Modular Fluid Sensor Assembly for Remote Quality Sampling
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Solution Overview
Problem
Existing fluid sensor assemblies in applications like fueling and DEF systems face challenges in accurately monitoring fluid quality due to integration issues, leading to inaccurate measurements and requiring the replacement of entire sensing units, which is inefficient and costly.
Innovation Solution
A modular fluid sensor assembly design that includes a separable header assembly and fluid level sensor, allowing for independent replacement and upgrade of components without removing the entire unit from the tank, with a closed sample loop for fluid sampling and testing outside the tank for improved accuracy and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If fluid sensors are integrated into a common sensor unit, then the sensor assembly is compact and easy to install, but repair or replacement requires removal of the entire sensor unit which increases maintenance cost and complexity
Solution Approach 1:
The sensor assembly is divided into separate modular components including individual sensor modules (fluid level sensor, fluid quality sensor), a mounting head, and a housing. Each sensor module can be independently removed and replaced through the mounting head without affecting other components, enabling selective maintenance while maintaining compact integration during operation.
2Reliability
If fluid quality is monitored inside the fluid tank, then real-time monitoring is achieved, but measurement accuracy deteriorates due to difficult monitoring conditions
Solution Approach 1:
A sample fluid passage system acts as an intermediary between the fluid tank and the sensor modules. The system draws a sample of fluid from the tank through a sample fluid passage and delivers it to a separate testing location where sensor modules can accurately measure fluid quality parameters without the interference of tank environment constraints.
3Reliability
If the entire sensor unit is replaced for maintenance, then system reliability is restored, but maintenance cost and time increase significantly
Solution Approach 1:
The sensor assembly is divided into separate modular components including individual sensor modules (fluid level sensor, fluid quality sensor), a mounting head, and a housing. Each sensor module can be independently removed and replaced through the mounting head without affecting other components, enabling selective maintenance while maintaining compact integration during operation.
Solution Approach 2:
Individual sensor modules can be discarded and replaced independently when they fail or require calibration, while the housing, mounting head, and other functional components are recovered and retained for continued use, significantly reducing maintenance time and cost compared to replacing the entire assembly.
Data Source
Figure 1~2
Figure 3~4
AI summary
A fluid sensor assembly (100) for sensing a fluid (102) contained in a fluid tank (104) of a vehicle (106) includes a housing unit (110) having a base plate (120), a sample suction line (122), and a sample return line (124). The fluid sensor assembly (100) includes a header assembly (102) having a header housing (134) separably coupled to the housing unit (110). The header housing (134) is located exteriorly of the fluid tank (104) of the vehicle (106). The header assembly (102) has a sample tank (152) in fluid communication with the sample suction line (122) and the sample return line (124). The sample tank (152) receives fluid (102) from the fluid tank (104) and a fluid quality sensor (154) senses a quality characteristic of the fluid (102) in the sample tank (152) for quality sampling of the fluid (102) at a location remote from an interior of the fluid tank (104).