A portion of this patent document contains material subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyrights whatsoever. The following notice applies to this document: Copyright ©2006 Engineered Products Company, Inc.
Various embodiments of the present invention concern devices for monitoring fluid-filter performance, particularly devices that are responsive to differential pressures. Some embodiments of the invention may also be used in other applications.
Many modern systems include filters to ensure proper or reliable performance. For example, automobiles and other vehicles include air or fuel filters to remove dirt and other particulates from the fuel that is ignited within their internal combustion engines. As a consequence of their proper operation, these filters collect particulates over time and increasingly restrict the flow of air and fuel into engines. Eventually, the filters become more restrictive than desirable and require replacement.
To facilitate timely filter replacement, automobiles and other systems sometimes include filter-monitoring devices, which monitor pressure or vacuum levels that result from fluid flow through associated filters. These devices are calibrated to detect when particular pressure or vacuum conditions occur and to respond to such occurrences in particular ways.
For example, some devices respond to the difference in pressure between the inlet and outlet of a fuel filter and provide a variable electrical resistance indicative of the differential pressure. This electrical resistance is typically wired to circuitry that can interpret a voltage related to the resistance as indicative or not indicative of an overly clogged filter and turn on a warning light or send a signal to an engine computer for further processing.
The present inventors have recognized that commercially available differential pressure sensors suffer several problems. For example, these differential sensors are generally too complex and costly to be used widely in many types of vehicles. They also recognized that the complexity of these sensors frequently resulted in less than desirable reliability, especially under extreme operating conditions. Moreover, the inventors recognized that many differential pressure sensors were limited to either horizontal or vertical orientations, which not only limited how vehicle manufacturers could design their fluid flow systems, but also limited the production volume of these sensors and ultimately increased their production cost.
Accordingly, the present inventors have recognized a need to improve conventional differential pressure sensors.
To address this and/or other needs, the present inventors devised, among other things, various embodiments of differential filter-monitoring devices and related components, subassemblies, methods, and systems. One exemplary low-cost differential filter-monitoring sensor includes a diaphragm that flexes in response to differential pressures across a filter, and thus moves a magnet within a guide sleeve. A hall-effect sensor adjacent the guide sleeve exhibits an electrical resistance based on location of the magnet in the guide sleeve, and circuitry coupled to the hall-effect sensor translates the electrical resistance into an electrical voltage. Among its many notable features, the exemplary embodiment provides a t
This description, which incorporates the above-identified figures and appended claims, describes one or more specific inventive embodiments. These embodiments, offered not to limit but only to exemplify and teach one or more inventions, are shown and described in sufficient detail to enable those skilled in the art to implement or practice the invention(s). The description may use terms, such as upper or lower in reference to specific features of various as embodiments; however, unless included in the claims, such terms are merely to aid correlating the drawings with the written description and thus promote understanding of the invention. Moreover, where appropriate to avoid obscuring the invention(s), the description may omit certain information known to those of skill in the art.
Engine 110 includes a fuel (or more generally fluid) inlet 112. In the exemplary embodiment, engine 110 is an internal combustion engine. Fluid inlet 112 is coupled to fuel tank 120 via fluid line 130.
Fluid line 130 includes a fuel filter 132 and fuel pumps 134 and 136. In the exemplary embodiment, fuel filter 132 and pumps 134 and 135 take any convenient or desirable form. Some embodiments omit one of the fuel pumps. Fuel filter 130 provides a filtered fuel flow from fuel tank 120 through pump 136, through filter 134, through fuel pump 134 to filter fuel inlet 112 into engine 110.
Coupled to fluid line 130 across the inlet and outlet of fuel filter 132 is differential sensor 140. Sensor 140 includes a low or negative pressure port 141, a high or positive pressure port 142, and a sensor-connector module 143. (The low and high pressure ports may also be referred to as inlet and outlet ports, respectively.) In the Figure, the sensor is shown in a horizontal orientation (based on the inlet and outlet ports), but its novel design allows it to operative effectively with a vertical, diagonal, and in fact any desirable orientation. The sensor, which in the exemplary embodiment is fully isolated from fluid line 130 and takes the form of a magnetic sensor, may be used with multiple types and makes of filters. Sensor-connector module 143 includes a connector in electrical communication with vehicle computer system 150, which may take any convenient or desirable form.
In the exemplary embodiment, differential sensor 140 has the following operating conditions:
The exterior of sensor 140 is shown in perspective views A and B of
More particularly, three-piece housing assembly 410 includes an upper housing (cap) portion 412, a lower housing portion 414, and a retaining collar 416. Upper housing portion 412, which is generally horn-shaped in the exemplary embodiment, includes a high (positive) pressure port (or inlet) 4121, a guide sleeve 4122, a sensor-connector socket 4123, and a sensor-connector module 4124.
High pressure port 4121, which corresponds to port 142 in the prior figures, is integrally molded as part of an interior surface of upper housing portion 412. In the exemplary embodiment, port 4121 is generally a right cylindrical opening that is laterally offset from a central axis 401 of the sensor and includes internal threads to facilitate fluid-tight coupling to a fluid line or filter. Guide sleeve (or tube) 4121 is integrally molded as part of the interior surface of upper housing in coaxial alignment with central axis 401.
Guide sleeve 4122 is integrally molds as part of an interior surface of upper housing portion 412. In the exemplary embodiment, port 4121 is generally a right cylindrical tube or recess.
