Liquid Level Sensor Wire Harness Groove Design
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Solution Overview
Problem
In a liquid surface detecting device, wire harnesses can wobble and become displaced within grooves, leading to detachment from terminal units due to container deformation, causing potential electrical erosion and maintenance issues.
Innovation Solution
A liquid surface detecting unit configuration that includes a reservoir cup, a body attached to the cup's side wall with grooves guiding the wire harnesses, and partitioning walls extending beyond terminals to prevent displacement and erosion, eliminating the need for additional covers and allowing easy maintenance checks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wire harnesses are placed in open grooves, then ease of installation is improved, but wire harness displacement and detachment occur due to container deformation
Solution Approach 1:
The groove is divided into two functional sections: an open upper portion for easy wire harness insertion and a closed lower portion for secure retention. This segmentation allows the groove to provide both ease of installation and connection stability without requiring additional fastening components.
Solution Approach 2:
The groove transitions from a two-dimensional open channel to a three-dimensional enclosed space with a bottom closure. This dimensional change creates a pocket-like structure that physically restrains the wire harness in the vertical direction, preventing detachment while maintaining horizontal accessibility.
2Object-affected harmful factors
If additional covers are provided to protect terminal units from electric erosion, then protection performance is improved, but device complexity increases
Solution Approach 1:
The protective function is merged with the existing groove structure by closing the groove bottom to form an enclosure. This integration eliminates the need for separate protective covers while maintaining protection against electric erosion, thereby reducing device complexity.
Solution Approach 2:
The closed groove structure serves multiple functions simultaneously: it guides the wire harness during installation, secures the wire harness in position, and protects the terminal unit from electric erosion. This multi-functionality replaces what would otherwise require multiple separate components.
3Object-affected harmful factors
If partitioning walls extend beyond terminals, then protection from electric erosion is improved, but manufacturing complexity increases
Solution Approach 1:
The partitioning walls are designed to extend beyond the terminals during the manufacturing process, establishing protective coverage in advance. This preliminary extension ensures that when the device is assembled and operated, the terminals are already protected from electric erosion without requiring additional post-assembly modifications.
Solution Approach 2:
The partitioning walls provide localized protection specifically at the terminal regions where electric erosion is most likely to occur. By extending the walls only to the necessary degree beyond the terminals, protection is concentrated where needed rather than uniformly throughout the entire structure, optimizing both protection and manufacturability.
Data Source
AI summary
A liquid surface detecting unit includes a reservoir cup; a body attached to a side wall of the reservoir cup; an arm rotatably supported by the body; a sensor unit stored in the body and configured to detect rotating motion of the arm; a terminal unit extending from the sensor unit; and a wire harness connected to the terminal unit and extending to an outside of the body. The body may include a groove surrounding and guiding the wire harness together with the side wall of the reservoir cup, the wire harness extending from the terminal unit to the outside of the body.