Controller Integrated Fuel Pump Module Flange Molding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing variable pressure control fuel pump systems for vehicles are complex, leading to increased manufacturing costs and component count due to the need for electrical wiring, connector assemblies, controller housings, and mounting brackets, which also result in electrical noise and motor performance issues caused by voltage drops.
Innovation Solution
A controller integrated fuel pump module where a printed circuit board assembly is molded within a flange, eliminating the need for separate components like electrical wiring, connector assemblies, and mounting brackets, with a monolithic design that includes a connector unit, supply port, and pressure sensor, and uses a molding portion to house the PCB assembly, reducing complexity and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If separate controller components with electrical wiring are used, then control functionality is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The controller is merged with the fuel pump module by integrating the PCB assembly into the flange structure. The flange serves dual purposes: mechanically securing the pump module to the fuel tank and housing the controller components, thereby reducing overall system complexity while maintaining control functionality.
Solution Approach 2:
The flange is designed as a multi-functional component that performs both mechanical support (securing the pump module) and control housing (containing the PCB assembly). This universal design eliminates the need for separate controller housing and mounting bracket components.
2Reliability
If long electrical wiring is used to connect controller and fuel pump, then control signals can be transmitted, but voltage drop and electrical noise increase
Solution Approach 1:
The controller and fuel pump are merged into a single integrated module with the PCB assembly housed within the flange. This eliminates long electrical wiring connections between separate components, thereby reducing voltage drop and electrical noise while maintaining reliable signal transmission through short internal connections.
3Ease of manufacture
If multiple separate components are used, then functional requirements are met, but manufacturing cost and assembly complexity increase
Solution Approach 1:
Multiple separate components (controller housing, mounting bracket, electrical wiring, connector assembly) are merged into a single integrated structure where the flange houses the PCB assembly and mechanically secures the pump module, reducing component count and manufacturing cost.
Solution Approach 2:
The flange is designed as a universal component that replaces multiple separate parts by providing both mechanical support and control housing functions, thereby simplifying manufacturing and reducing assembly complexity.
4Reliability
If separate controller housing and mounting bracket are used, then controller is protected and secured, but device complexity and cost increase
Solution Approach 1:
The controller housing and mounting bracket functions are merged into the flange structure. The flange provides both mechanical protection for the PCB assembly and secures the fuel pump module to the fuel tank, eliminating the need for separate housing and bracket components.
Solution Approach 2:
The flange serves as a multi-functional component that simultaneously provides controller protection, mounting support, and structural integration, thereby reducing component count while maintaining reliability.
Data Source
AI summary
A controller integrated fuel pump module for a vehicle, may include a reservoir cup configured to be fixed to an interior of a fuel tank, a fuel pump installed in an interior of the reservoir cup to pump fuel introduced into the interior of the reservoir cup, and a flange for fixing the reservoir cup and the fuel pump to the fuel tank, wherein a receiving part may be formed to an outer surface of the flange and may include an inner space, and wherein a printed circuit board (PCB) assembly configured to mount devices of a controller to a PCB may be molded in the receiving part, in a state in which the PCB assembly may be received in the receiving part, and a molding portion surrounds the PCB assembly in the receiving part.