Fuel Delivery Unit Sensor Integration on Pump Holder
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Solution Overview
Problem
Conventional fuel delivery units in motor vehicles face challenges due to the external placement of the fill level sensor, which reduces the surge pot's diameter and volume, complicates assembly, and increases the risk of damage during installation, particularly in fuel tanks with low overall heights.
Innovation Solution
The fill level sensor is integrated onto the pump holder, allowing for a larger cross-sectional design of the surge pot and a more protected installation, reducing the complexity and cost of fastening elements, and enabling a simpler and more reliable insertion process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the fill level sensor is arranged on the outside of the surge pot, then the sensor can be installed, but the diameter and volume of the surge pot are reduced
Solution Approach 1:
The fill level sensor is integrated onto the pump holder, which is already a component within the surge pot assembly. This merging of components eliminates the need for external sensor mounting structures, thereby maximizing the surge pot's internal volume while reducing overall assembly complexity.
Solution Approach 2:
Instead of mounting the sensor externally on the surge pot surface, the sensor is relocated to the pump holder structure, utilizing the three-dimensional space already available within the surge pot assembly. This dimensional repositioning allows the surge pot to maintain its full diameter and volume.
2Volume of moving object
If the surge pot is flattened on one side to accommodate external sensors, then sensors can be installed, but the surge pot volume is reduced
Solution Approach 1:
By combining the fill level sensor with the pump holder assembly, the sensor is positioned within the existing surge pot structure rather than requiring external mounting. This allows the surge pot to maintain its optimal circular cross-sectional shape and maximum volume.
3Reliability
If the fuel delivery unit is pre-assembled with external sensors, then assembly is simplified, but damage risk during insertion increases
Solution Approach 1:
The fill level sensor is integrated into the pump holder, which is a robust component already positioned within the surge pot. This integration protects the sensor from damage during insertion while maintaining straightforward assembly procedures.
Solution Approach 2:
The pump holder structure serves as a protective housing for the fill level sensor before insertion into the fuel tank. This pre-positioning within the robust pump holder cushions the sensor against potential damage during the insertion process.
4Volume of moving object
If conventional baffles with large overall height are used, then surge pot volume is maintained, but they cannot be used in fuel tanks with low overall heights
Solution Approach 1:
The pump holder with integrated sensor is designed as a compact assembly that optimizes space utilization within the surge pot. This integrated design allows for efficient spatial arrangement that maintains surge volume while accommodating low overall height constraints.
Data Source
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AI summary
The invention relates to a fuel delivery unit (4) in a fuel tank (1) of a motor vehicle, composed of a surge pot (5), a fuel pump (6) which is arranged in said surge pot and serves for delivering fuel out of the surge pot (5) to an internal combustion engine of the motor vehicle, a pump holder (8) for fastening the fuel pump (6) in the surge pot (5), and a fill level sensor (13) for determining the fill level in the fuel tank (1). The fill level sensor (13) is arranged on the pump holder (8).