Fuel Level Sensor Diagnostic via Transfer Mechanism Activation

Solution Overview

Problem

Conventional fuel level monitoring systems in vehicles with primary and secondary fuel tanks face issues with stuck-in-full failures in fuel level sensors, leading to inaccurate fuel volume calculations and unnecessary activation of fuel transfer mechanisms.

Innovation Solution

A diagnostic system that includes a fuel level sensor, a sensor diagnostic module, and a fuel transfer mechanism, which activates for a predetermined time period to evaluate the operation of the fuel level sensors, determines the fuel levels in both tanks, and deactivates the transfer mechanism based on fuel change thresholds to identify and address stuck-in-full failures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional fuel level monitoring systems are used, then fuel level sensors can monitor fuel levels, but stuck-in-full failures occur leading to inaccurate fuel volume calculations

Engineering Contradiction:

Improvefuel level sensor accuracyVSAvoidfuel volume calculation accuracy

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The system performs a preliminary diagnostic test by activating the fuel transfer mechanism for a predetermined time period before using sensor readings for fuel volume calculations. This preliminary action allows the system to verify sensor functionality and detect stuck-in-full failures before they affect measurement accuracy.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses feedback from the fuel level sensor during the diagnostic test to determine whether the sensor is functioning properly. By comparing the fuel level change during the predetermined time period with expected values, the system can detect sensor failures and provide feedback to correct or invalidate the measurement.

Inventive Principle:

Principle #23Feedback

2Ease of operation

If fuel transfer mechanism is activated continuously, then fuel levels can be maintained, but unnecessary transfer operations occur due to sensor failures

Engineering Contradiction:

Improvefuel level maintenanceVSAvoidunnecessary transfer operation time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The system performs a preliminary diagnostic test by activating the fuel transfer mechanism for a predetermined time period before using sensor readings for fuel volume calculations. This preliminary action allows the system to verify sensor functionality and detect stuck-in-full failures before they affect measurement accuracy.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses feedback from the fuel level sensor during the diagnostic test to determine whether the sensor is functioning properly. By comparing the fuel level change during the predetermined time period with expected values, the system can detect sensor failures and provide feedback to correct or invalidate the measurement.

Inventive Principle:

Principle #23Feedback

3Reliability

If diagnostic tests are performed continuously, then sensor failures can be detected, but system complexity increases

Engineering Contradiction:

Improvesensor failure detectionVSAvoiddiagnostic system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system performs diagnostic tests periodically by activating the fuel transfer mechanism for a predetermined time period at specific intervals rather than continuously. This periodic action reduces the complexity of the diagnostic system while still enabling reliable detection of sensor failures.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The fuel transfer mechanism serves dual purposes: it performs its primary function of transferring fuel between tanks and simultaneously serves as a diagnostic tool for testing fuel level sensor functionality. This multi-functionality reduces system complexity by eliminating the need for separate diagnostic equipment.

Inventive Principle:

Principle #6Universality (Multi-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 system effectively identifies and resolves stuck-in-full failures, ensuring accurate fuel volume calculations and preventing unnecessary fuel transfer, thereby enhancing the reliability of fuel level monitoring and diagnostics.

Implementation Method 1

a fuel level sensor that senses a fuel level in a fuel tank

Methodology Applied

Scientific EffectBuoyancy: Archimedes' Principle (Buoyancy)

Implementation Method 2

activates a fuel transfer mechanism for a time period

Methodology Applied

Scientific EffectPumping: Pump

Data Source

PatentUS7878057B2System for detecting failures in fuel systems

Publication Date: 2011.02.01 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A diagnostic system and method includes a fuel level sensor that senses a fuel level in a fuel tank and a sensor diagnostic module that monitors a fuel transfer mechanism for a time period, that calculates a change in the fuel level, and that evaluates operation of the first fuel level sensor based on the change and the predetermined period.