Liquid Level Detection Device Welding Protrusion Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing liquid level detection devices face issues with bonding strength between components, particularly in the welding process, which can lead to insufficient strength and corrosion due to gaps between molded parts, resulting in production inefficiencies and equipment stoppages.
Innovation Solution
A liquid level detection device design featuring a holder with a magnet that rotates with liquid level changes, a main body unit with magnetic detection elements, and a cover welded to the main body unit using protrusions, along with a manufacturing method involving insertion molding with positioning rings to ensure accurate placement and secure bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If laser welding is used to fix the contact surface of first and second cases, then the welding process can be automated, but the welding strength becomes insufficient and the welding state is difficult to grasp
Solution Approach 1:
The welding process is segmented into two distinct stages: first, positioning welding to fix the cover at a predetermined position, and second, peripheral welding to provide strong bonding around the periphery. This segmentation allows each welding stage to serve a specific function, ensuring both automation capability and sufficient welding strength.
Solution Approach 2:
The positioning welding is performed as a preliminary action before the final peripheral welding. This preliminary positioning welding establishes the correct spatial relationship between components, ensuring that subsequent peripheral welding can be performed with proper alignment and achieve the required bonding strength.
2Ease of manufacture
If the positioning part in the first molded product is not covered by the second molded product, then the manufacturing process can be simplified, but fuel soaks through the gap and corrodes the internal circuit
Solution Approach 1:
The solution moves from a two-dimensional planar sealing approach to a three-dimensional protrusion-based sealing structure. The positioning protrusion extends vertically to contact the positioning groove, creating a mechanical interlock that prevents fuel infiltration while maintaining manufacturing simplicity through integrated mold design.
Solution Approach 2:
The sealing structure combines the positioning protrusion (from the first molded product) with the positioning groove (in the second molded product) to create a composite mechanical sealing system. This composite structure provides both positioning functionality and corrosion protection by eliminating gaps where fuel could penetrate.
3Device complexity
If the positioning part is not set on the pin during mold setting, then the mold design can be simplified, but fitting failure occurs and production efficiency is lowered
Solution Approach 1:
The positioning protrusion and positioning groove are merged into an integrated positioning mechanism that is built into the molded products themselves. This eliminates the need for separate pins and complex mold setting procedures, reducing mold design complexity while ensuring accurate positioning to prevent fitting failures and maintain high production efficiency.
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
The solution enhances bonding strength between components, prevents corrosion, and improves production efficiency by ensuring proper alignment and secure welding, thus addressing the challenges of insufficient welding and corrosion in existing devices.
Implementation Method 1
a holder that has a magnet inside, and rotates in accordance with displacement of a float floating on liquid that is a measuring object of liquid level
Implementation Method 2
a main body unit that rotatably supports the holder, and has a magnetic detection element for detecting a change in a magnetic pole accompanying rotation of the magnet
Implementation Method 3
the cover is welded to the main body unit by melting a protrusion formed in the main body unit or the cover
Data Source
AI summary
Provided is a liquid level detection device with excellent bonding strength between components. This liquid level detection device is provided with a holder which has a magnet inside and which rotates in response to displacement of a float floating in the liquid the level of which is to be measured, a main body unit which rotatably supports the holder and has a magnetic detection element which detects magnetic pole change accompanying rotational movement of the magnet, and a cover which covers the holder and which is attached by welding to the main body unit to prevent the holder from falling away from the main body unit. The cover is welded to the main body unit by melting protrusions formed on the main body unit.