Fuel Cap Assembly With Side-Diverting Outlets for Accurate Level Sensing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Automated fuel delivery systems face inaccuracies in fuel level readings due to fluid level sensors, leading to inappropriate initiation or termination of refueling operations.
Innovation Solution
The fuel cap assembly includes a sensor element and a fuel tube with side-diverting fuel outlets that extend through the sidewall, reducing turbulence and improving measurement accuracy by directing fuel away from the sensor, allowing for precise fuel level determination and controlled refueling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fuel is delivered directly into the fuel tank through a standard outlet, then fuel delivery speed is improved, but fluid level sensor accuracy deteriorates due to turbulence and air bubbles
Solution Approach 1:
The fuel delivery system is segmented into multiple outlet ports positioned at different locations and orientations along the fuel tube. This segmentation allows fuel to be delivered through multiple distributed points rather than a single outlet, reducing localized turbulence intensity while maintaining overall delivery rate, thereby improving sensor accuracy without sacrificing productivity
Solution Approach 2:
Different outlet ports are positioned with specific orientations (e.g., sideways outlets, upward outlets) to create localized flow patterns that minimize turbulence in the sensor measurement zone. The local flow characteristics are optimized at each outlet position to reduce air bubble formation and turbulence near the sensor, while maintaining high overall delivery speed
2Device complexity
If a single central fuel outlet is used, then device complexity is reduced, but fuel level measurement accuracy deteriorates due to turbulence and air bubbles affecting sensor readings
Solution Approach 1:
The single central outlet is segmented into multiple outlet ports distributed along the fuel tube. Each port is simple in structure but collectively they provide superior measurement accuracy by reducing turbulence and air bubble formation in the sensor zone, maintaining relatively simple device complexity while dramatically improving measurement precision
3Productivity
If fuel outlet is positioned at the end of the fuel tube, then fuel delivery efficiency is improved, but sensor element accuracy deteriorates due to turbulence and air bubbles
Solution Approach 1:
The outlet ports are positioned in different spatial dimensions and orientations along the fuel tube length, not just at the end. Sideways outlets and upward outlets create three-dimensional flow distribution patterns that deliver fuel efficiently while directing flow away from the sensor measurement zone, maintaining delivery efficiency while improving sensor accuracy
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 ensures accurate fuel level measurements and controlled refueling, preventing premature or late termination of fuel delivery, thus enhancing the reliability of automated fuel delivery systems.
Implementation Method 1
reducing turbulence and improving measurement accuracy by directing fuel away from the sensor
Data Source
AI summary
An example fuel cap assembly includes a fuel cap, a sensor element extending from the fuel cap, and a fuel tube extending from the fuel cap next to the sensor element. The fuel tube includes an outlet end having at least one side-diverting fuel outlet that extends through a sidewall of the fuel tube. A fuel cap assembly kit and method of filling a fuel tank are also disclosed.