Oil level regulator
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Solution Overview
Problem
Existing oil mirror regulators have complex designs and high production costs due to multi-axis milling processes, which result in material losses and increased costs, and also suffer from inefficient oil flow and potential disturbances within the regulator.
Innovation Solution
A rotationally symmetrical base body design for the oil mirror regulator, produced using a lathe instead of a milling center, reduces material losses and costs, minimizes oil channel length for improved flow efficiency, and features a separate electronic module for simplified assembly and attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the base body is designed with asymmetries and integrated electronics as in known oil level regulators, then the device functionality is complete, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The device is divided into separate functional modules: the base body (housing) is designed with rotationally symmetric simple geometry for easy manufacturing, while the electronics are mounted separately on the base body rather than being integrated into complex internal structures. This segmentation allows the base body to be produced on simple lathes without multi-axis milling centers.
Solution Approach 2:
The invention intentionally avoids asymmetries in the base body design. The base body is designed with rotationally symmetric geometry, and any asymmetric functional requirements (like oil inlet/outlet positions) are accommodated through separate mounted components rather than by complicating the base body shape, thereby simplifying manufacturing.
2Adaptability or versatility
If multi-axis milling centers are used to manufacture the base body with integrated channels and electronics, then the design flexibility is improved, but the production cost and time increase
Solution Approach 1:
The base body is designed as a simple rotationally symmetric structure that can be manufactured on a lathe, separating the manufacturing process from the electronic assembly process. This allows parallel production of base bodies and electronic modules, significantly improving productivity compared to integrated multi-axis milling.
Solution Approach 2:
Instead of achieving design flexibility through complex 3D milling operations, the invention moves asymmetric functional elements (electronics, connectors) to the external surface of the rotationally symmetric base body, utilizing the external mounting surface as an additional dimension for functional arrangement without complicating the base body geometry.
3Reliability
If the oil channels are made longer to connect various components, then the device functionality is complete, but the flow losses and disturbances increase
Solution Approach 1:
The oil inlet channel and outlet channel are positioned at approximately the same height level in the base body, creating an equipotential arrangement that minimizes gravitational flow resistance and reduces the need for long vertical channel sections, thereby improving oil flow efficiency.
Solution Approach 2:
The base body is designed with rotationally symmetric curved geometry, and the oil channels are routed to follow smooth curved paths rather than sharp angles or straight-line connections, reducing flow disturbances and maintaining laminar flow throughout the oil passage.
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 new design enhances cost-effectiveness, improves oil flow efficiency, and simplifies assembly and attachment, leading to a more economical and efficient oil mirror regulator.
Implementation Method 1
a Hall sensor for detecting the position of the float within the chamber
Implementation Method 2
a solenoid valve attached to the base body and connected between the oil inlet channel and the oil outlet channel for controlling an oil flow
Implementation Method 3
a float is arranged in the chamber... the position of the float in the chamber corresponds to the oil level in the compressor
Data Source
Figure 1
Figure 2~3
Figure 4A~4D
AI summary
The invention relates to an oil level regulator comprising a base body, a chamber formed in the base body, delimited by a sight glass and provided for receiving oil, in which a float is arranged, a Hall sensor for detecting the position of the float within the chamber, an oil inlet channel formed in the base body, an oil outlet channel formed in the base body and communicating with the chamber, a solenoid valve attached to the base body and connected between the oil inlet channel and the oil outlet channel for controlling an oil flow from the oil inlet channel to the oil outlet channel, wherein the base body is based on a basic shape that is rotationally symmetrical with respect to an axis of symmetry.