Fuel Pump Controller Mounted on Lock Ring Extension
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Solution Overview
Problem
Current fuel pump controller mounting arrangements require extensive wiring, leading to increased costs, electro-radiated emissions, and voltage drops, and face challenges with heat dissipation due to large heat sink sizes.
Innovation Solution
A fuel pump controller mounting arrangement where the controller is secured to a lock ring that is removably attached to the fuel pump module flange and fuel tank, with an extension member allowing direct communication and eliminating the need for wiring, and incorporating a metallic heat sink for efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the fuel pump controller is mounted to the vehicle trunk or under the vehicle hood, then the controller can be positioned away from the fuel pump module, but an extensive amount of wiring is required which increases cost, causes electro-radiated emissions, and creates voltage drops
Solution Approach 1:
The fuel pump controller is merged with the fuel pump module by mounting the controller directly to the module's flange, eliminating the need for extensive wiring between separate components. This integration removes the harmful effects of long wire runs including electro-radiated emissions and voltage drops.
2Device complexity
If the fuel pump controller is secured to the fuel pump module flange, then wiring complexity is reduced, but the flange size must be undesirably large to provide adequate heat sinking
Solution Approach 1:
The heat dissipation function is segmented from the flange structure. The flange maintains its original mechanical mounting function while a separate heatsink component is introduced to handle thermal management. This allows the flange to remain compact while still providing adequate heat sinking for the controller.
Solution Approach 2:
A dedicated heatsink acts as an intermediary between the fuel pump controller and the flange. The controller mounts to the flange while the heatsink interfaces with the controller to conduct heat away, allowing the flange to maintain a compact size without compromising thermal management.
3Ease of operation
If extensive wiring is used between the fuel pump controller and fuel pump module, then the controller can be positioned for ease of access, but the overall cost increases and electrical efficiency decreases
Solution Approach 1:
The controller is merged with the fuel pump module into a single integrated assembly, eliminating extensive wiring and associated energy losses from voltage drops. The integrated design maintains operational efficiency while the entire assembly can still be accessed for maintenance by removing the fuel pump module from the tank.
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 reduces wiring costs and emissions, improves electrical efficiency by eliminating voltage drops, and provides effective heat management, enhancing the overall design of the fuel pump system.
Implementation Method 1
incorporating a metallic heat sink for efficient heat dissipation
Data Source
AI summary
A fuel supply system for a vehicle includes a fuel pump module with a fuel pump module flange at a surface thereof. A lock ring is removably secured to the fuel pump module flange and to a fuel tank for retaining the fuel pump module to the fuel tank. An extension member is secured to the lock ring and extends a distance from the fuel pump module. A fuel pump controller is in communication with the vehicle and the fuel pump module for relaying signals therebetween. The fuel pump controller is fixedly secured to the extension member.