Sensor-connector socket 4123, shown in perspective in
Sensor-connector module 4124, which corresponds to sensor-connector module 143 in
Sensor 4124A has three leads (not visible in
In the exemplary embodiment, sensor connector module 4124 is permanently mounted within sensor-connector socket 4123 using potting epoxy, thereby facilitating handling of the upper housing portion 412 as a single part during final assembly of the differential sensor. (The exemplary embodiment molds the majority of upper housing portion 412 from glass-filled Nylon 6/6.)
In addition to upper housing portion 412, housing assembly 412 includes lower housing portion 414 and retaining collar 416. More particularly, lower housing portion 414, which generally has a pan- or cup-like shape in the exemplary embodiment, includes a low pressure port (or inlet) 4141 and an outer sidewall 4142. Low pressure port 4141, which is formed as an interiorly threaded cylindrical tube concentric with axis 401 and guide sleeve 4122, includes a sidewall 4141A. In the exemplary embodiment, low pressure port 4141, which corresponds with port 141 in
The height of sidewall 4141A and outer sidewall 4142 are selected not only to permit movement of diaphragm 422, but also to prevent it from traveling too far during over-pressure situations. Lower housing portion 4142 engages with a lower flange portion 4125 of upper housing portion 412, for example via a snap fit.
Collar 416, which is formed of aluminum in the exemplary embodiment, encircles the interface between upper housing portion 412 and lower housing portion 414 to add further integrity and aesthetic appeal to the sensor. Collar 416 includes upper and lower rolled edges 416A and 416B. Collar 418 is edge rolled after assembly of the other components of the sensor.
Diaphragm assembly 420, which provides a generally fluid tight seal between upper and lower housing portions 412 and 414 and which therefore effectively defines upper and lower pressure chambers 413 and 415, includes a diaphragm 422, a retaining ring 424, and a magnet carrier pin 426. (‘Generally fluid-tight,’ as used herein, refers to a seal that has a leakage rate low enough to not interfere with effective operation of the diaphragm and the filter-monitoring differential sensor.) Diaphragm assembly 420 is also shown in perspective in
Diaphragm 422 includes an annular outer bead 4221 and an inner annular bead 4222, which peripherally bound a convex annular portion 4223. Outer bead 4221 is sandwiched between adjacent annular portions of the upper and lower housing portions 412 and 414, specifically lower rim of upper housing portion 412 and annular ledge 4142B. Inner annular bead 4222 is sandwiched between retaining ring 424 and magnet carrier pin 426, which engage each other via a snap fit. The exemplary embodiment forms diaphragm 422 from silicon, fluorosilicone, or other suitable material.
Retaining ring 424 includes an annular trough 4241 which seats an upper portion of calibration spring 440. Retaining ring 224 also secures and seals the diaphragm against an annular flange portion 4261 of magnet carrier pin 426.
Magnet carrier pin 426 includes, in addition to annular flange portion 4261, an annular wall portion 4262, a plate portion 4263, and a pin portion 4264. Annular wall portion 4262 includes a lower ridge portion 4262A which cooperates with annular flange portion 4261 to facilitate the snap fit with retaining ring 424. Plate portion 4263 is bounded by annular wall portion 4262, and positioned intermediate lower ridge portion 4262A and annular flange portion 4261. Pin portion 4264, which generally defines a right cylinder coaxial with axis 401, extends orthogonally from a central region of plate portion 4263, with its upper portion extending into the guide sleeve. Pin portion 4264 has an substantially uniform outer most diameter that is sized to provide a tightly toleranced fit with the guide sleeve to reduce or minimize its ability to move in response to vibration and transient pressure changes. Additionally, pin portion 4264 includes outer ribs, grooves, or coarse texturing (not visible in the Figure), to ensure pressure equalization between upper chamber 413 and the space between the end of pin portion 4264 and the top of the guide sleeve. Pin portion 4264 also includes a cylindrical recess 4264A for carrying magnet 430.
Magnet 430, which is heat staked or epoxied into recess 4264A, includes respective north and south poles 431 and 432. The north pole is shown oriented toward the low pressure port. In the exemplary embodiment, magnet 430 takes a right cylindrical form with a beveled edge on one end to denote the north pole. The magnet is also positioned substantially coaxially with axis 401 and with its physical or magnetic midpoint in alignment with Hall-effect sensor 4123A. One suitable type of magnet is samarium cobalt.
Calibration spring 440, which in the exemplary embodiment is formed of stainless steel, has an upper end 441 seated within annular trough 4241 and a lower end 442 fitted around the sidewall of negative pressure port. The spring can be selected to calibrate operation of the differential sensor.
When operated as intended, the high and low pressure ports of the differential sensor are coupled across a filter. As the filter operates, a differential pressure develops between the low and high pressure ports, eventually exceeding the bias force of the calibration spring and causing the diaphragm assembly to move the magnet axially within the confines of the guide sleeve. The hall-effect sensor is sufficiently close to the magnet to change an electrical parameter, such as voltage or current that is communicated through sensor-connector module. Customer circuitry coupled to the connector interprets the output signal as indicating a clogged or unclogged filter condition.
In
Exemplary electrical characteristics of the hall-effect sensors for the two- and three-wire configurations in
The embodiments described above are intended only to illustrate and teach one or more ways of practicing or implementing the present invention, not to restrict its breadth or scope. The actual scope of the invention, which embraces all ways of practicing or implementing the teachings of the invention, is defined only by the issued claims and their equivalents.
The present application claims the benefit under 35 U.S.C.119(e) of U.S. Provisional Patent Application 60/854,041 which was filed on Oct. 24, 2006 and which is incorporated herein by reference.
Number | Date | Country | |
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60854041 | Oct 2006 | US |