Adaptive Fuel Delivery Module for Variable Speed Pump Control
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Solution Overview
Problem
Conventional mechanical returnless fuel systems operate fuel pumps at a constant speed, leading to increased electrical energy consumption, premature pump failure, noise, vibration, and harshness, as well as requiring complex software coordination and exposed pressure sensors that hinder maintenance.
Innovation Solution
An adaptive fuel delivery module with a pressure sensor and fuel pump voltage control module that adjusts fuel pump speed based on engine demand by maintaining average back pressure, eliminating the need for vehicle ECU communication and reducing electrical energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the fuel pump operates at 100% capacity constantly in a mechanical returnless fuel system, then the fuel delivery requirement is met, but electrical energy consumption increases and pump life decreases
Solution Approach 1:
The patent applies dynamics by enabling the fuel pump to vary its operating speed dynamically based on actual engine fuel demand. The pump transitions from constant 100% speed operation to variable speed operation, adjusting its rotational speed to match real-time fuel requirements, thereby reducing energy consumption when full capacity is not needed
Solution Approach 2:
The patent implements feedback through a pressure sensor that continuously monitors fuel pressure in the fuel rail and communicates this information to the control module. The control module uses this pressure feedback to determine engine fuel demand and adjusts the pump speed accordingly, creating a closed-loop control system that optimizes energy usage while meeting fuel delivery requirements
2Productivity
If the fuel pump operates at 100% capacity constantly, then fuel delivery is ensured, but noise, vibration and harshness increase
Solution Approach 1:
The fuel pump system transitions from static constant-speed operation to dynamic variable-speed operation. By continuously adjusting the pump speed based on actual fuel demand signals from the pressure sensor, the system operates at lower speeds during low-demand conditions, significantly reducing noise, vibration and harshness while maintaining adequate fuel delivery
3Measurement precision
If a pressure sensor is exposed and projecting from the fuel line, then fuel pressure can be monitored, but access to the engine is hindered and maintenance becomes difficult
Solution Approach 1:
The patent applies the nesting principle by integrating the pressure sensor within the fuel pump module housing rather than exposing it externally. The sensor is nested inside the module, eliminating protruding components that would obstruct access to the engine, while still enabling accurate fuel pressure monitoring through the module's internal sensing capabilities
4Extent of automation
If extensive software programming and cross-coordination with vehicle ECU is required, then electronic control of fuel pump is achieved, but device complexity increases
Solution Approach 1:
The fuel pump control system operates autonomously using self-service principles. The control module within the fuel pump module directly processes pressure sensor signals and independently controls pump motor speed without requiring communication with or coordination with the vehicle's main ECU, thereby reducing system complexity while maintaining automated control functionality
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
The adaptive fuel delivery module reduces electrical energy consumption, prolongs fuel pump life, decreases noise and vibration, and simplifies maintenance by allowing fuel pump speed adjustments based on engine demand without requiring vehicle ECU interaction.
Implementation Method 1
a pressure sensor, which is part of the fuel pump module
Implementation Method 2
The ECU may then communicate with a fuel pump controller which may use pulse width modulation ('PWM'), as an example, to control the voltage level across the fuel pump
Data Source
AI summary
A returnless fuel system has a fuel pump whose speed is varied by varying the voltage across the fuel pump. Controlling the fuel pump speed entails sensing the back pressure with a pressure sensor that may lie between the jet pump supply orifice and the pressure regulator in the pressure regulator case. A trigger circuit determines the absolute value of the difference between the sensed back pressure and an average, or predetermined target, pressure and compares it to a predetermined pressure value. If the absolute value is greater than the predetermined value, then a control circuit is invoked that compares the sensed pressure to a high threshold pressure and a low threshold pressure, and based upon such comparisons, the speed of the fuel pump is varied or maintained such that the mean pressure of the fuel system is targeted under all engine consumption conditions.