阅读说明：本技术 一种耐用型浮子式水位传感器及其生产方法 (Durable float type water level sensor and production method thereof ) 是由 童庆喜 于 2020-12-15 设计创作，主要内容包括：本发明公开了一种耐用型浮子式水位传感器,包括：上、中、下三个中空的柱管组成的传感器主壳体,固定有磁环的水位浮子,于下柱管内部设有干簧管集成板；于下柱管内壁与干簧管集成板之间灌设有硅脂层；于中柱管内部为灌有固化的环氧树脂体的环氧树脂体腔,干簧管集成板信号由导线束引出。本发明巧妙采用干簧管集成板设计,将干簧管置入电路板卡槽位置,并对整体干簧管集成板位置灌硅脂以做全面保护干簧管的玻璃管。提高了工作效益和提升了产品的适配性及方便性。还解决产品安装和检修方面的不便；解决产品试验过程中、及使用过程中出现较高不良率的问题,提高了公司产品质量和口碑,为企业带来较大的好处。(The invention discloses a durable float-type water level sensor, comprising: the sensor comprises a sensor main shell consisting of an upper hollow column tube, a middle hollow column tube and a lower hollow column tube, a water level floater fixed with a magnetic ring, and a reed pipe integrated plate arranged in the lower column tube; a silicone grease layer is filled between the inner wall of the lower column tube and the reed pipe integrated plate; the interior of the center pillar is an epoxy resin body cavity filled with a cured epoxy resin body, and the reed pipe integrated board signals are led out by a conductor bundle. The invention skillfully adopts the design of the reed switch integrated board, the reed switch is arranged in the position of the circuit board integrated board, and the position of the integrated reed switch integrated board is filled with silicone grease to form a glass tube for comprehensively protecting the reed switch. The working efficiency is improved, and the adaptability and the convenience of the product are improved. The inconvenience in the aspects of product installation and maintenance is also solved; the problem of higher defective rate in the product test process and the use process is solved, the product quality and public praise of companies are improved, and great benefits are brought to enterprises.)

1. A durable float-type water level sensor, comprising: the sensor comprises a sensor main shell which is integrally formed by plastic, wherein the sensor main shell consists of an upper hollow column tube, a middle hollow column tube and a lower hollow column tube which are mutually communicated, the bottom of the lower column tube is sealed, and the inner hollow part of the lower column tube is a reed switch integrated plate fixing groove of the sensor; the outer diameter of the central column pipe is larger than that of the lower column pipe, and the outer wall of the central column pipe is provided with an outer connecting thread matched with an installation thread opening of the automobile filter; the cross section of the outer wall of the upper column tube is designed into an equal hexagonal or equal octagonal shape which is convenient for screwing the sensor by a wrench; a sensor sealing ring is arranged at the joint of the upper column pipe and the outer wall of the middle column pipe;

a hollow water level floater is sleeved on the outer wall of the lower column tube and can move up and down along the lower column tube, and a magnetic ring is fixed inside the water level floater; the bottom of the lower column tube is provided with an annular water level floater limiting buckle for preventing the water level floater from separating; a reed switch integrated plate is arranged inside the lower column tube; the upper end of the reed pipe integrated board is provided with a reed pipe integrated board leading-out wire bundle extending out of the middle column pipe, and the tail end of the reed pipe integrated board leading-out wire bundle is provided with a sensor quick-connection connector; a silicone grease layer is filled between the inner wall of the lower column tube and the reed pipe integrated plate;

an epoxy resin body cavity filled with a cured epoxy resin body is formed in the inner part of the center pillar, and the epoxy resin body is a cured whole formed by mixing epoxy resin (A glue and B glue); the epoxy resin body is fixed with a lead-out wire bundle which penetrates through the reed pipe integrated board.

2. The durable float-type water level sensor as claimed in claim 1, wherein said sensor main housing further comprises a cylindrical drainage chamber independent of the epoxy resin chamber inside the center pillar, said drainage chamber having a drainage hole formed through the bottom wall of the center pillar at the bottom thereof; the annular inner vertical wall of the drainage oral cavity is provided with drainage port threads; a water outlet plug cover with external threads is arranged in the water outlet mouth in a matching way, and a plug cover sealing ring which plays a role of sealing when the water outlet plug cover is screwed down is arranged at the bottom of the water outlet mouth.

