Inline Pump Assembly with Sealed Housing and Staged Control
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Solution Overview
Problem
Current high flow fuel pumps are inefficient and costly, leading to overheating, pressure loss, and potential damage due to mismatched horsepower ratings, and are often bulky, noisy, and prone to leaks, making them unsuitable for off-track applications.
Innovation Solution
A compact, sealed housing assembly containing multiple fuel pumps with individual control options, a common inlet and outlet, and integrated pressure regulation and filtration, reducing return flow and heat buildup, and minimizing metal-to-metal connections to enhance reliability and reduce noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single large self-sealed pump is used to meet high flow requirements, then the pump can handle high horsepower applications, but the device becomes significantly larger, heavier, more expensive, and noisier
Solution Approach 1:
The patent divides a single large pump into multiple smaller pumps working in parallel. Specifically, it uses multiple in-tank pumps (typically 2-4 pumps) that can be staged individually, replacing what would traditionally require a single large self-sealed pump. This segmentation achieves the same total flow capacity while reducing individual pump size and overall system complexity.
2Device complexity
If multiple in-line pumps are used to reduce size and cost, then the pump assembly becomes more compact and economical, but the number of joints increases, creating more potential leak points
Solution Approach 1:
The patent merges multiple pump units into a single integrated in-tank assembly with a common inlet and outlet housing. This consolidation reduces the number of external connections and joints compared to using separate pumps, while maintaining the benefits of multiple smaller pump units. The integrated design improves reliability by minimizing leak points.
3Productivity
If pumps are operated at high current to achieve peak flow, then the desired flow rate is achieved, but heat buildup increases, causing vapor lock and potential pump damage
Solution Approach 1:
The patent implements periodic or staged operation of multiple pumps rather than continuous operation of a single pump at maximum capacity. The controller can activate pumps sequentially or in stages based on demand, allowing fuel to be drawn from different sources and reducing continuous heat generation in the fuel return path. This staged operation prevents excessive heat buildup while maintaining required flow rates.
4Productivity
If a higher flow pump is selected for lower horsepower applications, then the pump can meet peak demand, but return flow increases, causing overheating, pressure loss, and potential pump damage
Solution Approach 1:
The patent employs dynamic control of multiple pump units based on actual engine demand. Rather than using a single oversized pump that operates inefficiently at partial load, the system can activate only the necessary number of pumps based on real-time requirements. This dynamic staging optimizes efficiency across the entire operating range, minimizing return flow and energy loss while maintaining peak flow capability when needed.
Data Source
AI summary
A pump assembly and methods of use and conversion including a sealed housing, at least one in-tank, not sealed pump contained in the sealed housing, an outlet check valve inside each pump, and an over pressure relief passage formed around the pumps in the sealed housing. The pump assembly may also include a common fuel inlet, a common fuel outlet; at least two of the pumps, a compact design, a mounting bracket, a sealed electrical inlet, a pre filter, a post filter, a pressure regulator, a returnless fuel supply, a pressure regulator, a return line.