Claims:We claim:
1. A controller (102) to prevent dry-run of Fuel Supply Module (FSM) in a vehicle, said FSM comprises a filter (110), a pump (108), and a pressure regulator arranged in a manner that at least said filter (110) is immersed in fuel stored in a tank (118) of said vehicle, and said pump (108) draws fuel through said filter (110) and supplies to a fuel injector (104) at a predetermined pressure which is maintained by said pressure regulator, characterized in that, said controller (102) configured to:
determine an event when fuel in said tank (118) is detected to be at a lowest level (112) measurable by a Fuel Level Sensor (FLS) (106);
calculate a cumulative volume of fuel consumed based on operating parameter of said fuel injector (104) from said detected event onwards, and
trigger an alert when said cumulative volume exceeds at least one threshold value.

2. The controller (102) as claimed in claim 1, wherein said operating parameters of said fuel injector (104) comprises an opening time of said fuel injector (104), a fuel pressure (or a flow rate of said fuel) and a fuel density.

3. The controller (102) as claimed in claim 1, wherein said at least one threshold value comprises a first safe value (114) and a second safe value (116), wherein said second safe value (116) is greater than said first safe value (114), and wherein said cumulative volume is correlated to fuel level inside said tank (118).

4. The controller (102) as claimed in claim 1, configured to curtail at least one of said vehicle and said FSM when said cumulative volume of said fuel exceeds said at least one threshold value.

5. The controller (102) as claimed in claim 1, wherein said cumulative volume of said fuel consumption is calculated by summation of fuel injected at every injection.

6. A method for preventing dry-run of a Fuel Supply Module (FSM) in a vehicle, said FSM comprises a filter (110), a pump (108), and a pressure regulator arranged in a manner that at least said filter (110) is immersed in fuel stored in a tank (118) of said vehicle, and said pump (108) draws fuel through said filter (110) and supplies to a fuel injector (104) at a predetermined pressure which is maintained by said pressure regulator, characterized by, said method comprises the steps of:
determining an event when fuel in said tank (118) is detected to be at a lowest level (112) measurable by a Fuel Level Sensor (FLS) (106);
calculating a cumulative volume of fuel consumed based on operating parameter of said fuel injector (104) from detecting said event onwards, and
triggering an alert when said cumulative volume exceeds said at least one threshold value.

7. The method as claimed in claim 6, wherein said operating parameters of said fuel injector (104) comprises an opening time of said fuel injector (104), a fuel pressure (or flow rate of said fuel) and a fuel density.

8. The method as claimed in claim 6, wherein said at least one threshold value comprises a first safe value (114) and a second safe value (116), wherein said second safe value (116) is greater than said first safe value (114).

9. The method as claimed in claim 6 comprises curtailing any one of said FSM and said vehicle when said level of fuel exceeds said at least one threshold value.
10. The method as claimed in claim 6, wherein said cumulative volume of fuel consumption is calculated by summing quantity of fuel injected at every injection.
, Description:Complete Specification:
The following specification describes and ascertains the nature of this invention and the manner in which it is to be performed:

Field of the invention:
[0001] The present invention relates to a controller to prevent dry-run of fuel supply module in a vehicle and method thereof.

Background of the invention:
[0002] In a typical gasoline system, generally there is a fuel tank that stores fuel such as gasoline or diesel or any other liquid fuel. Since modern systems uses port fuel injection (or direct injection), this requires fuel from the tank to be supplied to the injector at a certain fuel pressure (typically this values ranges from 2.5-5 bar in a two wheeler fuel supply system). In order to pressurize fuel to specified fuel pressure, a Fuel Supply Module (FSM) is used as a start of the art methodology. The FSM generally consists of a fuel filter, pump, and a pressure regulator. The FSM is generally immersed in the fuel where it draws fuel through a fuel filter which then is supplied to the pump, this pump pressurizes the fuel with desired flow rate and the pressure regulator ensures the fuel pressure is up to the required quantity. Since the FMS is immersed in fuel, this ensures that as long as the pump is operational, there is fuel flowing through the pump. This fuel also cools the impeller of the pump while in operation. When there is no fuel in the pump and yet the pump is operated, this leads overheating and failure of the pump. Current state of the art systems do not have a strategy to detect that the pump is not getting sufficient fuel form the fuel tank.

