Fuel Pump Eddy Current Heating for Cold Start

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Solution Overview

Problem

Diesel and biodiesel fuels become too viscous in cold temperatures, preventing them from freely flowing into the fuel pump inlet, leading to engine starting issues, as existing solutions like electrical heaters are inefficient and consume precious electrical power.

Innovation Solution

A fuel pump with a reciprocating double solenoid actuator is used as both a pumping mechanism and a heating element, employing high-frequency current pulses to generate Eddy currents in the magnetic circuits, effectively heating the surrounding fuel and ensuring free flow into the pump inlet, while minimizing electrical energy consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If electrical heaters are used to heat fuel in cold conditions, then fuel flow is improved, but electrical energy consumption increases

Engineering Contradiction:

Improvefuel flowVSAvoidelectrical energy consumption

Core Design Contradiction:

Ease of operationVSUse of energy by moving object

Solution Approach 1:

The fuel pump is merged with a heating element, combining two separate functions (pumping and heating) into a single integrated component. The pump housing contains both the pumping mechanism and the heating element, allowing the system to both move and heat fuel simultaneously without requiring separate external heaters.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The pump serves itself by using its own operational characteristics to generate heat. The reciprocating motion of the pump creates friction and mechanical energy that is converted to thermal energy, heating the fuel within the pump housing without requiring external power sources or separate heating systems.

Inventive Principle:

Principle #25Self-service

2Temperature

If external electric heaters are used to heat fuel, then heating effectiveness is improved, but device complexity increases

Engineering Contradiction:

Improvefuel temperatureVSAvoidheating system complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The heating element is merged within the pump housing, eliminating the need for separate external heaters and associated control systems. The pump housing itself becomes the heating chamber, simplifying the overall system architecture by removing redundant components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The pump housing acts as an intermediary structure that both contains the pumping mechanism and serves as the heating chamber. This multi-functional housing eliminates the need for separate heating chambers or external heater assemblies, reducing system complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If high-frequency current pulses are applied to the pump, then heating efficiency is improved, but electrical energy consumption increases

Engineering Contradiction:

Improveheating efficiencyVSAvoidelectrical energy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The pump operates with periodic reciprocating motion, creating alternating compression and expansion cycles. This periodic action naturally generates thermal energy through friction and mechanical work, heating the fuel intermittently as the pump cycles on and off rather than requiring continuous high-frequency electrical pulses.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The patent replaces electrical heating systems with a mechanically-generated heating approach. The reciprocating pump mechanism itself generates the heat through mechanical friction and compression, substituting the need for external electrical heaters with the pump's own mechanical operation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 ensures continuous fuel flow into the pump inlet, even in cold conditions, by generating heat directly within the pump components, reducing heating time and energy consumption, and is more effective than relying solely on external electric heaters.

Implementation Method 1

employing high-frequency current pulses to generate Eddy currents in the magnetic circuits, effectively heating the surrounding fuel

Methodology Applied

Scientific EffectEddy currents: Eddy Currents

Implementation Method 2

generating heat directly within the pump components

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS8694230B2Fuel systems and methods for cold environments

Publication Date: 2014.04.08 STURMAN DIGITAL SYSTEMS LLC

AI summary

Fuel systems and methods for cold environments which includes a fuel pump having at least one solenoid coil in an unlaminated magnetic circuit, the fuel pump being disposed in a fuel tank, and a pump drive and pulsing system, the pump drive providing pump actuation current to the solenoid coil and the pulsing system providing short current pulses to the solenoid coil to cause Eddy current losses in the unlaminated magnetic circuit. The method includes, before cranking the engine for starting the engine, providing short, successive current pulses to the solenoid coil to cause eddy current heating in the unlaminated circuit and heating of the fuel in and around the fuel pump, turning on the fuel pump to commence fuel flow to the engine, and cranking the engine for starting after the fuel pump has been turned on. Various features are disclosed.