3. The durable float-type water level sensor according to claim 1 or 2, wherein the reed switch integrated board comprises an elongated circuit substrate, a reed switch and a circuit element, wherein a reed switch groove having a height greater than that of the reed switch is formed in a lower portion of the circuit substrate, and upper and lower ends of the reed switch are connected to corresponding connection ends of the upper and lower circuit boards of the reed switch groove by soldering.

4. The durable float-type water level sensor as claimed in claim 3, wherein the height of the silicone layer is less than the height of the inner cavity of the reed pipe integrated plate fixing groove of the sensor and greater than the height of the joint of the bottom of the reed pipe integrated plate and the lead-out wire bundle of the reed pipe integrated plate.

5. The durable float-type water level sensor according to claim 4, wherein the presently preferred size is such that the diameter of the inner tube of the reed pipe integrated plate fixing groove of the sensor is 4.1mm, the injection weight of the silicone layer is 0.2 g-0.3 g; the height of the silicone layer was 26 mm.

6. A method of producing a durable float-type water level sensor as claimed in claims 1 to 5, wherein: the method comprises the following steps:

(1) blowing the inner cavity of the reed pipe integrated plate fixing groove for 1-2 seconds by using high-pressure air blowing to realize early-stage cleaning;

(2) injecting silicone grease into an inner cavity of a reed switch integrated plate fixing groove with a reed switch integrated plate leading out a wire bundle by using a needle tube filled with silicone grease, wherein the height of the silicone grease is 1/2 of the height of the inner cavity of the reed switch integrated plate fixing groove, and then inserting a reed switch to lead the reed switch to the inner bottom of the inner cavity of the reed switch integrated plate fixing groove; visually detecting that the height of the silicone grease is close to the upper end surface of the inner cavity of the fixing groove of the reed pipe integrated plate, if the silicone grease is not enough for injection supplement of a needle tube;

(3) filling epoxy resin (a mixture of glue A and glue B) into the epoxy resin cavity until the epoxy resin cavity is fully leveled to the upper end face of the central cylinder and curing the epoxy resin cavity;

(4) the semi-finished product is detected to be qualified, and the durable float type water level sensor is provided.

7. The production method of a durable float-type water level sensor according to claim 6, wherein: the inner diameter of the inner cavity of the reed pipe integrated plate fixing groove is 4.1mm, 0.2g of silicone grease is injected, then the reed pipe integrated plate with the reed pipe integrated plate leading out wire bundles is inserted, the height of the inner cavity of the reed pipe integrated plate fixing groove is 30mm, the height of the silicone grease in the inner cavity of the reed pipe integrated plate fixing groove is 26mm, and the silicone grease does not reach the top end face of the inner cavity of the reed pipe integrated plate fixing groove.

Technical Field

The invention relates to a sensing element, in particular to a durable float type water level sensor.

Background

The traditional fuel oil coarse filter generally mainly comprises a filter shell, a filter element, a filter base and a manual oil transfer pump, wherein the lower end of the filter element is provided with a part capable of depositing and filtering oil dirt, impurities and water, and the part is provided with a pollution discharge plug screw for an operator to regularly discharge accumulated water, dirt and the like according to own experience. Due to human factors, the situation that an operator forgets to clean the filter or worrys that the filter is full of accumulated water and is cleaned too early is inevitable. Because the presence of water can cause damage to the fuel injector operating in a high precision, high atomization regime. In view of the fact that the traditional fuel oil coarse filter cannot meet the operation requirements of modern engines, the conventional fuel oil coarse filter is gradually changed into an oil-water separator at present, and correspondingly, the impurity separation mode is changed into forced separation of a special filtering paper core from the original natural precipitation of water, so that the method is very important for reminding an operator of draining accumulated water in time. The adoption of the oil-water separator not only improves the water separation function, but also needs to increase a water level alarm of a water accumulation cup of the separator. The applicant applied for a utility model patent in 2019: patent No. < novel leadless float water level sensor >: 201921635915.4, although the structure can realize water accumulation alarm, the single lead is arranged at the end of the sensor body and connected by the movable joint, and the operation and the maintenance are difficult for the installation position with smaller space; in addition, in the transportation process or the installation and use process of the structure, the reed pipe of the float-type sensor is easily damaged by external force, so that the whole sensor fails, and the product quality and the reputation of a company are seriously influenced. The invention is to solve the problems under the background, and provides a leadless floater water level sensor which can reduce the reject ratio of products after performance test, high and low temperature resistance test and drop test, reduce the complaint rate of customers to the product quality and greatly improve the product quality assurance.