[0003] A patent literature 201911044991 discloses a fuel tank system of vehicle. The patent literature describes a vehicle comprising a fuel tank, and a fuel pump module. The fuel tank having a fuel chamber. The fuel pump module is disposed on one of at-least one side wall. The fuel pump module comprises a fuel pump, a pump retainer, a fuel filter, and a fuel retaining structure coupled to the fuel pump and enclose at least portion of the fuel filter. The fuel retaining structure comprises a first portion, and a second portion. With the present invention, dry run of the fuel pump is eliminated.

Brief description of the accompanying drawings:
[0004] An embodiment of the disclosure is described with reference to the following accompanying drawing,
[0005] Fig. 1 illustrates a block diagram of a controller to prevent dry-run of the FSM in a vehicle, according to an embodiment of the present invention, and
[0006] Fig. 2 illustrates a method for preventing dry-run of the FSM in a vehicle, according to the present invention.

Detailed description of the embodiments:
[0007] Fig. 1 illustrates a block diagram of a controller to prevent dry-run of the FSM in a vehicle, according to an embodiment of the present invention. The FSM comprises a filter 110, a pump 108, and a pressure regulator (not shown) arranged in a manner that at least the filter 110 is immersed in fuel stored in a tank 118 of the vehicle. The pump 108 draws fuel through the filter 110 and supplies to a fuel injector 104 at a predetermined pressure which is maintained by the pressure regulator, characterized in that, the controller 102 configured to, determine an event when fuel in the tank 118 is detected to be at a lowest level 112 measurable by a Fuel Level Sensor (FLS) 106. The controller 102 then calculates a cumulative volume of fuel consumed based on operating parameter of the fuel injector 104 from the detected event onwards. Thereafter, the controller 102 triggers an alert when the cumulative volume exceeds at least one threshold value. In addition, if the fuel injection system of the vehicle has variable pressure, then a model to determine the pressure at a given operating point is used for implementation by the controller 102.

[0008] A typical FLS 106 used in automotive application is not very precise. The FLS 106 only shows in blocks on how much fuel is available. The block refers to certain quantity of fuel indicated by level. For example, consider the entire tank 118 is divided in four levels, in that case, a fourth level indicates filled tank 118 or close to filled tank 118, a third level indicates fuel level below three-fourth of the tank 118, a second level indicates the fuel is below half level of the tank 118, and first level indicates that the fuel is below one-fourth of the tank 118. These levels are just for explanation and must not be understood in limiting manner. Alternatively, the FLS 106 provides a continuous voltage to show the fuel level between minimum and maximum measurable points. General limitation with such FLS 106 is that the entire capacity of the fuel tank 118 is not covered. This is due to physical limitations of the float motion of the FLS 106. Due to the design of the tank 118, the float is not able to cover above a certain level of fuel and go below a certain level of fuel level. Generally, the FLS 106 is not able to measure fuel greater than the fourth level and below first level (number of levels may vary based on type of FLS 106 or can be continuously varying). A float type FLS 106 is described, however the present invention is applicable for other types of FLS 106 (without float as well) which are unable to measure the complete capacity of the tank 118.

[0009] Further, the controller 102 comprises memory element such as Random Access Memory (RAM) and/or Read Only Memory (ROM), Analog-to-Digital Converter (ADC) and vice-versa Digital-to-Analog Convertor (DAC), clocks, timers and at least one processor (capable of implementing machine learning) connected with each other and to other components through communication bus channels. The memory element is pre-stored with logics or instructions or programs or applications and/or threshold values/levels, which is/are accessed by the at least one processor as per the defined routines. The internal components of the controller 102 are not explained for being state of the art, and the same must not be understood in a limiting manner. The controller 102 may also comprise communication units to communicate with a server or cloud through wireless or wired means such as Global System for Mobile Communications (GSM), 3G, 4G, 5G, Wi-Fi, Bluetooth, Ethernet, serial networks, and the like. In an embodiment, the controller 102 is the Engine Control Unit (ECU) of the vehicle. In another embodiment, the controller 102 is separate from the ECU but interfaced with the same.

