Modular Coolant Sensor with Extracted Resistor Pigtail
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current coolant level sensors in garbage trucks are unreliable due to mechanical and electrical failures from high temperatures and extreme forces, leading to resource wastage and downtime when entire sensors need to be replaced, even if only one component fails.
Innovation Solution
A coolant level sensor with three interoperable components: a housing component, an interchangeable cartridge assembly, and a resistor pigtail, where the cartridge assembly includes a pre-encapsulated reed switch and resistors, allowing for easy replacement of failing parts without replacing the entire sensor, and the resistor harness is positioned away from high temperatures to extend its lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire coolant level sensor is replaced when one component fails, then the reliability of the cooling system is maintained, but resource waste and downtime increase due to replacing functioning parts
Solution Approach 1:
The coolant level sensor is divided into separate modular components including a housing, reed switch assembly, and resistor pigtail. This segmentation allows individual components to be replaced independently rather than replacing the entire sensor assembly, reducing resource waste when only one component fails.
Solution Approach 2:
The modular design enables recovery and retention of functioning components after a failure. When one component fails, the other components can be recovered and reused, eliminating the need to discard the entire sensor assembly and reducing material waste.
2Reliability
If the entire coolant level sensor is replaced when one component fails, then the cooling system reliability is maintained, but downtime and labor costs increase
Solution Approach 1:
The sensor is segmented into replaceable modules that can be swapped independently. This allows mechanics to perform quick component-level replacements rather than replacing the entire sensor assembly, significantly reducing replacement time and vehicle downtime.
Solution Approach 2:
The modular architecture provides dynamic adaptability in maintenance operations. Different components can be replaced based on their specific failure modes and availability, allowing for flexible and efficient repair strategies that minimize downtime.
3Device complexity
If the resistor pigtail remains in the cooling system, then the sensor structure is simple, but the resistor fails due to constant exposure to high temperatures
Solution Approach 1:
The resistor pigtail is extracted from its traditional position within the cooling system and relocated to an external position. This extraction removes the resistor from direct exposure to high temperatures and extreme forces, preventing thermal degradation and mechanical damage while maintaining electrical functionality.
Solution Approach 2:
The resistor pigtail serves as an intermediary component that can be connected or disconnected as needed. By positioning it externally, it mediates between the cooling system's electrical requirements and the harsh thermal environment, allowing the system to function without subjecting the resistor to damaging conditions.
4Ease of operation
If the reed switch is positioned to monitor coolant level directly, then the sensor function is effective, but the reed switch is destroyed by extreme forces during waste removal operations
Solution Approach 1:
The reed switch is extracted from direct exposure to extreme mechanical forces while maintaining its monitoring function. The modular design allows the reed switch assembly to be positioned optimally for detection while protecting it from the harshest environmental conditions during waste removal operations.
Solution Approach 2:
The modular construction provides protective cushioning for the reed switch assembly. By designing the sensor as separate modules with appropriate mounting and connection mechanisms, the reed switch is protected from extreme forces before they can cause damage, similar to how shock absorbers protect sensitive components.
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
This design enhances the durability and maintainability of coolant level sensors, reducing resource waste and downtime by allowing for component-level replacements and minimizing exposure to high temperatures, thus improving the reliability and efficiency of waste removal operations.
Implementation Method 1
The reed switch may be positioned within the cartridge assembly such that the reed switch is configured to face the float assembly
Data Source
AI summary
The present disclosure relates to a coolant level sensor device for application in vehicles, comprising three interoperable component parts: a housing component, an interchangeable cartridge assembly, and a resistor pigtail. The housing component may be configured to permanently and/or semi-permanently reside within the engine cooling system such that the housing component may receive the interchangeable cartridge assembly selectively connected with the resistor pigtail. The interchangeable cartridge assembly may comprise a reed switch that may be replaceable when damaged. Further, the interchangeable cartridge mechanism may be configured to connect with the resistor pigtail, which may include at least one resistor, such that the at least one resistor may be removed from close proximity to the high temperatures generated by the engine, thus increasing the life of the resistor components. This three part configuration may allow for the easy replacement of elements of the coolant level sensor prone to failure, without the need to replace functioning components.