Fuel Pump Module Reservoir Inversion for Dynamic Stall Prevention

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Solution Overview

Problem

Saddle-type vehicles, such as motorcycles and all-terrain vehicles, face fuel supply issues during dynamic maneuvers where fuel migrates away from the fuel pump inlet, leading to engine stalling due to the extreme orientations and limited space for conventional fuel tank reservoirs.

Innovation Solution

A fuel tank assembly with a fuel pump module that includes a module housing supporting a fuel pump, a reservoir with a wicking filter, and a fuel return passageway, which ensures fuel supply to the pump even when the vehicle is in abnormal orientations by returning excess fuel to the inlet via the filter, preventing engine stall.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional fuel tank reservoir is used in saddle-type vehicles, then fuel supply during normal operation is maintained, but the reservoir becomes ineffective during extreme dynamic maneuvers due to fuel migration and limited space

Engineering Contradiction:

Improvefuel supply reliabilityVSAvoidadaptability to extreme orientations

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The reservoir is inverted with the closed end facing upward and the open end facing downward toward the fuel pump inlet. This inversion allows fuel to pool at the closed end during normal operation, and during extreme maneuvers, fuel migrates to the open end where it can still be drawn into the pump, maintaining supply reliability across all orientations

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The reservoir is positioned and oriented in three-dimensional space within the fuel tank, specifically disposed between the inner wall and outer wall portions, with its axis oriented to exploit gravitational and inertial forces during dynamic maneuvers. This spatial arrangement ensures fuel remains accessible to the pump inlet regardless of vehicle orientation

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Loss of energy

If the reservoir opens upward to allow fuel drainage under gravity, then fuel returns to the tank during normal operation, but fuel freely drains away from the pump during extreme or inverted orientations

Engineering Contradiction:

Improvefuel return efficiencyVSAvoidfuel supply continuity

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The reservoir is inverted so the open end faces downward toward the pump inlet rather than upward. This configuration allows fuel to drain back to the tank during normal operation through gravity while preventing fuel from draining away from the pump during inverted or extreme orientations, as the open end remains positioned to maintain fuel contact with the pump inlet

Inventive Principle:

Principle #13The other way round (Inversion)

3Adaptability or versatility

If the vehicle operates in extreme dynamic maneuvers, then vehicle performance and maneuverability are improved, but fuel migrates away from the pump inlet causing engine stall

Engineering Contradiction:

ImprovemaneuverabilityVSAvoidfuel pump operation

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The reservoir pre-positions fuel near the pump inlet by pooling it at the closed end during normal operation. During dynamic maneuvers, this pre-positioned fuel serves as a reserve that migrates to the pump inlet, ensuring continuous fuel supply without interruption to pump operation or engine performance

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The reservoir acts as an intermediary fuel storage chamber between the main fuel tank and the pump inlet. It captures and holds excess fuel, then releases it to the pump inlet during dynamic maneuvers when direct fuel access would be lost, mediating the fuel supply to maintain continuous operation

Inventive Principle:

Principle #24Intermediary (Mediator)

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 effectively maintains fuel supply to the engine during dynamic conditions by utilizing a wicking filter to redirect pooled fuel back to the pump inlet, preventing engine stalling and ensuring continuous operation.

Implementation Method 1

A fuel tank assembly with a fuel pump module that includes a module housing supporting a fuel pump, a reservoir with a wicking filter

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Data Source

PatentUS10882395B2Fuel module pump holder having fuel retaining reservoir

Publication Date: 2021.01.05 ROBERT BOSCH CORP

AI summary

A fuel tank assembly includes a fuel tank and a fuel pump module. The module supports a fuel pump that delivers fuel to an engine of a vehicle, and includes a module housing that provides a cavity that receives the fuel pump, a reservoir that is actively filled with excess fuel discharged from a fuel pressure regulator, and a fuel return passageway that directs excess fuel discharged from the pressure regulator to the reservoir. When the fuel tank assembly is inverted, as may occur when the vehicle is operating under certain dynamic conditions, the discharged fuel is retained within the reservoir, and is supplied to the fuel pump inlet via a wicking filter that extends between the reservoir and the fuel pump inlet. As a result, engine stall due to lack of fuel during certain dynamic conditions can be delayed or avoided.