DESC:FORM 2
The Patent Act 1970
(39 of 1970)
&
The Patent Rules, 2005

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

TITLE OF THE INVENTION
“FUEL LEVEL SENSING SYSTEM FOR A TWO-WHEELED VEHICLE”

Endurance Technologies Limited
E-92, M.I.D.C. Industrial Area, Waluj,
Aurangabad – 431136, Maharashtra, India

The following specification particularly describes and ascertains the nature of this invention and the manner in which it is to be performed.

Field of Invention

[001] The present invention is related to fuel level sensing system for a two wheeled vehicle. More particularly, the present invention is related to capacitance difference based fuel level sensing system integrated with rollover sensors and thereby calculating the volume of fuel available in the fuel tank of a two wheeled vehicle.

Background of the Invention

[002] Numerous devices have been proposed for measuring the level of gasoline such as petrol in the fuel tanks of two-wheeled vehicles. Conventionally, the fuel level sensing system provided in motor vehicles ordinarily utilizes a combination of a float, a connecting arm, a contact needle, and a resistive material track to measure the level of fuel inside a fuel tank. As floats have to stay in contact with the fuel to correctly measure its level, it is necessary to fit the fuel level sensing system either on the outer surface of the fuel tank or within the fuel tank itself depending upon attachment points that can be made available without compromising upon the integrity of the fuel tank. In a conventional system, the float is linked with the contact needle via the connecting arm. Therefore, any change in fuel level inside the tank is reflected in the movement of the contact needle. It has been observed that the contact needle, which is in contact with the resistive material track, tends to wear out the resistive material track over a period of time when the fuel tank undergoes multiple filling and emptying cycles.

[003] To solve the aforementioned problem, magnetic tank sensors were developed which commonly sense the position of a float by a mechanical linkage attached from a

float to a magnet. After further development on this concept, a non-conventional magnetic sensor based on Hall Effect is being employed for measuring the level of fuel in the tank of the vehicle. However, this solution leads to the problem of the life of the mechanical component and also has poor reliability.

[004] However, the aforementioned solutions apart from technical limitations, are limited to use in the standard shape of the fuel tank having a symmetric geometry of inner volume of the fuel tank. These solutions are not reliable, accurate and workable in as such form when one has to measure the level and volume of the fuel in the non-standard shape of the fuel tank. Hence, there is a long pending unmet need /gap to provide a fuel level sensing system that will accurately measure level and volume of the fuel along with other properties of the fuel (i.e. temperature, quality, etc.) in any of the non-standard shape of the fuel tanks of the two wheeled vehicle. The said gap is being filled by the present invention.

Objectives of the Present Invention

[005] The main object of the present invention is to provide a fuel level sensing system for a two wheeled vehicle.

[006] Another object of the present invention is to provide a fuel level sensing system that captures the temperature and quality of the fuel to indicate accurate volume of the fuel in the fuel tank of a two wheeler.

[007] Another objective of the present invention is to provide a fuel level sensing system that provides accurate volume of the fuel in any of the non-standard shapes of the fuel tank of a two wheeled vehicle.

[008] Yet, another objective of the present invention is to provide a fuel level sensing system integrated with a rollover sensing unit making the system compact.

[009] Yet another objective of the present invention is to provide a fuel level sensing system integrated with a rollover/tilt sensing unit for vehicles that provides an accurate volume of the fuel; is reliable, durable, cost-effective and simple in construction; requires no maintenance at all and automatically cuts the fuel supply when the rollover / tilt of the vehicle is beyond the threshold.

Brief Description of Drawings

[0010] This invention is illustrated in the accompanying drawings, throughout which like reference letters / numerals indicate corresponding parts in the various figures. The embodiments herein and advantages thereof will be better understood from the following description when read with reference to the following drawings, wherein

[0011] Figure 1 discloses an isometric view of a fuel level sensing system for a two wheeler in accordance with first embodiment of the present invention.

[0012] Figure 2 discloses a section view of a fuel level sensing system for a two wheeler in accordance with first embodiment of the present invention.
[0013] Figure 3 discloses an exploded view of a fuel level sensing system for a two wheeler in accordance with first embodiment of the present invention.

[0014] Figure 4 discloses an isometric view of assembly of the fuel level sensing system inside the fuel tank of a two wheeler in accordance with the present invention.

