Pipe Connector With Permeable Wall For Urea Sensor
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Solution Overview
Problem
Current urea solution quality sensors in SCR systems face challenges due to varying tank geometries, contamination, air bubbles, and ice formation, leading to inaccurate measurements and increased maintenance costs, especially in commercial and off-road vehicles.
Innovation Solution
A line connector with a permeable wall section for an optical sensor integrated into the flow channel, allowing surface measurement of the urea solution without direct contact, reducing contamination risks and simplifying maintenance by avoiding immersion in the urea solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sensor is submerged in the urea solution in the tank, then the measurement of urea solution quality is enabled, but the sensor is exposed to contamination, air bubbles, and ice formation which adversely affect measurement accuracy
Solution Approach 1:
The tank is divided into two separate systems: a large tank for storing urea solution and a small measurement chamber for actual quality assessment. The sensor operates in the isolated measurement chamber which is filled with urea solution through a connection line, separating the sensor from harmful factors in the main tank while enabling continuous measurement
Solution Approach 2:
A connection line acts as an intermediary between the urea solution tank and the measurement chamber. This line transports small amounts of urea solution to the sensor without requiring the sensor to be directly exposed to the large tank environment, thereby isolating the sensor from contamination, air bubbles, and ice formation while maintaining measurement capability
2Reliability
If the sensor is located in the tank wall, then the sensor is protected from direct contact with urea solution, but the entire tank must be emptied for sensor replacement and maintenance
Solution Approach 1:
The measurement system is segmented into a permanent tank structure and a removable measurement chamber assembly. The sensor is housed in the small measurement chamber which can be independently accessed and replaced without affecting the main tank, enabling easy maintenance while keeping the sensor protected during operation
Solution Approach 2:
The measurement chamber is designed with dynamic accessibility - it can be sealed during operation to protect the sensor, and opened when maintenance is required. This allows the system to switch between protected operational state and accessible maintenance state, combining sensor protection with ease of repair
3Ease of repair
If the sensor is removed from the tank for maintenance, then the sensor can be replaced without emptying the tank, but the sensor loses continuous measurement capability during removal
Solution Approach 1:
The measurement function is segmented from the storage function. The small measurement chamber maintains continuous connection to the urea solution through the connection line, so when the sensor is replaced in this isolated chamber, the main tank remains full and operational, minimizing measurement interruption time
4Measurement precision
If a large amount of urea solution is used in the tank for measurement, then the measurement represents the bulk solution quality, but any leak causes significant loss and environmental damage
Solution Approach 1:
The system separates bulk storage from measurement function. The large tank stores the urea solution while a small measurement chamber performs the actual measurement. This segmentation allows bulk quality representation through continuous sampling via the connection line while minimizing the amount of solution at risk in case of leaks
Solution Approach 2:
Instead of measuring the entire bulk solution directly, the system uses partial action by sampling a small portion of the urea solution through the connection line into the measurement chamber. This partial measurement approach maintains measurement precision while dramatically reducing the quantity of solution exposed to potential leaks
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 enables precise urea solution quality control with minimal deviations in concentration measurements across a wide temperature range and reduces maintenance efforts by eliminating the need for tank emptying and protecting electrical components from urea solution exposure.
Implementation Method 1
a wall section 8 which is permeable to an optical sensor signal is formed in the area of the flow channel
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention relates to a pipe connector comprising a connector piece (1) with a flow channel (2) extending longitudinally within the connector piece (1) for a fluid, in particular a urea solution. The connector piece (1) has a connection section (3, 4) at each of its two ends, configured such that a flexible media line (6), a pipe, or a unit with a unit connection can be connected, and the flow channel (2) is provided with an electric heating element (7). In the region of the flow channel (2), a wall section (8) permeable to an optical sensor signal is formed in a wall of the connector piece (1) between the connection sections (3, 4) located at the two ends.A receiving housing (9) encompassing the permeable wall section (8) is formed on the connector (1), which has a receiving opening (11) opposite the permeable wall section (8) for mounting an optical sensor unit (12) inside the receiving housing (9).