Line Connector with Integrated Optical Sensor for Urea Measurement
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Solution Overview
Problem
Existing urea solution quality measurement systems in vehicles face challenges due to varying tank geometries, contamination by pollutants, air bubbles, and ice formation, which affect sensor accuracy and require complex and costly maintenance.
Innovation Solution
A line connector with a built-in optical sensor in its flow-through channel, integrated into the urea solution line, allowing for direct measurement of the solution quality without tank geometry dependencies, using a permeable wall section for IR light reflection and a sealed sensor unit to prevent contamination and leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sensor is seated in the tank wall or immersed in the tank, then the measurement of urea solution quality can be performed, but the system becomes dependent on tank geometry and requires complex installation for each tank variant
Solution Approach 1:
The sensor is extracted from the tank environment and integrated into the line connector, which is a common component across all tank variants. This allows the sensor to measure urea solution quality in the flow line without being affected by tank geometry variations, thereby reducing installation complexity while maintaining measurement capability.
2Measurement precision
If the sensor is seated in the tank wall or immersed in the tank, then the measurement can be performed, but pollutants and air bubbles in the tank adversely affect the measurement accuracy
Solution Approach 1:
The sensor is extracted from the tank environment where pollutants and air bubbles are present, and relocated to the line connector where the urea solution flows through a filtered line. This positioning eliminates exposure to tank contaminants while maintaining the ability to measure solution quality in the flow line.
3Measurement precision
If the sensor is seated in the tank wall or immersed in the tank, then the measurement can be performed, but ice chunks in the tank can damage the sensor through mechanical sloshing
Solution Approach 1:
The sensor is extracted from the tank environment where ice chunks form and slosh, and relocated to the line connector where the urea solution flows through a controlled environment. This positioning protects the sensor from mechanical damage by ice while maintaining measurement capability in the flow line.
4Measurement precision
If the sensor is seated in the tank header unit, then the measurement can be performed, but service requires full disassembly of the header unit which is costly and time-consuming
Solution Approach 1:
The sensor is integrated into the line connector, which is a separate, modular component from the tank and header unit. This segmentation allows the sensor to be accessed and replaced by simply removing the line connector, eliminating the need for costly and time-consuming header unit disassembly while maintaining measurement functionality.
5Measurement precision
If the sensor is seated in the tank wall or immersed in the tank, then the measurement can be performed, but leakage results in loss of large volumes of urea solution and potential environmental damage
Solution Approach 1:
The sensor is extracted from the tank environment and relocated to the line connector, which contains only a small volume of urea solution in the flow line. This positioning ensures that any leakage from the sensor results in minimal urea solution loss compared to tank-level leakage, while maintaining the ability to measure solution quality.
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
Enables high-precision quality control of urea solution concentrations between -8°C and 50°C with ±2% deviation detection, reducing maintenance complexity and avoiding damage from leaks or ice, while ensuring accurate and defined operating performance.
Implementation Method 1
a wall section permeable to an optical sensor signal is formed in a wall of the coupling piece surrounding the flow-through channel, and a receiving housing surrounding the perimeter of the permeable wall section is formed on the coupling piece and features a receiving opening positioned opposite the permeable wall section for mounting an optical sensor unit inside of the receiving housing
Implementation Method 2
the flow-through channel is provided with an electrical heating unit
Data Source
AI summary
A line connector for a fluid, in particular a urea solution, including a connecting piece with an interior flow-through channel extending in the longitudinal direction of the connecting piece. The connecting piece includes at each of its two ends a coupling section designed such that a flexible media line or a tubing or an aggregate can be connected to an aggregate connector. The flow-through channel is also provided with an electrical heating unit. In the region of the flow-through channel, between the connecting sections, an enclosed perimeter receiving housing is formed on the coupling piece, in which an optical sensor unit is disposed for measuring of properties of the fluid flowing in the flow-through channel. A ready-made media line, including a tubular or hose-like media line and a line connector connected on one or both sides to this media line is also disclosed.