[0015] Figure 5 discloses an isometric view of a fuel level sensing system for a two wheeler in accordance with second embodiment of the present invention.

[0016] Figure 6 discloses a section view of a fuel level sensing system for a two wheeler in accordance with second embodiment of the present invention.

[0017] Figure 7 discloses an exploded view of a fuel level sensing system for a two wheeler in accordance with second embodiment of the present invention.

[0018] Figure 8 discloses a flow diagram explaining the working of the fuel level sensing system for a two wheeler in accordance with the present invention.

Detailed Description of the Present Invention

[0019] The invention will now be described in detail with reference to the accompanying drawings which must not be viewed as restricting the scope and ambit of the invention. The preferred embodiment of a fuel level sensing system (500) for a two-wheeler, which addresses the problems and limitations of the prior art, comprises a fuel sensing unit (FS1), a housing (10), a control unit (CU), a display unit (D) and a wire harness (40). The fuel sensing unit (FS1) comprises a pair of flexible plates (30A and 30B), a plurality of spacer (20) and an outer cover (15). The control unit (CU) further comprises of a capacitance sensor (C), a rollover sensor (R), a temperature detection mean (T), a printed circuit board (PCB) and a micro-controller unit (MCU).

[0020] The each of the flexible plates (30A and 30B) of the fuel sensing unit (FS1) is made up of stainless steel and is configured to bend in shape of regular or irregular profile. The said plates (30A and 30B) are parallel to each other maintaining a constant distance throughout its length and do have the most optimized thickness preferably in the range of 0.5 mm to 1.0 mm in order to have accuracy in capacitance between the two plates. The outer surface of both the plates (30A and 30B) is treated suitably with thin layer of treating elements preferably selected from chrome, nickel and like material to avoid oxidation and rust. To maintain the constant and uniform spacing (G) between the plates (30A and 30B), the said plates are separated by the plurality of the spacers (20) positioned at equal distance from the inner surface of the plates throughout the length of the plates (30A and 30B). The spacers (20) are made of plastic material and are configured to act as insulating body between these plates (30A and 30B).

[0021] Further, this arrangement of the plates (30A and 30B) along with the spacers (20) is covered with the outer cover (15). The outer cover (15) is made of two split pieces (15A and 15B) and each of the split pieces (15A and 15B) is made up of engineered plastic and seamlessly snap fitted with each other to form the outer cover (15). The outer cover (15) is configured to have at least a hole (H1) at its top end and a hole (H2) at its bottom end so as to make free passage for the fuel inside said cover (15) to be in touch with the plates (30A and 30B).
[0022] The bottom end of the of the fuel sensing unit (FS1) is mounted on the housing (10) in such a way that the plates (30A and 30B) of said sensing unit (FS1) are in continuous communication with the capacitance sensor (C), the rollover sensor (R) and the temperature detection means (T) of the control unit (CU). The top end of these plates (30A and 30B) is freely positioned within the outer cover (15). The said capacitance sensor (C), the rollover sensor (R) and the temperature detection mean (T) are positioned on the printed circuit board (PCB) of the control unit (CU) and are in continuous communication with the micro-controller unit (MCU) mounted on the printed circuit board (PCB). The micro-controller unit (MCU) of the control unit (CU) is configured to receive various inputs, code it, analyze and process it and again decode it to derive the desired output either in analogue or digital form. The control unit (CU) is in communication with the display unit (D) and a power unit, preferably the battery of the vehicle, through the cable harness (40). The said display unit (D) is mounted at suitable position of the handlebar of the two wheeled vehicle.

[0023] The control unit (CU), comprising an intelligent assembly of the printed circuit board (PCB), the capacitance sensor (C), the rollover sensor (R), the temperature detection mean (T) and a micro-controller unit (MCU), is accommodated inside the housing (10). The said housing (10) is filled up with a liquid resin after positioning the control unit therein and then said liquid resin is made to solidify to restrict the movement of the control unit (CU).

[0024] The fuel level sensing system (500) is fitted inside the fuel tank (FT) at the inner bottom surface of the fuel tank (FT) by fastening the housing (10) in the fuel tank (FT), and said fastening is selected from screwing, threading, bolting, riveting and like. The fuel tank (FT) is configured to have any irregular and/or asymmetric shape or is of any of the non-standard fuel tank of the two wheeled vehicle.

