Fuel Feed Module Flange Resistor Integration
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Solution Overview
Problem
Fuel feed pumps in motor vehicles face structural damage and corrosion due to exposure of electrical resistors to mechanical stresses and corrosive fuels, particularly when using high ethanol content fuels, leading to potential failure and resistance variations.
Innovation Solution
The electrical resistor is integrated into the flange of the fuel feed module, providing mechanical isolation and fluid separation, and overmolded with plastic material for enhanced protection, ensuring minimal corrosive influence and stable resistance over the module's lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrical resistor is positioned on or in the fuel feed pump, then the resistor can be directly integrated into the ground path, but the resistor comes into contact with fuel and is exposed to mechanical stresses causing structural damage and corrosion
Solution Approach 1:
The resistor is extracted from the fuel feed pump assembly and relocated to the flange component. This separation removes the resistor from the harmful environment of fuel contact and mechanical vibrations while maintaining its electrical function in the ground path through conductive integration via contact elements.
Solution Approach 2:
Contact elements serve as intermediaries to establish the electrical connection between the resistor (now located in the flange) and the ground path of the fuel feed pump. This mediator approach allows the resistor to fulfill its electrical function without being physically exposed to fuel and mechanical stresses.
2Ease of manufacture
If the electrical resistor is exposed on the fuel feed pump, then integration into the ground path is simplified, but the resistor is exposed to increased corrosion from fuel contact
Solution Approach 1:
The resistor is merged with the flange component, forming an integrated assembly where the resistor is positioned within or on the flange structure. This combination provides mechanical protection and isolation from fuel while the flange's contact elements maintain the necessary electrical connection to the ground path.
Solution Approach 2:
Different parts of the assembly have different functions: the flange provides mechanical protection and electrical connection, while the resistor provides electrical resistance. By positioning the resistor in the flange rather than on the fuel-exposed pump body, the design protects the resistor from corrosion while maintaining ground path 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 solution effectively protects the resistor from mechanical shocks and corrosive fuel effects, maintaining resistance stability and preventing structural damage, ensuring reliable operation and consistent fuel delivery.
Implementation Method 1
electrical resistors are introduced into the ground path of the fuel feed pump
Implementation Method 2
the electrical resistor is integrated into the flange of the fuel feed module
Data Source
AI summary
A fuel feed module for delivering fuel from a fuel tank includes a fuel feed pump and a flange. The fuel feed module is fixable to the fuel tank by the flange. The fuel feed module includes a resistor, which is electrically conductively integrated into a ground path of the fuel feed pump, the resistor being integrated into the flange of the fuel feed module.