Accelerating Plastic Fuel Tank Aging in PHEVs
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Solution Overview
Problem
In plug-in hybrid electric vehicles (PHEVs), new plastic fuel tanks take longer to age due to infrequent engine operation, leading to inaccurate fuel level readings and increased noise and vibration, as they expand by reacting with fuel vapors, which are not frequently purged into the engine.
Innovation Solution
An on-board aging process is implemented during vehicle-off conditions when the energy storage device is charged via the grid, where the fuel pump is operated to increase fuel vapors and accelerate the aging of the plastic fuel tank by reacting with the tank walls, and the aging is monitored and controlled using sensors and a control system to reach a predetermined level.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the vehicle operates primarily in electric mode with infrequent engine use, then fuel economy is improved, but the fuel tank aging process is prolonged leading to inaccurate fuel level readings and increased noise and vibration
Solution Approach 1:
The system performs preliminary aging action by operating the fuel pump during plug-in charging events to generate fuel vapors that react with the plastic fuel tank walls, accelerating the aging process before normal operation resumes. This preliminary action ensures the tank reaches dimensional equilibrium even when engine operation is infrequent.
Solution Approach 2:
The system uses the vehicle's own battery charging process to drive the fuel pump, which in turn generates fuel vapors for tank aging. The plug-in event itself serves dual purposes: recharging the battery and accelerating fuel tank aging, eliminating the need for separate aging operations.
2Object-affected harmful factors
If the fuel tank is sealed to prevent vapor emissions during electric mode operation, then environmental compliance is improved, but the aging process is slowed down
Solution Approach 1:
The system implements periodic fuel pump operation during plug-in charging events to generate fuel vapors for tank aging. This periodic action occurs at specific intervals when the vehicle is charged, allowing the tank to age without requiring continuous engine operation or venting to atmosphere.
Solution Approach 2:
The fuel pump acts as an intermediary device that generates fuel vapors internally during plug-in events. These vapors serve as a mediator between the sealed tank system and the aging process, enabling chemical reaction with the tank walls without requiring the tank to be open to atmosphere or connected to the engine.
3Productivity
If the fuel pump is operated continuously to accelerate aging, then aging speed is improved, but energy consumption increases
Solution Approach 1:
The fuel pump operates periodically during plug-in charging events rather than continuously. This periodic operation accelerates the aging process by concentrating vapor generation during specific time windows when energy is already being supplied to the vehicle system, avoiding the need for continuous pump operation.
Solution Approach 2:
The system changes operational parameters by utilizing the plug-in charging state as a trigger for fuel pump operation. During these events, the battery is being charged anyway, so additional energy consumption for pump operation is minimized. The aging speed is optimized by adjusting pump runtime and intensity based on the charging event parameters.
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 method expedites the aging of the fuel tank, improving the accuracy of fuel level readings and reducing noise and vibration by ensuring the tank reaches dimensional equilibrium more quickly, even in vehicles that operate primarily in electric mode.
Implementation Method 1
new plastic fuel tanks take longer to age due to infrequent engine operation, leading to inaccurate fuel level readings and increased noise and vibration, as they expand by reacting with fuel vapors
Data Source
AI summary
Methods and systems are provided for aging a new plastic fuel tank in a vehicle. In one example, during a plug-in event to recharge a battery of the vehicle, the fuel tank is isolated and the fuel pump is actuated to agitate fuel within the tank and increase fuel vapors until the plastic fuel tank becomes aged to a predetermined degree by fuel vapors generated therein. In this manner, the fuel tank is aged more rapidly, resulting in more accurate fuel level readings and less noise and vibration.