[0025] As far as working of the fuel level sensing system of the present invention is concerned, the fuel in the fuel tank (FT) enters inside the cover (15) through the holes (H1 and H2) provided thereon making the steel plates (30A and 30B) submerged in the fuel. The capacitance sensor (C) of the control unit (CU) of the system (500) detects the dielectric constant based on capacitance difference between the two plates (30A and 30B) and communicates the same to the micro controller unit (MCU). As the level of the fuel in the fuel tank changes, the capacitance between two plates (30A and 30B) gets changed accordingly. Further, any changes in the fuel quality lead to changes in the dielectric parameter of the fuel, which help in determining the quality of the fuel.

[0026] Further, the fuel temperature detection means (T) and rollover sensor (R) which are intelligently integrated with the printed circuit board (PCB) of the control unit (CU) of the fuel level sensing system (500) continuously records the temperature of the fuel inside the fuel tank (FT) and the orientation/tilt of the vehicle, respectively. The temperature of the fuel is directly proportional to the dielectric constant between the flexible plates (30A and 30B). The capacitance between the two plates varies with respect to the variation in the temperature of the fuel inside the fuel tank (FT). Thus, when rider puts the ignition ON, the system gets automatically connected with the battery of the vehicle and the comprehensive inputs from capacitance sensor and the temperature sensor are fed to the micro-controller unit (MCU), where the micro-controller unit (MCU) processes all these input to derive accurate level of the fuel in the fuel tank. The output of the exact fuel level, either in analog form or digital form, is displayed on the display unit (D) which is in continuous communication with the control unit (CU) through the wire harness (40). The rollover sensor (R) of the fuel level sensing system (500) is configured to continuously monitor the orientation/tilt of the vehicle during its running condition and accordingly communicates with micro controller unit (MCU) to cut off the fuel supply automatically in case the tilt of the vehicle is beyond the threshold. In the event of an accident, when the vehicle has overturned or is lying on its side, the rollover sensor sends the signal/inputs to the micro-control unit (MCU) regarding the orientation of the vehicle. The micro-control unit (MCU) processes all these inputs and cut off the supply of fuel to the internal combustion engine and avoids the burning / fire condition of the vehicle. Thus, the system imparts safety feature as well.

[0027] In another embodiment of the fuel sensing unit (FS2) of the fuel level sensing system (500) for the non-standard fuel tank for the two-wheeled vehicle comprises a stainless steel bar (32) and a plastic cover with a metal strip (35). The bar (32) is made up of flexible and bendable stainless steel and is configured to have a cross section selected from circular, square, rectangular, hexagonal or any polygon.

[0028] The outer cover (35) is made of two split pieces (35A and 35B) and each of the split pieces (35A and 35B) is made up of engineered plastic and seamlessly snap fitted with each other to form the outer cover (35). The outer surface of said cover (35) is covered / coated with the metallic strip selected from the stainless steel and inner surface of the said cover acts as an insulator between the steel bar (32) and stainless steel coated outer surface of the cover (35). The outer cover (35) is configured to have at least a hole (H3) at its top end and a hole (H4) at its bottom end so as to make free passage for the fuel inside said cover (35) to be in touch with the steel bar (32).
[0029] The cover (35) of the fuel sensing unit (FS2) coated with stainless steel strip is configured to have at least a hole (H3) at its top end and a hole (H4) at its bottom end so as to facilitate the fuel in the fuel tank (FT) to enter inside the cover (35) making the steel bar (32) submerged in the fuel. The cover (35) is positioned over the steel bar (32) in such a way that the inner plastic surface of the cover maintains a uniform gap (g) with the steel bar (32). This gap (g) is configured to facilitate the free flow of the fuel around the steel bar (32) thereby making the steel bar (32) submerged in the fuel.

[0030] The bottom end of the of the fuel sensing unit (FS2) is mounted on the housing (10) in such a way that the steel bar (32) of said sensing unit (FS2) is in continuous communication with the capacitance sensor (C), the rollover sensor (R) and the temperature detection means (T) of the control unit (CU). The top end of the steel bar (32) is freely positioned within the outer cover (35). The said capacitance sensor (C), the rollover sensor (R) and the temperature detection mean (T) are positioned on the printed circuit board (PCB) of the control unit (CU) and are in continuous communication with the micro-controller unit (MCU) mounted on the printed circuit board (PCB). The micro-controller unit (MCU) of the control unit (CU) is configured to receive various inputs, code it, analyze and process it and again decode it to derive the desired output either in analogue or digital form. The control unit (CU) is in communication with the display unit (D) and a power unit, preferably the battery of the vehicle, through the cable harness (40). The said display unit (D) is mounted at suitable position of the handlebar of the two wheeled vehicle.