Disclosure of Invention

The invention aims to overcome the defects of the prior art and provides a durable float type water level sensor which can realize accumulated water alarm and conveniently discharge accumulated water and solves the inconvenience in product installation and maintenance by a simple and reasonable structure 1; 2. the problem of higher defective rate in the product test process and the use process is solved, the product quality and public praise of companies are improved, and great benefits are brought to enterprises. The product is verified as follows: the reject ratio of the new process product after performance test, high and low temperature resistance test and drop test is 60 percent less than that of the prior process, the product flows into 100 thousands of markets, and the customer complaint rate is reduced by 80 percent.

The technical scheme adopted by the invention for solving the technical problems is as follows: a durable float-type water level sensor comprising: the sensor comprises a sensor main shell which is integrally formed by plastic, wherein the sensor main shell consists of an upper hollow column tube, a middle hollow column tube and a lower hollow column tube which are mutually communicated, the bottom of the lower column tube is sealed, and the inner hollow part of the lower column tube is a reed switch integrated plate fixing groove of the sensor; the outer diameter of the central column pipe is larger than that of the lower column pipe, and the outer wall of the central column pipe is provided with an outer connecting thread matched with an installation thread opening of the automobile filter; the cross section of the outer wall of the upper column tube is in an equihexagonal or equioctagonal design, so that the sensor is conveniently screwed and fixed by a wrench; a sensor sealing ring is arranged at the joint of the upper column pipe and the outer wall of the middle column pipe;

a hollow water level floater is sleeved on the outer wall of the lower column tube and can move up and down along the lower column tube, and a magnetic ring is fixed inside the water level floater; the bottom of the lower column tube is provided with an annular water level floater limiting buckle for preventing the water level floater from separating; a reed switch integrated plate is arranged inside the lower column tube; the upper end of the reed pipe integrated board is provided with a reed pipe integrated board leading-out wire bundle extending out of the middle column pipe, and the tail end of the reed pipe integrated board leading-out wire bundle is provided with a sensor quick-connection connector; thus, the signal transmission of the sensor can be realized at a position far away from the sensor; a silicone grease layer is filled between the inner wall of the lower column tube and the reed pipe integrated plate;

an epoxy resin body cavity filled with a cured epoxy resin body is formed in the inner part of the center pillar, and the epoxy resin body is a cured whole formed by mixing epoxy resin (A glue and B glue); the epoxy resin body is fixed with a lead-out wire bundle which penetrates through the reed pipe integrated board;

furthermore, the sensor main shell is also provided with a cylindrical drainage cavity independent of the epoxy resin body cavity in the inner part of the center pillar pipe, and the bottom of the drainage cavity is provided with a drainage hole penetrating through the bottom wall of the center pillar pipe; the annular inner vertical wall of the drainage oral cavity is provided with drainage port threads; a drainage outlet plug cover with external threads is arranged in the drainage oral cavity in a matching way, and a plug cover sealing ring which plays a role of sealing when the drainage outlet plug cover is screwed down is arranged at the bottom of the drainage oral cavity;

furthermore, the reed switch integrated board is composed of a long strip-shaped circuit substrate, a reed switch and a circuit element, wherein a reed switch groove with the height larger than that of the reed switch is arranged at the lower part of the circuit substrate, and the upper end and the lower end of the reed switch are welded and connected with connecting ends of circuit boards at the upper end and the lower end of the reed switch groove, which are correspondingly arranged.

