity while maintaining ease of rotor installation.
Solution Approach 2:
The rotor is extracted from the sealed chamber concept and placed in an open region of the housing. This allows the rotor to be installed without compromising the seal, as the rotor operates outside the sealed environment where the printed circuit board is protected.
Data Source
AI summary
A level sensor for a motor vehicle includes a housing, a rotor rotatably mounted on the housing, and a printed circuit board enclosed in the housing. The printed circuit board includes at least one stator and is connected to a plug which can be attached to an opening in the housing, and seals the opening thereby. The printed circuit board and electronic components are readily and permanently protected against environmental influences. Housing has a chamber for accommodating the printed circuit board, and the opening is allocated to the chamber. The chamber is closed on all sides, with the exception of the opening. The printed circuit board can be inserted in the chamber in the manner of a drawer and can be positioned therein.