[0031] In this embodiment, similar to the first embodiment, the said capacitance sensor (C), the rollover sensor (R) and the temperature detection mean (T) are mounted on the printed circuit board (PCB) and these sensors are in communication with the one end of the assembly of the steel bar (32) and the steel strip (35), and sensors are configured to receive the input from the assembly of the steel bar (32) and the steel strip (35). Further, the micro-controller unit (MCU) which is mounted on the printed circuit board (PCB) and is configured to receive inputs from capacitance sensor (C), the rollover sensor (R) and the temperature detection mean (T).

[0032] As far as the working fuel level sensing system with this embodiment of the fuel sensing unit (FS2) is concerned, the fuel in the fuel tank (FT) enters inside the cover (35) through the holes (H3 and H4) provided thereon making the steel bar (32) submerged in the fuel. As the level of the fuel in the fuel tank changes, the capacitance between the steel bar (32) and the steel strip coated over the cover (35) gets changed accordingly. Further, any changes in the fuel quality lead to changes in the dielectric parameter of the fuel, which help in determining the quality of the fuel. Further, the fuel temperature detection means (T) and rollover sensor (R) which are intelligently integrated with the printed circuit board (PCB) of the control unit (CU) of the fuel level sensing system (500) continuously records the temperature of the fuel inside the fuel tank (FT) and the orientation/tilt of the vehicle, respectively. The temperature of the fuel is directly proportional to the dielectric constant between the steel bar (32) and the steel strip coating over the cover (35). The capacitance between the steel bar and the steel strip coating varies with respect to the variation in the temperature of the fuel inside the fuel tank (FT). Thus, when rider puts the ignition ON, the system gets automatically connected with the battery of the vehicle to get activated and the comprehensive inputs from capacitance sensor and the temperature sensor are fed to the micro-controller unit (MCU), where the micro-controller unit (MCU) processes all these input to derive accurate level of the fuel in the fuel tank. The output of the exact fuel level, either in analog form or digital form, is displayed on the display unit (D) which is in continuous communication with the control unit (CU) through the wire harness (40).

[0033] The fuel level sensing system (500) for a two-wheeler of the present invention employed in any of the non-standard fuel tanks of the vehicle provides following technical advantages that contributes to the advancement of technology:
- It provides a reliable and accurate fuel level sensing system to work out the accurate volume of the fuel for any non-standard shape fuel tank of the vehicle.
- It provides a simple construction, durable and maintenance free which causes improvement in the life and cost effective.
- It reduces the requirement of additional sensor so that assembly time can be reduced.
- It provides more reliability because of no moving part and worn out material.
- It provides corrosion free component which leads the long life.
- The fuel level sensing system is provided with an integrated rollover/tilt sensing unit for detecting the angle of the vehicle orientation. During the accident, this unit will cut-off the supply of fuel to the engine and prevent the chances of fire.
- It is very simple, compact, low cost, reliable and accurate fuel level and volume sensing system with no maintenance at all for any of the non-standard shapes of the fuel tank of a two wheeled vehicle.

[0034] The foregoing description of the specific embodiment of the invention will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
,CLAIMS:We Claim

1. A fuel level sensing system (500) for a two-wheeler comprising of a fuel sensing unit (FS1, FS2), a housing (10), a control unit (CU), a display unit (D) and a wire harness (40);
wherein,
- the bottom end of the of the fuel sensing unit (FS1, FS2) is mounted on the housing (10);
- the housing (10) accommodates the control unit (CU) and said control unit (CU) is configured to comprise a capacitance sensor (C), a rollover sensor (R), a temperature detection mean (T), a printed circuit board (PCB) and a micro-controller unit (MCU);
- said housing (10) is filled up with a liquid resin after positioning the control unit therein and then said liquid resin is made to solidify to restrict the movement of the control unit (CU);
- the control unit (CU) is in communication with the display unit (D) and a battery of the vehicle through the cable harness (40); and
- the display unit (D) is mounted on the handlebar of the two wheeled vehicle.

