Top-Fill Fuel Flow Control Module for Pulsating Pressure
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Solution Overview
Problem
Existing flow-control modules for fuel tanks are not designed to operate properly with fuel lines under pulsating pressure and cannot remain in an OFF state when the tank is full, especially in top-fill tanks with pulsating inlet fluid pressure, leading to potential overfilling and pressure-related issues.
Innovation Solution
A fully-integrated flow-control module for top-fill fuel tanks that includes a main control valve which automatically closes when the tank is full and opens when the fuel level drops, featuring a two-piece inlet/vent head and a multi-component control valve unit with a float guide, bleed paths, and a main valve plunger that can engage a valve seat to cut off fuel flow, allowing operation under pulsating pressure and maintaining an OFF state when the tank is full.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a flow-control module is used with pulsating pressurized fuel source, then fuel can be supplied under pressure, but the module cannot remain in OFF state when tank is full due to pressure fluctuations
Solution Approach 1:
A bleed valve serves as an intermediary component that releases excess pressure from the fuel line. This mediator allows the main control valve to maintain its OFF state by preventing pressure buildup that would otherwise force it open, thus resolving the contradiction between maintaining pressurized fuel supply and ensuring valve state stability.
Solution Approach 2:
The bleed valve provides a controlled release of excess fuel pressure through a small opening. By allowing partial fuel flow through the bleed valve, the system prevents excessive pressure accumulation that would compromise the main valve's ability to remain closed, enabling reliable operation under pulsating pressure conditions.
2Productivity
If a two-piece float assembly and flow control valve assembly are used in bottom-fill tanks, then fuel flow can be controlled, but the assembly becomes complex and cannot be used in smaller tanks
Solution Approach 1:
The float assembly and flow control valve assembly are merged into a single integrated unit. The float directly actuates the control valve within the same housing, eliminating the need for separate assemblies and complex interconnections. This integration maintains fuel flow control functionality while significantly reducing device complexity and enabling use in smaller tanks.
Solution Approach 2:
The integrated flow control module is designed to be universally applicable to various tank sizes and configurations. By combining multiple functions (fuel flow control, level sensing, and pressure regulation) into a single compact unit, the device can be adapted to both small and large tanks without requiring separate assembly configurations.
3Object-generated harmful factors
If an open breather is provided in the fuel tank, then gas can escape during filling, but the tank can still rupture from high pressure when filling is overridden
Solution Approach 1:
The bleed valve acts as an intermediary pressure relief mechanism between the fuel line and the tank environment. It provides continuous pressure regulation during filling operations, preventing the dangerous pressure buildup that occurs when the main shut-off is overridden, thereby protecting tank integrity while allowing controlled gas escape.
Solution Approach 2:
The bleed valve provides beforehand cushioning by continuously releasing excess pressure during the filling process. This preventive measure cushions against the harmful effects of pressure buildup before they can reach dangerous levels that would compromise tank integrity, even if the main shut-off mechanism fails.
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 module effectively manages fuel flow by closing the main valve plunger when the tank is full, preventing overfilling and maintaining constant pressure in fuel feed lines, even under pulsating conditions, ensuring safe and efficient operation.
Implementation Method 1
a float assembly and a flow control valve assembly both installed within the tank near the top thereof
Implementation Method 2
A bleed pin spring, compressed within a float cage, biases the bleed pin downwardly
Data Source
AI summary
A fully-integrated, flow-control module for top-fill fuel tanks operates with a fuel line attached that supplies fuel under pulsating pressure. There are two bleed paths in the module, which open and close sequentially in response to the position of a fuel float within the module. In order for a main valve plunger, which controls fuel entry into the tank, to fully close, both bleed paths must be closed. A first bleed path closes first, followed by closure of the second. For the main valve plunger to fully open, both bleed paths must be open. The second bleed path opens first. Movement of the main valve plunger is controlled by both a biasing spring and pressure beneath the plunger. Pressure beneath the plunger builds up to a level sufficient for the biasing spring to fully close the plunger against a valve seat when both bleed paths are closed.