[0010] In accordance to the present invention, the controller 102 is implementable in the vehicle selected from a group comprising a two-wheeler such as a motorcycle, a three-wheeler, a four-wheeler, and the like. More specifically, those vehicle which comprises the liquid fuel based engines and use FLS 106 to measure fuel in the tank 118, which again is unable to measure the entire capacity of the tank 118.

[0011] In accordance to an embodiment of the present invention, the operating parameters of the fuel injector 104 comprises an opening time of the fuel injector 104, a fuel pressure (or a flow rate of the fuel) and a fuel density.

[0012] In accordance to an embodiment, the at least one threshold value comprises a first safe value 114 and a second safe value 116. The second safe value 116 is greater than the first safe value 114. Further, the cumulative volume is either used directly with the at least one threshold value or is correlated to fuel level inside the tank 118 and then compared with correlated at least one threshold values for taking a decision. In an embodiment, the controller 102 is configured to curtail at least one of the vehicle and the FSM when the cumulative volume of the fuel exceeds the at least one threshold value. The cumulative volume of the fuel consumption is calculated by summation of fuel injected at every injection.

[0013] According the present invention, a working of the controller 102 is described and the same must not be taken in limiting manner. The controller 102 first detects that the fuel level is below the lowest level 112 which is measurable by the FLS 106 and then starts accumulating the quantity of fuel volume consumed or injected through the fuel injector 104. The controller 102 keeps adding the volume till a first safe value 114 of fuel volume is injected. Once the first safe level of fuel volume is injected (or the first safe value 114 is exceeded), the controller 102 issues a warning to the rider/driver to fill fuel immediately. Beyond the first safe value 114, the controller 102 still keeps track of the injected fuel volume. Once the cumulative volume of fuel injected exceeds the second safe value 116, beyond which there is very high risk of dry running the fuel pump 108, the controller 102 curtails the vehicle or the FSM such as shuts down the vehicle or the FSM to prevent component damage. The curtailment is made gradually to prevent any untoward incident with the driver or rider of the vehicle.

[0014] A simple graph 120 is illustrated in Fig. 1. The X-axis 122 is time and Y-axis 124 is fuel volume in respective suitable units such as seconds (s) and milliliter (ml). A curve starts once the lowest level 112 of fuel measurable by the FLS 106 is detected. The curve corresponds to cumulative volume of fuel consumption which increases on each injection and when it reaches/exceeds first safe value 114, a first warning is issued to the rider/driver. The alert/message comprises but not limited to refuel the tank 118 or just an indication of present level of fuel in the tank 118. Once the driver/rider ignores or forgets to refuel, the cumulative volume keeps increasing and reaches/exceeds the second safe value 116, at which the controller 102 curtails at least one of the vehicle and the FSM, or implements limp-home functionality or induces speed limitation with indication to fill fuel immediately.

[0015] In accordance to an embodiment of the present invention, the alert is displayed over an instrument cluster or display screen of the vehicle. Alternatively, if a communication device such as smartphone, smartwatch, wearable devices is connected to the vehicle, the controller 102 sends an alert message to the communication device. Alternatively, the alert is programmed to use the existing lamp in the vehicle by using specific pattern of light, or uses audio signal or uses haptic means.

[0016] In accordance to an embodiment of the present invention, the controller 102 is calibrated to the tank 118 based on the type of vehicle being used. Such as the at least one threshold value which comprises a first safe value 114 and the second safe value 116, the operating parameters of the type of fuel injector 104, the cumulative volume computation, etc.