2. The fuel level sensing system (500) for a two-wheeler as claimed in claim 1, wherein
- the fuel sensing unit (FS1) is configured to comprise a pair of flexible plates (30A and 30B), a plurality of spacer (20) and an outer cover (15);
- each of the flexible plates (30A and 30B) of the fuel sensing unit (FS1) is made up of stainless steel, and said plates (30A and 30B) are parallel to each other maintaining a constant and uniform gap (G) throughout its length;
- said uniform spacing (G) between the plates (30A and 30B) is maintained by separating the said plates the spacers (20) positioned at equal distance from the inner surface of the plates throughout the length of the plates (30A and 30B);
- said spacers (20) are made of plastic material and are configured to act as insulating body between the plates (30A and 30B); and
- the arrangement of the plates (30A and 30B) along with the spacers (20) is covered with the outer cover (15).

3. The fuel level sensing system (500) for a two-wheeler as claimed in claim 2, wherein
- the outer cover (15) is configured to make of two split pieces (15A and 15B) and each of the split pieces (15A and 15B) is made up of engineered plastic and seamlessly snap fitted with each other to form the outer cover (15); and
- said outer cover (15) is configured to have at least a hole (H1) at its top end and a hole (H2) at its bottom end so as to make free passage for the fuel inside said cover (15) to be in touch with the plates (30A and 30B).

4. The fuel level sensing system (500) for a two-wheeler as claimed in claim 3, wherein
- the plates (30A and 30B) are configured to have the thickness in the range of 0.5 mm to 1.0 mm so as to have accuracy in capacitance between said plates; and
- the outer surface of both the plates (30A and 30B) is treated with thin layer of treating elements selected from chrome and nickel to avoid oxidation and rust.

5. The fuel level sensing system (500) for a two-wheeler as claimed in claim 1, wherein
- the fuel sensing unit (FS2) is configured to comprise a stainless steel bar (32) and a plastic cover (35) coated with a steel strip on outer surface of said cover (35);
- said outer cover (35) is made of two split pieces (35A and 35B) and each of the split pieces (35A and 35B) is made up of engineered plastic and seamlessly snap fitted with each other to form the outer cover (35); and
- the outer surface of said cover (35) is covered / coated with the metallic strip selected from the stainless steel and inner surface of the said cover is configured to act as an insulator between the steel bar (32) and stainless steel coated outer surface of the cover (35).

6. The fuel level sensing system (500) for a two-wheeler as claimed in claim 5, wherein the bar (32) is made up of flexible and bendable stainless steel and is configured to have a cross section selected from circular, square, rectangular, hexagonal or any polygon.

7. The fuel level sensing system (500) for a two-wheeler as claimed in claim 5, wherein
- the outer cover (35) is configured to have at least a hole (H3) at its top end and a hole (H4) at its bottom end so as to make free passage for the fuel inside said cover (35) to be in touch with the steel bar (32);
- said cover (35) is positioned over the steel bar (32) in such a way that the inner plastic surface of the cover maintains a uniform gap (g) with the steel bar (32); and
- said gap (g) is configured to facilitate the free flow of the fuel around the steel bar (32) thereby making the steel bar (32) submerged in the fuel.

8. The fuel level sensing system (500) for a two-wheeler as claimed in any of the claims 4 and 7, wherein
- the fuel sensing unit (FS1, FS2) is in continuous communication with the capacitance sensor (C), the rollover sensor (R) and the temperature detection means (T) of the control unit (CU);
- said capacitance sensor (C), the rollover sensor (R) and the temperature detection mean (T) are positioned on the printed circuit board (PCB) of the control unit (CU) and are in continuous communication with the micro-controller unit (MCU) mounted on said printed circuit board (PCB);
- said micro-controller unit (MCU) of the control unit (CU) is configured to receive various inputs, code it, analyze and process it and again decode it to derive the desired output either in analogue or digital form; and
- said micro controller unit (MCU) is in communication with the display (D) through the wire harness (40).

9. The fuel level sensing system (500) for a two-wheeler as claimed in claim 8, wherein
- said fuel level sensing system (500) is fitted inside the fuel tank (FT) at the inner bottom surface of the fuel tank (FT) by fastening the housing (10) in the fuel tank (FT); and
- said fastening is selected from screwing, threading, bolting and riveting.

Dated this 11th day of April 2024

Sahastrarashmi Pund
Head – IPR
Endurance Technologies Ltd.

To,
The Controller of Patents,
The Patent Office, at Mumbai.