Sensor Mounting Table Insulation for Aftertreatment Heat Management
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The integration of multiple components in a single unit aftertreatment system for internal combustion engines poses challenges in mounting sensors effectively, as existing solutions lack efficient insulation and cooling features, leading to increased heat transfer and complexity in sensor packaging.
Innovation Solution
A sensor mounting table with a substantially flat surface offset from a heat shield, incorporating insulative material and integrated insulation to reduce heat transfer, along with a low profile design that combines sensors and wiring, providing a single module solution for mounting all necessary sensors and wiring harnesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If sensors are mounted directly on the aftertreatment system, then sensor mounting is simplified, but heat transfer to sensors increases
Solution Approach 1:
A sensor mounting table is introduced as an intermediary component between the aftertreatment system and the sensors. This mounting table includes an insulative material that mediates the thermal interaction, reducing heat transfer to sensors while providing a stable mounting surface. The insulative material acts as a thermal barrier, allowing sensors to be mounted close to the aftertreatment system without excessive heat exposure.
2Volume of moving object
If multiple sensors and wiring are integrated in a single unit, then packaging efficiency improves, but material complexity increases
Solution Approach 1:
Multiple sensors and their associated wiring harnesses are merged into a single integrated sensor mounting table. This consolidation reduces the overall packaging volume by eliminating the need for separate mounting structures for each sensor. The wiring harnesses are routed through channels in the mounting table, integrating electrical connections into the structural component, thereby reducing material complexity despite the integration of multiple functions.
3Length of moving object
If sensors are positioned close to the aftertreatment system, then wiring length is reduced, but heat exposure to sensors increases
Solution Approach 1:
The sensor mounting table incorporates insulative material specifically at the interface with the aftertreatment system, creating a localized thermal barrier. This allows sensors to be positioned close to the aftertreatment system for minimal wiring length, while the insulative material provides targeted heat protection only where needed. The local application of insulation maintains sensor temperature within acceptable ranges without requiring excessive distance from the heat source.
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 solution minimizes heat transfer to sensors, reduces material complexity, and facilitates easier packaging and integration, while allowing for predictable sensor orientation and wiring management, enhancing the reliability and ease of upgrading or replacing sensors in a single unit aftertreatment system.
Implementation Method 1
an insulative material disposed between at least a portion of the substantially flat mounting surface of the sensor mounting plate and the heat shield
Data Source
AI summary
A sensor mounting table for mounting sensors to an aftertreatment system may include a sensor mounting plate having a substantially flat mounting surface for mounting one or more sensors associated with the aftertreatment system. The substantially flat mounting surface may be offset from a heat shield of the aftertreatment system. The sensor mounting table may further include an insulative material disposed between at least a portion of the substantially flat mounting surface of the sensor mounting plate and the heat shield. The sensor mounting plate may be configured to be attached to the aftertreatment system to secure the insulative material between the substantially flat mounting surface of the sensor mounting plate and the heat shield.