[0017] Fig. 2 illustrates a method for preventing dry-run of the FSM in a vehicle, according to the present invention. The FSM comprises the filter 110, the pump 108, and the pressure regulator arranged in a manner that at least the filter 110 is immersed in fuel stored in the tank 118. The pump 108 draws fuel through the filter 110 and supplies to the fuel injector 104 at the predetermined pressure, which is maintained by the pressure regulator, characterized by, the method comprises the plurality of steps of which a step 202 comprises measuring fuel level in the tank 118 by the FLS 106. A step 204 comprises determining the event when fuel in the tank 118 is detected to be at the lowest level 112 measurable by the FLS 106. A step 206 comprises calculating the cumulative volume of the fuel consumed based on operating parameter of the fuel injector 104 from the detected event onwards. A step 208 comprises triggering the alert when the cumulative volume exceeds at least one threshold value. The at least one threshold value comprises the first safe value 114 and the second safe value 116. The second safe value 116 is greater than the first greater volume. Further, within the step 208, a step 210 comprises a condition where if the cumulative volume exceeds the first safe value 114, then a warning 214 is issued to the driver/rider. A further step 212 comprises a condition where if the cumulative volume exceeds the second safe value 116, then a curtailment 216 is effected. The curtailment is at least one of the shutting down the vehicle, the FSM, or speed limitation, limp-home function, and the like. The curtailment is carried out gradually to prevent any accidents incase the vehicle is in middle of a traffic or crowd. It must be noted that, the curtailment can be initiated when the first safe value 114 is exceeded.

[0018] According the method, the operating parameters of the fuel injector 104 comprises the opening time of the fuel injector 104, the fuel pressure (or the flow rate of the fuel) and the fuel density (fuel density can be arrived at based on market fuel available or based on fuel temperature or based on fuel concentration (ethanol content etc)). The fuel density is either entered manually or obtained automatically by connecting to internet through connectivity. Further, the cumulative volume of fuel consumption is calculated by summing quantity of fuel injected at every injection. The method is executed by the controller 102.

[0019] According to the present invention, the method is explained in detail without limiting to the same. At first, the fuel level information is made available to the controller 102 either by directly hardwiring the FLS 106 to the controller 102 or sending the information over Controller Area Network (CAN) from another control unit which has measured the fuel level. Once the controller 102 detects that the fuel level has gone below the lower limit 112 (or measurable limit) of the FLS 106, the controller 102 initiates counting of fuel consumption in terms of cumulative volume. The driver/rider may be operating the vehicle at multiple operating points, for which there would be a varying quantity of fuel that is required. The varying quantity of fuel is supplied through the fuel injector 104. The controller 102 records the quantity of fuel that is injected. Based on the opening time of the fuel injector 104, the controller 102 computes the volume of fuel injected, i.e. (total fuel injection time multiplied by flow rate of through the fuel injector 104 or fuel pressure) divided by fuel density. As explained before, the tank design and fitment is done for each type of vehicle and tank 118 for the FSM, an estimation is made on how much volume below the lowest level 112 of the FLS 106 can the FSM be operational without dry run. A two-stage response is triggered. First a warning is given to the rider/driver if the fuel level consumed is exceeds the first safety value. This is an indication that the driver/rider must fill the fuel tank 118 immediately. The injected fuel volume is continuously summed by the controller 102 and the cumulative volume (VC) is known at any operation time. The fuel volume injected is same as the fuel volume removed from the fuel tank 118. In a scenario where the driver/rider has not filled the fuel and continues to use the vehicle even after the warning, a curtailment or (fail-safe reaction) is triggered by the controller 102 if the cumulative volume consumed crosses the second safe value. At this point, the vehicle maybe shut down to prevent dry run of the FSM and component damage.

[0020] In accordance to the present invention, a controller 102 and strategy to prevent dry run of the FSM is provided. The controller 102 and the method determine when the fuel pump 108 will be exposed to dry run conditions. In the present invention, the existing FLS 106 along with the controller 102 is used. The method helps in detecting when the risk of fuel pump 108 dry run is high. In the present invention, there is no additional cost for making function available. The controller 102 and the method is retrofittable to the existing vehicles.

[0021] It should be understood that embodiments explained in the description above are only illustrative and do not limit the scope of this invention. Many such embodiments and other modifications and changes in the embodiment explained in the description are envisaged. The scope of the invention is only limited by the scope of the claims.