Gentech Custom Solution keeps super car cool

One of the world’s oldest super car marques required a sensor for its engine coolant expansion tank. Coolant level is critical in high performance engines where overheating, through low coolant levels, can cause very costly damage. The sensor system was required to alert the driver when levels were low and in addition it was required to be aesthetically and mechanically in line with the rest of the vehicles high levels of automotive engineering.

Design parameters:

• Operating temperature –40°C to +110C°
• Sensor required to be mounted at top of tank
• Tank manufactured from aluminium
• Operating pressure 4 bar
• Required to measure low level
• Relatively low manufacturing levels for automotive sector
• Aesthetically in line with high value engine

Solution:

A custom designed float switch, based around a Gentech VCS range sensor, was engineered to meet the requirement. To allow the top mounted sensor to measure low levels, an extended switch tube was adapted. The sensor mounting boss was machined from aluminium with a ¾” BSP thread. The mounting boss allowed the sensor to be torqued into position with an ‘O’ ring seal. Connectors and a flying lead completed the sensor.

Design outcome:

• Based around Gentech VCS Product Range technology
• Rugged aluminium housing with threaded boss
• Gentech able to manufacture cost effectively in low volumes
• AMP connector with conduit cable and 12 volt operating voltage
• The switch closes on low liquid level
• Float manufactured in PPS for high temperature operation

Similar applications:

• Expansion tank manufacturers
• Trucks
• Buses
• Prestige and super cars