Furthermore, the height of the silicone grease layer is less than the height of an inner cavity of a reed pipe integrated board fixing groove of the sensor and is greater than the height of the bottom of the reed pipe integrated board at the joint of the reed pipe integrated board and a lead bundle led out of the reed pipe integrated board;

the currently preferred size is that the diameter of an inner pipe of a reed pipe integrated plate fixing groove of the sensor is 4.1mm, and the injection weight of the silicone grease layer is 0.2 g-0.3 g; the height of the silicone grease layer is 26 mm;

the production method of the sensor comprises the following steps:

1. blowing the inner cavity of the reed pipe integrated plate fixing groove for 1-2 seconds by using high-pressure air blowing to realize early-stage cleaning;

2. injecting silicone grease into an inner cavity of a reed switch integrated plate fixing groove with a reed switch integrated plate leading out a wire bundle by using a needle tube filled with silicone grease, wherein the height of the silicone grease is 1/2 of the height of the inner cavity of the reed switch integrated plate fixing groove, and then inserting a reed switch to lead the reed switch to the inner bottom of the inner cavity of the reed switch integrated plate fixing groove; visually detecting that the height of the silicone grease is close to the upper end surface of the inner cavity of the fixing groove of the reed pipe integrated plate, if the silicone grease is not enough for injection supplement of a needle tube;

3. filling epoxy resin (a mixture of glue A and glue B) into the epoxy resin cavity until the epoxy resin cavity is fully leveled to the upper end face of the central cylinder and curing the epoxy resin cavity;

4. the semi-finished product is detected to be qualified, and the durable float type water level sensor is provided.

Further, concrete to the actual optimization sample, the internal diameter of tongue tube integrated board fixed slot inner chamber is 4.1mm, pour into silicone grease 0.2g, then insert the tongue tube integrated board that takes the tongue tube integrated board to draw the wire bundle, the height of tongue tube integrated board fixed slot inner chamber is 30mm, the height of silicone grease at tongue tube integrated board fixed slot inner chamber is 26mm, the silicone grease does not reach the top end face of tongue tube integrated board fixed slot inner chamber, so when pouring epoxy resin (A glues + B glues) in the epoxy resin coelom, some air can be detained at tongue tube integrated board fixed slot inner chamber top, so better play buffering, the effect of moving away to avoid possible earthquakes, the protection to the tongue tube integrated board and the tongue tube on this board has been improved, thereby whole sensor's quality has been promoted.

The invention has the beneficial effects that: through the innovative design and the combination of a specific innovative process, the reed switch of the float-type sensor is more effectively protected from being damaged by external force, the reed switch integrated board is ingeniously designed, the reed switch is placed in the circuit board integrated board groove, and silicone grease is filled in the position of the integrated reed switch integrated board to form a glass tube for comprehensively protecting the reed switch. The working efficiency is improved, and the adaptability and the convenience of the product are improved. The inconvenience in the aspects of product installation and maintenance is also solved; the problem of higher defective rate in the product test process and the use process is solved, the product quality and public praise of companies are improved, and great benefits are brought to enterprises.

Drawings

Fig. 1 is an exploded view of a durable float-type water level sensor according to embodiment 1;

FIG. 2 is a schematic structural diagram of a reed pipe integrated plate;

fig. 3 is a schematic structural view of a durable float-type water level sensor.

Detailed Description

Example 1

A durable float-type water level sensor described in embodiment 1 of the present invention, as shown in fig. 1 to 3, includes: the sensor comprises a sensor main shell 1 which is integrally formed by plastic, wherein the sensor main shell consists of an upper hollow column tube, a middle hollow column tube and a lower hollow column tube which are mutually communicated, the bottom of the lower column tube is sealed, and the inner hollow part of the lower column tube is a reed switch integrated plate fixing groove 2 of the sensor; the outer diameter of the central column pipe is larger than that of the lower column pipe, and the outer wall of the central column pipe is provided with an outer connecting thread 3 matched with an installation thread opening of the automobile filter; the cross section of the outer wall of the upper column tube is in an equioctagonal design, so that the sensor is conveniently screwed and fixed by a spanner; a sensor sealing ring 12 is arranged at the joint of the outer wall of the upper column pipe and the outer wall of the middle column pipe;

