Rotationally Symmetrical Oil Level Regulator for Lower-Cost Assembly
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Solution Overview
Problem
Existing oil level regulators have complex designs and production processes, leading to high costs and inefficiencies, particularly due to the need for multi-axis milling centers and integrated electronics, which complicates manufacturing and assembly.
Innovation Solution
A rotationally symmetrical base body design for the oil level regulator, allowing for production on a lathe instead of a milling center, with separate external electronics and simplified channel configurations to minimize material loss and flow disturbances, enhancing economic efficiency and ease of assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a multi-axis milling center is used to produce the base body, then complex designs and precise oil channels can be achieved, but production costs increase and material losses occur
Solution Approach 1:
The base body is divided into functional zones (oil inlet region, oil outlet region, sensor region, valve region) that can be independently designed and manufactured, then assembled together. This segmentation allows simpler manufacturing processes for each segment while achieving complex overall functionality, reducing both cost and material waste.
Solution Approach 2:
The oil channels are designed as nested pathways within the base body structure, with inlet channels, outlet channels, and internal flow paths arranged in a compact nested configuration. This nesting approach minimizes the overall base body size and reduces material requirements while maintaining complex flow control functionality.
2Productivity
If complex oil channels are drilled and sealed after production, then precise oil flow control is achieved, but production time and costs increase
Solution Approach 1:
The oil channels are pre-formed as integral parts of the base body structure during the initial manufacturing process, rather than being drilled and sealed afterward. This preliminary formation of channels eliminates subsequent sealing operations, significantly reducing production time while maintaining precise channel dimensions through modern additive manufacturing or precision casting techniques.
3Device complexity
If the electronics are housed in the base body, then integration is improved, but assembly complexity and production costs increase
Solution Approach 1:
The electronic components (Hall sensor, control circuitry) are extracted from the base body and housed in a separate electronics module. This module can be independently manufactured and tested, then assembled to the base body through standardized interfaces. This extraction simplifies the base body manufacturing process and enables modular assembly, reducing overall production complexity and cost.
4Ease of operation
If long oil channels are used in the base body, then connectivity is achieved, but flow losses and disturbances increase
Solution Approach 1:
The oil channels are arranged in a three-dimensional configuration within the base body, utilizing vertical and radial dimensions in addition to horizontal pathways. This multi-dimensional routing allows oil to travel shorter distances between inlet and outlet while maintaining adequate mixing and flow control, significantly reducing flow losses and disturbances compared to linear channel arrangements.
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 rotationally symmetrical design reduces production costs, improves oil flow efficiency, and simplifies the manufacturing process, resulting in a more cost-effective and profitable oil level regulator with reduced assembly complexity.
Implementation Method 1
a Hall sensor for detecting the position of the float within the chamber
Implementation Method 2
a solenoid valve connected to the base body and connected between the oil inlet channel and the oil outlet channel for controlling oil flow
Implementation Method 3
a float is arranged in the chamber... with the oil level in the chamber with 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.