Saddle Fuel Tank Level Sensing Without a Balance Pipe
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Solution Overview
Problem
The existing fuel supply systems for road vehicles with internal combustion engines face challenges in accurately determining fuel quantity and balancing low-pressure fuel pump flow rates due to the presence of a connection pipe that puts the fuel tank's lower areas in hydraulic communication, leading to increased hydrocarbon emissions, mechanical vulnerabilities, and complexity in disassembly.
Innovation Solution
A fuel supply system that employs three level sensors and control units to measure and calculate the fuel levels in separate areas of the fuel tank, eliminating the need for a connection pipe by using conversion tables and filters to accurately determine the total fuel quantity and balance the flow rates of low-pressure fuel pumps, ensuring precise fuel management and efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a connection pipe is used to put the two lower areas of the fuel tank in hydraulic communication, then fuel can flow freely between the two lower areas following transversal accelerations, but this increases hydrocarbon vapour emissions and reduces mechanical resistance
Solution Approach 1:
The invention removes the connection pipe that caused hydrocarbon vapour emissions, and instead uses level sensors to detect fuel levels in separate lower areas and control fuel pumps to balance fuel extraction, achieving fuel flow management without the harmful connection pipe
Solution Approach 2:
The invention replaces the mechanical hydraulic communication system (connection pipe) with an electronic control system using level sensors and fuel pumps to achieve the same functional goal of balanced fuel supply while eliminating hydrocarbon emissions
2Ease of operation
If a connection pipe is used to put the two lower areas of the fuel tank in hydraulic communication, then fuel can flow freely between the two lower areas, but this increases device complexity and makes disassembly more difficult
Solution Approach 1:
The invention removes the connection pipe component entirely, reducing the number of parts and simplifying the system structure, while using level sensors and electronic control to achieve fuel distribution management
Solution Approach 2:
The level sensors serve multiple functions: detecting fuel levels in both lower areas, determining total fuel quantity, and providing data for balancing fuel pump operation, replacing the need for separate communication mechanisms
3Device complexity
If the connection pipe is eliminated to reduce complexity and emissions, then the system becomes simpler and emissions decrease, but determining the quantity of fuel present in the fuel tank becomes less precise
Solution Approach 1:
The invention uses level sensors in both lower areas that provide feedback signals to a control unit, which calculates the total fuel quantity by considering the fuel levels in both areas, ensuring precise measurement without requiring hydraulic communication
Solution Approach 2:
The invention replaces the mechanical hydraulic communication system with an electronic measurement and calculation system using level sensors and a control unit, achieving precise fuel quantity determination through electronic means rather than mechanical connection
4Object-generated harmful factors
If the connection pipe is eliminated to reduce emissions, then hydrocarbon vapour emissions decrease, but balancing the flow rates of the two low-pressure fuel pumps becomes more complicated
Solution Approach 1:
The invention uses level sensors that provide continuous feedback on fuel levels in both lower areas, allowing the control unit to monitor and adjust fuel pump operations to maintain balanced flow rates without requiring a physical connection between areas
Solution Approach 2:
The invention replaces the mechanical hydraulic balancing system (connection pipe) with an electronic control system that uses level sensor data to regulate fuel pump flow rates, achieving balanced operation through electronic control rather than mechanical connection
Data Source
AI summary
A fuel supply system for a road vehicle and having: a fuel tank, which is shaped like saddle due to the presence of a central saddle and delimits an inner volume divided into an upper area, which is located above the central saddle, and two lower areas, which are located under the upper area and are separated from one another by the central saddle; two low-pressure fuel pumps, which each suck from the bottom of a corresponding lower area; at least one high-pressure fuel pump, which receives fuel from both low-pressure fuel pumps; a level sensor arranged in the upper area and configured to measure a fuel level only in the upper area; and two level sensors, each arranged in a respective lower area and configured to measure a fuel level only in the respective lower area.