a hollow water level floater 4 is sleeved on the outer wall of the lower column tube and can move up and down along the lower column tube, and a magnetic ring 5 is fixed in the water level floater; the bottom of the lower column pipe is provided with an annular water level floater limiting buckle 6 for preventing the water level floater from separating; a reed switch integrated plate 7 is arranged inside the lower column tube; the upper end of the integrated plate of the reed switch is provided with a lead-out wire bundle 10 of the integrated plate of the reed switch, which extends out of the middle column tube, and the tail end of the lead-out wire bundle of the integrated plate of the reed switch is provided with a sensor quick-connection connector 11; thus, the signal transmission of the sensor can be realized at a position far away from the sensor; a silicone grease layer 8 is filled between the inner wall of the lower column tube and the reed pipe integrated plate;

an epoxy resin body cavity filled with a cured epoxy resin body 9 is formed in the inner part of the center pillar, and the epoxy resin body is a cured whole formed by mixing epoxy resin (A glue and B glue); the epoxy resin body is fixed with a lead-out wire bundle 10 which penetrates through the reed pipe integrated board;

the sensor main shell is also provided with a cylindrical drainage cavity 13 independent of the epoxy resin body cavity in the inner part of the center pillar tube, and the bottom of the drainage cavity is provided with a drainage hole 14 penetrating through the bottom wall of the center pillar tube; the annular inner vertical wall of the drainage oral cavity is provided with drainage port threads 15; a water outlet plug cover 16 with external threads is arranged in the water outlet mouth in a matching way, and a plug cover sealing ring 17 which plays a role of sealing when the water outlet plug cover is screwed down is arranged at the bottom of the water outlet mouth;

the reed switch integrated board is composed of a long strip-shaped circuit substrate 71, a reed switch 72 and a circuit element 73, wherein a reed switch groove 74 with the height larger than that of the reed switch is arranged at the lower part of the circuit substrate, and the upper end and the lower end of the reed switch are welded and connected with connecting ends 75 which are correspondingly arranged on circuit boards at the upper end and the lower end of the reed switch groove.

The height of the silicone grease layer is smaller than the height of an inner cavity of a reed pipe integrated plate fixing groove of the sensor and is larger than the height of the joint of the bottom of the reed pipe integrated plate and the lead-out wire bundle of the reed pipe integrated plate; the diameter of an inner tube of a reed switch integrated plate fixing groove of the sensor is 4.1mm, and the injection weight of the silicone grease layer is 0.2 g-0.3 g; the height of the silicone layer was 26 mm.

Example 2:

the invention also relates to a production method of the sensor, the inner diameter of the inner cavity of the reed pipe integrated plate fixing groove of the sensor is 4.1mm, the height of the inner cavity of the reed pipe integrated plate fixing groove is 30mm, and the production method comprises the following steps:

1. blowing the inner cavity of the reed pipe integrated plate fixing groove for 1-2 seconds by using high-pressure air blowing to realize early-stage cleaning;

2. injecting silicone grease into an inner cavity of a reed switch integrated plate fixing groove with a reed switch integrated plate leading out a wire bundle, wherein the silicone grease is 0.2g in weight, and then inserting a reed switch to enable the reed switch to reach the bottom in the inner cavity of the reed switch integrated plate fixing groove; the height of the silicone grease in the inner cavity of the reed pipe integrated plate fixing groove is 26 mm;

3. filling epoxy resin (a mixture of glue A and glue B) into the epoxy resin cavity until the epoxy resin cavity is fully leveled to the upper end face of the central cylinder and curing the epoxy resin cavity;

4. the semi-finished product is detected to be qualified, and the durable float type water level sensor is provided.

So, silicone grease does not arrive the top end face of tongue tube integrated board fixed slot inner chamber, so when pouring epoxy resin (the mixture that A glued + B glued) into again in the epoxy resin body cavity, partial air can be detained at tongue tube integrated board fixed slot inner chamber top, so better play buffering, the effect of moving away to avoid possible earthquakes, improved the protection to the tongue tube on tongue tube integrated board and this integrated board to the quality of whole sensor has been promoted.

The above description is only for the preferred embodiment of the present invention, and is not intended to limit the structure of the present invention in any way. Any simple modification, equivalent change and modification made to the above embodiments according to the technical spirit of the present invention still fall within the scope of the technical solution of the present invention.