Variable Vacuum Threshold for Evaporative Emissions Leak Testing

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Solution Overview

Problem

Existing evaporative emissions control system leak tests using mechanical vacuum switches with constant thresholds can produce unreliable results due to variations in ambient and fuel conditions, leading to false failures or passes, which may result in non-compliance with emissions regulations and unnecessary vehicle service costs.

Innovation Solution

Implementing an electronic controller that determines a variable vacuum threshold based on ambient and fuel conditions, using a pressure sensor and comparator circuit to wake up the controller when the threshold is reached, allowing for more accurate leak testing and reduced power consumption during engine shutdown.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a mechanical vacuum switch with a constant threshold is used for leak testing, then the device complexity is reduced and ease of operation is improved, but the reliability of the leak test deteriorates due to false passes and false fails caused by variations in ambient and fuel conditions

Engineering Contradiction:
Improveleak test reliabilityVSAvoidcontrol system complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies dynamics by transitioning from a static, fixed vacuum threshold to a dynamic, variable threshold that adapts to changing ambient and fuel conditions. The electronic controller continuously adjusts the vacuum threshold based on real-time sensor inputs (temperature, pressure, humidity), allowing the leak test to remain reliable across varying environmental conditions. This dynamic adjustment resolves the contradiction by maintaining high reliability without requiring a complex mechanical system, as the electronic adaptation is achieved through software algorithms rather than mechanical complexity.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent implements parameter changes by modifying the vacuum threshold parameter from a constant value to a variable value that changes with ambient conditions and fuel properties. The electronic controller calculates the appropriate vacuum threshold based on temperature, pressure, and humidity parameters, then adjusts the test criterion accordingly. This parameter adaptation eliminates false test results caused by environmental variations while using a relatively simple electronic control system, thus resolving the contradiction between reliability and device complexity.

Inventive Principle:
Principle #35Parameter changes

2Measurement precision

If the electronic controller remains awake continuously to monitor vacuum levels, then the measurement precision and response time are improved, but the energy consumption increases significantly during engine shutdown

Engineering Contradiction:
Improvevacuum level detection precisionVSAvoidcontroller power consumption
Core Design Contradiction:
Measurement precisionVSUse of energy by moving object

Solution Approach 1:

The patent applies periodic action by implementing an event-driven monitoring strategy where the electronic controller enters sleep mode during normal operation and only wakes up when specific trigger events occur (such as engine shutdown, vacuum threshold attainment, or diagnostic requests). This periodic activation pattern allows the system to maintain measurement precision when needed while dramatically reducing average power consumption during extended shutdown periods, effectively resolving the contradiction between continuous monitoring and energy efficiency.

Inventive Principle:
Principle #19Periodic action

Solution Approach 2:

The patent implements self-service through an autonomous wake-up mechanism where the system automatically activates the controller when vacuum levels reach predetermined thresholds or when diagnostic conditions are met, without requiring continuous power. The controller uses low-power wake-up inputs and event-triggered processing to maintain measurement capability while minimizing energy consumption, allowing the system to serve itself by intelligently activating only when necessary.

Inventive Principle:
Principle #25Self-service

3Measurement precision

If a variable vacuum threshold based on ambient and fuel conditions is used, then the accuracy of leak testing is improved, but the device complexity increases due to the need for sensors and computational processing

Engineering Contradiction:
Improveleak test accuracyVSAvoidsensor and control system complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent applies universality by designing the electronic controller to perform multiple functions: it manages engine shutdown operations, monitors vacuum levels, processes sensor data from temperature and pressure sensors, calculates variable vacuum thresholds, and conducts leak testing. By consolidating these diverse functions into a single multi-functional controller, the system achieves high measurement precision through variable threshold adjustment without proportionally increasing overall device complexity, as the same processing unit handles all tasks.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent uses intermediary elements (temperature sensors, pressure sensors, and humidity sensors) that provide raw data to the electronic controller, which then processes this information to calculate the appropriate vacuum threshold. These intermediary sensors are relatively simple components that convert physical conditions into electrical signals, allowing the complex threshold calculation to be performed through software rather than requiring complex hardware, thus achieving high accuracy with moderate overall system complexity.

Inventive Principle:
Principle #24Intermediary (Mediator)

4Use of energy by moving object

If the controller enters sleep mode to reduce power consumption, then the energy efficiency is improved, but the response time to detect vacuum threshold attainment deteriorates

Engineering Contradiction:
Improvepower consumption during shutdownVSAvoidresponse time to vacuum threshold
Core Design Contradiction:
Use of energy by moving objectVSSpeed

Solution Approach 1:

The patent implements preliminary action by pre-calculating and storing vacuum threshold values based on anticipated ambient conditions and fuel properties before the controller enters sleep mode. The system prepares wake-up trigger levels in advance, allowing it to quickly detect when the vacuum threshold is reached without requiring continuous monitoring. This preliminary preparation enables the controller to enter low-power mode while maintaining the ability to respond rapidly when diagnostic conditions are met, resolving the contradiction between energy efficiency and response time.

Inventive Principle:
Principle #10Preliminary action

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 approach enhances the accuracy of evaporative emissions control system testing, ensuring emissions compliance and reducing unnecessary service costs by using variable thresholds that account for real-time conditions, thereby providing a more robust and reliable leak test.

Implementation Method 1

a pressure sensor coupled to the evaporative emissions system and the fuel system, the pressure sensor measuring a pressure in the evaporative emissions system and fuel system

Methodology Applied
Scientific EffectPressure measurement:

Implementation Method 2

cooling of fuel within the fuel system generates a vacuum

Methodology Applied
Scientific EffectThermal contraction: Thermal Contraction

Implementation Method 3

monitoring changes in pressure within the evaporative emissions control system

Methodology Applied
Scientific EffectPressure change:

Data Source

PatentUS9759166B2Systems and methods for evaporative emissions testing
Publication Date: 2017.09.12 FORD GLOBAL TECH LLC
  • US9759166B2 patent drawing
  • US9759166B2 patent drawing
  • US9759166B2 patent drawing

AI summary

Methods and systems are provided for diagnosing degradation of an evaporative emissions system in a vehicle. One example method comprises following a vehicle-off event, waking an electronic controller to indicate an absence of a leak in the evaporative emissions system responsive to vacuum in the evaporative emissions system attaining a vacuum threshold, the vacuum threshold based on ambient conditions and fuel conditions at the vehicle-off event. The vacuum threshold may vary based on existing conditions and may enable a more reliable diagnosis of a status of the evaporative emissions system.